This invention relates generally to microsystems, and in particular, to a micro device incorporating a programmable rotational element for acting on a fluid flowing therepast.
As is known, Microsystems have emerged as a useful tool in such areas as electronics, research and clinical medicine. Microsystems are considered to be any device or unit made up of a number of microengineered and/or micromachined components, such as miniature pumps and valves. In an attempt to develop Microsystems that perform more complex functions, ongoing research is being conducted in the area of microelectromechanical systems (MEMS). Due to various innovations in the integrated circuit industry (e.g., micromachining), the development of microsystems has progressed rapidly. For example, various microsystems which incorporate microengineered and/or micromachined components such as sensors, actuators, valves and the like are now widely used in academia. These microsystems are designed for various applications, including microfluidics and drug delivery.
Further expansion of the uses for microsystems has been limited due to the difficulty and expense of fabrication. While silicon-based Microsystems have proven well suited to optical and physical sensing applications, the use of silicon-based devices in other applications is not straightforward. Silicon-based approaches typically rely on actuation methods (electrostatic, thermal, electromagnetic) that are not suitable for direct interface with liquid and organic systems. In addition, the integration of microscale valves and other microscale components into micro devices has proven problematic. Often, the manufacturing process that provides a useful microscale valve is vastly different from the manufacturing process that provides a useful microscale pump or sensor. Hence, different device components necessarily require different materials for construction and different types of manufacturing steps. As a result, the integrating of several microengineered components into a single micro device is both time consuming and expensive.
In order to overcome the limitations of prior MEMS technology, polymer-based fabrication techniques have been developed. During polymer-based fabrication, liquid-phase photopolymerization is utilized to allow for the rapid creation of microcomponents. As a result, photosensitive polymers can be patterned within a micro device without the additional necessity of a clean-room environment. Further, liquid-phase photopolymerization is a low-temperature process (<100 degrees Celsius) and allows the fabricator to construct a desired microcomponent at a designated area on a substrate. Hence, it is highly desirable to provide a method of fabricating a micro device that leverages the advantages of both silicon-based Microsystems with polymer-based fabrication techniques.
Therefore, it is a primary object and feature of the present invention to provide a micro device that incorporates a programmable element that functions without on-chip wiring or electricity.
It is a further object and feature of the present invention to provide a micro device that is simple and inexpensive to manufacture.
It is a still further object and feature of the present invention to provide a micro device that may be customized to a particular application without undue additional expense.
In accordance with the present invention, a micro device is provided that includes a body defining a chamber. The chamber has an input and an output for accommodating the flow of fluid therebetween. The micro device includes a moveable element disposed in the chamber and a clutch mechanism engageable with the moveable element for controlling the movement thereof.
The clutch mechanism has a first configuration wherein the moveable element is fixed in position and a second configuration wherein the moveable element is free move along a path. The clutch mechanism includes a polymeric material having a volume responsive to the value of an environmental property such as the pH or temperature of the fluid. The material has a first volume in response to the environmental property having a first value and a second volume in response to the property having a second value.
The moveable element includes a central hub that may have a blade extending radially therefrom and an opening therein for receiving the polymeric material. The opening is defined by an inner hub surface that is engaged by the polymeric material when the polymeric material has the second volume. As a result, the polymeric material prevents movement of the moveable element.
In a first embodiment, the blade has a terminal end radially spaced from and interconnected to the central hub by a generally arcuate edge. Alternatively, the blade may include first and second edges extending radially from the central hub and diverging from each other. It is contemplated for an alternate embodiment of the moveable element to include a radially outer edge having a plurality of teeth circumferentially spaced thereabout.
In accordance with a further aspect of the present invention, a micro device is provided that includes a body defining a chamber. The chamber has an input and an output for accommodating the flow of fluid therebetween. A rotational element is disposed in the chamber. The rotation element includes a central hub and is rotatable about an axis. A clutch mechanism is engageable with the rotational element in response to an environmental property. The clutch mechanism controls rotation of the rotational element.
The central hub of the rotational element has an opening therethrough for receiving a post disposed in the chamber. The clutch mechanism includes a polymeric material that extends about the post and that has a volume responsive to the value of the environmental property, such as the pH or temperature of the fluid. The polymeric material has a first volume in response to the property having a first value and a second volume in response to the property having a second value. The opening through the central hub of the rotational element is defined by an inner hub surface. In its second volume, the polymeric material engages the inner hub surface and prevents rotation of the rotational element.
In a first embodiment, the blade has a terminal end radially spaced from and interconnected to the central hub by a generally arcuate edge. Alternatively, the blade may include first and second edges extending radially from the central hub and diverging from each other. An alternate embodiment of the rotational element includes a radially outer edge having a plurality of teeth circumferentially spaced thereabout.
In accordance with a still further aspect of the present invention, a micro device is provided. The micro device includes a body defining a chamber for receiving fluid. A moveable element is disposed in the chamber and is moveable along a predetermined path in response to an external stimulus. The micro device further includes a clutch mechanism having a first disengaged configuration and a second engaged configuration wherein the clutch mechanism engages the moveable element.
The clutch mechanism is movable between the disengaged configuration and the engaged configuration in response to an environmental property, such as the pH or temperature of the fluid. The moveable element includes a central hub having an opening therethrough for receiving a post disposed in the chamber. The clutch mechanism includes polymeric material extending about the post. The polymeric material has a volume responsive to the value of the environmental property. The polymeric material is spaced from the moveable element with the clutch mechanism in the first disengaged configuration and the polymeric material engages the moveable element with the clutch mechanism in the second engaged configuration.
The body defines a first input channel having an output communicating with the chamber and an output channel having an input communicating with the chamber. In a first embodiment, the body may define a second input channel having an output communicating with the chamber. Alternatively, the body may define a feedback channel having an input communicating with the output channel downstream of the chamber and an output communicating with the input channel upstream of the chamber.
The drawings furnished herewith illustrate a preferred methodology of the present invention in which the above advantages and features are clearly disclosed as well as others which will be readily understood from the following description of the illustrated embodiment.
In the drawings:
a is a cross-sectional view of the completed micro device of the present invention with the hydrogel clutch mechanism thereof in an expanded configuration;
a is a top plan view of a first embodiment of a rotational element for the micro device of the present invention;
b is a top plan view of a second embodiment of a rotational element for the micro device of the present invention;
c is a top plan view of a third embodiment of a rotational element for the micro device of the present invention;
d is a top plan view of a fourth embodiment of a rotational element for the micro device of the present invention;
e is a top plan view of a fifth embodiment of a rotational element for the micro device of the present invention; and
Referring to
Optical mask 13 is spaced from upper surface 12 of slide 14 by a plurality of pieces 15a-15d of double sided adhesive tape so as to define a cavity therebetween. Mask 13 includes a plurality of fill holes 17a-17d to allow the cavity to be filled with a polymerizable material, e.g. a pre-polymer mixture of poly-isobornylacrylate, tetraethylene glycol dimethacrylate, and 2,2-dimethoxy-2-phenylacetophenone, and pattern 19 thereon corresponding to the desired shape to be transferred to the polymerizable material, as hereinafter described. Ultraviolet light generated by UV source 55,
Referring to
Referring to
Gasket 32 includes an upper surface 34 affixed to lower surface 20 of cartridge 16 adjacent the outer periphery thereof. Lower surface 36 of gasket 32 is affixed to upper surface 12 of microscope slide 14. As assembled, inner surface 38 of gasket 32, lower surface 20 of first layer 16 and upper surface 12 of microscope slide 14 define a cavity 40 for receiving polymerizable material 42 therein,
Referring to
As best seen in
Referring to
After formation of channel network 46, hydrogel 66 is injected into channel network 46 through any one of the openings 30a, 30c or 30d through the cartridge 16 and optical mask 68 is affixed to upper surface 18 of first layer 16,
In operation, it is contemplated to expose micro device 10 to an external stimulus such as an electric field or a rotating magnetic field so as to cause rotational element 23 to rotate in a user desired direction about post 51. First and second fluids may be introduced into channel network 46 at openings 30a and 30c in cartridge 16 so as to flow towards central chamber 56. As the first and second fluids flow into central chamber 56, mixing blades 27a-27d engage the first and second fluids causing such fluids to mix. Thereafter, due to the flow rates and pressures of the first and second fluids, the mixed fluid is urged into third leg 62 in channel network 46 toward opening 30e in cartridge 16. In response to a change in a predetermined environmental parameter, the volume of hydrogel 66 may increase to such point that hydrogel 66 engages inner surface 25a of central hub 25 of rotational element 23 thereby slowing the rate of rotation of rotational element 23 about post 51. It can be appreciated that if the predetermined environmental parameter reaches a predetermined level or value, hydrogel 66 will expand to such a volume as to prevent the further rotation of rotational element 23 despite the presence of the rotating magnetic field. It is contemplated for hydrogel 66 to expand to such a volume as to overlap portions of the upper and lower surfaces of rotational element 23. Once the level of the predetermined environmental parameter drops below the predetermined level, the volume of hydrogel 66 will shrink thereby allowing rotational element 23 to, once again, rotate about post 51.
Alternatively, in response to the predetermined environmental parameter reaching a predetermined level or value, hydrogel 66 may expand into a mushroom cap shaped configuration,
The efficiency of the mixing process within central chamber 56 is dependant on a variety of variables, including the dimensions of mixing blades 27a-27d, the diameter of central chamber 56, the flow rates and pressure of the first and second fluids flowing into central chamber 56 and the diameters of first, second, and third legs 58, 60 and 62, respectively, of channel network 46. As such, alternate rotational elements 70a-70d are contemplated as being within the scope of the present invention,
Referring to
Referring to
Referring to
It can be appreciated that channel network 46 may be fabricated to have different configurations within micro device 10 by simply varying the configurations of optical mask 44. In addition, it is contemplated as being within the scope of the present invention for micro device 10 to perform additional tasks beyond mixing. As such, rotational element 23 may take the form of a moveable element that moves along a linear path, arc-like path, or even an arbitrary part in response to a stimulus provided on micro device 10. Alternatively, as best seen in
Referring to
In operation, micro device 92 is exposed to an external stimulus such as an electric field or a rotating magnetic field so as to cause rotational element 23 to rotate in a user desired direction about the post 51 and hydrogel 66 combination. A first fluid is introduced into channel network 94 at opening 30c in cartridge 16 and flows toward central chamber 96 through input leg 98. As the first fluid flows into central chamber 96, blades 27a-27d engage the first fluid, thereby pumping such fluid into output leg 100. A portion of the first fluid returns to input leg 98 through feedback channel 102. In response to a change in a predetermined environmental parameters, the volume of hydrogel 66 increase to such point that hydrogel 66 engages inner surface 25a of central hub 25 of rotational element 23 thereby slowing the rate of rotation of rotational element 23 about post 51 and slowing the pumping of the first fluid into output leg 100. It can be appreciated that if the predetermined environmental parameter reaches a predetermined level, hydrogel 66 will expand to such a volume as to prevent the further rotation of rotational element 23. As heretofore described, hydrogel 66 may expand to such a volume as to overlap to upper surface of rotational element 23 or portions of the upper and lower surfaces of rotational element 23. Once the level of the predetermined environmental parameter drops below the predetermined level, the volume of hydrogel 66 will shrink thereby allowing rotational element 23 to, once again, rotate about post 51 and pump the first fluid into output leg 100.
As described, the method of fabrication provided herein may be used as a stand-alone process or to append an existing procedure. Unlike conventional lithography that requires the spinning and/or casting of photosensitive materials on entire substrates, liquid-phase photopolymerization can occur at designated areas on a substrate. The process can also be appended to MEMS structures that have been previously released. Since the process described herein is liquid based, topography in not a significant concern. In addition, the ability to control component operation via local fluid parameters expands control scheme possibilities while in situ processing simplifies fabrication and eliminates the need for assembly. Further, it can be appreciated that the method of fabricating micro device 10 described herein is merely exemplary and that micro device 10 may be fabricated in other manners without deviating from the scope of the present invention.
Various modes of carrying out the invention are contemplated as being within the scope of the following claims particularly pointing out and distinctly claiming the subject matter that is regarded as the invention.
This application claims the benefit of U.S. Provisional Application Ser. No. 60/572,983, filed May 20, 2004.
This invention was made with United States government support awarded by the following agencies: DOD ARPA F30602-00-2-0570. The United States has certain rights in this invention.
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