Polymeric Fluid Transfer and Printing Devices

• US 20080279727A1
• Filed: 03/01/2006
• Published: 11/13/2008
• Est. Priority Date: 03/01/2005
• Status: Abandoned Application

• Current Assignee: Robert C. Haushalter
• Original Assignee: Robert C. Haushalter
• Inventors: Haushalter, Robert C.
• Application Number:
  US11/817,560
• Publication Number:
  US 20080279727A1
• Time in Patent Office: Days
• US Class Current: 422/100
• CPC Class Codes: B01J 19/0046 Sequential or parallel reactions, e.g. for the synthesis of polypeptides or polynucleotides; Apparatus and devices for combinatorial chemistry or for making molecular arrays synthesis methods per se C40B50/00
• CPC Class Codes: B01J 2219/00317 Microwell devices, i.e. having large numbers of wells
• CPC Class Codes: B01J 2219/00385 Printing
• CPC Class Codes: B01J 2219/00387 Applications using probes
• CPC Class Codes: B01J 2219/00527 Sheets
• CPC Class Codes: B01J 2219/00585 Parallel processes
• CPC Class Codes: B01J 2219/00596 Solid-phase processes
• CPC Class Codes: B01J 2219/00605 the compounds being directly bound or immobilised to solid supports
• CPC Class Codes: B01J 2219/00659 Two-dimensional arrays
• CPC Class Codes: B01J 2219/00722 Nucleotides
• CPC Class Codes: B01J 2219/00725 Peptides
• CPC Class Codes: B01L 2200/12 Specific details about manufacturing devices
• CPC Class Codes: B01L 3/0248 Prongs, quill pen type dispenser
• CPC Class Codes: B01L 3/0255 characterized by the form or material of the pin tip
• CPC Class Codes: B01L 9/543 for disposable pipette tips, e.g. racks or cassettes
• CPC Class Codes: G01N 2035/1037 Using surface tension, e.g. pins or wires
• CPC Class Codes: G01N 35/1065 Multiple transfer devices

Abstract

A method and apparatus for making a polymeric printhead having one or more pins for fluid transfer and printing, including the steps of forming a positive mold of the printhead using a bulk micromachining process, forming a negative mold of the printhead from the positive mold using an electroforming process, and forming the printhead from a polymeric material in the negative mold, the polymeric printhead being operative for fluid transfer and/or printing. Also, printheads and pins, holders and dispensing trays microfabricated from a polymeric materials for fluid transfer and printing.

Claims

1. An apparatus for fluid transfer, the apparatus comprising:

a pin microfabricated from a polymeric material, the pin for transferring a predetermined volume of a fluid, the pin having a tip and a fluid reservoir communicating with the tip.

2. The apparatus according to claim 1, further comprising a holder microfabricated from a polymeric material, the holder having a first member for holding the pin.

3. The apparatus according to claim 2, wherein the holder further comprises a second member for collimating the pin.

4. The apparatus according to claim 1, further comprising a head member having surfaces for collimating the pin.

5. The apparatus according to claim 1, further comprising a head member and a spring coupling the pin to the head member.

6. The apparatus according to claim 1, further comprising at least a second pin, the pins forming an array.

7. The apparatus according to claim 6, further comprising a dispensing tray microfabricated from a polymeric material, the dispensing tray having an array of wells corresponding to the array of pins, for holding liquid to be transferred by the array of pins.

8. The apparatus according to claim 6, wherein the array of pins comprises up to 100,000 pins.

9. The apparatus according to claim 7, wherein the array of pins comprises up to 100,000 pins.

10. The apparatus according to claim 6, wherein the array of pins form a pin density between about 10⁻

4 and 10⁶ pins/mm².

11. The apparatus according to claim 7, wherein the array of pins form a pin density between about 10⁻

4 and 10⁶ pins/mm².

12. The apparatus according to claim 1, further comprising a head member and at least a second pin, the pins forming an array, the pins of the array unitarily formed with the head member to define a first printhead.

13. The apparatus according to claim 12, further comprising a dispensing tray microfabricated from a polymeric material, the dispensing tray having an array of wells corresponding to the array of pins, for holding liquid to be transferred by the array of pins.

14. The apparatus according to claim 12, wherein the array of pins comprises up to 100,000 pins.

15. The apparatus according to claim 13, wherein the array of pins comprises up to 100,000 pins.

16. The apparatus according to claim 12, wherein the array of pins form a pin density between about 10⁻

4 and 10⁶ pins/mm².

17. The apparatus according to claim 13, wherein the array of pins form a pin density between about 10⁻

4 and 10⁶ pins/mm².

18. The apparatus according to claim 12, further comprising at least a second printhead assembled together with the first printhead to form a two dimensional array of the pins.

19. The apparatus according to claim 18, further comprising a holder for assembling the printheads together.

20. The apparatus according to claim 19, wherein the head members of the printheads are configured to self-align the printheads with the holder.

21. The apparatus according to claim 12, further comprising a holder for holding the first printhead.

22. The apparatus according to claim 21, wherein the head member is configured to self-align the first printhead relative to the holder.

23. The apparatus according to claim 1, wherein the predetermined volume comprises between about 0.1 mL and 10⁻

4 pL.

24. The apparatus according to claim 1, wherein pin is capable of printing a spot having an area of about 10 mm² and 10⁻

6 μ

m².

25. A pin comprising:

a tip; and

a fluid reservoir communicating with the tip,

wherein the pin is microfabricated from a polymeric material and is operative for transferring a predetermined volume of a fluid.

26. The pin according to claim 25, further comprising a head for suspending the pin in a holder.

27. The pin according to claim 26, wherein the tip of the pin is configured for printing or dispensing the fluid.

28. The pin according to claim 25, further comprising a spring opposite the tip for biasing the pin.

29. The pin according to claim 25, wherein the predetermined volume comprises between about 0.1 mL and 10⁻

4 pL.

30. The pin according to claim 25, wherein pin is capable of printing a spot having an area of about 10 mm² and 10⁻

6 μ

m².

31. A holder for use in fluid transfer and printing, the holder comprising:

a first member; and

a first aperture formed in the first member for receiving a microfabricated pin for transferring a predetermined volume of a fluid,

wherein the holder is microfabricated from a polymeric material.

32. The holder according to claim 31, further comprising at least a second aperture to form an array of apertures for receiving a microfabricated array of pins.

33. The holder according to claim 32, wherein the array of apertures comprises up to 100,000 apertures.

34. The holder according to claim 32, wherein the array of apertures form an aperture density between about 10⁻

4 and 10⁶ apertures/mm².

35. The holder according to claim 31, further comprising:

a second member having a second aperture axially aligned with the first aperture.

36. A dispensing tray for use in fluid transfer and printing, the dispensing tray comprising:

a well for holding a fluid to be transferred by a microfabricated pin for transferring a predetermined volume of a fluid,

wherein the tray is microfabricated from a polymeric material.

37. The dispensing tray according to claim 36, further comprising at least a second well to form an array of wells for holding fluid to be transferred by a microfabricated array of pins.

38. The dispensing tray according to claim 37, wherein the array of wells comprises up to 100,000 wells.

39. The dispensing tray according to claim 37, wherein the array of wells form a well density between about 10⁻

4 and 10⁶ wells/mm².

40. A method comprising steps of:

forming a positive mold of an article using a bulk micromachining process;

forming a negative mold of the article from the positive mold using an electroforming process; and

forming the article from a polymeric material in the negative mold, the polymeric article being operative for fluid transfer and printing.

41. The method according to claim 40, wherein the article comprises a pin for transferring a predetermined volume of a fluid.

42. The method according to claim 41, wherein the article further comprises a head member having surfaces for collimating the pin.

43. The method according to claim 41, wherein the article further comprises a head member and a spring coupling the pin to the head member.

44. The method according to claim 41, wherein the article further comprises at least a second pin, the pins forming an array.

45. The method according to claim 44, wherein the array of pins comprises up to 100,000 pins.

46. The method according to claim 44, wherein the array of pins form a pin density between about 10⁻

4 and 10⁶ pins/mm².

47. The method according to claim 41, wherein the predetermined volume comprises between about 0.1 mL and 10⁻

4 pL.

48. The method according to claim 41, wherein pin is capable of printing a spot having an area of about 10 mm² and 10⁻

6 μ

m².

49. The method according to claim 41, wherein the article further comprises a head member and at least a second pin, the pins forming an array, the pins of the array being unitary with the head member to define a first printhead.

50. The method according to claim 49, further comprising the step of assembling at least a second printhead together with the first printhead to form a two dimensional array of the pins.

51. The method according to claim 41, wherein the pin includes a head for suspending the pin in a holder.

52. The method according to claim 51, wherein the pin further includes a tip for printing or dispensing a fluid.

53. The method according to claim 41, further comprising a spring opposite the tip for biasing the pin.

54. The method according to claim 40, wherein the article comprises a fluid dispensing tray, the dispensing tray having a well for holding a fluid to be handled by a microfabricated pin.

55. The method according to claim 54, wherein the dispensing tray further comprises at least a second well to form an array of wells for holding fluid to be handled by a microfabricated array of pins.

56. The method according to claim 55, wherein the array of wells comprises up to 100,000 wells.

57. The method according to claim 55, wherein the array of wells form a well density between about 10⁻

4 and 10⁶ wells/mm².

58. The method according to claim 40, wherein the article comprises a holder comprising a first member and a first aperture formed in the first member for receiving a microfabricated pin.

59. The method according to claim 58, wherein the first member of the holder further comprises at least a second aperture to form an array of apertures for receiving a microfabricated array of pins.

60. The method according to claim 59, wherein the array of apertures comprises up to 100,000 apertures.

61. The method according to claim 59, wherein the array of apertures form an aperture density between about 10⁻

4 and 10⁶ apertures/mm².

62. The method according to claim 40, further comprising the step of removing flashing from the article.

63. The method according to claim 62, wherein the flashing removing step is performed by at least one of die cutting, computer numerical controlled cutting, and grinding.

64. The method according to claim 40, further comprising the step of polishing surfaces of the article.

65. The method according to claim 64, wherein the polishing step is performed by a chemical polishing process.

66. The method according to claim 40, wherein the bulk micromachining process includes the step of micromachining a silicon wafer or substrate to form at least one mold section.

67. The method according to claim 66, wherein the positive first mold forming step further comprises the step of bonding the at least one mold section to a wafer or substrate.

68. The method according to claim 40, wherein the article forming step is performed by a molding process selected from the group consisting of casting, compression molding, stamping, and injection molding.

69. The method according to claim 40, wherein the polymeric material is selected from the group consisting of polycarbonates and polymethylmethacrylates, polyolefins, and polyetherketones.

70. The method according to claim 40, wherein the polymeric material comprises a thermoplastic polymer.

71. The method according to claim 40, wherein the negative second mold is formed of a metal.