Method of forming articles including waveguides via capillary micromolding and microtransfer molding

• US 6,355,198 B1
• Filed: 01/08/1998
• Issued: 03/12/2002
• Est. Priority Date: 03/15/1996
• Status: Expired due to Term

• Current Assignee: President and Fellows of Harvard College (Harvard Corporation)
• Original Assignee: President and Fellows of Harvard College (Harvard Corporation)
• Inventors: Whitesides, George M., Xia, Younan, Kim, Enoch, Prentiss, Mara G., Jackman, Rebecca J., Mrksich, Milan, Smith, Stephen P., Marzolin, Christian, Zhao, Xiao-Mei
• Primary Examiner(s): THEISEN, MARY LYNN F
• Application Number:
  US09/004,583
• Time in Patent Office: 1,524 Days
• Field of Search: 264/112, 264/299, 264/330, 264/259
• US Class Current: 264/259
• CPC Class Codes: A61K 47/6957 the form being a device or a kit, e.g. stents or microdevices
• 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 2219/00382 Stamping
• CPC Class Codes: B01J 2219/00416 Vacuum
• CPC Class Codes: B01J 2219/0043 for direct application of reagents, e.g. through openings in a shutter
• CPC Class Codes: B01J 2219/00466 in a slurry
• CPC Class Codes: B01J 2219/00605 the compounds being directly bound or immobilised to solid supports
• CPC Class Codes: B01J 2219/0061 The surface being organic
• CPC Class Codes: B01J 2219/00612 the surface being inorganic
• CPC Class Codes: B01J 2219/00619 using hydrophilic or hydrophobic regions
• CPC Class Codes: B01J 2219/00626 Covalent
• CPC Class Codes: B01J 2219/0063 Other, e.g. van der Waals forces, hydrogen bonding
• CPC Class Codes: B01J 2219/00637 by coating it with another layer
• CPC Class Codes: B01J 2219/00648 by the use of solid beads
• CPC Class Codes: B01J 2219/00659 Two-dimensional arrays
• CPC Class Codes: B01J 2219/00713 Electrochemical synthesis
• CPC Class Codes: B29C 31/04 Feeding of the material to be moulded, e.g. into a mould cavity B29C39/08 takes precedence; using a material distribution system to two or more fixed injection moulds B29C45/125
• CPC Class Codes: B29C 33/42 characterised by the shape of the moulding surface, e.g. ribs or grooves
• CPC Class Codes: B29C 37/0053 Moulding articles characterised by the shape of the surface, e.g. ribs, high polish mould construction therefor B29C33/42; surface shaping of articles B29C59/00; by incorporating filler in or near the surface B29C70/64
• CPC Class Codes: B29C 39/24 Feeding the material into the mould
• CPC Class Codes: B29C 43/021 : characterised by the shape of the surface
• CPC Class Codes: B29C 67/246 : Moulding high reactive monomers or prepolymers, e.g. by reaction injection moulding [RIM], liquid injection moulding [LIM] casting monomers B29C39/006, mixing construction B29B7/74
• CPC Class Codes: B29D 11/00346 : having nanosize structures or features, e.g. fillers
• CPC Class Codes: B29D 11/00663 : Production of light guides
• CPC Class Codes: B29K 2105/0002 : monomers or prepolymers
• CPC Class Codes: B29L 2011/0016 : Lenses
• CPC Class Codes: B81B 2201/0214 : Biosensors; Chemical sensors
• CPC Class Codes: B81C 1/00031 : Regular or irregular arrays of nanoscale structures, e.g. etch mask layer photomechanical, e.g. photolithographic, production of textured or patterned surfaces G03F7/00; lithographic processes for making patterned surfaces using printing and stamping G03F7/0002
• CPC Class Codes: B81C 1/00206 : Processes for functionalising a surface, e.g. provide the surface with specific mechanical, chemical or biological properties
• CPC Class Codes: B81C 2201/034 : Moulding
• CPC Class Codes: B81C 99/0085 : using moulds and master templates, e.g. for hot-embossing
• CPC Class Codes: B82Y 30/00 : Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: C40B 60/14 : for creating libraries
• CPC Class Codes: G01N 2021/7776 : Index
• CPC Class Codes: G01N 21/7703 : using reagent-clad optical fibres or optical waveguides using measurement of total internal reflection or attenuated total reflection G01N21/552; optical fibres or waveguides per se G02B
• CPC Class Codes: G02B 6/138 : by using polymerisation
• CPC Class Codes: H05K 3/0079 : characterised by the method of application or removal of the mask H05K3/0091 takes precedence
• CPC Class Codes: H05K 3/061 : Etching masks

Abstract

Chemically or biochemically active agents or other species are patterned on a substrate surface by providing a micromold having a contoured surface and forming, on a substrate surface, a chemically or biochemically active agent or fluid precursor of a structure. A chemically or biochemically active agent or fluid precursor also can be transferred from indentations in an applicator to a substrate surface. The substrate surface can be planar or nonplanar. Fluid precursors of polymeric structures, inorganic ceramics and salts, and the like can be used to form patterned polymeric articles, inorganic salts and ceramics, reactive ion etch masks, etc. at the surface. The articles can be formed in a pattern including a portion having a lateral dimension of less than about 1 millimeter or smaller. The indentation pattern of the applicator can be used to transfer separate, distinct chemically or biochemically active agents or fluid precursors to separate, isolated regions of a substrate surface. Waveguide arrays, combinatorial chemical or biochemical libraris, etc. can be made. Differences in refractive index of waveguide and cladding can be created by subjecting the waveguide and cladding, made of indentical prepolymeric material, to different polymerization or cross-linking conditions. Interferometers are defined by coupling arrays of waveguides, where coupling can be controlled by altering the difference in refractive index between cladding and waveguide at any desired location of the array. Alteration and refractive index can be created photochemically, chemically, or the like. Sensors also are disclosed, including biochemical sensors.

Claims

1. A method of creating a pattern of a species at a defined region proximate a substrate surface, comprising:

providing an article having a contoured surface including at least one indentation defining a pattern;

forming at a first region proximate a substrate surface, in a pattern corresponding to the indentation pattern, a fluid precursor of the species; and

allowing the fluid precursor to harden at the first region of the substrate surface, in a pattern corresponding to the indentation pattern and in an area including a portion having a lateral dimension of less than about 1 mm, while leaving a second region proximate the substrate surface, contiguous with the first region, free of the species.

2. A method as in claim 1, wherein the fluid precursor comprises a chemically active agent in a fluid carrier, and the allowing step comprises allowing the fluid carrier to dissipate thereby depositing the chemically active agent at the first region of the substrate surface.

4. A method as in claim 1, wherein the forming step comprises transferring the fluid precursor from the contoured surface of the article to the first region of the substrate surface in the pattern.

5. A method as in claim 1, wherein the forming step comprises transferring the fluid precursor essentially instantaneously from the contoured surface of the article to the first region of the substrate surface.

6. A method as in claim 1, wherein the pattern includes distinct, isolated first and second indentation regions, the forming step comprising transferring at least one fluid precursor from the contoured surface of the article to distinct first and second portions of the substrate surface while leaving an intervening portion of the substrate surface free of the at least one precursor.

7. A method as in claim 6, wherein the transferring step involves transferring the at least one fluid precursor to the first and second portions of the substrate surface simultaneously.

8. A method as in claim 1, wherein the forming step involves positioning the article proximate the substrate surface and applying the fluid precursor to the first region proximate the substrate surface via capillary action involving the at least one indentation.

9. A method as in claim 1, wherein the forming step comprises positioning the contoured surface of the article proximate the substrate surface thereby creating at least one channel defined by the at least one indention and the first region of the substrate surface, and introducing the fluid precursor into the channel thereby positioning the fluid precursor proximate the first region of the substrate surface.

10. A method as in claim 9, involving allowing the fluid precursor to flow, via capillary action, into the channel.

11. A method as in claim 1, wherein the allowing step comprises allowing the fluid precursor to harden in an area including a portion having a lateral dimension of less than about 500 microns.

12. A method as in claim 11, wherein the allowing step comprises allowing the fluid precursor to harden in an area including a portion having a lateral dimension of less than about 100 microns.

13. A method as in claim 12, wherein the allowing step comprises allowing the fluid precursor to harden in an area including a portion having a lateral dimension of less than about 50 microns.

14. A method as in claim 13, wherein the allowing step comprises allowing the fluid precursor to harden in an area including a portion having a lateral dimension of less than about 20 microns.

15. A method as in claim 1, wherein the fluid precursor is a sol-gel.

3. A method as in claimed 2, wherein the chemically active agent is a prepolymeric species and the allowing step comprises forming a polymeric article from the prepolymeric species.