Multi-layer microfluidic devices

• US 6,648,015 B1
• Filed: 10/03/2002
• Issued: 11/18/2003
• Est. Priority Date: 01/20/1998
• Status: Expired due to Term

• Current Assignee: Caliper Technologies Corp (Revvity, Inc.)
• Original Assignee: Caliper Technologies Corp (Revvity, Inc.)
• Inventors: Chow, Calvin Y. H.
• Primary Examiner(s): CHAMBERS, A MICHAEL
• Application Number:
  US10/265,202
• Time in Patent Office: 411 Days
• Field of Search: 137/827, 137/833, 137/551, 137/557, 204/601, 251/367
• US Class Current: 137/557
• CPC Class Codes: B01J 19/0093 Microreactors, e.g. miniaturised or microfabricated reactors laboratory containers with capillary fluid transport in microfabricated channels or chambers B01L3/5027
• CPC Class Codes: B01J 2219/00317 Microwell devices, i.e. having large numbers of wells
• CPC Class Codes: B01J 2219/00351 Means for dispensing and evacuation of reagents
• CPC Class Codes: B01J 2219/00587 High throughput processes
• CPC Class Codes: B01J 2219/00702 Processes involving means for analysing and characterising the products
• CPC Class Codes: B01J 2219/00783 Laminate assemblies, i.e. the reactor comprising a stack of plates
• CPC Class Codes: B01L 2200/16 Reagents, handling or storing thereof
• CPC Class Codes: B01L 2300/0816 Cards, e.g. flat sample carriers usually with flow in two horizontal directions
• CPC Class Codes: B01L 2300/0864 comprising only one inlet and multiple receiving wells, e.g. for separation, splitting
• CPC Class Codes: B01L 2300/0867 Multiple inlets and one sample wells, e.g. mixing, dilution
• CPC Class Codes: B01L 2300/0874 Three dimensional network
• CPC Class Codes: B01L 2300/0887 Laminated structure
• CPC Class Codes: B01L 2400/0415 electrical forces, e.g. electrokinetic
• CPC Class Codes: B01L 2400/0418 electro-osmotic flow [EOF]
• CPC Class Codes: B01L 2400/0487 fluid pressure, pneumatics
• CPC Class Codes: B01L 3/5027 by integrated microfluidic structures, i.e. dimensions of channels and chambers are such that surface tension forces are important, e.g. lab-on-a-chip B01L3/5023 takes precedence; micromixers B01F33/30; microreactors for synthesis B01J19/0093; microcapillary devices in general B81B1/00
• 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 2201/047 Optical MEMS not provided for in B81B2201/042 - B81B2201/045
• CPC Class Codes: B81B 2201/058 Microfluidics not provided for in B81B2201/051 - B81B2201/054
• CPC Class Codes: B81C 1/00119 : Arrangement of basic structures like cavities or channels, e.g. suitable for microfluidic systems
• CPC Class Codes: B81C 2201/019 : Bonding or gluing multiple substrate layers
• CPC Class Codes: C40B 60/14 : for creating libraries
• CPC Class Codes: G01N 27/44791 : Microapparatus sample containers with integrated microfluidic structures B01L3/5027
• CPC Class Codes: Y10S 366/03 : Micromixers: variable geometry from the pathway influences mixing/agitation of non-laminar fluid flow
• CPC Class Codes: Y10T 137/2191 : By non-fluid energy field affecting input [e.g., transducer]
• CPC Class Codes: Y10T 137/2224 : Structure of body of device
• CPC Class Codes: Y10T 137/7897 : Vacuum relief type
• CPC Class Codes: Y10T 137/8158 : With indicator, register, recorder, alarm or inspection means
• CPC Class Codes: Y10T 137/8326 : Fluid pressure responsive indicator, recorder or alarm
• CPC Class Codes: Y10T 137/8359 : Inspection means

Abstract

The present invention provides multi-layer microfluidic systems, by providing additional substrate layers, e.g., third, fourth, fifth and more substrate layers, mated with the typically described first and second layers. Microfabricated elements, e.g., grooves, wells and the like, are manufactured into the surfaces between the various substrate layers. These microfabricated elements define the various microfluidic aspects or structures of the overall device, e.g., channels, chambers and the like. In preferred aspects, a separate microscale channel network is provided between each of the substrate layers.

Claims

1. A multi-layered microfluidic device comprising:

a body structure comprising at least first, second and third substrate layers mated together, the second substrate layer being disposed between the first and third substrate layers;

at least a first microscale channel segment disposed in the second substrate layer;

at least a first port disposed through the first substrate layer, the at least first port being fluidly coupled to the at least first microscale channel segment; and

detection means associated with said body structure for detecting a detectable signal from the at least first microscale channel segment or for transmitting a detectable signal from the at least first microscale channel segment to the exterior of the body structure.

2. The microfluidic device of claim 1, further comprising at least a second microscale channel segment disposed in the third substrate layer.

3. The microfluidic device of claim 2, further comprising at least a second port disposed through both the second substrate layer and the first substrate layer and which is fluidly coupled to the at least second channel segment.

4. The microfluidic device of claim 3, wherein the at least second port is fluidly coupled to the at least first channel segment.

5. The microfluidic device of claim 3, wherein the at least first port is disposed through the first substrate layer but not through the second substrate layer.

6. The microfluidic device of claim 2, wherein the at least first port is disposed through at least both the first and second substrate layers.

7. The microfluidic device of claim 6, wherein the at least first port is disposed through the first, second and third substrate layers.

8. The microfluidic device of claim 6, wherein the at least first port is fluidly coupled to both the at least second channel segment and the at least first channel segment.

9. The microfluidic device of claim 2, wherein said detection means comprises at least first and second detection windows on the body structure that are capable of transmitting a detectable signal from the first and second microscale channel segments respectively to the exterior of the body structure.

10. The microfluidic device of claim 1, further comprising at least a second microscale channel segment disposed in the second substrate layer.

11. The microfluidic device of claim 10, wherein the at least first channel segment is disposed on a top surface of the second substrate layer and the at least second channel segment is disposed on a bottom surface of the second substrate layer.

12. The microfluidic device of claim 1, wherein the at least first port comprises a diameter within the range of about 30 μ

m to about 500 μ

m.

13. The microfluidic device of claim 1, wherein the at least first port comprises a diameter within the range of about 30 μ

m to about 250 μ

m.

14. The microfluidic device of claim 1, wherein the at least first port comprises a diameter within the range of about 30 μ

m to about 100 μ

m.

15. The microfluidic device of claim 1, further comprising at least a fourth substrate layer mated to the first or third substrate layer.

16. The microfluidic device of claim 1, wherein the at least first microscale channel segment has at least one cross-sectional dimension between about 0.1 and 200 microns.

17. The microfluidic device of claim 1, wherein the at least first microscale channel segment has at least one cross-sectional dimension between about 0.1 and 100 microns.

18. The microfluidic device of claim 1, wherein at least one of the first, second and third substrate layers is made from a polymeric material.

19. The microfluidic device of claim 1, wherein at least one of the first, second and third substrate layers is made from glass.

20. The microfluidic device of claim 1, wherein the first, second and third substrate layers are mated together with an adhesive.

21. The microfluidic device of claim 1, wherein the second substrate layer includes an interconnected microscale channel network that includes the at least first microscale channel segment.

22. The microfluidic device of claim 1, further comprising a plurality of ports disposed through the first substrate layer.

23. The microfluidic device of claim 1, further comprising a plurality of ports disposed through the first substrate layer, at least one of the plurality of ports not being fluidly coupled to the at least first microscale channel segment.

24. The microfluidic device of claim 1, wherein said detection means comprises a detection window on the body structure that is capable of transmitting a detectable signal from the at least first microscale channel segment to the exterior of the body structure.

25. The microfluidic device of claim 1, wherein said detection means comprises at least one of the following located within sensory communication of the at least first microscale channel segment:

an optical sensor, an electrochemical sensor, a pressure sensor, and a pH sensor.