Fabrication method of topographically modulated microstructures using pattern homogenization with UV light
First Claim
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1. A method of fabricating comprising the steps of:
- creating a binary transparency mask;
exposing a photoresist material to UV light through the binary transparency mask while holding the product of n×
a>
5500 μ
m per unit of patterned area (in mm2) in the mask so that the pattern is transferred to the photoresist material as a homogeneous smooth surface, wherein n is the number of transparent pixels/mm2 and a is a pixel length (μ
m); and
creating a three dimensional microfluidic device from the exposed photoresist material;
wherein the device includes at least one microchannel having an x, y, and z parameter.
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Abstract
A method for microfabrication of a microfluidic device having sub-millimeter three dimensional relief structures is disclosed. In this method, homogeneous surfaces, which do not exhibit apparent pixel geometry, emerge from the interaction of the overlapping of diffracted light under opaque pixels and the nonlinear polymerization properties of the photoresist material. The method requires a single photolithographic step and allows for the fabrication of microstructures over large areas (centimeters) with topographic modulation of features smaller than 100 micrometers. The method generates topography that is useful in a broad range of microfluidic applications.
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Citations
19 Claims
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1. A method of fabricating comprising the steps of:
creating a binary transparency mask;
exposing a photoresist material to UV light through the binary transparency mask while holding the product of n×
a>
5500 μ
m per unit of patterned area (in mm2) in the mask so that the pattern is transferred to the photoresist material as a homogeneous smooth surface, wherein n is the number of transparent pixels/mm2 and a is a pixel length (μ
m); and
creating a three dimensional microfluidic device from the exposed photoresist material;
wherein the device includes at least one microchannel having an x, y, and z parameter.- View Dependent Claims (2, 3, 4, 5, 6)
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7. A method of fabricating a device comprising the steps of:
- exposing a photoresist material to UV light through a mask with transparent and opaque pixels while holding the product of n×
a>
5500 μ
m per unit of patterned area (in mm2) in the mask, wherein n is the number of transparent pixels/mm2 and a is a pixel length μ
m; and
fabricating from the photoresist material a three dimensional microfluidic device with a plurality of microstructures with a modulated topography while inducing a homogenization effect. - View Dependent Claims (8, 9, 10)
- exposing a photoresist material to UV light through a mask with transparent and opaque pixels while holding the product of n×
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11. A method of fabricating a device comprising the steps of:
- forming a swatch in a mask with a plurality of 8×
4 pixels that differ in average grayscale tone;
exposing a photoresist material to UV light through the mask with transparent and opaque pixels;
holding the product of n×
a>
5500 μ
m per unit of patterned area (in mm2) in the swatch so that the pattern is transferred to the photoresist material as a homogeneous smooth surface, wherein n is the number of transparent pixels/mm2 and a is a pixel length (μ
m); and
fabricating from the photoresist material a three dimensional microfluidic device with a plurality of microstructures with a modulated topography while inducing a homogenization effect.
- forming a swatch in a mask with a plurality of 8×
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12. A method of fabricating a device comprising the steps of:
- providing a mask with transparent and opaque pixels;
providing a photoresist material with an optical adhesive having low contrast;
subjecting the photoresist material to UV light;
promoting partial polymerization in areas of the photoresist material subject to diffracted UV light;
transferring discrete patterns from the mask as homogeneous patterns to the photoresist material while holding the product of n×
a>
5500 μ
m per unit of patterned area (in mm2) in the mask, wherein n is the number of transparent pixels/mm2 and a is a pixel length (μ
m); and
creating at least one 3D microchannel in the photoresist material while inducing a homogenization effect. - View Dependent Claims (13, 14, 15, 16, 17, 18, 19)
- providing a mask with transparent and opaque pixels;
Specification