Polymer-based platform for microfluidic systems
First Claim
1. A method of forming a microfluidic system platform comprising the steps of:
- providing a mold frame having frame walls surrounding a mold cavity;
providing a set of mold forms for use in molding hollow microfluidic features, the set of mold forms comprising elongated mold forms for use in molding microfluidic channels, and block mold forms for use in molding microfluidic cavities;
constructing a three-dimensional model construction of a microfluidic flow path network in the mold cavity by interconnecting mold forms selected from the set of mold forms and suspending the model construction in the mold cavity via the frame walls;
introducing a hardenable liquid into the mold cavity to immerse the model construction thereby;
hardening the liquid to form (1) a platform structure having a shape of the mold cavity and (2) the microfluidic flow path network in the platform structure having a seamless shape of the model construction and including at least two access ports for enabling fluidic communication with the formed microfluidic flow path network; and
removing the model construction from the platform structure through the at least two access ports so as to avail the formed microfluidic flow path network.
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Abstract
A method of forming a polymer-based microfluidic system platform using network building blocks selected from a set of interconnectable network building blocks, such as wire, pins, blocks, and interconnects. The selected building blocks are interconnectably assembled and fixedly positioned in precise positions in a mold cavity of a mold frame to construct a three-dimensional model construction of a microfluidic flow path network preferably having meso-scale dimensions. A hardenable liquid, such as poly (dimethylsiloxane) is then introduced into the mold cavity and hardened to form a platform structure as well as to mold the microfluidic flow path network having channels, reservoirs and ports. Pre-fabricated elbows, T'"'"'s and other joints are used to interconnect various building block elements together. After hardening the liquid the building blocks are removed from the platform structure to make available the channels, cavities and ports within the platform structure. Microdevices may be embedded within the cast polymer-based platform, or bonded to the platform structure subsequent to molding, to create an integrated microfluidic system. In this manner, the new microfluidic platform is versatile and capable of quickly generating prototype systems, and could easily be adapted to a manufacturing setting.
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Citations
64 Claims
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1. A method of forming a microfluidic system platform comprising the steps of:
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providing a mold frame having frame walls surrounding a mold cavity;
providing a set of mold forms for use in molding hollow microfluidic features, the set of mold forms comprising elongated mold forms for use in molding microfluidic channels, and block mold forms for use in molding microfluidic cavities;
constructing a three-dimensional model construction of a microfluidic flow path network in the mold cavity by interconnecting mold forms selected from the set of mold forms and suspending the model construction in the mold cavity via the frame walls;
introducing a hardenable liquid into the mold cavity to immerse the model construction thereby;
hardening the liquid to form (1) a platform structure having a shape of the mold cavity and (2) the microfluidic flow path network in the platform structure having a seamless shape of the model construction and including at least two access ports for enabling fluidic communication with the formed microfluidic flow path network; and
removing the model construction from the platform structure through the at least two access ports so as to avail the formed microfluidic flow path network. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 37, 38, 39, 40, 41, 42, 43, 44, 45, 47, 48, 49, 50, 51, 52, 53, 54)
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17. A method of forming an integrated microfluidic system comprising the steps of:
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providing a mold frame having frame walls surrounding a mold cavity;
providing a set of mold forms for use in molding hollow microfluidic features, the set of mold forms comprising elongated mold forms for use in molding microfluidic channels, and block mold forms for use in molding microfluidic cavities;
constructing a three-dimensional model construction of a microfluidic flow path network in the mold cavity by interconnecting mold forms selected from the set of mold forms and suspending the model construction in the mold cavity via the frame walls;
introducing a hardenable liquid into the mold cavity to immerse the model construction thereby;
hardening the liquid to form (1) a platform structure having a shape of the mold cavity and (2) the microfluidic flow path network in the platform structure having a seamless shape of the model construction and including at least two access ports for enabling fluidic communication with the formed microfluidic flow path network;
removing the model construction from the platform structure through the at least two access ports so as to avail the formed microfluidic flow path network; and
connecting a pre-formed microdevice to the platform structure so that fluidic communication is established with the formed microfluidic flow path network via at least one of the at least two access ports of the platform structure.
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36. A system for mold-forming a microfluidic system platform, the system comprising:
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a mold frame having frame walls surrounding a mold cavity;
a set of interconnectable mold forms for use in molding hollow microfluidic features, the set of mold forms comprising elongated mold forms for use in molding microfluidic channels, and block mold forms for use in molding microfluidic cavities; and
a three-dimensional model construction of a microfluidic flow path network suspended in the mold cavity via the frame walls and comprising releasably interconnected mold forms selected from the set of interconnectable mold forms, wherein, upon introducing and hardening a hardenable liquid in the mold cavity, a platform structure may be mold-formed having a shape of the mold cavity, and the microfluidic flow path network may be mold-formed in the platform structure having a shape of the model construction and having at least two access ports through which the model construction may be removed.
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46. A microfluidic system platform comprising:
a molded structure having a seamless three-dimensional microfluidic flow path network molded therein, the microfluidic flow path network including at least two molded access ports for enabling fluidic communication with the microfluidic flow path network.
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55. An integrated microfluidic system comprising:
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a molded structure having a seamless three-dimensional microfluidic flow path network molded therein, the microfluidic flow path network including at least two molded access ports for enabling fluidic communication with the microfluidic flow path network; and
at least one pre-formed microdevice externally connected to the molded structure to establish fluidic communication with the microfluidic flow path network through at least one of the access ports. - View Dependent Claims (56, 57, 58, 59, 60, 61, 62, 63, 64)
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Specification