Spiral Multichannel Microsphere Device
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Solution Overview
Problem
Current methods for mass-producing monodisperse polymer-based microspheres are limited in scalability and efficiency, particularly in forming a large amount of microspheres through a highly controlled method involving immiscible fluids in microchannel structures.
Innovation Solution
A multichannel microsphere producing unit is designed with a central plate, upper and lower plates, and supply and discharge lines arranged in a rolled-up shape to maximize space, featuring microchannels that merge immiscible fluids to form droplets, which then solidify into microspheres, allowing for efficient production and collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional single-channel microsphere production method is used, then the production process is simple, but the production quantity is limited
Solution Approach 1:
The production system is divided into multiple independent microchannels, each capable of producing microspheres separately. This segmentation allows parallel production across multiple channels, significantly increasing total output while maintaining the simplicity of individual channel design and operation
Solution Approach 2:
Multiple microchannel systems are merged into a single integrated device with shared supply and discharge line networks. The rolled-up configuration merges supply lines and discharge lines into compact structures that serve multiple microchannels simultaneously, increasing productivity while controlling overall device complexity
2Area of stationary object
If supply lines are arranged in a conventional linear configuration, then the layout is simple, but the space utilization is low
Solution Approach 1:
The supply lines and discharge lines are arranged in rolled-up or curved configurations rather than straight linear paths. This curvature allows the lines to efficiently utilize the available substrate area, fitting more lines and microchannels into a compact space while maintaining proper fluid flow paths
Solution Approach 2:
The system transitions from a two-dimensional planar arrangement to a three-dimensional rolled-up structure. By stacking and rolling supply and discharge lines in multiple layers, the design maximizes space utilization on the substrate while keeping the footprint compact
3Productivity
If microsphere formation parts are sparsely arranged, then the fluid flow is simple, but the production efficiency is low
Solution Approach 1:
The supply lines and discharge lines are designed as universal structures that serve multiple microsphere formation parts simultaneously. The rolled-up configuration creates multi-functional pathways that can supply fluid to and collect fluid from numerous microchannels through shared infrastructure, increasing production efficiency without proportionally increasing device complexity
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 configuration enables the production of a larger quantity of microspheres with controlled size distribution, maximizing space utilization and ensuring high yield and quality of microspheres by efficiently arranging microsphere formation parts along the supply lines and discharge lines.
Implementation Method 1
capable of discretely adjusting volumes of fluids in immiscible phases with a low Reynolds number and a laminar flow state
Implementation Method 2
droplets are formed
Data Source
AI summary
In the present invention, two adjacent supply lines for supplying two immiscible fluids are spirally disposed on a substrate where microchannels for microsphere production based on a droplet-based highly controlled method for mass-production of microspheres (HCMMM) are formed, and microsphere forming parts each comprising microchannels are arranged between and along the two supply lines, whereby a much larger amount of microspheres can be produced. Further, the two supply lines are disposed in a spiral configuration, and the microsphere forming parts can be disposed by branching microchannels from the two supply lines on inner and outer sides of the spiral configuration, whereby the limited space on a wafer normally having a circular shape can be maximally used to form multiple microsphere forming parts.