Composite Woven Microfluidic Channels Without Complex Lithography
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Solution Overview
Problem
Current microfluidic systems face challenges in cost-effectiveness, production rate, and material limitations, with existing methods being labor-intensive and requiring sophisticated equipment, while paper-based systems suffer from poor control over fluid flow and contamination risks.
Innovation Solution
A fluidic device comprising a solid matrix with embedded textile fibers, where channels are entangled with the textile component, allowing for open flow paths and controlled channel designs, enabling flexible and cost-effective production of mini, micro, and millifluidic systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional microfabrication methods (photolithography, etching) are used to create microchannels, then manufacturing precision and channel definition are improved, but device complexity and production cost increase
Solution Approach 1:
The patent extracts the channel-forming element (fiber) from the final device structure. Fibers are embedded in the polymer matrix during casting, then selectively removed to create channels. This eliminates the need for complex post-fabrication channel creation steps while maintaining precise channel geometry defined by the fiber arrangement.
Solution Approach 2:
The patent performs preliminary action by pre-positioning fibers in the desired channel configurations before polymer matrix casting. The fibers are arranged and fixed in the mold cavity prior to polymerization, establishing the channel network geometry in advance. This preliminary fiber placement simplifies the overall fabrication process compared to creating channels after device assembly.
2Productivity
If injection molding is used for mass production, then productivity is improved, but material selection is limited and high initial tooling cost is required
Solution Approach 1:
The patent changes the material state parameter by using thermoplastic polymers that can be molded in different states (molten, semi-solid). This allows the same basic fiber-embedding technique to be applied across various material systems with different processing parameters, expanding material versatility while maintaining mass production capability through adaptive parameter adjustment.
Solution Approach 2:
The patent creates a universal fabrication approach where the fiber-embedding-in-matrix technique can be applied to multiple material systems (thermoplastics, elastomers, biodegradable polymers). The core methodology remains the same while accommodating different materials through parameter adjustments, making the process universally applicable across diverse applications.
3Device complexity
If paper-based microfluidics are used, then device complexity and cost are reduced, but fluid flow control precision and contamination resistance worsen
Solution Approach 1:
The patent creates a composite structure combining inert polymer matrix material with functional fiber elements. The polymer provides precise, non-absorbent channel walls for controlled fluid flow, while the embedded fibers define the channel geometry. This composite approach merges the fabrication simplicity of fiber-based methods with the flow control precision of solid-walled channels.
Solution Approach 2:
The patent applies local quality by using different materials for different functions: the polymer matrix provides smooth, inert channel walls for precise fluid control, while the fiber elements provide structural definition and positioning. Each material is optimized for its specific role, achieving both fabrication simplicity and flow control precision.
4Device complexity
If sacrificial wire methods are used to create 3D channels, then device complexity is reduced, but labor intensity and skill requirements increase
Solution Approach 1:
The patent implements self-service by using the fibers themselves as both the structural support during casting and the channel-defining elements after embedding. The fibers automatically maintain their positions and configurations during the polymerization process, eliminating the need for manual positioning and support structures that would increase labor requirements.
Data Source
AI summary
A fluidic device comprising at least: a/ a solid matrix (5), b/ a textile component (4), embedded in said matrix and mechanically cohesive with said matrix, c/ at least one channel (6) embedded in said matrix and entangled with said textile component (4), said channel (6) being at least partly open. A method for making a fluidic device comprising providing a textile component (4) comprising support fibers (1.1), (1.2) and at least a movable fiber (2) entangled with said textile (4), embedding at least part of said textile 4 and part of said movable fiber (2), in a matrix precursor material (5), applying a treatment in order to obtain a solid matrix (5).