High Aspect Ratio Polymer Layer via Molding
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Solution Overview
Problem
Existing devices for filtering biological solutions or fluids made from silicon or inorganic materials are expensive, fragile, and require costly surface treatments for durability and biocompatibility, with production techniques being inefficient for high aspect ratio microstructures.
Innovation Solution
A patterned polymer layer with high aspect ratio is produced using acrylic and/or epoxy polymerizable materials with a mold of organic or inorganic nature, employing polymerization molding to create microstructures with improved mechanical properties and wettability, eliminating the need for expensive surface treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dry etching or laser-beam micro-machining techniques are used to create high aspect ratio microstructures, then manufacturing precision is improved, but production cost increases and device fragility worsens
Solution Approach 1:
The patent changes the material parameter from inorganic (silicon) to organic (polymer) and the manufacturing parameter from subtractive (etching) to additive (molding). This allows achieving high aspect ratio microstructures with good precision while reducing production cost and improving mechanical properties through the inherent flexibility and toughness of polymer materials.
2Manufacturing precision
If inorganic materials like silicon are used for device substrates, then manufacturing precision is improved, but device reliability worsens due to fragility
Solution Approach 1:
The patent changes the material parameter from inorganic (silicon) to organic (polymer). Polymers inherently possess better mechanical properties including flexibility, toughness, and resistance to breakage, thereby improving device reliability while maintaining the ability to form precise high aspect ratio microstructures through molding techniques.
3Reliability
If surface treatments are applied to inorganic materials to improve wettability, then device reliability is improved, but device complexity and production cost increase
Solution Approach 1:
The patent changes the material parameter from inorganic (silicon) to organic (polymer). Polymers naturally exhibit good wettability with biological solutions without requiring additional surface treatments. This eliminates complex surface treatment processes including plasma treatments, chemical coatings, and functionalizing agents, thereby reducing device complexity and production cost while maintaining reliability.
4Ease of manufacture
If polymerization molding is used without mold surface treatment, then ease of manufacture is improved, but manufacturing precision worsens due to adhesion issues
Solution Approach 1:
The patent changes the surface treatment parameter from no treatment or complex treatments to a simple polymerization inhibitor treatment. This thin layer prevents polymer adhesion to the mold during curing, enabling easy mold release while preserving the fidelity of high aspect ratio microstructure replication. The inhibitor layer is sufficiently thin not to compromise the precision of the molded features.
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
The solution provides a cost-effective, durable, and biocompatible patterned polymer layer with high aspect ratio, enhancing mechanical properties and wettability, suitable for biomedical applications without requiring additional surface treatments.
Implementation Method 1
a phase of polymerization moulding that uses an acrylic and/or epoxy polymerizable material
Data Source
Figure 1(a)~1(d)
Figure 2(a)~2(d)
Figure 3(a)~3(b)
AI summary
The present invention relates to a device comprising a patterned polymer layer with high aspect ratio to be used in contact with biological solutions or fluids, as well as the method of production of said layer, comprising a phase of polymerization moulding, that uses an acrylic and/or epoxy polymerizable material with a mold of organic or inorganic nature.