Stacked Microfluidic Dialysis Device with Compression-Sealed Membranes
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Solution Overview
Problem
Conventional microfluidic devices face challenges in efficiently dialyzing blood at lower flow rates for extended periods outside a clinical setting, with limitations in mass transfer rates due to thick boundary layers and risks of cross-contamination, and require complex and costly manufacturing processes.
Innovation Solution
The development of a microfluidic device with a configuration that includes semi-permeable membranes and a stackable, compression-sealed design with orthogonal vias and flow fields, reducing boundary layer thickness and cross-contamination risks, and allowing for efficient mass transfer and heat exchange using laminae with microchannels or flow fields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional microfluidic devices are used for dialysis, then mass transfer occurs through membranes, but thick boundary layers reduce mass transfer efficiency
Solution Approach 1:
The device divides the fluid flow path into multiple discrete microchannels separated by spacers, creating segmented flow patterns that enhance mixing and reduce boundary layer thickness compared to conventional single-channel designs
Solution Approach 2:
The invention transitions from planar 2D microchannels to three-dimensional stacked layers with vertical flow paths, adding a third dimension to mass transfer and significantly reducing diffusion distances across the membrane
2Reliability
If dialysis is performed outside a clinical setting at lower flow rates, then patient safety is improved by reducing blood outside the body, but dialysis effectiveness decreases
Solution Approach 1:
Multiple stacked layers with numerous microchannels provide extensive membrane surface area in a compact device, enabling adequate dialysis treatment even at reduced flow rates suitable for home use
Solution Approach 2:
The three-dimensional stacked architecture increases the membrane surface area available for mass transfer without proportionally increasing device volume, maintaining dialysis effectiveness at lower flow rates
3Ease of manufacture
If microfluidic devices are manufactured using conventional processes, then production cost is reduced, but manufacturing precision may be insufficient
Solution Approach 1:
The device is divided into separate laminated layers that can be manufactured independently using conventional techniques, then assembled together, allowing each layer to be produced with standard tolerances while achieving precise final microchannel dimensions through the stacking process
Solution Approach 2:
By moving critical precision requirements to the vertical stacking dimension rather than requiring high-precision lateral microchannel fabrication, the invention enables manufacturing with conventional techniques while maintaining functional precision
4Productivity
If multiple membranes are stacked to increase treatment capacity, then dialysis effectiveness is improved, but cross-contamination risk increases
Solution Approach 1:
Fluidic isolation elements and spacers physically segment and isolate adjacent microchannels and membrane surfaces, preventing cross-contamination between multiple treatment channels while maintaining high treatment capacity through parallel processing
Solution Approach 2:
Spacer elements and sealing structures act as intermediary components between adjacent membranes and fluid channels, providing physical barriers that prevent direct contact and cross-contamination while allowing the stacked structure to function
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 enhances mass transfer efficiency, reduces cross-contamination, and enables the use of conventional manufacturing techniques, making it feasible for low-cost, high-volume production of devices capable of dialyzing blood at lower flow rates for extended periods.
Implementation Method 1
configured for mass transfer by dialysis
Implementation Method 2
Mass transfer rates through membranes in conventional systems may be affected by diffusion rates through the relatively thick boundary layer
Implementation Method 3
Increasing fluid velocity near the membrane surface, for example by stirring, is a common method of decreasing the boundary layer thickness, thus the effective diffusion length
Implementation Method 4
a fifth lamina is positioned over the fourth lamina such that the fourth via of the fourth lamina is sealed by the compression of the compression seal between the fifth lamina and the fourth lamina
Data Source
Figure 1~2
Figure 3~4
Figure 5~6A
AI summary
The present disclosure concerns embodiments of a microfluidic transfer device. The device mitigates risk of cross contamination between working fluids and is amenable to high-volume, low-cost manufacturing techniques. The device may be configured for mass transfer, heat transfer, or both. For instance, certain disclosed embodiments incorporate semi-permeable membranes to transfer target substances from one fluid to another. Moreover, the device may incorporate both heat and mass transfer components.