This specification relates to micro-based systems and more particularly to micro pump systems/devices.
Mechanical pump systems and compressor systems are well-known. Pumps are used to move fluid (such as liquids or gases or slurries) by mechanical action. Pumps can be classified according to the method used to move the fluid, e.g., a direct lift pump, a displacement pump, a peristaltic pump, and a gravity pump. Micro pumps are now also known. One example of a micro pump is described in my published application US-2015-0267695-A1, published Sep. 24, 2015 filed Feb. 26, 2015 the entire contents of which are incorporated herein by reference. Techniques for fabricating such micro pumps are also disclosed in the above mentioned published application. Also disclosed in my published application US-2016-0131126-A1, published May 12, 2016 and filed Oct. 29, 2015 the entire contents of which are incorporated herein by reference, are additional micro pump examples, exemplary applications and microelectromechanical systems (MEMS) fabrication techniques including roll to roll processing.
Described are peristaltic micro pump systems. Exemplary techniques to fabricate such peristaltic micro pump systems include using lithographic etching and patterning techniques as well as roll to roll fabrication techniques.
The described peristaltic micro pump systems are provided by cascade connecting individual micro pump units. These units do not include internal, fixed inlet and outlet valve members/structures such as those disclosed in the above applications. By operating the individual micro pump units in a phased sequence, such operation can effectively provide inlet and outlet isolation functions, thus obviating the need for fixed internal inlet valve structures and outlet valve structures.
According to an aspect, a micro pump includes a plurality of micro pump elements, each micro pump element including a pump body having walls that enclose a pump chamber that is compartmentalized into plural compartments, a plurality of inlet ports each with unobstructed fluid ingress into corresponding ones of the plural compartments and a plurality of outlet ports each with unobstructed fluid egress from corresponding ones of the plural compartments, a plurality of membranes disposed in the pump chamber, with the plurality of membranes affixed to the walls of the pump body, and which compartmentalized the chamber to provide the plural compartments, and a plurality of electrodes, with a first pair of the plurality of electrodes disposed on a pair of opposing walls of the pump body, and each of the remaining ones of the plurality of electrodes disposed on a major surface of a corresponding one of the plurality of membranes, with the plurality of micro pump elements arranged in a series connected configuration that has outlets of a first one of the plurality of micro pump elements fluidly connected to inlets of an immediately adjacent one of the plurality of micro pump elements.
Other aspects include methods of manufacture and methods of use.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention are apparent from the description and drawings, and from the claims.
Referring now to
The pumping direction is shown by arrow 15. However, as explained below, the pump direction is dynamically reversible. That is, as will be discussed below the designation of ports as inlets or outlets is with respect to drive sequences. The walls 12a, 12b, 12c and 12d, and the two walls (not shown) of the pump body define the single chamber 14. The single chamber 14 is compartmentalized by membranes 18a-18f that are anchored or affixed to two opposing walls, e.g., the two walls 12c, 12d (also referred to herein as endcaps 12c, 12d). The membranes 18a-18f are disposed to extend from the wall 12a to the wall 12b and the two walls that are not shown in this view. The membranes 18a-18f separate the pump chamber 14 into seven compartments 21a-21g. (In an implementation, the walls 12a, 12b, 12c and 12d of the pump body are provided by stacking of micro pump modules as will be discussed below.)
In this implementation, each compartment 21a-21g includes a pair of ports 22, 24. For discussion purposes, an inlet is generally designated as 22 and an outlet is generally designated as 24. These ports 22, 24 are illustrated in phantom in
For example, the compartment 21a includes inlet 22 in the wall 12a and outlet 24 in the wall 12b, with the compartment 21a being defined by a portion of the wall 12a, the wall (or endcap) 12c, a portion of the wall 12b, the two walls (not shown in
The compartment 21g (like compartment 21a) at the opposite end of the pump chamber 14 is defined by the fixed wall (or endcap) 12d of the pump body 12, the two walls (not shown), and the corresponding membrane 18f All intermediate compartments 21b-21f between the compartments 21a, 21g have walls formed by two membranes and corresponding portions of the walls 12a and 12b and the two walls (not shown). In some embodiments of the micro pump stack element 10, there is at least one intermediate compartment defined by portions of walls 12a, 12b and two membranes. Although six membranes (and five intermediate compartments) are shown in the figures, the pump chamber can be extended or reduced with additional or fewer intermediate compartments. The compartments 21a-21g are fluidically isolated from each other.
An electrode (not explicitly shown in
Without activation, the membranes rest at nominal positions as shown in
In the implementations, where the compartments 21a, 21g each have the nominal volume Vj that is half the nominal volume of the intermediate compartments 21b-21f, the distance between the membrane 18a, 18g in their nominal positions and the end walls 12c or 12d is about 25 microns. The nominal volume Vi can range from nanoliters to microliters to milliliters, e.g., 0.05 microliters. The compartments can also have different dimensions. The dimensions are chosen based on, e.g., specific process requirements, as well as, power consumption, application considerations and so forth.
For example, the compartments 21a, 21b having a width of 25 microns can allow a start-up function with a reduced peak drive voltage. Drive voltages are discussed further below. As an example, the micro pump element 10 can have an internal volume having a length of about 1.5 mm, a width of about 1.5 mm, a total height (the cumulative height of different compartments) of 0.05 mm, and a total volume of about 0.1125 μl.
One application of the micro pump element 10 is as a basic unit to build a series connected micro pump of which a peristaltic micro pump is a specific example, all of which is discussed in
Voltages are applied to the membranes 18a-18f according to a sequence. In response to a one portion of such as sequence, a compartment, e.g., compartment 21a, is compressed when the adjacent membrane 18a defining that compartment moves towards the endcap 12c (see
As shown in
Referring now to
Referring now to
The series configuration of plural micro pump elements 10a-10c (using the stack 10 of
In the series configuration 30, each of the plural micro pump stacks 10a-10c has pairs of ports. These ports operate as either inlets or outlets or in some implementations can be i/o (inlet/outlet) ports that can change function (inlet or outlet) dynamically and pump accordingly. For discussion purposes inlet ports are referred to as 22 and outlet ports are referred to as 24. These ports 22, 24 are illustrated in phantom in
The series configuration 30 of the micro pump elements 10a-10c shows the inlet ports 22 and the outlet ports 24 on opposing walls of the pump body. This is generally desirable, but not necessarily a requirement. Also in the series configuration 30, the micro pump stacks 10a and 10c operate as either input stages or output stages or I/O (input/output) pump stages whose functions can be changed dynamically, and the micro pump stack 10b being the middle stack operates as an interior isolation pump stage. The inlet ports 22 of the input stage 10a connect to a source of fluid and the outlet ports 24 of a last one of the micro pump elements 10a-10c are configured to connect to a sink to store pressurized fluid from the micro pump.
For discussion purposes, inlets are generally 22 and outlets are generally 24 and stage 10a is an input stage and 10c is an output stage. Thus, inlets 22a of the micro pump stack 10a are fluidly coupled to a source of fluid, such as a liquid or gas, e.g., ambient air. Outlets 24a of the micro pump stack 10a are fluidly coupled to inlets 22b of the micro pump stack 10b. Outlets 24b of the micro pump stack 10b are fluidly coupled to inlets 22c of the micro pump stack 10c and outlets 24c of the micro pump stack 10c are fluidly coupled to a sink for fluid pumped through the pump. This sink can be pressurized air from the ambient that is blown out of the micro pump or stored for instance in a tank (not shown).
Each of the micro pump stacks 10a-10c are driven using circuitry discussed below and driven according to phases such as those of
Compared to a conventional pump used for similar purposes, the series configuration 30 and the micro pump elements 10a-10c use less material that is subject to less stress, and are driven using less power. The series configuration 30 has a size in the micron to millimeter scale, and can provide wide ranges of flow rates and pressure. Generally, the flow rate can be in the scale of microliters to milliliters. An approximate flow rate provided by a micro pump can be calculated as:
Flow Rate is given approximately by the total volume of the micro pump×drive frequency×(l-loss factor).
Generally, the pressure is affected by how much energy, e.g., the drive voltage, is put into the micro pump 30. In some implementations, the higher the voltage, the larger the pressure. The upper limit on voltage is defined by break down limits of the series configuration 30 and the lower limit on the voltage is defined by a membrane's ability to sufficiently flex in response to the voltage. The pressure across a series configuration 30 can be in the range of about micro psi to tenths of a psi. A selected range of flow rate and pressure can be accomplished by selection of pump materials, pump design, and pump manufacturing techniques.
One described version of the series configuration 30 is a peristaltic type pump in the displacement type category. In one implementation, pumping occurs according to six phases, as set out in
In operation, the membrane of a conventional pump (not including the micro pump discussed in the above incorporated by reference application) typically, the pump has a single pump chamber that is used in pumping. Gas is charged and discharged once during the charging and discharging operations of a pumping cycle, respectively. The gas outflows only during half of the cycle, and the gas inflows during the other half of the cycle.
In the instant series configuration 30 each compartment is used in pumping. For example, two membranes between two fixed end walls form three compartments for pumping. The micro pump can have a higher efficiency and can consume less energy than a conventional pump performing the same amount pumping, e.g., because the individual membranes travel less distance and therefore are driven less. The efficiency and energy saving scales as the number of membranes and compartments between the two fixed end walls increases.
Generally, to perform pumping, each compartment includes a gas inlet and a gas outlet. The inlet and the outlet are valve-less, e.g., there are neither passive nor active valves that open or close in response to pressure applied to the valves, in contrast to the embodiments discussed in the above incorporated by reference application.
Referring now to
In this alternative series configuration 30′, the micro stack generally 10 effectively has three stages of a general stack 10 and has pairs of ports generally 22 and 24. The effective three stages of the general stack 10 is provided by a specific patterned electrode element 27 on the membranes and end caps (not referenced, but see
Also in this series configuration 30′ the specific patterned electrode element 27 comprises three, spaced and electrically isolated electrode regions 27a, 27b, 27c. These electrode regions are activated according to the same phases and signals discussed below. Presuming that the micro pump stack 10 has a suitable aspect ratio of width of electrode regions to height of compartments that is sufficiently low to enable the membrane to flex in three regions, similar to the arrangement of
In the implementation of
The membranes are driven to move (flex) by electrostatic force. An electrode is attached to each of the fixed end walls and the membranes. During the charging operation of a compartment, two adjacent electrodes of the compartment have the same positive or negative voltages, causing the two electrodes and therefore, the two membranes to repel each other. During the discharging operation of a compartment, two adjacent electrodes of the compartment have opposite positive or negative voltages, causing the two electrodes and therefore, the two membranes to attract to each other. This is evident in
The two electrodes of a compartment form a parallel plate electrostatic actuator. The electrodes generally have small sizes and low static power consumption. A high voltage can be applied to each electrode to actuate the compartment while the actuation is performed at a relatively low current.
As described previously, each membrane of the micro pump moves in two opposite directions relative to its central, nominal position. Accordingly, compared to a compartment in a conventional pump, to expand or reduce a compartment by the same amount of volume, the membrane of this specification travels a distance less than, e.g., half of, the membrane in the conventional pump. As a result, the membrane experiences less flexing and less stress, leading to longer life and allowing for greater choice of materials. The starting drive voltage for the electrode on the membrane needs be sufficient to drive the membranes such that each travels at least half of the distance or over half the distance, which would slightly flatten the membranes where a pair of driven membranes touched. For a compartment having two membranes, since both membranes are moving, the time it takes to reach the pull-in voltage can be shorter.
Microelectromechanical systems such as micro pumps having the above described features are fabricated using roll to roll (R2R) processing. Roll-to-roll processing is becoming employed in manufacture of electronic devices using a roll of flexible plastic or metal foil as a base or substrate layer. Roll to roll processing has been used in other fields for applying coatings and printing on to a flexible material delivered from a roll and thereafter re-reeling the flexible material after processing onto an output roll. After the material has been taken up on the output roll or take-up roll the material with coating, laminates or print materials are diced or cut into finished sizes.
Below are some example criteria for choosing the materials of the different parts of the micro pump.
Pump body—The material used for the body of a pump needs to be strong or stiff enough to hold its shape to provide the pump chamber volume. In some implementations, the material is etch-able or photo-sensitive so that its features can be defined, machined and/or developed. Sometimes it is also desirable that the material interact well, e.g., adheres with the other materials in the micro pump. Furthermore, the material is electrically non-conductive. Examples of suitable materials include SU8 (negative epoxy resist), and PMMA (Polymethyl methacrylate) resist, Polyvinylidene fluoride (PVDF), Polyethylene terephthalate (PET), Polytetrafluoroethylene (PTFE) such as Teflon® The Chemours Company.
Membrane—The material for this part forms a tympanic structure (a thin tense membrane covering the pump chamber) that is used to charge and discharge the pump chamber. As such, the material is required to bend or stretch back and forth over a desired distance and has elastic characteristics. The membrane material is impermeable to fluids, including gas and liquids, is electrically non-conductive, and possesses a high breakdown voltage. Examples of suitable materials include silicon nitride and Polyvinylidene fluoride (PVDF), Polyethylene terephthalate (PET), Polytetrafluoroethylene (PTFE) such as Teflon® The Chemours Company.
Electrodes—These structures are very thin and comprised of material that is electrically conductive. Because the electrodes do not conduct much current, the material can have a high electrical sheet resistance, although the high sheet resistance feature is not necessarily desirable. The electrodes are subject to bending and stretching with the membranes, and therefore, it is desirable that the material is supple to handle the bending and stretching without fatigue and failure. In addition, the electrode material and the membrane material will need to adhere well to each other, e.g., will not delaminate from each other, under the conditions of operation. Examples of suitable materials include aluminum, gold, and platinum.
Electrical interconnects—The drive voltage is conducted to the electrode on each membrane of each compartment. Electrically conducting paths to these electrodes can be built using conductive materials, e.g., aluminum, gold, and platinum.
Referring now to
Referring to
Specific details on modularized micro pump fabrication using silicon based lithographic as well as roll to roll processing are discussed below.
Referring now to
The membrane 52, the pump end cap 44, and the pump body 50 can have the same dimensions, and the electrodes 48, 54 can have smaller dimensions than the membrane 52 and the other elements. In some implementations, the membrane 52 has a dimension in a range of about a hundred microns to millimeters up to about several centimeters for thicknesses of about 5 microns. For thinner membranes, the dimensions can be smaller. The limit on the low end of the thickness range is up to where there is no permanent deformation of the membrane. For the higher end of the thickness range the limit is where membrane remains tympanic. The pump body 50 would have corresponding dimensions. The thickness of the pump body defines the nominal size of the compartment 49 (similar to compartments
Referring to
A charging operation is established when pressure external to a module layer is larger than pressure inside the module layer, and thus a fluid flows from outside the module layer into the compartment. When the internal pressure is higher than the external pressure, a discharge operation is established and fluid flows from the compartment away to the outside of the module layer. Discharge occurs by displacement meaning that the pump can discharge fluid at ambient pressure. During the discharge operation, the fluid in the compartment does not flow out from the inlet due to the configuration, as driven as discussed below. Effectively, during the charging operation, the outlet is closed so that the fluid does not flow out of the compartment, and during the discharging operation, the outlet is open and the fluid flows out of the compartment.
Referring now to
Referring now to
The micro pump stacks 10a-10c are driven according to the phases denoted in the peristaltic sequence. Other sequences may be possible. In the peristaltic sequence, as shown in
The first stack 10a inputs air into channels 1, 3, 5, and 7 (compartments 18a, 18c, 18e and 18g
Simultaneously, the first stack 10a closes off channels 2, 4, and 6 (compartments 18b, 18d, and 18f
Meanwhile, the second stack 10b has its compartments 18b, 18d and 18f obstructed by the membranes in compartments 18a, 18c, 18e and 18g of the first stack 10a and by the membranes in compartments 18a, 18c, 18e and 18g of the third stack 10c, thus effectively providing functionality of valves at inlets and outlets of the second stack 10b. Any air that was in the compartments 18a, 18c, 18e and 18g of the first stack and the third stack is pumped into compartments 18b, 18d and 18f of the second stack and in this example the output of the micro pump 30.
For example, referring back to
The material of the membranes and the voltages to be applied to the membranes and the end walls are chosen such that when activated, each membrane expands at least half the distance d between the nominal positions of adjacent membranes and in some implementations the membrane can be driven to expand an additional amount more than half of the distance (thus distorting the membranes somewhat). In the end compartments where the distance between the nominal position of the membrane and the fixed wall is d 2, the activated membrane reduces the volume of the compartment to close to zero (in a discharging operation) and expands the volume of the compartment to close to 2*Ve. For the intermediate compartments, by moving each membrane by d/2, a volume of a compartment is expanded to close to 2*Vi in a charging operation and reduced to close to zero in a discharging operation. The micro pump can operate at a high efficiency.
The period of the pumping cycle can be determined based on the frequency of the drive voltage signals. In some implementations, the frequency of the drive voltage signal is about Hz to about KHz, e.g., about 2 KHz. A flow rate or pressure generated by the pumping of the micro pump can be affected by the volume of each compartment, the amount of displacement the membranes make upon activation, and the pumping cycle period. Various flow rates, including high flow rates, e.g., in the order of ml/s, and pressure, including high pressure, e.g., in the order of tenths of one psi, can be achieved by selecting the different parameters, e.g., the magnitude of the drive voltage. As an example, a micro pump can include a total of 15 module layers.
The sets of electrical signals are applied to the micro pump elements such that a first set of the electrical signals cause in a first one of the plurality of micro pump elements, a first one of the plural compartments to compress and at least one adjacent one of the plural compartments to expand substantially simultaneously and a second set of the electrical signals applied simultaneously with the first set to cause in a second, adjacent one of the plurality of micro pump elements a first one of the plural compartments to expand and at least one adjacent one of the plural compartments to compress substantially simultaneously. Other sets of electrical signals cause corresponding actions, especially according to a peristaltic sequence having six phases, which for a micro pump where the plurality of micro pump elements consist essentially of an input element, a pump element and an output element, according to:
A drive circuit for applying voltages to the electrodes takes a low DC voltage supply and converts it to a pulse level waveform. The frequency and shape of the waveform can be controlled by a voltage controlled oscillator. The drive voltage can be stepped up by a multiplier circuit to the required level. To operate compartments of the pump in their discharging state, voltages of opposite polarities are applied to the electrodes on opposing walls and membranes of these compartments to make the membranes flex according to the sequence. These signals applied to the electrodes are thus the true and complement versions of the waveforms of
Referring now to
The micro pump systems described above can be integrated in different products or devices to perform different functions. For example, the micro pump systems can replace a fan or a blower in a device, e.g., a computer or a refrigerator, as air movers to move air. Compared to the conventional fans or blowers, the micro pumps may be able to perform better at a lower cost with a higher reliability. In some implementations, these air movers are directly built into a host at a fundamental level in a massively parallel configuration. In general, the series configuration 30 can be used in many applications that call for peristaltic pumps.
In some implementations, the micro pump systems receive power from a host product into which the systems are integrated. The power can be received in the form of a single, relatively low voltage, e.g., as low as 5V or lower, to a drive circuitry of the micro pump systems, e.g., the drive circuitry 500 of
The module layer stack can be viewed as module layers connected in parallel. The volume of each individual module layer, Vi or Ve, is small. In some implementations, even the total volume of all layers in the stack is relatively small. In some implementations, multiple stacks or micro pumps can be connected in parallel to increase the total volume flow rate.
Similarly, the pressure capability of an individual micro pump is relatively low. Even though there are multiple module layers in a stack, the layers do not increase the total pressure of the stack because they are connected in parallel. However, the pressure of the stack can be increased when multiple stacks or micro pumps are connected in series.
In some implementations, the micro pumps 30 are connected in series are driven at different speeds to compensate for different mass flow rates. For example, built-in plenums or plumbing in a tree type configuration can also be used to compensate for different mass flow rates. Effectively, the serially connected stacks in each row can provide a total pressure substantially equal the sum of the individual stack pressures.
Alternative Operation Modes
An alternative mode of operation of the series connected set of valve-less micro pump elements is dynamic mode change. With these valve-less micro pump elements connected in a series configuration this need not be a fixed correspondence between inlet and outlet functions. Thus by driving the micro pump elements according to a first peristaltic sequence in a first mode of operation, a first one of the plurality of micro pump elements having a port that is an inlet port of the series configuration, and a last one of the plurality of micro pump elements having a port that is an outlet port of the series configuration. However, by driving the micro pump elements according to a second, different peristaltic sequence for a second, different mode of operation, with the port of the first one of the plurality of micro pump being the outlet port of the series configuration, and the port of the last one of the plurality of micro pump elements being the inlet port of the series configuration the second mode dynamically changes the ports that function as the input port and output port of the series configuration. Properly therefore these are referred to as I/O ports.
In this mode the first and second peristaltic sequences each have six phases, with the first peristaltic sequence given as:
Alternative Construction/Operation Modes
A novel construction of a series connected set of valve-less micro pump elements is can have built in redundancy that together with dynamic mode changes can provide various novel operation modes. With these valve-less micro pump elements connected in a series configuration the series connection can have a variable number of or arrangement of units devoted to inlet, pump, and outlet functions. Such a micro pump would have several (more than three), e. g., four, ten or 15, or more or many more micro pump elements each having a pump chamber compartmentalized into plural compartments, with compartments of the plural compartments having inlet ports providing unobstructed fluid ingress into the compartments and outlet ports providing unobstructed fluid egress from the compartments, together with membranes disposed anchored between opposing walls of the pump body and forming the plural compartments and electrodes disposed on major surfaces of the membranes.
Drive circuitry provide signals to the plurality of electrodes according to a sequence, with a first portion of the plurality of micro pump elements driven by a first subset of signals in the sequence, a second portion of the plurality of micro pump elements driven by a second subset of signals in the sequence, and with a third portion of the plurality of micro pump elements driven by a third subset of signals in the sequence. The first portion of micro pump elements provides an input element, the second portion of the plurality of micro pump elements provides a pump element and the third portion of the plurality of micro pump elements provides an output element of the series configuration. These micro pump elements are dynamically configurable, meaning that the functions of the first and third portions are dynamically configurable by adjusting the sequence. The first, second and third subsets of signals are applied as a peristaltic sequence, with each of the first, second and third subsets of the peristaltic sequence having six phases, with an exemplary peristaltic sequence being
Exemplary Applications
Exemplary applications of the series configuration 30 can be those as discussed in the above mentioned incorporated by reference publications, without substantial variation, presuming use of the series interconnected micro pump modules in a valve-less configuration. Similarly, construction of the series interconnected micro pump modules in a “valve-less” configuration is without substantial variation to the techniques described in the above incorporated by reference publications but for modifications of masks or elimination processing that was needed for formation of inlet and outlet valves on the micro pump modules and subsequent fabrication of the micro pumps using the series configuration.
Fabrication techniques can include the Roll to Roll processing as described below or as described in the above incorporated by reference publications.
Roll to Roll Processing for Producing Micro Pumps
A roll to roll processing line comprises several stations that can be or include enclosed chambers at which deposition, patterning, and other processing occurs. Processing viewed at a high level thus can be additive (adding material exactly where wanted) or subtractive (removing material in places where not wanted) or combinations of both. Deposition processing includes evaporation, sputtering, and/or chemical vapor deposition (CVD), as needed, as well as printing. The patterning processing can include depending on requirements techniques such as scanning laser and electron beam pattern generation, machining, optical lithography, gravure and flexographic (offset) printing depending on resolution of features being patterned. Ink jet printing and screen printing can be used to put down functional materials such as conductors. Other techniques such as imprinting and embossing can be used.
The original raw material roll is of a web of flexible material. In roll to roll processing the web of flexible material can be any such material and is typically glass or a plastic or a stainless steel. While any of these materials (or others) could be used, plastic has the advantage of lower cost considerations over glass and stainless steel and is a biocompatible material for production of the micro pump when used in a CPAP type (continuous positive airway pressure) breathing device (see incorporated by reference applications). In other applications. of the micro-pump, e.g., as a cooling component for electronic components other materials such as stainless steel or other materials that can withstand encountered temperatures would be used, such as Teflon and other plastics that can withstand encountered temperatures.
The membrane material is required to bend or stretch back and forth over a desired distance and thus should have elastic characteristics. The membrane material is impermeable to fluids, including gas and liquids, is electrically non-conductive, and possesses a high breakdown voltage. Examples of suitable materials include silicon nitride and Teflon. The material of the electrodes is electrically conductive. The electrodes do not conduct significant current. The material can have a high electrical resistance, although the high resistance feature is not necessarily desirable. The electrodes are subject to bending and stretching with the membranes, and therefore, it is desirable that the material is supple to handle the bending and stretching without fatigue and failure. In addition, the electrode material and the membrane material adhere well, e.g., do not delaminate from each other, under the conditions of operation. Examples of suitable materials include, e.g., aluminum, gold, silver, and platinum layers (or conductive inks such as silver inks and the like).
Referring to
Referring to
For the example where the microelectromechanical system is the micro pump, the layers would have thicknesses as mentioned above approximately 50 microns for the pump body. However, other thicknesses are possible even for the micro pump. The sheet 304 from a roll (not shown) is patterned at an ablation station, e.g., a laser ablation station. A mask (not shown), (or a direct write process not shown), is used to configure the laser ablation station to remove material to define or form the compartments of the micro pump, as well as alignment holes (not shown but will be discussed below). Vias are also provided for electrical connections, as shown. The micro-machining ablates away the plastic to form the compartment of the micro pump while leaving the frame portion of the pump body and also forms the unobstructed passages for inlets and outlets.
Referring now to
Prior to lamination of the second sheet 308 to the first sheet 304, the second sheet 308 is also provided with several dispersed holes (not shown) over some areas that will expose the pump bodies structures. These dispersed holes are used by a machine vision system to reveal and recognize underlying features of the pump body units on the first sheet 304. Data is generated by noting the recognized features in the first sheet through the holes. These data will be used to align a third ablation station when forming electrodes from the layer over the pump bodies (discussed below). The second sheet 308 is laminated to and thus sticks (or adheres) to the first sheet 304.
At this point, a composite sheet 310 of repeatable units of the micro pump, e.g., pump body and movable and releasable features, with membranes are formed, but without electrodes formed from the layer on the membrane. The machine vision system produces a data file that is used by the laser ablation system in aligning a third laser ablation station with a fourth mask (or direct write) such that a laser beam from the laser ablation system provides the electrodes 210 (
Referring now to
A jig (not shown) that can comprise vertical four posts mounted to a horizontal base is used to stack individual ones of cut units. On the jig an end cap (e.g., a 50 micron PET sheet with a metal layer) is provided and over the end cap a first repeatable unit is provided. The repeatable unit is spot welded (applying a localized heating source) (or laminated) to hold the unit in place on the jig. As each repeatable unit is stacked over a previous repeatable unit that unit is spot welded. The stack is provided by the inlets on one side and outlets one the opposing side. The passages can be staggered resulting from arrangement of the passages so as to have a solid surface separating each of the passages in the stack (See
Other stacking techniques for assembly are possible with or without the alignment jig, pin or holes.
Elements of different implementations described herein may be combined to form other embodiments not specifically set forth above. Elements may be left out of the structures described herein without adversely affecting their operation. Furthermore, various separate elements may be combined into one or more individual elements to perform the functions described herein. Other embodiments are within the scope of the following claims. For example, a micro pump may include a micro pump element that includes a pump body having walls that enclose a pump chamber, a plurality of inlet ports with unobstructed fluid ingress into the pump chamber and a plurality of outlet ports with unobstructed fluid egress from the pump chamber, top and bottom caps on opposing portions of the pump body, plural membranes that compartmentalized the pump chamber to provide plural compartments in the pump chamber, with each of the plurality of membranes carrying on a major surface thereof three mutually electrically isolated electrode elements that cause the membrane to undulate according to different phases of signals applied successively to the mutually electrically isolated electrode elements.
This application claims priority under 35 U.S.C. § 119(e) to provisional U.S. Patent Application 62/470,460, filed on Mar. 13, 2017, entitled: “Micro Pump Systems and Processing Techniques” the entire contents of which are hereby incorporated by reference.
Number | Date | Country | |
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62470460 | Mar 2017 | US |
Number | Date | Country | |
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Parent | 15917905 | Mar 2018 | US |
Child | 17395532 | US |