Patent Application
20190348683
The present invention relates to a flow path chip and a manufacturing method for the flow path chip.
A microchannel device is used as a device for mixing, reacting, or separating small amounts of fluids.
International Publication No. 2013/121889 discloses a microchannel device including a plate-shaped body in which a processing chamber, an inlet path extending to the processing chamber, and an outlet path extending from the processing chamber are formed, and a processing body placed inside the processing chamber, wherein the processing body includes a porous body and a coating layer made of a synthetic resin and enveloping the porous body, the coating layer is in close contact with an inner surface of the processing chamber, and an infiltration port communicating the inlet path and the porous body with each other and an exudation port communicating the porous body and the outlet path with each other are formed in the coating layer.
In the microchannel device (flow path chip) disclosed in International Publication No. 2013/121889, joining between a first body plate and a second body plate and close contact between the coating layer and the inner surface of the processing chamber need to be certainly ensured such that a solution to be processed reliably passes through the porous body.
However, when a strong pressing force is applied in a heating and pressing step to certainly ensure the joining and the close contact, there is a possibility that the porous body is damaged. On the other hand, when a weak pressing force is applied, there is a possibility that the joining and the close contact are not properly carried out and a fluid leakage is caused.
The present invention provides a flow path chip having a structure sandwiching a stored member including a porous body between two members, wherein the two members are properly joined to each other and a possibility of damage of the porous body placed inside a processing chamber (storage portion), which is formed by the two members, is reduced, and further provides a manufacturing method for the flow path chip.
A flow path chip according to one aspect of the present invention includes a first plate, a second plate joined to the first plate, and a porous body disposed between the first plate and the second plate, the flow path chip having a flow path formed by the first plate and the second plate, wherein the flow path includes a storage portion storing the porous body, the storage portion is defined by a first surface formed by part of a surface of the first plate and a second surface formed by part of a surface of the second plate, at least part of the first surface and at least part of the second surface are each a surface of an easily-deformable layer, and the porous body is sandwiched between the first plate and the second plate in a state that at least part of the easily-deformable layer is deformed.
In that type of flow path chip, because the porous body is made of a brittle material, the porous body may be damaged within the storage portion in some cases when the porous body is sandwiched to be fixedly held between the first plate and the second plate. However, with the above-described feature that at least part of the first surface and at least part of the second surface, those first and second surfaces defining the storage portion storing the porous body, are each given by the easily-deformable layer, the easily-deformable layer can deform depending on an external shape of the porous body when the porous body is sandwiched to be fixedly held between the first plate and the second plate. Accordingly, damage of the porous body is avoided.
The above-described flow path chip may further include a coating layer disposed between the porous body and the easily-deformable layer and covering the porous body.
When the first plate and the second plate are sandwiched to be fixedly held between the first plate and the second plate, a pressing force applied to the porous body is moderated by the coating layer as well. Hence the possibility of damage of the porous body is reduced in a more stable fashion.
In the above-described flow path chip, the easily-deformable layer may be made of a modified substance formed through modification of at least one of the first plate and the second plate by a modifier.
Since a material constituting the first plate and/or the second plate is part of a direct material of the easily-deformable layer, a problem of peeling-off of the easily-deformable layer is harder to occur. Accordingly, when a fluid is supplied to flow through the flow path, a fluid leakage from an isolated section is harder to occur, and the fluid can more stably pass through the porous body.
In the above-described flow path chip, the first plate and the second plate may include a portion in which both the plates are joined to each other by an adhesive, and the adhesive may be made of the modifier.
In this Description, the term “adhesive” implies a material that contributes to fixing relative positions of (i.e., joining) two members to be joined. The adhesive may form an adhesive layer, and the two to-be-joined members may be joined by the adhesive layer positioned between those two members. Alternatively, at least one of the two to-be-joined members may be modified by the adhesive to form a modified substance, and those two members may be joined by the modified substance. An example of the modified substance is a substance resulting from softening of a material of the to-be-joined members. In this case, softening of at least one of the to-be-joined members increases an anchoring effect with respect to the other member. As a result, the relative positions of the two to-be-joined members can more easily be fixed.
Because the modifier, i.e., the material used to form the easily-deformable layer, and the adhesive, i.e., the material used to join the first plate and the second plate, are common, the number of kinds of substances (constituent substances) used to manufacture the flow path chip can be reduced. In the case of performing a composition analysis by using the flow path chip, the smaller number of kinds of substances constituting the flow path chip implies that the number of substances, which may become impurities in the analysis, is smaller. Accordingly, it is expected that reduction in accuracy of the analysis is suppressed.
In the above-described flow path chip, the first plate and the second plate may be each made of a polyolefin-based material, and the adhesive may contain an alkane.
A member made of a polyolefin-based material can be joined to another member by using an alkane, and the polyolefin-based material can be softened (or modified) by the alkane. Accordingly, when the first plate and the second plate are each made of the polyolefin-based material and a joining material contains the alkane, the joining between the first plate and the second plate can be more reliably obtained, and the easily-deformable layer having effective properties can be more easily formed.
A manufacturing method for a flow path chip including a first plate having a first recess, a second plate having a second recess and joined to the first plate, and a porous body disposed between the first plate and the second plate, the flow path chip having a flow path formed by the first recess and the second recess, the flow path including a storage portion storing the porous body. The manufacturing method includes a first coating step of coating an adhesive to join the first plate and the second plate on at least one of a to-be-joined surface of the first plate to the second plate and a to-be-joined surface of the second plate to the first plate, a second coating step of coating the adhesive on at least part of a surface of the first recess and at least part of a surface of the second recess, and modifying at least part of the surface of the first recess and the surface of the second recess into a surface of an easily-deformable layer, a loading step of disposing a stored member including the porous body to be positioned in contact with at least one of the surface of the first recess and the surface of the second recess, and a joining step of joining the first plate and the second plate by contacting the to-be-joined surface of the first plate and the to-be-joined surface of the second plate with each other in an opposing relation, forming the flow path, which includes the storage portion storing the stored body, in a state that at least part of the easily-deformable layer is deformed by the stored member, and obtaining the flow path chip.
According to the above-described manufacturing method, since the material used to join the first plate and the second plate and the material used to form the easily-deformable layer are common, an increase in the number of kinds of materials necessary for the manufacturing is suppressed, and the flow path chip including the easily-deformable layer can be efficiently manufactured.
In the above-described manufacturing method, the first coating step and the second coating step may be performed as one step. According to this manufacturing method, since the material used to join the first plate and the second plate and the material used to form the easily-deformable layer are common, an operation of coating the adhesive on the to-be-joined surface of the first plate to the second plate and an operation of coating the adhesive on the surface of the first recess can be performed at the same time or in a continuous manner. Similarly, an operation of coating the adhesive on the to-be-joined surface of the second plate to the first plate and an operation of coating the adhesive on the surface of the second recess can be performed at the same time or in a continuous manner. Thus, the first coating step and the second coating step for the first plate or the second plate can be completed by one coating operation, and operation efficiency in an entire coating process can be increased. As a result, the flow path chip can easily be manufactured.
In the above manufacturing method, characteristics of the formed easily-deformable layer may be controlled by adjusting an amount of the adhesive per unit area coated on the at least part of the surface of the first recess and the surface of the second recess. Because the easily-deformable layer is formed through modification of the material constituting the first plate or the material constituting the second plate, characteristics (such as thickness (depth) and physical properties (softness)) of the formed easily-deformable layer can be controlled by adjusting the amount of the coated adhesive. It is hence possible to easily perform fine control of manufacturing conditions in such a manner as changing the characteristics of the formed easily-deformable layer depending on a shape of the stored member, including the porous body, which is sandwiched between the first plate and the second plate, and reducing the possibility of damage of the porous body in a more stable fashion. Accordingly, the flow path chip having higher quality can be manufactured.
An embodiment of the present invention will be described below with reference to the drawings. It is to be noted that similar constituent elements in the drawings are denoted by the same reference signs and detailed description of those constituent elements is omitted as appropriate.
The first plate 11 and the second plate 12 are joined to each other by using, as an adhesive, an n-alkane that is one type of alkanes. As mentioned above, the term “adhesive” used in this Description implies a material that contributes to fixing relative positions of (i.e., joining) two members to be joined (here, the first plate 11 and the second plate 12). Accordingly, at least one of the two to-be-joined members may be modified by the adhesive to form a modified substance, and those two members may be joined by the modified substance. In the flow path chip 10 according to this embodiment, one type of alkanes, particularly a linear alkane (n-alkane), is used as a material for forming the modified substance. The carbon number of the n-alkane is not limited to particular one, but it is preferably set to about 5 to 9 in some cases from the viewpoint of high easiness in handling and high strength of joining. Details of a joining method using the n-alkane will be described later.
As illustrated in
A column (processing body) 40 including a porous body 41 is disposed inside the storage portion 32. More specifically, the column 40 is sandwiched between the first plate 11 and the second plate 12.
In the flow path chip 10 according to this embodiment, the porous body 41 providing a stationary phase of the column 40 is a structural body having a monolithic structure and made of mainly silica (silica monolith). Because the silica monolith is a sintered body of silica gel, it is harder than the material (resin material) constituting the first plate 11 and the second plate 12, but is brittle.
The column 40 includes pressure adjustment portions 42 and 43, each having a columnar outer shape, at both ends of the porous body 41 in a flow direction therein. The pressure adjustment portions 42 and 43 have the function of adjusting flow of a fluid (blood as one practical example) flowing through the flow path FP formed in the flow path chip 10. In other words, the pressure adjustment portions 42 and 43 have substantially the same pressure loss as the porous body 41. With the provision of the pressure adjustment portions 42 and 43, the flow of the fluid fed under pressure is adjusted, and disturbance of the fluid passing through the column 40 is suppressed. Furthermore, the pressure adjustment portions 42 and 43 have the functions of a filter and a diffuser, and are made of a material harder than that of the column 40.
The column 40 includes a coating layer 44 positioned so as to cover the porous body 41 and the pressure adjustment portions 42 and 43. The coating layer 44 is made of, for example, a heat-shrinkable resin that is shrunk by heating. The coating layer 44 has the shape of a tube, and the column 40 having a columnar outer shape is formed by placing the porous body 41 and the pressure adjustment portions 42 and 43 into the tube, and by heating them. The type of the heat-shrinkable resin is not limited to particular one. Examples of the heat-shrinkable resin may include a tetrafluoroethylene-hexafluoropropylene copolymer (4,6-fluorinated ethylene propylene, FEP) and polyetheretherketone (PEEK). In use, when the fluid is supplied from the inflow portion 21 into the storage portion 32 through the first flow path 31, pressure at several MPa or higher is applied to the inside of the column 40. From the viewpoint of making a gap hard to be formed between the porous body 41 and the coating layer 44 even under such a condition, it is preferable to use PEEK as the heat-shrinkable resin. Using PEEK as the heat-shrinkable resin enables an analysis to be properly performed in some cases even when supply pressure of the fluid exceeds 10 MPa.
A first surface S1 among surfaces defining the recess of the first plate 11 constituting the storage portion 32, the first surface S1 being positioned to face the second plate 12, and a second surface S2 among surfaces defining the recess of the second plate 12 constituting the storage portion 32, the second surface S2 being positioned to face the first plate 11, are each a surface of an easily-deformable layer 321 (see
When the storage portion 32 of the flow path chip 10 does not include the easily-deformable layer 321, the bent portion BP of the column 40B is brought into direct contact with the material of the second plate 12 (i.e., the cycloolefin-containing polyolefin in the flow path chip 10 according to this embodiment). Because the recess formed in the second plate 12 and defining the storage portion 32 has a shape not corresponding to the bent portion BP of the column 40B, contact pressure at the bent portion BP is relatively high in the column 40B sandwiched between the first plate 11 and the second plate 12 in the storage portion 32. When a large external force is applied in accordance with the contact pressure, the column 40B may be damaged in the bent portion BP. If the column 40B is damaged, the flow path chip 10 can no longer fulfill the purpose of analyzing the fluid with the aid of the column 40B. Thus, pressure under which the first plate and the second plate are held in a sandwiched state (i.e., joining pressure) needs to be reduced in order to obtain the flow path chip 10 capable of performing the analysis with the aid of the column 40B including the bent portion BP illustrated in
In contrast, in the flow path chip 10 according to this embodiment, the first surface S1 and the second surface S2 of the storage portion 32 are each the surface of the easily-deformable layer 321. Therefore, the bent portion BP of the column 40B comes into contact with the easily-deformable layer 321 on the side closer to the second surface S2. In a contact portion, the easily-deformable layer 321 is preferentially deformed, and the external force applied to a porous body 41B, which is positioned in the bent portion BP of the column 40B is moderated. Moreover, because the easily-deformable layer 321 is also preferentially deformed in portions other than the bent portion BP, uniformity of the pressure applied to the column 40B in the storage portion 32 can be increased. Such an increase in uniformity of the pressure applied to the column 40B contributes to increasing accuracy of the analysis using the column 40B. In more detail, the coating layer 44 covering the porous body 41B can make the storage portion 32 of the flow path chip 10 and the porous body 41 held in a more closely contact state with a smaller gap between them. As a result, when the fluid is supplied to flow through the flow path FP of the flow path chip 10, it is possible to reduce a possibility of causing the problem that the fluid leaks through a joined interface between the first plate 11 and the second plate 12, and to allow the fluid to more stably pass through the porous body 41.
In this regard,
As mentioned above, the material of the easily-deformable layer 321 is not limited insofar as it is softer than the material constituting the first plate 11 and the second plate 12. In the flow path chip 10 according to the embodiment of the present invention, however, the easily-deformable layer 321 is preferably made of the modified substance that is formed through modification of each of the first plate 11 and the second plate 12 by a modifier. In other words, the material constituting the first plate 11 and the second plate 12 (i.e., the cycloolefin-containing polyolefin in the flow path chip 10 according to this embodiment) is preferably part of a direct material of the easily-deformable layer 321. The above point will be described in more detail below.
First, a problem attributable to the presence of the easily-deformable layer 321 at a position where it is not to be present is less apt to occur. When the easily-deformable layer 321 is additionally disposed as a separate member on the first plate 11 and/or the second plate 12 (by printing as one of practical means) instead of utilizing the modification, the easily-deformable layer 321 is formed at the position where it is not to be present, if a misalignment occurs in a step of disposing the easily-deformable layer 321. The easily-deformable layer 321 disposed at the position where it is not to be present is interposed between the first plate 11 and the second plate 12 to be joined to each other, thus causing a possibility of adversely affecting the joining between both the plates. In contrast, when the easily-deformable layer 321 is formed by utilizing the modification, there is no possibility that a problem is caused due to the presence of the separately-disposed member between the first plate 11 and the second plate 12 to be joined to each other.
Furthermore, a problem of peeling-off of the easily-deformable layer 321 from each of the first plate 11 and the second plate 12 is less apt to occur. If the peeling-off of the easily-deformable layer 321 occurs, the fluid is difficult to stably pass through the porous body 41 in some cases when the fluid is supplied into the flow path FP of the flow path chip 10.
In the flow path chip 10 according to this embodiment, the modifier used to form the easily-deformable layer 321 is made of an n-alkane that is the above-mentioned adhesive used to join the first plate 11 and the second plate 12. As described above, the n-alkane modifies the material constituting the first plate 11 and the second plate 12 and increases strength of joining between both the plates. The modified substance formed by the n-alkane has low mechanical characteristics, namely it is relatively soft. Therefore, the modified substance is preferable as the material of the easily-deformable layer 321. Because the modifier, i.e., the material used to form the easily-deformable layer 321, and the adhesive, i.e., the material used to join the first plate 11 and the second plate 12, are common, the number of kinds of substances (constituent substances) used to manufacture the flow path chip 10 can be reduced. In the case of performing a composition analysis by using the flow path chip 10, the smaller number of kinds of substances constituting the flow path chip 10 implies that the number of substances, which may become impurities in the analysis, is smaller. Accordingly, it is expected that reduction in accuracy of the analysis is suppressed by using the flow path chip 10 according to this embodiment.
A manufacturing method for the flow path chip 10 according to this embodiment is not limited. The flow path chip 10 can be efficiently manufactured by using the manufacturing method described below.
In the manufacturing method for the flow path chip 10 according to the embodiment of the present invention, as illustrated in
As illustrated in
As illustrated in
A method of preparing the first plate 11 and the second plate 12 is not limited. The first plate 11 and the second plate 12 may be obtained by molding such as injection molding. Alternatively, the first plate 11 and the second plate 12 may be formed by carrying out machining, such as grooving and drilling, on plate-like members. The molding and the machining may be carried out in a combined manner.
After preparing the first plate 11 and the second plate 12 (S101), as illustrated in
Then, as illustrated in
As illustrated in
Here, in at least part of the surface S21 of the first recess 132 and the surface S22 of the second recess 232, it is preferable to adjust the amount of the coated adhesive AD per unit area, and to control characteristics of the formed easily-deformable layer 321. In other words, because the easily-deformable layer 321 is formed through modification of the material constituting the first plate 11 or the material constituting the second plate 12 caused by the adhesive AD, the characteristics (such as thickness (depth) and physical properties (softness)) of the formed easily-deformable layer 321 can be controlled by adjusting the amount of the coated adhesive AD. It is hence possible to easily perform fine control of manufacturing conditions in such a manner as changing the characteristics of the formed easily-deformable layer 321 depending on a shape of the stored member (column 40B), including the porous body 41, which is sandwiched between the first plate 11 and the second plate 12, and reducing a possibility of damage of the porous body 41 in a more stable fashion. Accordingly, the flow path chip 10 having higher quality can be manufactured.
After forming the easily-deformable layer 321, as illustrated in
Thereafter, the first plate 11 including the easily-deformable layer 321 formed therein is placed on and contacted with the second plate 12 such that the to-be-joined surfaces S11 and S12 are positioned to face each other. Then, as illustrated in
Thus, the flow path FP which includes the storage portion 32 storing the column 40B is formed in such a state that at least part of the easily-deformable layer 321 is deformed by the column 40B, whereby the flow path chip 10 is obtained.
According to the above-described manufacturing method, since the material used to join the first plate 11 and the second plate 12 and the material used to form each easily-deformable layer 321 are common (i.e., the adhesive AD made of an n-alkane), an increase in the number of kinds of materials necessary for the manufacturing is suppressed, and the flow path chip 10 including the easily-deformable layer 321 can be efficiently manufactured.
Furthermore, according to the above-described manufacturing method, the first coating step of coating the adhesive AD on the to-be-joined surfaces S11 and S12 and the second coating step of coating the adhesive AD on the surface S21 of the first recess 132 and the surface S22 of the second recess 232 are performed as one step. Since the material used to join the first plate 11 and the second plate 12 and the material used to form each easily-deformable layer 321 are common (i.e., the adhesive AD), an operation of coating the adhesive AD on the to-be-joined surface S11 and an operation of coating the adhesive AD on the surface S21 of the first recess 132 in the first plate 11 can be performed at the same time or in a continuous manner. Similarly, an operation of coating the adhesive AD on the to-be-joined surface S12 and an operation of coating the adhesive AD on the surface S22 of the second recess 232 in the second plate 12 can be performed at the same time or in a continuous manner. Thus, the first coating step and the second coating step for the first plate 11 or the second plate 12 can be completed by one coating operation, and operation efficiency in an entire coating process can be increased. As a result, the flow path chip 10 can easily be manufactured.
The embodiments and the application examples have been described above, but the present invention is not limited to those embodiments and examples. For instance, other forms resulting from not only appropriately modifying the embodiments and the application example through addition, deletion, and design change of constituent elements by those skilled in the art, but also appropriately combining features of the embodiments with each other also fall within the scope of the present invention insofar as not departing from the gist of the present invention.
For instance, the material constituting each of the first plate 11 and the second plate 12 is not always required to be the resin material and to be optically transparent. When at least one of the first plate 11 and the second plate 12 has optical transparency, at least part of the second flow path 33 through which the fluid having passed through the column 40 flows has optical transparency. Accordingly, a separation state of the fluid can be optically measured in the second flow path 33.
While, in the flow path chip 10, the first plate 11 and the second plate 12 are joined to each other by using the adhesive AD made of an n-alkane, the present invention is not limited to that case. The first plate 11 and the second plate 12 may be joined to each other by fusion or by forming a layer made of another adhesive between both the plates.
While, in the flow path chip 10, the entire first surface S1 and the entire second surface S2 are each formed by the surface of the easily-deformable layer 321, the present invention is not limited to that case. In another example, adhesivity of the column 40 to the storage portion 32 may be increased by causing the pressure adjustment portions 42 and 43 to be partially deformed, without forming the easily-deformable layers 321 in regions where the pressure adjustment portions 42 and 43 are positioned.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2017-031010 | Feb 2017 | JP | national |
This application is a Continuation of International Application No. PCT/JP2018/002703 filed on Jan. 29, 2018, which claims benefit of Japanese Patent Application No. 2017-031010 filed on Feb. 22, 2017. The entire contents of each application noted above are hereby incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/JP2018/002703 | Jan 2018 | US |
| Child | 16525304 | US |
