US-12617129-B2 - Method of manufacturing a microfluidic architecture

Abstract

A method of manufacturing a microfluidic architecture having at least one channel disposed therein. Steps can include pouring an uncured polymeric material into a mould to produce a first layer; at least partially curing the first layer; and forming the at least one channel by disposing a support material on the first layer; pouring an uncured polymeric material onto the first layer to form a second layer to thereby encapsulate the support material; and at least partially curing the second layer such that the first layer and second layer together form the microfluidic architecture; wherein the support material undergoes a phase change during the process of forming the at least one channel. The phase change of the support material enables the material to be more easily disposed and/or removed after formation of the channel.

Inventors

• Ugur Tanriverdi

Assignees

• UNHINDR LTD

Dates

Publication Date

20260505

Application Date

20200918

Priority Date

20190919

Claims (20)

1. 1 . A method of manufacturing a device having a fluidic architecture comprising at least one channel disposed therein, the method comprising: pouring a first polymeric material in an uncured state into a mould to produce a first layer; at least partially curing the first layer; disposing a support material on the first layer, the support material comprising a substantially flat sheet of material; pouring a second polymeric material in an uncured state to be in contact with the first layer and the support material to form a second layer to thereby encapsulate the support material; and curing the second layer such that bonds are formed between the first layer and the second layer to provide a block having an internal discontinuity immediately adjacent the support material, the discontinuity having an interior sidewall formed by at least a portion of the second layer which normally conforms to the support material and which is displaced away from the support material to form a channel responsive to introduction of a fluid within the block and along the support material, wherein the support material does not undergo a phase change.
2. 2 . The method of claim 1 , wherein each of the first polymeric material and the second polymeric material is an elastomeric material comprising one or more of a silicone, acrylic, a nitrile, a rubber, and polyurethane.
3. 3 . The method of claim 1 , further comprising: pouring a third polymeric material in an uncured state into a mould to produce a third layer; at least partially curing the third layer; disposing the third layer on the second layer before the curing of the second layer is complete; and curing the second and third layers together such that bonds are formed between the second layer and the third layer.
4. 4 . The method of claim 1 , wherein the first polymeric material and the second polymeric material are the same material.
5. 5 . The method of claim 1 , wherein the first polymeric material and the second polymeric material are different materials.
6. 6 . The method of claim 1 , further comprising disposing an electronic component within the block.
7. 7 . The method of claim 1 , wherein the channel forms a portion of a network of channels.
8. 8 . The method of claim 7 , wherein the network of channels includes a manifold arranged to receive and/or store a fluid and a plurality of branches in fluid connection with the manifold.
9. 9 . The method of claim 1 , wherein the support material comprises waxed paper or a metal foil.
10. 10 . The method of claim 1 , wherein the support material is further arranged to interact with the fluid disposed in the channel by absorbing a substance from the fluid or releasing a substance into the fluid.
11. 11 . The method of claim 1 , wherein the device is a fluidic chip.
12. 12 . The method of claim 1 , wherein the block comprises two channels joined in selective fluid communication by an electronic component.
13. 13 . The method of claim 1 , wherein at least one of the surface area or the volume of the block increases responsive to the fluid passing through the channel.
14. 14 . The method of claim 1 , wherein the block is incorporated into a liner for a device arranged for skin contact.
15. 15 . A method of manufacturing a device having a fluidic architecture comprising at least one channel disposed therein, the method comprising: pouring a first polymeric material in an uncured state into a mould to produce a first layer; at least partially curing the first layer; disposing a support material on the first layer, the support material comprising a substantially flat sheet of material; pouring a second polymeric material in an uncured state to be in contact with the first layer and the support material to form a second layer; and curing the second layer to join the first layer and the second layer together to form a block, the block having an internal discontinuity immediately adjacent the support material comprising an interior sidewall formed by at least a portion of the second layer that is not joined to the first layer and is configured to expand to form a channel responsive to introduction of a fluid along the support material, wherein the support material does not undergo a phase change.
16. 16 . The method of claim 15 , wherein each of the first polymeric material and the second polymeric material is an elastomeric material comprising one or more of a silicone, acrylic, a nitrile, a rubber, and polyurethane.
17. 17 . The method of claim 15 , further comprising: pouring a third polymeric material in an uncured state into a mould to produce a third layer; at least partially curing the third layer; disposing the third layer on the second layer before the curing of the second layer is complete; and curing the second and third layers together such that bonds are formed between the second layer and the third layer.
18. 18 . The method of claim 15 , wherein the first polymeric material and the second polymeric material are the same material.
19. 19 . The method of claim 15 , wherein the first polymeric material and the second polymeric material are different materials.
20. 20 . The method of claim 15 , further comprising disposing an electronic component through at least one opening in the channel.

Description

Related Applications The present application makes a claim of priority to PCT/GB2020/052267 filed Sep. 18, 2020, which in turn makes a claim of priority to GB 1913529.2 filed Sep. 19, 2019, the contents of these applications being incorporated by reference. BACKGROUND TO THE INVENTION The present invention relates to microfluidic architectures, such as microfluidic chips, and a method of manufacturing such architectures. Such architectures include small channels through which fluid can pass, and may be made from polymeric materials. Production of such microfluidic architectures requires high precision manufacturing, and the size of channels which can be incorporated into such architectures may be limited by the manufacturing processes and/or materials available. When polymeric materials are used to produce microfluidic architectures, a support structure is typically used to maintain the shape of the channels within the polymeric architecture during curing of the polymeric material. However, it may then be difficult to remove the material which is used to support the channels after the curing has been completed. In some known methods, soluble materials such as sugar may be used as a material to support the channels during curing. Other soluble materials may also be used, such as a soluble material which can be deposited using additive layer manufacturing. In this approach, water or another liquid may be used to dissolve the soluble material in order to remove the support substance after curing. However, if the channels have complex shapes, or are long, it may be difficult to remove the soluble material due to the length and complexity of the channel. It is an aim of the present invention to at least partially address the problems noted above. SUMMARY OF THE INVENTION According to the present disclosure, there is provided a method of manufacturing a microfluidic architecture comprising at least one channel disposed therein, the method comprising pouring an uncured polymeric material into a mould to produce a first layer, at least partially curing the first layer, and forming the at least one channel by, disposing a support material on the first layer, pouring an uncured polymeric material onto the first layer to form a second layer to thereby encapsulate the support material, and at least partially curing the second layer such that the first layer and second layer together form the microfluidic architecture, wherein the support material undergoes a phase change during the process of forming the at least one channel. That is, the phase of the support material itself may change from a solid, a liquid, or a gas, to another of a solid, a liquid or a gas. This may allow the support material to be more easily disposed and/or removed than arrangements in which a solid material is dissolved by a different liquid. Optionally, the first layer comprises at least one open channel, the support material is a fluid when disposed on the first layer, and forming the at least one channel includes: at least partially filling the open channel with the fluid, solidifying the fluid, thereby providing said phase change, closing at least a portion of the channel by pouring the uncured polymeric material onto the first layer to form the second layer to thereby encapsulate the solidified support material. That is, disposing the support material on the first layer includes at least partially filling the open channel with the fluid. The phase change is solidifying the support material. This may allow the shape of the channels to be determined by the mould, and the support material to be easily disposed on the first layer. Optionally, the fluid is a liquid, and the phase change is solidifying the liquid by freezing. Optionally, the support material is a solid when disposed on the first layer. This may allow the shape of the channels to be pre-formed as a separate component. Optionally, wherein the phase change is a sublimation. This may allow the support material to be more easily removed than arrangements in which the material is dissolved in a liquid. Optionally, the polymeric material is an elastomeric material. Optionally, the elastomeric material comprises one or more of a silicone, acrylic, a nitrile, a rubber, and polyurethane. Optionally, the method further comprises removing the support material from the channel. Optionally, the steps of removing the support material from the channel and curing the second layer temporally overlap. Optionally, the method further comprises pouring an uncured polymeric material into a mould to produce a third layer, at least partially curing the third layer, disposing the third layer on the second layer before curing of the second layer is complete, and curing the second and third layers together such that bonds are formed between the second and third layer. This may allow multiple layered architectures to be formed. Optionally, the method further comprises filling an open channel in the third laye