Mobile monolithic polymer elements for flow control in microfluidic devices

• US 6,988,402 B2
• Filed: 09/04/2003
• Issued: 01/24/2006
• Est. Priority Date: 10/24/2000
• Status: Expired due to Term

• Current Assignee: National Technology & Engineering Solutions Of Sandia LLC (Honeywell International Inc.)
• Original Assignee: Sandia National Laboratories (Government of the United States of America)
• Inventors: Rehm, Jason E., Kirby, Brian J., Shepodd, Timothy J., Hasselbrink, Ernest F. Jr.
• Primary Examiner(s): Lefkowitz, Edward
• Assistant Examiner(s): THOMPSON, JEWEL VERGIE
• Application Number:
  US10/655,337
• Publication Number:
  US 20050097951A1
• Time in Patent Office: 873 Days
• Field of Search: 732/53, 210/635, 210/656, 428/375, 96/1, 204/157.15, 204/450, 427/115
• US Class Current: 73/253
• CPC Class Codes: F15C 5/00 Manufacture of fluid circuit elements; Manufacture of assemblages of such elements integrated circuits
• CPC Class Codes: F16K 2099/0074 using photolithography, e.g. etching
• CPC Class Codes: F16K 2099/0084 Chemistry or biology, e.g. "lab-on-a-chip" technology
• CPC Class Codes: F16K 99/0001 Microvalves microdevices B81B1/00; manufacture or treatment of devices or systems in or on a substrate B81C1/00; microfluidic structures B01L3/5027; micropumps F04B19/006
• CPC Class Codes: F16K 99/0005 Lift valves
• CPC Class Codes: F16K 99/0011 Gate valves or sliding valves
• CPC Class Codes: F16K 99/0017 Capillary or surface tension valves, e.g. using electro-wetting or electro-capillarity effects
• CPC Class Codes: F16K 99/003 Valves for single use only
• CPC Class Codes: F16K 99/0034 Operating means specially adapted for microvalves
• CPC Class Codes: F16K 99/004 using radiation
• CPC Class Codes: F16K 99/0044 using thermo-electric means
• CPC Class Codes: F16K 99/0051 using electrostatic means
• CPC Class Codes: F16K 99/0057 the fluid being the circulating fluid itself, e.g. check valves
• CPC Class Codes: F16K 99/0059 actuated by a pilot fluid
• CPC Class Codes: G01F 3/06 comprising members rotating in a fluid-tight or substantially fluid-tight manner in a housing
• CPC Class Codes: G01F 3/24 with measuring chambers moved during operation wet gas-meters G01F3/30
• CPC Class Codes: Y10T 428/2933 Coated or with bond, impregnation or core

Abstract

A cast-in-place and lithographically shaped mobile, monolithic polymer element for fluid flow control in microfluidic devices and method of manufacture. Microfluid flow control devices, or microvalves that provide for control of fluid or ionic current flow can be made incorporating a cast-in-place, mobile monolithic polymer element, disposed within a microchannel, and driven by fluid pressure (either liquid or gas) against a retaining or sealing surface. The polymer elements are made by the application of lithographic methods to monomer mixtures formulated in such a way that the polymer will not bond to microchannel walls. The polymer elements can seal against pressures greater than 5000 psi, and have a response time on the order of milliseconds. By the use of energetic radiation it is possible to depolymerize selected regions of the polymer element to form shapes that cannot be produced by conventional lithographic patterning and would be impossible to machine.

Claims

1. A method for making a mobile, monolithic polymer element in a microchannel, comprising;

a) injecting a monomer mixture dissolved in a solvent into the microchannel, wherein the composition of the monomer mixture is such that the polymer formed by polymerizing the monomer does not bond to the microchannel wall;

b) polymerizing the monomer by application of radiation; and

c) flushing unpolymerized monomer mixture from the microchannel.

2. The method of claim 1, wherein the radiation is UV, visible, or infrared radiation.

8. A device for controlling fluid flow in a microchannel, comprising

a mobile monolithic polymer element disposed in the microchannel, wherein said polymer element is made by the method of claim 1;

at least one retaining means disposed in the microchannel; and

means for applying a displacing force to the either end of the microchannel.

3. A method for making a monolithic polymer element in a microchannel such that the polymer element conforms to the configuration of the microchannel and does not bond to the microchannel wall, comprising the steps of:

preparing a monomer mixture comprising at least;

a cross-linking agents selected from the group including ethylene glycol diacrylate, diethylene glycol diacrylate, propylene glycol diacrylate, butanediol diacrylate, neopentyl glycol diacrylate, hexanediol diacrylate, pentaerythritol triacrylate, pentaerythritol tetracrylate, trimethylolpropane triacrylate,

a nonpolar monomer selected from the group branched or straight chain C₁–

C₁₂ alkyl acrylates, fluorinated or methacrylate versions of these monomers, or styrene, and

a monomer capable of carrying a charge at a pH of between about 2 and 12 selected from the group including C₁–

C₁₂ alkyl or aryl acrylates substituted with sulfonate, phosphate, boronate, carboxylate, amine, or ammonium;

adding the monomer mixture to a solvent, comprising at least;

one of the group including C₁–

C₆ alcohols, C₄–

C₈ ethers, C₃–

C₆ esters, C₁–

C₄ esters, C₁–

C₄ carboxylic acids, methyl sulfoxide, sulfolane, or N-methyl pyrrolidone, dioxane, dioxolane, or acetronitrile, and

a polymerization initiator, wherein the monomer/solvent mixture forms a single phase mixture at a temperature below about 40°

C., and wherein the monomer to solvent ratio is between about 90;

10 to 30;

70;

loading the mixture into a capillary tube;

polymerizing the mixture by exposing at least a potion of the mixture to radiation; and

flushing unpolymerized monomer from the microchannel.

4. The method of claim 3, wherein the portion of the monomer mixture exposed to radiation is defined by focusing a point or collimated source of radiation into the shape desired for polymerization.

5. The method of claim 3, wherein the portion of the monomer mixture exposed to radiation is defined by a mask.

6. The method of claim 3, wherein the radiation includes thermal, visible, or UV radiation, and wherein the wavelength of the UV radiation is equal to or greater than about 257 nm.

7. A mobile polymer monolith disposed in a microchannel and made by the method of claim 3.

9. A method for making a shaped monolithic polymer element disposed within a microchannel, comprising:

a) injecting a monomer mixture dissolved in a solvent into the microchannel, wherein the composition of the monomer mixture is such that the polymer formed by polymerizing the monomer does not bond to the microchannel wall;

b) polymerizing the monomer by application of radiation;

c) flushing unpolymerized monomer mixture from the microchannel;

d) exposing the surface of the polymer element to radiation to depolymerize a portion of the surface and thereby shape the polymer element; and

flushing the microchannel with a liquid to remove depolymerized material.

10. The method of claim 9, wherein the source of radiation is a laser.

11. The method of claim 10, wherein the laser is a frequency doubled Argon-ion laser operating at 257 nm.

12. A method of making a mobile, monolith polymer element in a microchannel, comprising:

a) preparing a monomer mixture by mixing together 1,3-butanedioldiacrylate, tetrahydrofurfuryl acrylate, hexyl acrylate, acryloyloxyethyltrimethylammonium methyl sulfate, and a photoinitiator;

b) preparing a solvent mixture by mixing together acetonitrile, methoxyethanol, and phosphate buffer;

c) mixing together the monomer and solvent mixtures in the ratio of about 60;

40 by volume;

d) loading the combined mixture into a microchannel;

e) polymerizing the combined mixture by exposure to UV radiation; and

,

f) flushing unreacted monomer from the microchannel.

13. A mobile monolithic polymer element disposed within a microchannel made by the method of claim 12.

17. A device for controlling fluid flow in a microchannel, comprising

a mobile monolithic polymer element disposed in the microchannel, wherein said polymer element is made by the method of either claim 12 or claim 14;

spaced apart retaining means disposed in the microchannel;

a bypass duct; and

means for applying a displacing force to the either end of the microchannel.

14. A method of making a mobile monolithic polymer element in a microchannel, comprising:

a) preparing a monomer/solvent mixture by combining together

pentaerythritol triacrylate (PETRA),

hyroquinone monomethyl ether,

1-propanol, and

an amount of photo-initiator equal to about 0.5% of the weight of the PETRA;

b) injecting the monomer/solvent mixture into a microchannel; and

c) photopolymerizing the mixture.

15. The method of claim 14, wherein the photo-initiator is 2,2′

-azobisisobutyronitrile.

16. A mobile monolithic polymer element disposed within a microchannel made by the method of claim 14.