Microfluidic devices with mechanically-sealed diaphragm valves

• US 8,763,642 B2
• Filed: 08/20/2011
• Issued: 07/01/2014
• Est. Priority Date: 08/20/2010
• Status: Active Grant

• Current Assignee: IntegenX Inc. (Thermo Fisher Scientific Incorporated)
• Original Assignee: IntegenX Inc. (Thermo Fisher Scientific Incorporated)
• Inventors: Vangbo, Mattias
• Primary Examiner(s): Fristoe, Jr., John K
• Assistant Examiner(s): Arundale, R. K.
• Application Number:
  US13/202,877
• Publication Number:
  US 20130139895A1
• Time in Patent Office: 1,046 Days
• Field of Search: 137/859, 251/61.1, 251/331
• US Class Current: 137/859
• CPC Class Codes: B01L 2300/0816 Cards, e.g. flat sample carriers usually with flow in two horizontal directions
• CPC Class Codes: B01L 2400/0638 membrane valves, flap valves
• CPC Class Codes: B01L 2400/0655 pinch valves
• CPC Class Codes: B01L 3/502738 characterised by integrated valves microvalves F16K99/0001
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: F04B 19/006 Micropumps F04B43/043 and F04B43/095 take precedence
• CPC Class Codes: F04B 43/043 Micropumps
• CPC Class Codes: F16K 15/144 the closure elements being fixed along all or a part of their periphery
• CPC Class Codes: F16K 2099/008 Multi-layer fabrications
• CPC Class Codes: F16K 2099/0084 Chemistry or biology, e.g. "lab-on-a-chip" technology
• CPC Class Codes: F16K 2099/0094 Micropumps
• CPC Class Codes: F16K 99/0015 Diaphragm or membrane valves
• CPC Class Codes: F16K 99/0055 actuated by fluids
• CPC Class Codes: F16K 99/0059 actuated by a pilot fluid
• CPC Class Codes: Y10T 137/0324 With control of flow by a condition or characteristic of a fluid
• CPC Class Codes: Y10T 137/0402 Cleaning, repairing, or assembling

Abstract

This invention provides a fluidic device comprising a diaphragm valve having a fluidics layer, an actuation layer and an elastic layer between the fluidics layer and the actuation layer, the elastic layer having a diaphragm that is mechanically sealed against the fluidics layer and the actuation layer by a sealing ring in the actuation layer.

Claims

1. A device comprising at least one diaphragm valve comprised in a combination that comprises a fluidics layer comprising a fluidic conduit, an actuation layer comprising an actuation conduit and an elastic layer sandwiched between the fluidics layer and the actuation layer, wherein:

(A) at least one diaphragm valve comprises a diaphragm provided by the elastic layer, said diaphragm being mechanically scaled against the fluidics layer and against a raised sealing ring of the actuation layer, wherein the sealing ring is configured to exert localized pressure on the elastic layer against the fluidics layer to form a pressure seal;

(B) each diaphragm valve of (A) comprises;

a) a valve seat against which the diaphragm is configured to sit;

b) a valve relief defined at least in part by the sealing ring, and into which the diaphragm is configured to be deflected, thereby defining a valve chamber; and

c) a valve inlet and a valve outlet comprised in the fluidics layer and in fluid communication with the valve chamber,

wherein the diaphragm is configured to be actuated by positive or negative pressure transmitted through an actuation conduit in the actuation layer that communicates with the valve relief; and

(C) the fluidics layer comprises a via layer and a fluidics manifold, wherein;

the via layer has a first face mated with the elastic layer and a second face mated with the fluidics manifold, wherein the valve inlet and valve outlet of each diaphragm valve of (A) are configured as vias through the via layer and each via is in fluid communication with a microfluidic channel disposed in the second face of the via layer, and

the fluidics manifold comprises at least one compartment scaled by the second face of the via layer, wherein the at least one compartment is in fluid communication with the microfluidic channel that is in fluid communication with the via.

2. The device of claim 1, further comprising a mechanical fastener configured to fasten the combination into a sandwich, wherein the mechanical fastener transmits pressure to a pressure seal.

3. The device of claim 2, wherein the mechanical fastener is selected from a screw, a clip, a snap, a staple, a rivet, a band and a pin.

4. The device of claim 1 wherein the elastic layer comprises a urethane, a nitrile, a latex or silicone.

5. The device of claim 1, wherein the at least one diaphragm valve of (A) is a plurality of diaphragm valves.

6. The device of claim 1, wherein the fluidics manifold comprises a second compartment that opens toward the via layer and the via layer comprises an aperture exposing the second compartment to the elastic layer.

7. The device of claim 1, wherein the fluidics manifold and/or the actuation layer comprises a polymer selected from poly(acrylonitrile butadiene styrene) (“

ABS”

), acrylic, acetal, rubber, nylon, polycarbonate, polyether, polyester, polyurethane, polypropylene, polyolefin, cycloolefin, and co-polymers or filled versions thereof.

8. The device of claim 1, wherein the fluidics manifold and/or the actuation layer are comprised of a rigid material.

9. The device of claim 1, wherein at least one actuation conduit is configured to transmit positive or negative pressure to a plurality of the diaphragm valves of (A).

10. The device of claim 1, wherein at least one actuation conduit is configured to transmit positive or negative pressure to a fluidic conduit.

11. The device of claim 1, wherein at least one actuation conduit traverses the actuation layer from a first face to a second, opposing face.

12. The device of claim 1, wherein the actuation layer comprises an internal actuation conduit configured to transmit positive or negative pressure to at least one diaphragm valve of (A).

13. The device of claim 1, wherein the via layer has a thickness of no more than about 0.5 mm.

14. The device of claim 1, wherein the scaling ring is in contact with the elastic layer.

15. The device of claim 1, wherein one or more macrofluidic chambers or channels arc disposed in the fluidics manifold.

16. The device of claim 15, wherein the via layer comprises one or more microfiuidic channels in fluid communication with said one or more macrofluidic chambers or channels.

17. The device of claim 16, wherein the device tolerates a lateral shift of the via layer in relation to the actuation layer of as much as 20% with respect to a center of a sealing ring and a midpoint between two via serving as a valve inlet and a valve outlet, respectively.

18. The device of claim 1, wherein the elastic layer comprises polydimethylsiloxane (PDMS).

19. The device of claim 1, wherein the layers are pressure sealed against one another by gluing or by vacuum.

20. The device of claim 1, wherein the layers arc pressure sealed against one another by heat sealing or by ultrasonic welding.

21. A system comprising:

a) a device comprising at least one diaphragm valve comprised in a combination that comprises a fluidics layer comprising a fluidic conduit, an actuation layer comprising an actuation conduit and an elastic layer sandwiched between the fluidics layer and the actuation layer, wherein;

(A) at least one diaphragm valve comprises a diaphragm provided by the elastic layer, said diaphragm being mechanically scaled against the fluidics layer and against a raised sealing ring of the actuation layer, wherein the sealing ring is configured to exert localized pressure on the elastic layer against the fluidics layer to form a pressure seal;

(B) each diaphragm valve of (A) comprises;

i) a valve seat against which the diaphragm is configured to sit;

ii) a valve relief defined at least in part by the scaling ring, and into which the diaphragm is configured lo be deflected, thereby defining a valve chamber; and

iii) a valve inlet and a valve outlet comprised in the fluidics layer and in fluid communication with the valve chamber,

wherein the diaphragm is configured to be actuated by positive or negative pressure transmitted through an actuation conduit in the actuation layer that communicates with the valve relief; and

(C) the fluidics layer comprises a via layer and a fluidics manifold, wherein;

the via layer has a first face mated with the elastic layer and a second face mated with the fluidics manifold, wherein the valve inlet and valve outlet of each diaphragm valve of (A) arc configured as vias through the via layer and each via is in fluid communication with a microfluidic channel disposed in the second face of the via layer, and

the fluidics manifold comprises at least one compartment sealed by the second face of the via layer, wherein the at least one compartment is in fluid communication with the microfluidic channel that is in fluid communication with the via;

b) a source of positive and/or negative pressure in communication with the actuation conduits; and

c) a control unit comprising logic to open and/or close valves in a programmed sequence.

22. The system of claim 21 further comprising:

d) a magnet assembly configured to deliver a regulatable magnetic field to a chamber in the fluidic manifold.

23. The system of claim 21 further comprising:

d) a thermal control assembly configured to regulate temperature in a chamber in the fluidic manifold.

24. The system of claim 21, further comprising:

d) an optical assembly.

25. The system of claim 21, further comprising a mechanical fastener configured to fasten the combination into a sandwich, wherein the mechanical fastener transmits pressure to a pressure seal.

26. The system of claim 21, wherein the elastic layer comprises a urethane, a nilrile, a latex or silicone.

27. The system of claim 21, wherein the at least one diaphragm valve of (A) is a plurality of diaphragm valves.

28. The system of claim 21, wherein the fluidics manifold and/or the actuation layer comprises a polymer selected from poly(acrylonitrile butadiene styrene) (“

ABS”

), acrylic, acetal, rubber, nylon, polycarbonate, polyether, polyester, polyurethane, polypropylene, polyolefin, cycloolefin, and co-polymers or filled versions thereof.

29. The system of claim 21, wherein the via layer has a thickness of no more than about 0.5 mm.

30. The system of claim 21, wherein one or more macrofluidic chambers or channels arc disposed in the fluidics manifold and the via layer comprises one or more microfluidic channels in fluid communication with said one or more macrofluidic chambers or channels.

31. The system of claim 30, wherein the device tolerates a lateral shift of the via layer in relation to the actuation layer of as much as 20% with respect to a center of a sealing ring and a midpoint between two vias serving as a valve inlet and a valve outlet, respectively.

32. The system of claim 30, wherein the layers arc pressure scaled against one another by heat sealing or ultrasonic welding.

33. A method comprising:

a) providing a device comprising at least one diaphragm valve comprised in a combination that comprises a fluidics layer comprising a fluidic conduit, an actuation layer comprising an actuation conduit and an elastic layer sandwiched between the fluidics layer and the actuation layer, wherein;

(A) at least one diaphragm valve comprises a diaphragm provided by the elastic layer, said diaphragm being mechanically scaled against the fluidics layer and against a raised sealing ring of the actuation layer, wherein the sealing ring is configured to exert localized pressure on the elastic layer against the fluidics layer to form a pressure seal;

(B) each diaphragm valve of (A) comprises;

i) a valve seat against which the diaphragm is configured to sit;

ii) a valve relief defined at least in part by the sealing ring, and into which the diaphragm is configured to be deflected, thereby defining a valve chamber; and

iii) a valve inlet and a valve outlet comprised in the fluidics layer and in fluid communication with the valve chamber,

wherein the diaphragm is configured to be actuated by positive or negative pressure transmitted through an actuation conduit in the actuation layer that communicates with the valve relief; and

(C) the fluidics layer comprises a via layer and a fluidics manifold, wherein;

the via layer has a first face mated with the elastic layer and a second face mated with the fluidics manifold, wherein the valve inlet and valve outlet of each diaphragm valve of (A) are configured as vias through the via layer and each via is in fluid communication with a microfluidic channel disposed in the second face of the via layer, and

the fluidics manifold comprises at least one compartment sealed by the second face of the via layer, wherein the at least one compartment is in fluid communication with the microfluidic channel that is in fluid communication with the via;

wherein the at least one compartment is a plurality of compartments;

b) opening at least one of the diaphragm valves of (A); and

c) moving liquid through the diaphragm valve from one eompartment to another.