Heat-reduction methods and systems related to microfluidic devices

• US 9,528,142 B2
• Filed: 06/05/2015
• Issued: 12/27/2016
• Est. Priority Date: 02/14/2001
• Status: Active Grant

• Current Assignee: HandyLab Incorporated (Becton Dickinson & Co)
• Original Assignee: HandyLab Incorporated (Becton Dickinson & Co)
• Inventors: Handique, Kalyan
• Primary Examiner(s): Warden, Jill
• Assistant Examiner(s): Handy, Dwayne K
• Application Number:
  US14/731,739
• Publication Number:
  US 20150376682A1
• Time in Patent Office: 571 Days
• Field of Search: 422/68.1, 422/502, 422/503, 422/504, 422/547, 422/551, 422/552
• US Class Current: 1/1
• CPC Class Codes: B01L 2300/0816 Cards, e.g. flat sample carriers usually with flow in two horizontal directions
• CPC Class Codes: B01L 2300/1822 using Peltier elements
• CPC Class Codes: B01L 2300/1827 using resistive heater
• CPC Class Codes: B01L 2300/1883 using thermal insulation
• CPC Class Codes: B01L 2300/1894 Cooling means; Cryo cooling
• CPC Class Codes: B01L 2400/0442 thermal energy, e.g. vaporisation, bubble jet
• 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 7/00 Heating or cooling apparatus autoclaves B01J3/04; Heat insulating devices
• CPC Class Codes: C12Q 1/6806 Preparing nucleic acids for analysis, e.g. for polymerase chain reaction [PCR] assay C12Q1/6804 takes precedence
• CPC Class Codes: H05B 3/22 non-flexible
• CPC Class Codes: H05K 3/10 in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern
• CPC Class Codes: Y10T 29/49155 Manufacturing circuit on or in base

Abstract

Systems and methods for preventing or reducing unwanted heat in a microfluidic device while generating heat in selected regions of the device are described. Current can be supplied to a heating element through electric leads that are designed so that the current density in the leads is substantially lower than the current density in the heating element. Unwanted heat in the microfluidic complex can be reduced by thermally isolating the electric leads from the microfluidic complex by, for example, running each lead directly away from the microfluidic complex. Unwanted heat can be removed from selected regions of the microfluidic complex using one or more cooling devices.

Claims

1. A method for reducing transfer of heat to selected regions of a microfluidic complex, the method comprising:

providing a microfluidic complex comprising at least one thermally actuated component and a heating surface;

providing a substrate comprising first side, a second side, a thermally isolating layer between the first side and the second side, a heating element positioned between the first side and the thermally isolating layer, and a conductive lead;

positioning the heating surface of the microfluidic complex adjacent to the first side of the substrate; and

applying a current to the heating element thereby heating the microfluidic complex through the heating surface, wherein the conductive lead passes from the heating element, through the thermally isolating layer, and to a current source, so as to substantially thermally isolate the conductive lead from the microfluidic complex.

2. The method of claim 1, further comprising thermally actuating the at least one thermally actuated component.

3. The method of claim 2, wherein thermally actuating comprises actuating at least one thermally actuated valve.

4. The method of claim 2, wherein thermally actuating comprises melting a material in the at least one thermally actuated component.

5. The method of claim 2, wherein thermally actuating comprises applying heat to at least one reaction chamber.

6. The method of claim 1, wherein the microfluidic complex comprises at least one thermally actuated component in each of a plurality of flow channels, and wherein the method further comprises thermally actuating a first thermally actuated component in a first flow channel with the heating element without thermally actuating a second thermally actuated component in an adjacent flow channel.

7. The method of claim 1, wherein providing a microfluidic complex comprises providing a microfluidic complex comprising a plurality of flow channels, and wherein the method further comprises thermally actuating at least one thermally actuated component in each flow channel with at least one of a plurality of heating elements in the substrate.

8. The method of claim 1, wherein a portion of the conductive lead passing through the thermally isolating layer is orthogonal to the plane in which the at least one heating element resides.

9. A method for reducing transfer of heat generated by a heating element in a microfluidic processing system, the method comprising:

providing a substrate having at least one heating element;

providing a microfluidic complex comprising a first heating surface proximate to at least one thermally actuated component of the microfluidic complex;

placing the first heating surface of the microfluidic complex in thermal communication with the at least one heating element of the substrate; and

supplying electric current to the at least one heating element from a terminal at the edge of the substrate, wherein the at least one heating element is thermally isolated from the edge of the substrate from which electric current is supplied.

10. The method of claim 9, wherein electric current is supplied to the at least one heating element with a conductive lead, at least a portion of the conductive lead thermally isolated from the microfluidic complex.

11. The method of claim 10, wherein the conductive lead comprises a vertical portion and a horizontal portion, the vertical portion orthogonal to the plane in which the at least one heating element resides.

12. The method of claim 11, wherein the horizontal portion resides in a plane parallel to the plane in which the at least one heating element resides.

13. The method of claim 9, further comprising applying heat to the thermally actuated component through the first heating surface of the microfluidic complex.

14. The method of claim 9, further comprising manipulating a thermally actuated component in a first portion of the microfluidic complex without manipulating a thermally actuated component in a second portion of the microfluidic complex adjacent to the first portion.

15. The method of claim 9, further comprising melting a material in a first thermally actuated component of the microfluidic complex using the at least one heating element without melting a material in a second thermally actuated component of the microfluidic complex.

16. A method of manufacturing a microfluidic processing system, the method comprising:

providing a substrate comprising a heating element configured to apply heat to a thermally actuated component;

providing a microfluidic complex comprising a first heating surface proximate to a thermally actuated component of the microfluidic complex; and

thermally isolating a conductive lead from the microfluidic complex.

17. The method of claim 16, wherein thermally isolating the conductive lead comprises routing a horizontal portion of the conductive lead at a first distance from the microfluidic complex, the heating element located a second distance from the microfluidic complex, the first distance greater than the second distance.

18. The method of claim 17, wherein thermally isolating the conductive lead further comprises connecting the heating element and the horizontal portion of the conductive lead with a vertical extension spanning from the first distance to the second distance.

19. The method of claim 16, wherein thermally isolating the conductive lead further comprises routing the conductive lead from a terminal.

20. The method of claim 16, wherein the conductive lead has a lower current density than the heating element.