Patent Application
20170326547
The present invention relates to a fluid handling device and a method of manufacturing the fluid handling device.
In recent years, microchannel chips have been used to accurately and speedily analyze a trace amount of a substance such as a protein or a nucleic acid. Microchannel chips have an advantage in that only a small amount of a reagent or a sample is required, and thus are expected to be used for various uses such as laboratory tests, food tests, and environment tests.
In such a microchannel chip, a microchannel which allows a reagent or a sample to flow therethrough is formed by bonding a substrate and a film together (see, for example, PTL 1).
A channel device (microchannel chip) disclosed in PTL 1 includes a substrate for a first channel device, a substrate for a second channel device, and a plastic film. A groove which will become a channel is formed in one surface of the substrate for a first channel device. In the channel device disclosed in PTL 1, one surface of the substrate for a second channel device and one surface of the plastic film are joined by thermal fusing. Subsequently, the surface of the substrate for a first channel device, in which the groove is formed, and the other surface of the plastic film are joined by thermal fusing. It is considered that a method of manufacturing the channel device disclosed in PTL 1 performs thermal fusing at a temperature considerably higher than the glass transition temperature of the plastic film to thereby strongly join the substrate for a first channel device and the substrate for a second channel device.
The method of manufacturing a channel device disclosed in PTL 1 joins a substrate for a first channel device and a substrate for a second channel device via a plastic film, which are not as flexible as the plastic film. It is considered that, during such a process, thermal fusing is performed at a temperature considerably higher than the glass transition temperature of the plastic film for firmly closing the groove with the plastic film to form a channel Accordingly, there is a disadvantage such that the plastic film deformed by heat to become flowable enters inside the groove to cause deformation of the shape of the channel.
An object of the present invention is to provide a fluid handling device in which substrates are suitably joined via film(s) without the shape of a channel being deformed, and a method of manufacturing the device.
A fluid handling device of the present invention includes a resin-made first substrate having a first surface in which a groove is formed; a resin-made first film joined to the first surface of the first substrate; a resin-made second film having a first surface joined to a second surface of the first substrate, the second surface of the first substrate being in a front-rear relation with the first surface of the first substrate; and a resin-made second substrate joined to a second surface of the second film, the second surface of the second film being in a front-rear relation with the first surface of the second film, in which a recess overlapping the groove in plan view is formed in a surface of the second substrate, the surface being joined to the second film, and following expression (1) is satisfied
Tg1s, Tg2s>Tg1f, Tg2f (1)
where Tg1s represents a glass transition temperature of the first substrate, Tg1f represents a glass transition temperature of the first film, Tg2s represents a glass transition temperature of the second substrate, and Tg2f represents a glass transition temperature of the second film.
Further, the method of the present invention for manufacturing a fluid handling device is a method of manufacturing the fluid handling device according to the present invention, in which joining between the first film and the first substrate, joining between the first substrate and the second film, and joining between the second film and the second substrate are each performed by thermal fusing.
According to the present invention, it is possible to provide a fluid handling device in which substrates are suitably joined without the shape of a channel being deformed.
In the following, embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the following description, as a typical example of a fluid handling device of the present invention, a microchannel chip will be described.
(Configuration of Microchannel Chip)
As shown in
Channel 220 is a channel for liquid to flow therethrough. Any liquid may flow through channel 220. Examples of the liquids include reagents and liquid samples. In addition, the viscosity of the liquid introduced to channel 220 is not limited as long as the liquid can advance in channel 220.
Channel 220 includes first branching channel 221, second branching channel 222 and combined channel 223. One end (upstream end) of first branching channel 221 communicates with first liquid introduction part 231 for introduction of liquid, and the other end (downstream end) communicates with second branching channel 222 and combined channel 223. One end (upstream end) of second branching channel 222 communicates with second liquid introduction part 232 for introduction of liquid, and the other end (downstream end) communicates with first branching channel 221 and combined channel 223. One end (upstream end) of combined channel 223 communicates with first branching channel 221 and second branching channel 222, and the other end (downstream end) communicates with communication part 250 communicating with liquid reservoir 240. Combined channel 223 and liquid reservoir 240 are disposed so as to overlap each other in plan view.
The cross-sectional area and cross-sectional shape of first branching channel 221, second branching channel 222 and combined channel 223 are not limited as long as liquid can move therethrough. The cross-sectional shapes of first branching channel 221, second branching channel 222 and combined channel 223 are, for example, a substantially rectangular shape with each side (width and depth) having a length of about several micrometers to several millimeters. In the present embodiment, both the cross-sectional areas and the cross-sectional shapes of first branching channel 221, second branching channel 222 and combined channel 223 are the same, with each of the channels having a width and depth of 50 μm. Further, first branching channel 221, second branching channel 222 and combined channel 223 each may be a channel with a width of about 1.0 mm and a depth of 0.1 mm, which allows liquid to advance therein by capillarity.
Liquid introduction parts 230 are inlets for introduction of liquid from outside to channel 220. Liquid introduction parts 230 include first liquid introduction part 231 and second liquid introduction part 232. First liquid introduction part 231 communicates with one end (upstream end) of first branching channel 221. The shape and the maximum diameter of first liquid introduction part 231 are not limited. In the present embodiment, the shape of first liquid introduction part 231 is cylindrical. In the present embodiment, the maximum outermost diameter (diameter) of first liquid introduction part 231 is set to a length so that a micro tip for introduction of liquid can be pressed in. This allows for introduction of liquid from first liquid introduction part 231 to first branching channel 221 while pressure is applied.
Second liquid introduction part 232 communicates with one end (upstream end) of second branching channel 222. The shape and the maximum outermost diameter of second liquid introduction part 232 are not limited. In the present embodiment, the shape of second liquid introduction part 232 is cylindrical. In the present embodiment, the maximum outermost diameter (diameter) of second liquid introduction part 232 is set to a length so that a micro tip for introduction of liquid can be pressed in. This allows for introduction of liquid from second liquid introduction part 232 to second branching channel 222 while pressure is applied.
Liquid reservoir 240 temporarily stores liquid. Liquid reservoir 240 communicates with the other end (downstream end) of combined channel 223 via communication part 250. The volume and the shape in plan view of liquid reservoir 240 are not limited.
Fluid discharging part 260 is an outlet for discharging fluid from liquid reservoir 240. Fluid discharging part 260 also functions as an air hole when liquid is introduced into channel 220, or enters liquid reservoir 240.
As shown in
One end (upstream end) of first branching groove 121 communicates with first through hole 124, and the other end (downstream end) of first branching groove 121 communicates with second branching groove 122 and combined groove 123. One end (upstream end) of second branching groove 122 communicates with second through hole 125, and the other end (downstream end) of second branching groove 122 communicates with first branching groove 121 and combined groove 123. One end (upstream end) of combined groove 123 communicates with first branching groove 121 and second branching groove 122, and the other end (downstream end) of combined groove 123 communicates with third through hole 126.
The thickness of first substrate 120 is not limited at a region where first branching groove 121, second branching groove 122, combined groove 123, first through hole 124, second through hole 125 and third through hole 126 are not formed. The thickness of first substrate 120 at the region is, for example, in a range of 1 to 10 mm. The type of resin composing first substrate 120 is not limited, and may be appropriately selected from publicly known resins. Examples of the resins composing first substrate 120 include cycloolefin polymers (COP), cycloolefin copolymers (COC), polyethylene terephthalate, polycarbonate, polymethylmethacrylate, polyvinyl chloride, polypropylene, polyether, polyethylene, polystyrene, silicone resins and elastomers. First substrate 120 can be manufactured by, for example, injection molding.
First branching channel 221, second branching channel 222 and combined channel 223 are formed by joining the first surface (front surface) of first substrate 120 and first film 140 so as to close openings of first branching groove 121, second branching groove 122 and combined groove 123.
As shown in
As shown in
Examples of the resins composing second film 160 include cycloolefin polymers, cycloolefin copolymers, polyethylene terephthalate, polycarbonate, polymethylmethacrylate, polyvinyl chloride, polypropylene, polyether, polyethylene, polystyrene, silicone resins and elastomers. The thickness of second film 160 may be appropriately set in accordance with the type (stiffness) of resin. In the present embodiment, second film 160 has a thickness of about 200 μm.
As shown in
Recess 183 opens at the first surface of second substrate 180, and communicates with sixth through hole 163 of second film 160. The shape in plan view, the volume and the like of recess 183 are not limited. The shape in plan view and the volume of recess 183 may be appropriately set in accordance with applications. Ninth through hole 184 is formed at the bottom surface of recess 183. Ninth through hole 184 opens at the bottom surface of recess 183 and at the second surface of second substrate 180. Ninth through hole 184 functions as fluid discharging part 260 or as an air hole when liquid is introduced.
Liquid reservoir 240 is formed by joining the second surface (rear surface) of second film 160 to the first surface (front surface) of second substrate 180 so as to close opening of recess 183. Further, liquid introduction parts 230 and fluid discharging part 260 are formed by joining the first surface (front surface) of second film 160, that is bonded to second substrate 180, to the second surface (rear surface) of first substrate 120 to which first film 140 is bonded. In a state where first film 140, first substrate 120, second film 160 and second substrate 180 are joined, combined groove 123 and recess 183 are disposed so as to overlap each other in plan view. The width of combined groove 123 is shorter than the length of recess 183 in the direction of the width at the same position as recess 183.
The thickness of second substrate 180 is not limited at a region where seventh through hole 181, eighth through hole 182, recess 183 and ninth through hole 184 are not formed. The thickness of second substrate 180 at the region is, for example, in a range of 1 to 10 mm. Examples of the resins composing second substrate 180 include cycloolefin polymers, cycloolefin copolymers, polyethylene terephthalate, polycarbonate, polymethylmethacrylate, polyvinyl chloride, polypropylene, polyether, polyethylene, polystyrene, silicone resins and elastomers. Second substrate 180 can be manufactured by, for example, injection molding.
The glass transition temperature Tg1s of first substrate 120, the glass transition temperature Tg1f of first film 140, the glass transition temperature Tg2s of the second substrate 180, and the glass transition temperature Tg2f of second film 160 satisfy the following expression (1)
Tg1s, Tg2s>Tg1f, Tg2f (1).
Any resins selected from the above-mentioned resins may be used for composing first substrate 120, first film 140, second film 160 and second substrate 180 as long as expression (1) is satisfied. Examples of combinations of commercially available resins which satisfy expression (1) include the following. ZEONEX F52R (Tg1s: 156° C.), Zeon Corporation can be used as a commercially available resin composing first substrate 120 and second substrate 180. ZEONOR Film ZF14 (Tg1f: 136° C.), Zeon Corporation can be used as a commercially available resin composing first film 140. ZEONOR 1060R (Tg2f: 100° C.), Zeon Corporation can be used as a commercially available resin composing second film 160. Tg1f≧Tg2f−5(° C.) is preferred, and Tg1f≧Tg2f(° C.) is more preferred for suppressing deformation of channel 220 in the case where the temperature for joining second film 160 to second substrate 180 is transferred to first film 140.
When the glass transition temperature Tg1s of first substrate 120 and the glass transition temperature Tg2s of second substrate 180 are lower than the glass transition temperature Tg1f of first film 140 and the glass transition temperature Tg2f of second film 160, first substrate 120 and second substrate 180 deform, and joining cannot be suitably performed.
Manufacturing Method of Microchannel Chip
The manufacturing method of microchannel chip 100 according to the present embodiment is not limited. For example, first substrate 120 and first film 140 may be joined at first joining temperature T1, followed by joining of second film 160 and second substrate 180 thereto at second joining temperature T2 (manufacturing method 1). First substrate 120, second film 160 and second substrate 180 may be joined at second joining temperature T2, followed by joining of first film 140 thereto at first joining temperature T1 (manufacturing method 2). It is necessary to set first joining temperature T1 so as not to cause deformation of the shape of a channel.
(Manufacturing Method 1)
As shown in
As shown in
(Manufacturing Method 2)
As shown in
As shown in
The first and second steps can be simultaneously performed. That is, thermal fusing by applying heat and pressure using heat plates may be performed while first film 140, first substrate 120, second film 160 and second substrate 180 are laminated.
(Method of Handling Microchannel Chip)
A method of handling (usage) of microchannel chip 100 will now be described. Firstly, microchannel chip 100 is disposed so that first liquid introduction part 231 and second liquid introduction part 232 open upward. At this time, liquid reservoir 240 is disposed above channel 220. A micro tip, filled with liquid, of a micro pipette is pressed into first liquid introduction part 231. At this time, the outer peripheral surface of the micro tip is closely fitted to the opening of first liquid introduction part 231, and thus the micro tip is fixed to first liquid introduction part 231.
Secondly, the liquid in the micro tip is introduced into first branching channel 221 with pressure from outside. As described above, since liquid reservoir 240 is disposed above channel 220, liquid cannot reach liquid reservoir 240 unless the liquid is introduced from first liquid introduction part 231 by applying pressure.
Introduction of liquid from second liquid introduction part 232 can be performed in the same manner as in the steps of introduction of liquid from first liquid introduction part 231. A micro tip, filled with liquid, of a micro pipette is pressed into second liquid introduction part 232. At this time, the outer peripheral surface of the micro tip is closely fitted to the opening of second liquid introduction part 232, and thus the micro tip is fixed to second liquid introduction part 232. The liquid in the micro tip is then introduced into second branching channel 222 with pressure from outside.
Introductions of liquid from first liquid introduction part 231 and second liquid introduction part 232 may be performed at the same time or different times.
These procedures allow for introduction of liquid to liquid reservoir 240 via first branching channel 221 and second branching channel 222.
(Effect)
As described above, first substrate 120 and second substrate 180 can be suitably joined in microchannel chip 100 according to Embodiment 1 because second film 160 and second substrate 180 are disposed to face the second surface, where first branching groove 121 is not formed, of first substrate 120; and Tg1s, Tg2s>Tg1f, Tg2f is satisfied when a glass transition temperature of the first substrate is Tg1s, a glass transition temperature of the first film is Tg1f, a glass transition temperature of the second substrate is Tg2s, and a glass transition temperature of the second film is Tg2f.
Microchannel chip 300 according to Embodiment 2 is different from microchannel chip 100 according to Embodiment 1 in the shapes of a second surface (rear surface) of first substrate 320 and a first surface (front surface) of second substrate 380. The configurations same as those of microchannel chip 100 according to Embodiment 1 are given the same symbols as those of microchannel chip 100, and the description thereof is omitted.
First substrate 320 includes first branching groove 121, second branching groove 122, combined channel 223, first through hole 124, second through hole 125 and third through hole 126. Recessed line(s) 322 is formed in the second surface (rear surface) of first substrate 320. The number and shape of recessed line(s) 322 are not limited. In the present embodiment, the number of recessed lines 322 is two. Recessed line 322 is disposed so that the ends thereof reach opposite two side surfaces. Recessed lines 322 may or may not be disposed parallel to each other. In the present embodiment, two recessed lines 322 are disposed parallel to each other. The cross-sectional shape of recessed line 322 is not limited. In the present embodiment, the cross-sectional shape of recessed line 322 is rectangular.
Second substrate 380 includes seventh through hole 181, eighth through hole 182, recess 183 and ninth through hole 184. Protruding lines 382 are formed on the first surface (front surface) of second substrate 380. Protruding line 382 is disposed at a position corresponding to recessed line 322 which is formed in first substrate 320. The number of protruding lines 382 is the same as that of recessed lines 322. Further, the cross-sectional shape of protruding line 382 is complementary to that of recessed line 322. In the present embodiment, the cross-sectional shape of protruding line 382 is rectangular. It is preferred that recess 183 is disposed at a region of second substrate 380 where seventh through hole 181, eighth through hole 182 and protruding line 382 are not formed. In the present embodiment, protruding line 382 is disposed at a region of second substrate 380 where seventh through hole 181, eighth through hole 182 and recess 183 are not formed.
Microchannel chip 300 according to the present embodiment can be manufactured in the same manner as in the steps for microchannel chip 100 according to Embodiment 1.
(Effect)
As described above, microchannel chip 300 according to Embodiment 2 has the same effects as that of microchannel chip 100 according to Embodiment 1. Further, since the second surface of first substrate 320 and the first surface of second substrate 380 are formed to be complementary in microchannel chip 300 according to Embodiment 2, the surface area of an area where first substrate 320 and second substrate 380 are in contact with each other becomes larger, and thus first substrate 320 and second substrate 380 can be more suitably joined.
While films 140 and 160, and substrates 120 and 180 are joined by thermal fusing in Embodiments 1 and 2, the surfaces of substrates 120 and 180 may be previously subjected to plasma or corona treatment in addition to thermal fusing. This allows the crosslinking strength to become increased during joining between substrates 120 and 180, and films 140 and 160, and thus first substrate 120 and second substrate 180 can be more strongly joined. A solvent such as acetone or ethanol, or an adhesive may be applied between films 140 and 160, and substrates 120 and 180. Joining by means of a laser may be used together.
Before the above-mentioned thermal fusing, a glass transition temperature(s) of first film 140 and/or second film 160 may be lowered by irradiation of first film 140 and/or second film 160 with ultraviolet rays. This allows for suppression of production costs by lowering the temperature required for the thermal fusing.
While recess 183 is disposed in second substrate 180 in Embodiments 1 and 2, another channel (second channel) communicating with channel 220 may be disposed in second substrate 180. Further, while an example in which two substrates 120 and 180, and two films 140 and 160 are joined is described in Embodiments 1 and 2, the number of substrates and films each may be 3 or more.
This application claims priority based on Japanese Patent Application No. 2014-250262, filed on Dec. 10, 2014, the entire contents of which including the specification and the drawings are incorporated herein by reference.
The fluid handling device of the present invention is particularly advantageous, for example, as a microchannel chip used in scientific fields, medical fields and the like.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2014-250262 | Dec 2014 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2015/080581 | 10/29/2015 | WO | 00 |
