Micro-fluidic interconnect

• US 7,004,198 B1
• Filed: 07/20/2004
• Issued: 02/28/2006
• Est. Priority Date: 07/20/2004
• Status: Active Grant

• Current Assignee: National Technology & Engineering Solutions Of Sandia LLC (Honeywell International Inc.)
• Original Assignee: Sandia Corporation (Martin Marietta Corporation)
• Inventors: Okandan, Murat, Galambos, Paul C., Benavides, Gilbert L., Hetherington, Dale L.
• Primary Examiner(s): CHAMBERS, A MICHAEL
• Application Number:
  US10/894,636
• Time in Patent Office: 588 Days
• Field of Search: 137/833, 137/554, 137/827, 251/368, 204/601, 204/606
• US Class Current: 137/827
• CPC Class Codes: B01J 2219/00783 Laminate assemblies, i.e. the reactor comprising a stack of plates
• CPC Class Codes: B01J 2219/0081 Plurality of modules
• CPC Class Codes: B01J 2219/00828 Silicon wafers or plates
• CPC Class Codes: B01L 2200/027 for microfluidic devices
• CPC Class Codes: B01L 2300/0816 Cards, e.g. flat sample carriers usually with flow in two horizontal directions
• 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 3/565 Seals in general F16L
• CPC Class Codes: B01L 9/527 for microfluidic devices, e.g. used for lab-on-a-chip
• 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 137/8242 Electrical

Abstract

An apparatus for simultaneously aligning and interconnecting microfluidic ports is presented. Such interconnections are required to utilize microfluidic devices fabricated in Micro-Electromechanical-Systems (MEMS) technologies, that have multiple fluidic access ports (e.g. 100 micron diameter) within a small footprint, (e.g. 3 mm×6 mm). Fanout of the small ports of a microfluidic device to a larger diameter (e.g. 500 microns) facilitates packaging and interconnection of the microfluidic device to printed wiring boards, electronics packages, fluidic manifolds etc.

Claims

1. A microfluidic interconnect comprising:

a first substrate comprising;

a first upper surface and an opposed first lower surface;

a cavity disposed in the first lower surface, the cavity having a first bounding surface, and a first fluidic opening disposed on the first bounding surface;

a first fluidic pathway disposed within the first substrate, fluidicaily connected to the first fluidic opening;

a second substrate comprising;

a second upper surface and an opposed second lower surface;

an extension disposed on the second upper surface, the extension having a second bounding surface and a second fluidic opening disposed on the second bounding surface;

a second fluidic pathway disposed within the second substrate, fluidically connected to the second fluidic opening;

means for bonding the first lower surface of the first substrate to the second upper surface of the second substrate, the bonding means having a through hole, substantially aligned with the extension on the second upper surface of the second substrate;

the extension and the cavity being dimensioned and spaced to interfit, fluidically connecting the first fluidic opening to the second fluidic opening, thereby fluidically connecting the first fluidic pathway in the first substrate with the second fluidic pathway in the second substrate.

2. The microfluidic interconnect of claim 1 wherein the first substrate further comprises a silicon substrate.

3. The microfluidic interconnect of claim 2 wherein the second substrate further comprises a silicon substrate;

.

4. The microfluidic interconnect of claim 3 wherein the bonding means comprises one or more selected from the group consisting of:

an anodic bond, and a direct bond.

5. The microfluidic interconnect of claim 4 wherein the first substrate further comprises a microfluidic device, in fluid communication with the first fluidic pathway.

6. The microfluidic interconnect of claim 5 wherein the diameter of the first fluidic opening is between about 20 microns and 100 microns.

7. The microfluidic interconnect of claim 6 wherein the diameter of the cavity is between about 100 microns and 500 microns.

8. The microfluidic interconnect of claim 7 wherein the diameter of the extension is between about 100 microns and 500 microns.

9. The microfluidic interconnect of claim 8 wherein the diameter of the second fluidic opening is between about 20 microns and 100 microns.

10. A microfluidic interconnect comprising:

a first substrate comprising;

a first upper surface and an opposed first lower surface;

a cavity disposed in the first lower surface, the cavity having a first bounding surface, and a first fluidic opening disposed on the first bounding surface;

a first fluidic pathway disposed within the first substrate, fluidically connected to the first fluidic opening;

a second substrate comprising;

a second upper surface and an opposed second lower surface;

an extension disposed on the second upper surface, the extension having a second bounding surface and a second fluidic opening disposed on the second bounding surface;

a second fluidic pathway disposed within the second substrate, fluidically connected to the second fluidic opening;

an adhesive layer in contact with the first lower surface of the first substrate and the second upper surface of the second substrate, the adhesive layer having a through hole, substantially aligned with the extension on the second upper surface of the second substrate;

the extension and the cavity being dimensioned and spaced to interfit, fluidically connecting the first fluidic opening to the second fluidic opening, thereby fluidically connecting the first fluidic pathway in the first substrate with the second fluidic pathway in the second substrate.

11. The microfluidic interconnect of claim 10 wherein the first substrate further comprises a silicon substrate.

12. The microfluidic interconnect of claim 11 wherein the second substrate further comprises a silicon substrate.

13. The microfluidic interconnect of claim 12 wherein the adhesive layer comprises one or more materials selected from the group consisting of liquid adhesive, sheet adhesive, double sided adhesive, conductive adhesive, non-conductive adhesive, thermoplastic polymer, thermoset polymer, transfer tape, epoxy, cyanate ester, cyanoacrylate, polyester, polyimide, fusible glass, solder and braze.

14. The microfluidic interconnect of claim 13 wherein the first substrate further comprises a microfluidic device, in fluid communication with the first fluidic pathway.

15. The microfluidic interconnect of claim 14 wherein the diameter of the first fluidic opening is between about 20 microns and 100 microns.

16. The microfluidic interconnect of claim 15 wherein the diameter of the cavity is between about 100 microns and 500 microns.

17. The microfluidic interconnect of claim 16 wherein the diameter of the extension is between about 100 microns and 500 microns.

18. The microfluidic interconnect of claim 17 wherein the diameter of the second fluidic opening is between about 20 microns and 100 microns.

19. A microfluidic interconnect comprising:

a first substrate comprising;

a first upper surface and an opposed first lower surface,

a cavity disposed in the first lower surface, the cavity having a first bounding surface, and a first fluidic opening disposed on the first bounding surface;

a first fluidic pathway disposed within the first substrate, fluidically connected to the first fluidic opening;

a second substrate comprising;

a second upper surface and an opposed second lower surface;

an extension disposed on the second upper surface, the extension having a second bounding surface and a second fluidic opening disposed on the second bounding surface;

a third fluidic opening disposed on the second lower surface;

a second fluidic pathway disposed within the second substrate, fluidically connecting the second fluidic opening to the third fluidic opening;

means for bonding the first lower surface of the first substrate to the second upper surface of the second substrate, the bonding means having a through hole, substantially aligned with the extension on the second upper surface of the second substrate;

the extension and the cavity being dimensioned and spaced to interfit, fluidically connecting the first fluidic opening to the second fluidic opening, thereby fluidically connecting the first fluidic pathway in the first substrate with the second fluidic pathway in the second substrate;

a third substrate comprising;

a third upper surface and an opposed third lower surface;

a fourth fluidic opening disposed on the third upper surface;

a third fluidic channel within the third substrate, fluidically connected to the fourth fluidic opening;

means for sealing the second lower surface of the second substrate, to the third upper surface of the third substrate, the sealing means having a through hole fluidically connecting the third fluidic opening to the fourth fluidic opening;

means for clamping the sealing means between the second lower surface of the second substrate and the third upper surface of the third substrate;

whereby the first fluidic pathway in the first substrate is fluidically connected to the second fluidic pathway in the second substrate and, the second fluidic pathway in the second substrate is fluidically connected to the third fluidic pathway in the third substrate.

20. The microfluidic interconnect of claim 19 wherein the first substrate further comprises a silicon substrate.

21. The microfluidic interconnect of claim 20 wherein the second substrate further comprises a silicon substrate.

22. The microfluidic interconnect of claim 21 wherein the bonding means comprises one or more selected from the group consisting of:

an anodic bond, and a direct bond.

23. The microfluidic interconnect of claim 22 wherein the first substrate further comprises a microfluidic device, in fluid communication with the first fluidic pathway.

24. The microfluidic interconnect of claim 23 wherein the diameter of the first fluidic opening is between about 20 microns and 100 microns.

25. The microfluidic interconnect of claim 24 wherein the diameter of the cavity is between about 100 microns and 500 microns.

26. The microfluidic interconnect of claim 25 wherein the diameter of the extension is between about 100 microns and 500 microns.

27. The microfluidic interconnect of claim 26 wherein the diameter of the second fluidic opening is between about 20 microns and 100 microns.

28. The microfluidic interconnect of claim 23 wherein the third substrate further comprises a material selected from the group consisting of:

polymer, plastic, glass-polymer composite, resin material, fiber-reinforced composite, printed wiring board composition, FR-4, epoxy-glass composite, epoxy, polyimide, fluoropolymer, polyether ether ketone, polydimethylsiloxane, ceramic, glass, glass-ceramic composite, glass-coated metal, alumina, beryllium oxide, silicon nitride, aluminum nitride, titanium nitride, titanium carbide, low temperature co-fired ceramic multilayered material and a high temperature co-fired ceramic multilayered material.

29. The microfluidic interconnect of claim 28 wherein fluidic connection of the third fluidic opening to the fourth fluidic opening further comprises a fanout.

30. The microfluidic interconnect of claim 28 wherein the third substrate further comprises an electronics package selected from the group consisting of:

a dual-inline, TO, quad flatpack, pin grid array, ball grid array, small outline, chip carrier and plastic leaded chip carrier.

31. The microfluidic interconnect of claim 30 further comprising means for electrically interconnecting the microfluidic device to the electronics package.

32. The microfluidic interconnect of claim 28 further comprising means for optically accessing the microfluidic device.

33. A microfluidic interconnect comprising:

a first substrate comprising;

a first upper surface and an opposed first lower surface;

a cavity disposed in the first lower surface, the cavity having a first bounding surface, and a first fluidic opening disposed on the first bounding surface;

a first fluidic pathway disposed within the first substrate, fluidically connected to the first fluidic opening;

a second substrate comprising;

a second upper surface and an opposed second lower surface;

an extension disposed on the second upper surface, the extension having a second bounding surface and a second fluidic opening disposed on the second bounding surface;

a third fluidic opening disposed on the second lower surface;

a second fluidic pathway disposed within the second substrate, fluidically connecting the second fluidic opening to the third fluidic opening;

means for bonding the first lower surface of the first substrate to the second upper surface of the second substrate, the bonding means having a through hole, substantially aligned with the extension on the second upper surface of the second substrate;

the extension and the cavity being dimensioned and spaced to interfit, fluidically connecting the first fluidic opening to the second fluidic opening, thereby fluidically connecting the first fluidic pathway in the first substrate with the second fluidic pathway in the second substrate;

a third substrate comprising;

a third upper surface and an opposed third lower surface;

a fourth fluidic opening disposed on the third upper surface;

a third fluidic channel within the third substrate, fluidically connected to the fourth fluidic opening;

an adhesive layer in contact with the second lower surface of the second substrate and the third upper surface of the third substrate, the adhesive layer having a through hole, fluidically connecting the third fluidic opening to the fourth fluidic opening;

whereby the first fluidic pathway in the first substrate is fluidically connected to the second fluidic pathway in the second substrate and, the second fluidic pathway in the second substrate is fluidically connected to the third fluidic pathway in the third substrate.

34. The microfluidic interconnect of claim 33 wherein the first substrate further comprises a silicon substrate.

35. The microfluidic interconnect of claim 34 wherein the second substrate further comprises a silicon substrate.

36. The microfluidic interconnect of claim 35 wherein the bonding means comprises one or more selected from the group consisting of:

an anodic bond, and a direct bond.

37. The microfluidic interconnect of claim 36 wherein the first substrate further comprises a microfluidic device, in fluid communication with the first fluidic pathway.

38. The microfluidic interconnect of claim 37 wherein the diameter of the first fluidic opening is between about 20 microns and 100 microns.

39. The microfluidic interconnect of claim 38 wherein the diameter of the cavity is between about 100 microns and 500 microns.

40. The microfluidic interconnect of claim 39 wherein the diameter of the extension is between about 100 microns and 500 microns.

41. The microfluidic interconnect of claim 40 wherein the diameter of the second fluidic opening is between about 20 microns and 100 microns.

42. The microfluidic interconnect of claim 37 wherein the third substrate further comprises a material selected from the group consisting of:

polymer, plastic, glass-polymer composite, resin material, fiber-reinforced composite, printed wiring board composition, FR-4 epoxy-glass composite, epoxy, polyimide, fluoropolymer, polyether ether ketone, polydimethylsiloxane, ceramic, glass, glass-ceramic composite, glass-coated metal, alumina, beryllium oxide, silicon nitride, aluminum nitride, titanium nitride, titanium carbide, low temperature co-fired ceramic multilayered material and a high temperature co-fired ceramic multilayered material.

43. The microfluidic interconnect of claim 42 wherein the adhesive layer comprises one or more materials selected from the group consisting of:

liquid adhesive, sheet adhesive, double sided adhesive, conductive adhesive, non-conductive adhesive, thermoplastic polymer, thermoset polymer, transfer tape, epoxy, cyanate ester, cyanoacrylate, polyester, polyimide, fusible glass, solder and braze.

44. The microfluidic interconnect of claim 43 wherein fluidic connection of the third fluidic opening to the fourth fluidic opening further comprises a fanout.

45. The microfluidic interconnect of claim 43 wherein the third substrate further comprises an electronics package selected from the group consisting of:

a dual-inline, TO, quad flatpack, pin grid array, ball grid array, small outline, chip carrier and plastic leaded chip carrier.

46. The microfluidic interconnect of claim 45 further comprising means for electrically interconnecting the microfluidic device to the electronics package.

47. The microfluidic interconnect of claim 43 further comprising means for optically accessing the microfluidic device.

48. A microfluidic interconnect comprising:

a first substrate comprising;

a first upper surface and an opposed first lower surface;

a cavity disposed in the first lower surface, the cavity having a first bounding surface, and a first fluidic opening disposed on the first bounding surface;

a first fluidic pathway disposed within the first substrate, fluidically connected to the first fluidic opening;

a second substrate comprising;

a second upper surface and an opposed second lower surface;

an extension disposed on the second upper surface, the extension having a second bounding surface and a second fluidic opening disposed on the second bounding surface;

a third fluidic opening disposed on the second lower surface;

a second fluidic pathway disposed within the second substrate, fluidically connecting the second fluidic opening to the third fluidic opening;

an adhesive layer in contact with the first lower surface of the first substrate and the second upper surface of the second substrate, the adhesive layer having a through hole, substantially aligned with the extension on the second upper surface of the second substrate;

the extension and the cavity being dimensioned and spaced to interfit, fluidically connecting the first fluidic opening to the second fluidic opening, thereby fluidically connecting the first fluidic pathway in the first substrate with the second fluidic pathway in the second substrate;

a third substrate comprising;

a third upper surface and an opposed third lower surface;

a fourth fluidic opening disposed on the third upper surface;

a third fluidic channel within the third substrate, fluidically connected to the fourth fluidic opening;

means for sealing the second lower surface of the second substrate, to the third upper surface of the third substrate, the sealing means having a through hole fluidically connecting the third fluidic opening to the fourth fluidic opening;

means for damping the sealing means between the second lower surface of the second substrate and the third upper surface of the third substrate

whereby the first fluidic pathway in the first substrate is fluidically connected to the second fluidic pathway in the second substrate and, the second fluidic pathway in the second substrate is fluidically connected to the third fluidic pathway in the third substrate.

49. The microfluidic interconnect of claim 48 wherein the first substrate further comprises a silicon substrate.

50. The microfluidic interconnect of claim 49 wherein the second substrate further comprises a silicon substrate.

51. The microfluidic interconnect of claim 50 wherein the adhesive layer comprises one or more materials selected from the group consisting of:

liquid adhesive, sheet adhesive, double sided adhesive, conductive adhesive, non-conductive adhesive, thermoplastic polymer, thermoset polymer, transfer tape, epoxy, cyanate ester, cyanoacrylate, polyester, polyimide, fusible glass, solder and braze.

52. The microfluidic interconnect of claim 51 wherein the first substrate further comprises a microfluidic device, in fluid communication with the first fluidic pathway.

53. The microfluidic interconnect of claim 52 wherein the diameter of the first fluidic opening is between about 20 microns and 100 microns.

54. The microfluidic interconnect of claim 53 wherein the diameter of the cavity is between about 100 microns and 500 microns.

55. The microfluidic interconnect of claim 54 wherein the diameter of the extension is between about 100 microns and 500 microns.

56. The microfluidic interconnect of claim 55 wherein the diameter of the second fluidic opening is between about 20 microns and 100 microns.

57. The microfluidic interconnect of claim 52 wherein the third substrate further comprises a material selected from the group consisting of:

polymer, plastic, glass-polymer composite, resin material, fiber-reinforced composite, printed wiring board composition, FR-4, epoxy-glass composite, epoxy, polyimide, fluoropolymer, polyether ether ketone, polydimethylsiloxane, ceramic, glass, glass-ceramic composite, glass-coated metal, alumina, beryllium oxide, silicon nitride, aluminum nitride, titanium nitride, titanium carbide, low temperature co-fired ceramic multilayered material and a high temperature co-fired ceramic multilayered material.

58. The microfluidic interconnect of claim 57 wherein fluidic connection of the third fluidic opening to the fourth fluidic opening further comprises a fanout.

59. The microfluidic interconnect of claim 57 wherein the third substrate further comprises an electronics package selected from the group consisting of a dual-inline, TO, quad flatpack, pin grid array ball grid array, small outline, chip carrier and plastic leaded chip carrier.

60. The microfluidic interconnect of claim 59 further comprising means for electrically interconnecting the microfluidic device to the electronics package.

61. The microfluidic interconnect of claim 57 further comprising means for optically accessing the microfluidic device.

62. A microfluidic interconnect comprising:

a first substrate comprising;

a first upper surface and an opposed first lower surface;

a cavity disposed in the first lower surface, the cavity having a first bounding surface, and a first fluidic opening disposed on the first bounding surface;

a first fluidic pathway disposed within the first substrate, fluidically connected to the first fluidic opening;

a second substrate comprising;

a second upper surface and an opposed second lower surface;

an extension disposed on the second upper surface, the extension having a second bounding surface and a second fluidic opening disposed on the second bounding surface;

a third fluidic opening disposed on the second lower surface;

a second fluidic pathway disposed within the second substrate, fluidically connecting the second fluidic opening to the third fluidic opening;

a first adhesive layer in contact with the first lower surface of the first substrate and the second upper surface of the second substrate, the first adhesive layer having a through hole, substantially aligned with the extension on the second upper surface of the second substrate;

the extension and the cavity being dimensioned and spaced to interfit, fluidically connecting the first fluidic opening to the second fluidic opening, thereby fluidically connecting the first fluidic pathway in the first substrate with the second fluidic pathway in the second substrate;

a third substrate comprising;

a third upper surface and an opposed third lower surface;

a fourth fluidic opening disposed on the third upper surface;

a third fluidic channel within the third substrate, fluidically connected to the fourth fluidic opening;

a second adhesive layer in contact with the second lower surface of the second substrate and the third upper surface of the third substrate, the second adhesive layer having a through hole, fluidically connecting the third fluidic opening to the fourth fluidic opening;

whereby the first fluidic pathway in the first substrate is fluidically connected to the second fluidic pathway in the second substrate and, the second fluidic pathway in the second substrate is fluidically connected to the third fluidic pathway in the third substrate.

63. The microfluidic interconnect of claim 62 wherein the first substrate further comprises a silicon substrate.

64. The microfluidic interconnect of claim 63 wherein the second substrate further comprises a silicon substrate.

65. The microfluidic interconnect of claim 64 wherein the first adhesive layer comprises one or more materials selected from the group consisting of:

liquid adhesive, sheet adhesive, double sided adhesive, conductive adhesive, non-conductive adhesive, thermoplastic polymer, thermoset polymer, transfer tape, epoxy, cyanate ester, cyanoacrylate, polyester, polyimide, fusible glass, solder and braze.

66. The microfluidic interconnect of claim 65 wherein the first substrate further comprises a microfluidic device, in fluid communication with the first fluidic pathway.

67. The microfluidic interconnect of claim 66 wherein the diameter of the first fluidic opening is between about 20 microns and 100 microns.

68. The microfluidic interconnect of claim 67 wherein the diameter of the cavity is between about 100 microns and 500 microns.

69. The microfluidic interconnect of claim 68 wherein the diameter of the extension is between about 100 microns and 500 microns.

70. The microfluidic interconnect of claim 69 wherein the diameter of the second fluidic opening is between about 20 microns and 100 microns.

71. The microfluidic interconnect of claim 66 wherein the third substrate further comprises a material selected from the group consisting of:

polymer, plastic, glass-polymer composite, resin material, fiber-reinforced composite, printed wiring board composition, FR-4, epoxy-glass composite, epoxy, polyimide, fluoropolymer, polyether ether ketone, polydimethylsiloxane, ceramic, glass, glass-ceramic composite, glass-coated metal, alumina, beryllium oxide, silicon nitride, aluminum nitride, titanium nitride, titanium carbide, low temperature co-fired ceramic multilayered material and a high temperature co-fired ceramic multilayered material.

72. The microfluidic interconnect of claim 71 wherein the second adhesive layer comprises one or more materials selected from the group consisting of:

liquid adhesive, sheet adhesive, double sided adhesive, conductive adhesive, non-conductive adhesive, thermoplastic polymer, thermoset polymer, transfer tape, epoxy, cyanate ester, cyanoacrylate, polyester, polyimide, fusible glass, solder and braze.

73. The microfluidic interconnect of claim 72 wherein fluidic connection of the third fluidic opening to the fourth fluidic opening further comprises a fanout.

74. The microfluidic interconnect of claim 71 wherein the third substrate further comprises an electronics package selected from the group consisting of:

a dual-inline, TO, quad flatpack, pin grid array, ball grid array, small outline, chip carrier and plastic leaded chip carrier.

75. The microfluidic interconnect of claim 74 further comprising means for electrically interconnecting the microfluidic device to the electronics package.

76. The microfluidic interconnect of claim 72 further comprising means for optically accessing the microfluidic device.