Drawn microchannel array devices and method of analysis using same

• US 20020072111A1
• Filed: 01/30/2001
• Published: 06/13/2002
• Est. Priority Date: 12/13/2000
• Status: Abandoned Application

• Current Assignee: Polymicro Technologies LLC (KOCH Industries Incorporated)
• Original Assignee: Polymicro Technologies LLC (KOCH Industries Incorporated)
• Inventors: Nelson, Gary W., Clarkin, James P., Macomber, Robert J.
• Application Number:
  US09/771,569
• Publication Number:
  US 20020072111A1
• Time in Patent Office: Days
• US Class Current: 435/287.1
• CPC Class Codes: B01L 2200/12 Specific details about manufacturing devices
• CPC Class Codes: B01L 2300/0654 Lenses; Optical fibres
• CPC Class Codes: B01L 3/502707 characterised by the manufacture of the container or its components by shaping or joining plastic parts B29C59/00, B29C65/00; by laminating B32B37/00; manufacture of microstructural devices in general B81C
• CPC Class Codes: B01L 3/502715 characterised by interfacing components, e.g. fluidic, electrical, optical or mechanical interfaces
• CPC Class Codes: B81B 1/002 Holes characterised by their shape, in either longitudinal or sectional plane
• CPC Class Codes: B81B 2201/058 Microfluidics not provided for in B81B2201/051 - B81B2201/054
• CPC Class Codes: G01N 27/44721 by optical means

Abstract

Micro channel array devices drawn from a bulk preform having an array of components to reduce the cross section. The reduced cross section fiber like structure is cut to produce individual arrays of small scale. End caps are drawn and optionally micro machined. The end caps are used to provide input and output ports and other structures for use with the micro channel arrays. A micro channel array may be used with different end caps for analysis and may form a lab on a chip or a component thereof.

Claims

1. A device for analyzing a plurality of sample components, comprising:

a drawn substrate having a length, the drawn substrate having at least two drawn channels formed therein;

the drawn channels extending in a direction parallel to the length, and inlets and outlets in cooperating relation with the drawn channels.

4. A device as in claim 1 or 3 with at least one drawn channel having a cross sectional area in the range of 0.0001 mm² to 1 mm², preferably 0.0025 mm² to 0.25 mm², and most preferably 0.005 mm² to 0.0075 mm².

5. A device as in claim 1 or 3 with at least one drawn channel having a length in the range of 1 mm to 1 km, preferably 3 mm to 1000 mm, and most preferably 10 mm to 250 mm.

6. A micro electro mechanical system utilizing a device as in claim 1 or 3.

7. A lab on a chip system utilizing a device as in claim 1 or 3.

8. A device as in claim 1 or 3, wherein the drawn substrate is formed using a drawing process in which one or more of draw rate, draw tensions, draw temperature, and draw pressure are varied such that a cross sectional area of each channel varies along the length.

9. A device as in claim 1 or 3, wherein the drawn channels further comprise a plurality of ports providing fluidic communication with the drawn channels.

10. A device as in claim 1 or 3, further comprising machined structures disposed within the substrate in cooperating relation with the drawn channels.

11. A device as in claim 1 or 3 wherein the drawn substrate further comprises an optical waveguide formed therein and extending in the direction parallel to the length.

12. A device as in claim 1 or 3 wherein the drawn substrate further comprises an electrical conductor extending in the direction parallel to the length.

13. A device as in claim 1 or 3 wherein the drawn substrate further comprises at least one optical isolator extending in the direction parallel to the length.

14. A device as in claim 1, wherein a first one of the at least two drawn channels has a cross-sectional geometry different from a cross-sectional geometry of a second one of the at least two drawn channels.

15. A device as in claim 1 wherein the drawn substrate comprises a material selected from the group comprising:

glass, ceramic, and thermoplastic polymers.

16. A device as in claim 1 wherein the drawn substrate comprises a material selected from the group comprising:

fused silica, fused quartz, and PMMA.

17. A device as in claim 1, further comprising an exterior coating on the drawn substrate comprising a material selected from the group comprising:

polyimide, acrylate, fluorinated acrylate, silicone, metal, optical cladding.

18. A device as in claim 1, further comprising an exterior coating on the drawn substrate comprising a material selected from the group which is:

magnetic, radio opaque, optically filtering, conductive, dielectric.

19. A device as in claim 1, further comprising an interior coating on the drawn channel comprising a material selected from the group comprising:

hydrophobic bonded phases, hydrophyllic bonded phases, polyacrlyamides, silver, silver halide, gold, and polytetrafluoroethylene.

20. A device as in claim 1, wherein at least a selected one of the at least two drawn channels has at least of a portion of a wall comprising a lens.

21. A device as in claim 1, wherein at least a selected one of the at least two drawn channels has at least a portion of a wall comprising a reflector.

22. A device as in claim 1, wherein the drawn substrate has at least one alignment groove on its exterior surface, down its length.

23. A device as in claim 1, further comprising an optical fiber interfaced into one of the drawn channels.

24. A device as in claim 23, further comprising a structure for redirecting light in the drawn channel interfaced with the optical fiber.

25. A device as in claim 24, wherein the structure for redirecting light comprises a reflecting surface located on the end of the optical fiber interfaced into the drawn channel.

26. A device as in claim 20, wherein the at least two drawn channels have a substantially constant spacing therebetween, a substantially constant relative rotational alignment and a substantially constant relative angular alignment along the length of the substrate.

27. A device as in claim 26, wherein two of the drawn channels have a portion of a wall comprising a lens and the two lenses have a substantially constant spacing therebetween, a substantially constant relative rotational alignment and a substantially constant relative angular alignment along the length of the substrate.

29. A device as in claim 28, wherein the drawn endcap channels are formed using a drawing process in which one or more of draw rate, draw tension, draw temperature and draw pressure are varied such that a cross sectional area of each channel varies along a length thereof.

2. A method of analyzing by introducing a plurality of sample components to a drawn substrate having a length, the drawn substrate having at least two drawn channels formed therein;

the drawn channels extending in a direction parallel to the length, and the substrate includes inlets and outlets disposed in cooperating relation with the drawn channels.

3. A device for analyzing a plurality of sample components, comprising:

a drawn substrate having a length, the drawn substrate having at least two drawn channels formed therein;

the drawn channels extending in a direction parallel to the length; and

at least one endcap substrate having at least one endcap channel, the at least one endcap channel being in fluid communication with at least one channel selected from the group comprising;

a selected one of the drawn channels, a plurality of the drawn channels, another endcap channel and combinations thereof.

28. A device as in claim 3, wherein the endcap substrate is a drawn substrate and the endcap channels are drawn endcap channels.

30. A device as in claim 3, wherein the endcap substrate further comprises an endcap channel having a cross-sectional geometry different from a cross-sectional geometry of the at least one endcap channel.

31. A device as in claim 3, wherein the endcap substrate comprises a material selected from the group comprising:

glass, ceramic, and thermoplastic polymers.

32. A device as in claim 3, wherein the endcap substrate comprises a material selected from the group comprising:

fused silica, fused quartz, and PMMA.

33. A device as in claim 3, wherein the at least one endcap channel has at least a portion of a wall comprising a lens.

34. A device as in claim 3, wherein the at least one endcap channel has at least a portion of a wall comprising a reflector.

35. A device as in claim 3, wherein the drawn endcap has at least one alignment groove on its exterior surface.

36. A device as in claim 3, wherein another endcap channel and at least one said endcap channel have a substantially constant spacing therebetween, a substantially constant relative rotational alignment and a substantially constant relative angular alignment along the length of the substrate.

37. A drawn substrate manufactured by a process comprising:

providing a preform body having at least one channel and at least one optical waveguide preform therein and extending along a length of the preform body;

drawing the preform body to extend the length thereof such that a length of the at least one channel is extended while substantially maintaining a cross sectional geometry of the at least one channel and such that a length of the at least one optical waveguide preform is extended while substantially maintaining a cross sectional geometry of the at least one optical waveguide preform; and

cutting the drawn preform body to a desired length.