Apparatus to collect, classify, concentrate, and characterize gas-borne particles

• US 6,386,015 B1
• Filed: 12/21/1999
• Issued: 05/14/2002
• Est. Priority Date: 08/30/1999
• Status: Expired due to Fees

• Current Assignee: Sandia Corporation (Martin Marietta Corporation)
• Original Assignee: Sandia Corporation (Martin Marietta Corporation)
• Inventors: Rader, Daniel J., Brockmann, John E., Wally, Karl, Torczynski, John R.
• Primary Examiner(s): LARKIN, DANIEL SEAN
• Application Number:
  US09/469,718
• Time in Patent Office: 875 Days
• Field of Search: 73/233.3, 73/280.1, 73/280.4, 73/280.5, 73/280.6, 73/310.2, 73/310.3, 73/310.5, 73/310.7, 73/530.1, 73/530.7, 73/617.1, 73/617.2, 738/632.1, 738/632.2
• US Class Current: 73/31.05
• CPC Class Codes: G01N 1/2202 involving separation of sample components during sampling
• CPC Class Codes: G01N 1/24 Suction devices G01N1/22 - G01N1/2294 take precedence
• CPC Class Codes: G01N 1/405 by adsorption or absorption
• CPC Class Codes: G01N 2001/2223 aerosol sampling devices

Abstract

An aerosol lab-on-a-chip (ALOC) integrates one or more of a variety of aerosol collection, classification, concentration (enrichment), and characterization processes onto a single substrate or layered stack of such substrates. By taking advantage of modern micro-machining capabilities, an entire suite of discrete laboratory aerosol handling and characterization techniques can be combined in a single portable device that can provide a wealth of data on the aerosol being sampled. The ALOC offers parallel characterization techniques and close proximity of the various characterization modules helps ensure that the same aerosol is available to all devices (dramatically reducing sampling and transport errors). Micro-machine fabrication of the ALOC significantly reduces unit costs relative to existing technology, and enables the fabrication of small, portable ALOC devices, as well as the potential for rugged design to allow operation in harsh environments. Miniaturization also offers the potential of working with smaller particle sizes and lower pressure drops (leading to reduction of power consumption).

Claims

1. An apparatus for manipulating particles comprising an aerosol, said apparatus comprising:

a substrate;

an aerosol inlet for receiving said particles, wherein said aerosol inlet is made on said substrate; and

an aerosol characterization module for providing a signal response corresponding to a property of said particles, wherein said aerosol characterization module is made on said substrate and in fluid communication with said aerosol inlet.

2. The apparatus, of claim 1, further comprising a gas moving means for assisting in drawing a portion of said particles through said apparatus, said gas moving means in fluid communication with said aerosol inlet and said aerosol characterization module.

3. The apparatus, of claim 2, wherein said gas moving means is a mechanical pump, a sorp pump, a fan, or any means for establishing a flow of particles through said apparatus.

4. The apparatus of claim 3, wherein said gas moving means is made on said substrate.

5. The apparatus of claim 1, wherein said apparatus is made by using a micro-machining process.

6. The apparatus of claim 1, further comprising an aerosol preconditioner, said aerosol preconditioner for providing means for classifying, sorting, grouping, concentrating, or focusing a portion of said particles, said aerosol preconditioner located on said substrate, between, and in fluid communication with, of said aerosol inlet and said aerosol characterization module.

7. The apparatus of claim 6, wherein said apparatus is made by using a micro-machining process.

8. The apparatus of claim 6, wherein said substrate comprises a plurality of substrates.

9. The apparatus of claim 8, wherein said plurality of substrates is a layered stack of substrates.

10. The apparatus of claim 9, wherein said apparatus is made by using a micro-machining process.

11. The apparatus of claim 1, further including one or more support components selected from the group consisting of an active process controller, a signal processor/data analyzer, and a telemetry unit, and combinations thereof, wherein said support components are in electrical communication with each other and with said aerosol characterization module, and wherein further said support components are made on said substrate.

12. The apparatus of claim 11, further including a gas moving means selected from the group consisting of a mechanical pump, a sorp pump, a fan, and equivalent means for establishing a flow of particles through said apparatus, said gas moving means in fluid communication with said aerosol inlet and said aerosol characterization module.

13. The apparatus of claim 11, wherein said apparatus is made by using a micro-machining process.

14. The apparatus of claim 11, wherein said substrate comprises a plurality of substrates.

15. The apparatus of claim 14, wherein said plurality of substrates is a layered stack of substrates.

16. The apparatus of claim 15, wherein said apparatus is made by using a micro-machining process.

17. The apparatus of claim 12, wherein said process controller comprises integrated microcircuitry devices selected from the group consisting of sensors, control devices, flow handling devices, and combinations thereof, said sensors, control devices, and flow handling devices collectively acting to control flow through and operation of said apparatus, said sensors, control devices, and flow handling devices in electrical communication with said characterization module and said gas moving means.

18. The apparatus of claim 11, wherein said signal processor includes integrated microcircuitry to receive a digital or analog signal generated by said aerosol characterization module, to arithmetically manipulate and interpret said digital or analog signal so as to provide a predefined output response and to provide said output response to said telemetry unit.

19. The apparatus of claim 11, further including a source of electrical power.

20. The apparatus of claim 12, further including a source of electrical power.

21. The apparatus of claim 6, further including one or more support components selected from the group consisting of an active process controller, a signal processor/data analyzer, and a telemetry unit, and combinations thereof, wherein said support components are in electrical communication with each other and with said aerosol preconditioner and said aerosol characterization module, and wherein further said support components are made on said substrate.

22. The apparatus of claim 21, further including a gas moving means selected from the group consisting of a mechanical pump, a sorp pump, a fan, and equivalent means for establishing a flow of particles through said apparatus, said gas moving means in fluid communication with said aerosol inlet, said aerosol preconditioner, and said aerosol characterization module.

23. The apparatus of claim 21, wherein said apparatus is made by using a micro-machining process.

24. The apparatus of claim 21, wherein said substrate comprises a plurality of substrates.

25. The apparatus of claim 24, wherein said plurality of substrates is a layered stack of substrates.

26. The apparatus of claim 25, wherein said apparatus is made by using a micro-machining process.

27. The apparatus of claim 22, wherein said active process controller comprises integrated microcircuitry devices selected from the group consisting of sensors, control devices, flow handling devices, and combinations thereof, said sensors, control devices, and flow handling devices collectively acting to control flow through and operation of said apparatus, said sensors, control devices, and flow handling devices in electrical communication with said preconditioner, said characterization module, and said gas moving means.

28. The apparatus of claim 21, wherein the signal processor includes integrated microcircuitry to receive a digital or analog signal generated by said aerosol characterization module, to arithmetically manipulate and interpret said digital or analog signal so as to provide a predefined output response and to provide said output response to said telemetry unit.

29. The apparatus of claim 21, further including a source of electrical power.

30. The apparatus of claim 22, further including a source of electrical power.

31. The apparatus of claim 1, additionally including at least a second aerosol characterization module on said substrate, wherein said aerosol characterization modules are combined either in parallel or in series to enable simultaneous analysis of a plurality of properties of said particles.

32. The apparatus of claim 31, wherein said substrate is a layered stack of substrates.

33. The apparatus of claim 32, wherein said apparatus is made by using a micro-machining process.

34. The apparatus of claim 6, further comprising a plurality of aerosol preconditioners and a plurality of associated aerosol characterization modules wherein said aerosol preconditioners and said associated aerosol characterization modules are arranged in an array made on said substrate.

35. The apparatus of claim 34, wherein said substrate is a layered stack of substrates.

36. The apparatus of claim 35, wherein said apparatus is made by using a micro-machining process.

37. An aerosol lab-on-a-chip (ALOC) device made by the method comprising the steps of:

providing a substrate;

forming an aerosol inlet on said substrate, said aerosol inlet for receiving particles comprising an aerosol; and

forming at least one aerosol characterization module on said substrate, wherein said aerosol inlet and said at least one aerosol characterization module are in fluid communication, said aerosol characterization module for providing a signal response corresponding to a property of said particles.

38. The device made by the method of claim 37, further including the step of providing a gas moving means for assisting in drawing at least some of said particles through said device, wherein said gas moving means is selected from the group consisting of a mechanical pump, a sorp pump, a fan, or equivalent means, and wherein said aerosol inlet, said at least one aerosol characterization module and said gas moving means are in fluid communication.

39. The device made by the method of claim 37, wherein said steps of forming are carried out using a micromachining process.

40. The device made by the method of claim 38, further including the step of forming at least one aerosol preconditioner on said substrate, wherein said preconditioner is located between, and in fluid communication with, said aerosol inlet and said at least one aerosol characterization module.

41. The device made by the method of claim 40, wherein said step of forming is carried out using a micromachining process.

42. The device made by the method of claim 40, wherein said step of forming at least one aerosol preconditioner on said substrate further includes forming said aerosol inlet, said at least one aerosol preconditioner, and said at least one aerosol characterization module on a layered stack of substrates.

43. The device made by the method of claim 42, wherein said steps of forming are carried out using a micromachining process.

44. The device made by the method of claim 40, wherein said step of forming at least one aerosol preconditioner on said substrate further includes the step of forming one or more support components selected from the group consisting of a process controller, a signal processor, and a telemetry unit, and combinations thereof, said support components in electrical communication with each other and with said at least one aerosol preconditioner and said at least one aerosol characterization module.

45. The device made by the method of claim 44, wherein said step of forming said process controller comprises forming one or more integrated microcircuitry devices selected from the group consisting of sensors, control devices, flow handling devices, and combinations thereof, said sensors, control devices, and flow handling devices collectively acting to control said gas flow through, and operation of, said ALOC device, said sensors, control devices, and flow handling devices in electrical communication with said at least one aerosol characterization module and said at least one aerosol preconditioner.

46. The device made by the method of claim 44, wherein said step of forming said signal processor includes forming one or more integrated microcircuitry devices to receive a digital or analog signal generated by said characterization module, to arithmetically manipulate and interpret said signal so as to provide a predefined output response, and to output said response to said telemetry.

47. The device made by the method of claim 44, further including the step of providing a source of electrical power.

48. The device made by the method of claim 44, wherein said steps of forming are carried out using a micromachining process.

49. The device made by the method of claim 42, wherein said step of forming at least one aerosol preconditioner on said substrate further includes the step of forming one or more support components selected from the group consisting of a process controller, a signal processor, and a telemetry unit, and combinations thereof, said support components in electrical communication with each other and with said at least one aerosol preconditioner and said at least one aerosol characterization module.

50. The device made by the method of claim 49, further including the step of providing a gas moving means, wherein said gas moving means is selected from the group consisting of a mechanical pump, a sorp pump, a fan, and equivalent means for establishing a flow of particles through said device, and wherein said gas moving means is in fluid communication with said aerosol inlet, said at least one aerosol preconditioner, and said at least one aerosol characterization module.

51. The device made by the method of claim 49, wherein said step of forming said process controller comprises forming one or more integrated microcircuitry devices selected from the group consisting of sensors, control devices, flow handling devices, and combinations thereof, said sensors, control devices, and flow handling devices collectively acting to control flow into said at least one aerosol characterization module, said sensors, control devices, and flow handling devices in electrical communication with said at least one aerosol preconditioner and said at least one aerosol characterization module.

52. The device made by the method of claim 49, wherein said step of forming said signal processor includes forming one or more integrated microcircuitry devices to receive a digital or analog signal generated by said characterization modules, to arithmetically manipulate and interpret said signal so as to provide a predefined output response, and to output said response to said telemetry.

53. The device made by the method of claim 49, further including the step of providing a source of electrical power.

54. The device made by the method of claim 49, wherein said step of forming is carried out using a micromachining process.

55. The device made by the method of claim 37, additionally including the step of forming at least a second aerosol characterization module on said substrate, wherein said aerosol characterization modules are combined in either in parallel or in series to enable simultaneous analysis of a plurality of properties of said particles.

56. The device made by the method of claim 40, further comprising the step of forming a plurality of aerosol preconditioners and a plurality of associated aerosol characterization modules on said substrate wherein said plurality of aerosol preconditioners and said plurality of associated aerosol characterization modules are arranged in an array.

57. The device made by the method of claim 42, further comprising the step of forming a plurality of aerosol preconditioners and a plurality of associated aerosol characterization modules on said layered stack of substrates, wherein said plurality of aerosol preconditioners and said plurality of associated aerosol characterization modules are arranged in an array.

58. An aerosol lab-on-a-chip (ALOC) machine comprising:

a plurality of devices comprising;

an aerosol inlet for receiving particles comprising an aerosol; and

an aerosol characterization module for providing a signal response corresponding to a property of an individual particle or collection of particles, said aerosol characterization module in fluid communication with said aerosol inlet;

wherein, said devices are arranged in an array fashion and wherein each said device is linked to one or more other devices either in parallel or in series.

59. The machine of claim 58, wherein said devices are fabricated by a micro-machining process and formed onto a single substrate or a layered stack of substrates.

60. The machine of claim 58, further comprising a gas moving means seleted from the group consisting of a mechanical pump, a sorp pump, a fan, and equivalent means for establishing a flow of particles through said machine.

61. The machine of claim 58, additionally including:

a process controller formed on said substrate and operatively connected to said array of devices;

a signal processor formed on said substrate and in communication with said plurality of aerosol characterization modules; and

a telemetry unit formed on said substrate and operatively connected to said signal processor.