Polyimide Flow Channel Device High Pressure Resistance
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Solution Overview
Problem
There is a need for a flow channel device that is durable enough to withstand high-pressure environments, as existing devices are not adequately resistant to the pressure of fluids flowing through them.
Innovation Solution
The method involves laminating polyimide films, alternating thermoplastic and non-thermoplastic polyimide films, and applying heat and pressure to enhance adhesion, while also using a metal film pattern for additional functionality and precision in forming flow channels, and housing the films in an air-tight chamber to prevent voids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional flow channel devices are used, then they can be manufactured with simple structures, but they cannot withstand high-pressure fluid environments
Solution Approach 1:
The patent employs a composite structure consisting of multiple polyimide film layers with different properties. Thermoplastic polyimide films provide pressure resistance and structural integrity, while non-thermoplastic polyimide films maintain dimensional stability and chemical resistance. This composite approach enables the flow channel device to withstand high pressures without requiring overly complex single-material structures.
Solution Approach 2:
The flow channel device is divided into multiple discrete polyimide film layers that are laminated together. Each layer serves specific functional purposes, and the segmented structure allows for optimized pressure distribution and stress management across different regions of the device, enhancing overall pressure resistance while maintaining manufacturability.
2Strength
If thermoplastic polyimide films are used to enhance adhesion, then the device can withstand high pressure, but the films may deform under heat affecting channel precision
Solution Approach 1:
Different regions of the polyimide film structure are assigned different material properties. Thermoplastic polyimide regions are strategically positioned where strong adhesion is needed to withstand pressure, while non-thermoplastic polyimide regions are placed in areas requiring dimensional stability for precise channel formation. This local differentiation of material qualities resolves the contradiction between adhesion strength and precision.
Solution Approach 2:
The patent uses a composite of thermoplastic and non-thermoplastic polyimide films in alternating layers. The thermoplastic layers provide the necessary adhesion strength through heat-activated bonding, while the non-thermoplastic layers act as dimensional stabilizers that resist deformation during heating processes, thereby maintaining channel formation precision.
3Strength
If pressure is applied during lamination to enhance adhesion, then the device becomes more durable, but voids may form in the flow channels
Solution Approach 1:
The lamination process is performed in a controlled sequence where pressure is applied gradually and uniformly across the polyimide film layers. The alternating structure of thermoplastic and non-thermoplastic films is prepared in advance to facilitate even pressure distribution, preventing void formation while achieving strong adhesion bonds between layers.
Solution Approach 2:
Pressure application is optimized for specific regions of the laminated structure. The rigid non-thermoplastic polyimide layers provide structural support that distributes applied pressure uniformly, preventing localized void formation in the flow channel regions while still enabling strong adhesion in the bonding zones between layers.
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 results in a flow channel device that can withstand high pressures, maintain precise channel shapes, and is suitable for handling biological samples and various fluids, including those with high flow rates and pressures, while also being chemically and thermally resistant.
Implementation Method 1
A plurality of the polyimide films are adhered by applying heat such that the ports are communicated with the channels
Implementation Method 2
Upon adhering the polyimide films, a pressure may be applied to a plurality of the polyimide films laminated. This further enhances the adhesion among the polyimide films.
Implementation Method 3
Housing a plurality of the polyimide films laminated within an air-tight holding chamber. Upon adhering the polyimide films laminated, the chamber may have a reduced pressure, which prevents voids from remaining within the flow channels.
Data Source
AI summary
There is provided a method of producing a fluid channel device including laminating a plurality of polyimide films including at least one polyimide film having a port and at least one polyimide film having a channel, the polyimide films including at least one thermoplastic polyimide film; and adhering a plurality of the polyimide films by applying heat such that the ports are communicated with the channels. There is also provided the flow channel device produced by the method.