Planar Polymeric Fluidic Devices With Hydrophilic Mask
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Solution Overview
Problem
Current methods for manufacturing fluidic devices, such as die cutting and rotary converting, are limited in producing small and complex structures, requiring multiple film constructions that are costly and difficult to assemble, and struggle with achieving small sample volumes and hydrophilic capillary features.
Innovation Solution
A fluidic device is formed by bonding select portions of planar polymeric layers with a hydrophilic mask material, creating an interstitial space for fluid flow without the need for cavities or vertical sidewalls, allowing for precise handling of smaller fluid volumes and simpler assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If die cutting and rotary converting processes are used to manufacture fluidic devices, then device assembly is achieved, but the ability to produce small and complex structures is limited and multiple film constructions are required
Solution Approach 1:
The patent combines multiple functions into a single planar layer by integrating the chamber formation, capillary features, and fluid transport pathways all within one flat polymeric layer, eliminating the need for multiple separate film constructions and complex 3D assembly processes
Solution Approach 2:
The invention transitions from traditional 3D cavity-based fluidic devices to a 2D planar architecture where fluid transport occurs through surface-level capillary channels and interstitial spaces, enabling simpler manufacturing while maintaining fluidic functionality
2Ease of manufacture
If double coated tape with notches is used to form fluidic device chambers, then chamber formation is achieved, but the volume of sample required cannot be reduced to less than approximately 1 microliter
Solution Approach 1:
The patent employs thin planar polymeric layers with precisely controlled thickness to define ultra-small fluidic chambers and transport channels, enabling sample volumes below 1 microliter while maintaining structural integrity and manufacturing feasibility
Solution Approach 2:
The invention changes the geometric parameters of the fluidic structure by transitioning from 3D notched chambers to 2D planar configurations with controlled thickness parameters, achieving smaller sample volumes through precise dimensional control in the vertical dimension
3Ease of manufacture
If thin layers of adhesives are used in film construction, then bond strength is reduced, but device assembly is achieved
Solution Approach 1:
The patent eliminates adhesive layers entirely by using self-bonding polymeric layers that form permanent bonds through thermal or pressure treatment, removing the need for separate adhesive materials and their associated bonding strength limitations
4Device complexity
If ultra thin films are used in fluidic device construction, then handling during manufacturing becomes difficult due to stretching or breaking, but device complexity is reduced
Solution Approach 1:
The patent utilizes inherently flexible and tear-resistant polymeric materials with optimized thickness and mechanical properties that maintain handling robustness during manufacturing while enabling the formation of thin-walled fluidic 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 the use of smaller fluid samples and reduces the complexity of device geometry, facilitating the transport of liquids through interstitial spaces between flat surfaces, enhancing performance and reducing material requirements.
Implementation Method 1
the surface energy of the cover film must be very high to induce spontaneous capillary action of aqueous samples such as body fluids
Implementation Method 2
a hydrophilic mask material disposed on a first portion of the first major surface of the first bondable polymeric layer. A surface of the hydrophilic mask material exhibits an advancing contact angle with water of less than 90 degrees
Data Source
AI summary
The present disclosure provides fluidic devices. A fluidic device includes a) a first bondable polymeric layer having a first major surface that is substantially planar; b) a second polymeric layer having a first major surface that is substantially planar; and c) a hydrophilic mask material disposed on a first portion of the first major surface of the first bondable polymeric layer. A surface of the hydrophilic mask material exhibits an advancing contact angle with water of less than 90 degrees. A second portion of the first major surface of the first bondable polymeric layer is bonded to a first portion of the first major surface of the second polymeric layer. The hydrophilic mask material and a second portion of the first major surface of the second polymeric layer are in direct contact with each other at at least one point. An open volume is defined by interstitial space located between the hydrophilic mask material and the second portion of the first major surface of the second polymeric layer. The open volume comprises two or more openings and at least one of the openings is located at an edge of the first bondable polymeric layer. The fluidic devices can be formed to have small volumes for use as precision fluidic devices, such as blood glucose testing strips.