Process for manufacturing integrated chemical microreactors of semiconductor material

• US 7,009,154 B2
• Filed: 02/23/2004
• Issued: 03/07/2006
• Est. Priority Date: 06/05/2000
• Status: Expired due to Term

• Current Assignee: STMicroelectronics SRL (STMicroelectronics NV)
• Original Assignee: STMicroelectronics SRL (STMicroelectronics NV)
• Inventors: Villa, Flavio, Barlocchi, Gabriele, Mastromatteo, Ubaldo, Cattaneo, Mauro
• Primary Examiner(s): PELHAM, JOSEPH MOORE
• Application Number:
  US10/784,509
• Publication Number:
  US 20040164068A1
• Time in Patent Office: 743 Days
• Field of Search: 219/521, 219/522, 219/544, 435/286.5, 435/287.2, 435/288.5
• US Class Current: 219/521
• 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: B01L 2200/12 Specific details about manufacturing devices
• CPC Class Codes: B01L 2300/0645 Electrodes
• CPC Class Codes: B01L 2300/1827 using resistive heater
• CPC Class Codes: B01L 2300/185 using a liquid as fluid
• CPC Class Codes: B01L 2300/1883 using thermal insulation
• 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 7/52 with provision for submitting samples to a predetermined sequence of different temperatures, e.g. for treating nucleic acid samples amplification or hybridisation processes per se C12Q1/68; controlling sequential reactions for synthesis B01J19/0046
• CPC Class Codes: B01L 7/525 with physical movement of samples between temperature zones
• CPC Class Codes: B81B 2201/0214 Biosensors; Chemical sensors
• CPC Class Codes: B81B 2201/051 Micromixers, microreactors
• CPC Class Codes: B81B 2203/0315 Cavities
• CPC Class Codes: B81B 2203/0338 Channels
• CPC Class Codes: B81C 1/00119 Arrangement of basic structures like cavities or channels, e.g. suitable for microfluidic systems
• CPC Class Codes: B81C 2201/053 Depositing a protective layers

Abstract

The microreactor is completely integrated and is formed by a semiconductor body having a surface and housing at least one buried channel accessible from the surface of the semiconductor body through two trenches. A heating element extends above the surface over the channel and a resist region extends above the heating element and defines an inlet reservoir and an outlet reservoir. The reservoirs are connected to the trenches and have, in cross-section, a larger area than the trenches. The outlet reservoir has a larger area than the inlet reservoir. A sensing electrode extends above the surface and inside the outlet reservoir.

Claims

1. A method, comprising applying a biological fluid to an integrated microreactor comprising:

a semiconductor material body having a surface;

a buried channel extending in said semiconductor material body at a distance from said surface, and having a first and a second end;

a first and a second trench extending from said surface respectively as far as said first and second ends of said buried channel, and being in fluid connection with said buried channel;

a reservoir region formed on the surface of the semiconductor material body, extending above said surface and defining a first and a second reservoir connected to said first and second trenches, respectively;

wherein the biological fluid is applied to the first reservoir and travels via the first trench to the buried channel where a biological test is performed, and wherein the biological fluid then travels via the second trench to the second reservoir.

2. The method of claim 1, wherein the integrated devise further comprises a heating element arranged between said surface and said reservoir region, above said buried channel.

3. The method of claim 2, wherein the integrated device further comprises an insulating material region surrounding said heating element.

4. The method of claim 1, wherein the second reservoir further comprises a sensing electrode structure inside said second reservoir;

where the sensing electrode senses the product of said biological test.

5. The method of claim 4, wherein said first and second reservoirs have, in cross section, larger areas than said first and second trenches.

6. The method of claim 5, wherein the biological fluid contains DNA and wherein the biological test comprises amplification and the product of said biological test is amplified DNA.

7. A method, comprising applying a biological fluid to an integrated microreactor comprising:

a semiconductor material body having a surface;

a buried channel extending in said semiconductor material body at a distance from said surface, and having a first and a second end;

a first and a second trench extending from said surface respectively as far as said first and second ends of said buried channel, and being in fluid connection with said buried channel;

a reservoir region formed on the surface of the semiconductor material body, extending above said surface and defining first and second reservoirs connected to said first and second trenches, respectively; and

a heating element arranged between said surface and said reservoir region, above said buried channel;

wherein the biological fluid is applied to the first reservoir and travels via the first trench to the buried channel where a biological test is performed, and wherein the biological fluid then travels via the second trench to the second reservoir.

8. The method of claim 7, the integrated microreactor further comprising an insulating material region surrounding said heating element.

9. The method of claim 8, the integrated microreactor further comprising a protective region arranged between said insulating material region and said reservoir region.

10. The method of claim 9, wherein the reservoir region is of a first resist and the protective region is of a second resist, and in that one of said resists is of a negative type and the other of said resists is of a positive type.

11. The method of claim 10, wherein said first resist is SU8.

12. The method of claim 11, wherein said first resist is a photosensitive dry resist.

13. The method claim 12, wherein the biological fluid contains DNA and wherein the biological test comprises amplification and the product of said biological test is amplified DNA.

14. A method, comprising:

introducing a biological fluid from a first reservoir into a first trench, the first reservoir and first trench being integrated in a semiconductor body, the first trench being formed in, and defined by, a resist layer formed on the surface of the semiconductor material body;

moving the biological fluid from the first trench into a buried channel, the buried channel extending in the semiconductor body at a distance from a surface of the semiconductor body, the first trench extending from the reservoir on the surface of the semiconductor material body to a first end of the buried channel;

the semiconductor material body having at least one integrated heating element positioned to heat the buried channel and an insulating material region surrounding said heating element;

heating and optionally cooling the biological fluid within the buried channel;

optionally repeating the heating and cooling steps as needed;

extracting the biological fluid from the buried channel into a second reservoir via a second trench, the second reservoir and second trench being integrated in the semiconductor body, the second trench extending from the second reservoir on the surface of the semiconductor material body as far as a second end of the buried channel; and

detecting a product within the biological fluid, where the detection step is performed by the use of an electrode, the electrode being integrated in the second reservoir.

15. The method of claim 14, wherein the biological fluid contains DNA and the product is amplified DNA.