Microfluidic device with integrated micro-structured electrodes and methods thereof
11707738 · 2023-07-25
Assignee
Inventors
- Jatin Panwar (Bangalore, IN)
- Rahul Roy (Bangalore, IN)
- Usama Ahmed Abbasi (Bangalore, IN)
- Prakhar Jain (Bangalore, IN)
- Viswanathan Kumaran (Bangalore, IN)
Cpc classification
B01L2200/12
PERFORMING OPERATIONS; TRANSPORTING
B81B2201/058
PERFORMING OPERATIONS; TRANSPORTING
B01L3/502707
PERFORMING OPERATIONS; TRANSPORTING
B81C1/00119
PERFORMING OPERATIONS; TRANSPORTING
B01L2200/0647
PERFORMING OPERATIONS; TRANSPORTING
B01L3/502715
PERFORMING OPERATIONS; TRANSPORTING
B01L2300/0816
PERFORMING OPERATIONS; TRANSPORTING
B81B1/006
PERFORMING OPERATIONS; TRANSPORTING
B01L3/502761
PERFORMING OPERATIONS; TRANSPORTING
International classification
B01L3/00
PERFORMING OPERATIONS; TRANSPORTING
B81B1/00
PERFORMING OPERATIONS; TRANSPORTING
B81C1/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The present disclosure provides a microfluidic device comprising a set of micro-structured electrodes. The electrodes are made of a fusible alloy such as Field's Metal and are patterned on a layer of PDMS. The molten fusible alloy is poured over the patterned PDMA layer and a suction force is applied to ensure uniformity of flow of the molten metal. A second layer comprising a flow channel orthogonal to the direction of the micro-structured electrodes is disposed under the first layer to form the microfluidic device. The device shows enhanced sensitivity to RBC detection at high frequencies that are also bio-compatible (above 2 MHz). Multiple layers of the micro-structures electrodes can be sandwiched between layers of flow channels to provide a 3D microfluidic device.
Claims
1. A method for fabricating a microfluidic device, said method comprising the steps of: coating a negative photoresist on a substrate; casting of an elastomeric polymer material to form microchannels; introducing a molten fusible alloy (FA) into a first layer made of the elastomeric polymer material and comprising one or more parallel independent microchannels for corresponding one or more electrodes, wherein the one or more parallel independent microchannels converge at a detection point; placing the first layer from over a second layer made of the elastomeric polymer material, wherein the second layer is un-patterned and is a sacrificial layer; fusing the first layer and the second layer with heat such that there are no air bubbles between the first layer and the second layer; and placing a third layer comprising a flow channel under the first layer such that the flow channel runs orthogonal to the one or more parallel independent microchannels on the first layer, wherein an object of interest present in a fluid medium passes through the flow channel by itself or to be dispersed as droplets at the detection point, and wherein the device detects presence of the object of interest based on change in impedance between the one or more electrodes at the detection point.
2. The method as claimed in claim 1, wherein the substrate is a silicon (Si) wafer coated with polydimethylsiloxane (PDMS).
3. The method as claimed in claim 1, wherein the molten fusible alloy is selected from a group consisting of Field's Metal, Rose's Metal, Cerrosafe, Wood's metal, Cerrolow 136 and Cerrolow 117.
4. The method as claimed in claim 1, wherein a controlled suction pressure is applied to exact smooth flow and even distribution of the molten fusible alloy on the one or more electrodes.
5. The method as claimed in claim 1, wherein said method further comprises the step of peeling the sacrificial layer before introducing the third layer.
6. The method as claimed in claim 1, wherein said method further comprises the step of subjecting the first layer and second layer to a plasma treatment.
7. The method as claimed in claim 1, wherein the microfluidic device is baked to increase hydrophobicity of the device.
8. The method as claimed in claim 1, wherein the microfluidic device comprises: the substrate coated with the negative photoresist; the elastomeric polymer to form the microchannels; and the first layer and the third layer disposed under the first layer.
9. The method as claimed in claim 1, wherein the second layer is fused to a glass slide to provide rigidity to the device.
10. The method as claimed in claim 1, wherein two or more layers comprising the one or more electrodes is disposed with a layer comprising a flow channel in between two layers comprising the one or more electrodes to provide a 3-dimensional (3D) device.
11. A microfluidic device fabricated by a method, said method comprising the steps of: coating a negative photoresist on a substrate; casting of an elastomeric polymer material to form microchannels; introducing a molten fusible alloy (FA) into a first layer made of the elastomeric polymer material and comprising one or more parallel independent microchannels for corresponding one or more electrodes, wherein the one or more parallel independent microchannels converge at a detection point; placing the first layer from over a second layer made of the elastomeric polymer material, wherein the second layer is un-patterned and is a sacrificial layer; fusing the first layer and the second layer with heat such that there are no air bubbles between the first layer and second layer; and placing a third layer comprising a flow channel under the first layer such that the flow channel runs orthogonal to the one or more parallel independent microchannels on the first layer, wherein an object of interest present in a fluid medium passes through the flow channel by itself or to be dispersed as droplets at the detection point, and wherein the device detects presence of the object of interest based on change in impedance between the one or more electrodes at the detection point.
Description
BRIEF DESCRIPTION OF DRAWINGS
(1) The accompanying drawings are included to provide a further understanding of the present invention and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present invention and, together with the description, serve to explain the principles of the present invention.
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DETAILED DESCRIPTION
(21) The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
(22) If the specification states a component or feature “may”, “can” “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.
(23) As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
(24) Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. These exemplary embodiments are provided only for illustrative purposes and so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those of ordinary skill in the art. The invention disclosed may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Various modifications will be readily apparent to persons skilled in the art. The general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the invention. Moreover, all statements herein reciting embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure). Also, the terminology and phraseology used is for the purpose of describing exemplary embodiments and should not be considered limiting. Thus, the present invention is to be accorded the widest scope encompassing numerous alternatives, modifications and equivalents consistent with the principles and features disclosed. For purpose of clarity, details relating to technical material that is known in the technical fields related to the invention have not been described in detail so as not to unnecessarily obscure the present invention.
(25) The use of any and all examples, or exemplary language (e.g., “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
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(27) In another embodiment, the fabricated micro-structured electrode is made of a metal alloy with a low melting point. Typically, metal alloys are preferable whose melting point is within about 100° C. the metal alloy can be selected from a group consisting Rose's metal, Cerrosafe, Wood's metal, Cerrolow 136, Cerrolow 117, Field's metal etc. in an exemplary embodiment, the metal alloy used in the fabrication of the proposed micro-structure is Field's metal (FM) comprising bismuth (about 32.5%), indium (about 51%), and tin (about 16.5%). In another embodiment, FM has a melting point of about 62° C., which is low enough that it can be handled easily during fabrication, but high enough that it does not deform during operation.
(28) In another embodiment, the composite patterned mould comprises multiple layers of patterned polymeric mould made of a polymer such as polydimethylsiloxane (PDMS).
(29) In another embodiment, the microfluidic device and the micro-structured electrode are fabricated separately using standard soft photolithographic processes. A standard epoxy based negative photoresist is spin coated on a silicon wafer to obtain a film thickness of about 20 μm.
(30) In another embodiment, electrode layer L1 comprises three independent channels of about 100 μm that converge to a width of about 30 μm (110) and an inter-electrode gap of about 20 μm (106, 108) at the detection point for electrodes along with inlet (102) and outlet (104) ports for the molten metal flow. A sacrificial base layer L2 made of PDMS is used for casting of the electrodes. In another embodiment, the low surface roughness and flexibility of PDMS provides an effective airtight seal when the layers L1 and L2 are placed over one another, and the air bubbles are removed. In another embodiment, the layers L1 and L2 are heated to at about 140° C. for about 20 minutes to fuse the two layers.
(31) In another embodiment, about 15 μl of molten FM (hereinafter, also referred to as Fusible Alloy (FA)) at about 140° C. is introduced into the inlet. To enhance flow of the molten metal alloy in the channel, a suction pressure (about 82 kPa) is applied at the outlet of the mould until the molten FM flows till the outlet port. In another embodiment, the suction pressure also serves to hold layers L1 and L2 together, thereby not requiring an additional bonding agent.
(32) In another embodiment, L1 is peeled off after FM solidifies. In another embodiment, a third layer L3 is a flow layer with a flow channel of about 70 μm width and converging to about 20 μm (112, 114) at the detection point and running perpendicular to the electrode channels of layer L. Layers L1 and L3 are aligned using guide marks present on them. After a plasma treatment, they are bonded. In another embodiment, a glass slide is bonded with the bottom of L3, the lowest layer, for additional device rigidity.
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(34) In another embodiment, in order to overcome the reduced hydrophobicity of the PDMS due to plasma treatment, the device is kept overnight in an oven at a temperature below the FM melting point, at about 45° C. In another embodiment, since the material used is uniform, the surface properties of the walls of the channels are uniform. This is especially pertinent, as non-uniform hydrophobicity can cause fluid droplets to cling to the walls of the channel.
(35) In another embodiment, the device fabricated has a fluidic channel (152) passing under an array of “in-contact” 2D co-planar micro-electrodes (154).
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(37) In an embodiment, a PDMS coated silicon wafer is formed by allowing a specified quantity (about 5 g) of PDMS with a 9:1 cross-linking ratio to flow freely through the edges of the wafer for about 30 minutes before cross-linking the PDMS. In another embodiment, a standard photolithography procedure is adopted to fabricate SU8 microchannels on the PDMS coated wafers.
(38) In another embodiment, the optimum baking temperature for SU8 is about 95° C., but, as PDMS does not provide good adhesion, the photoresist tends to recede from the edges and shrink towards the centre of the wafer. In order to circumvent this problem, a prolonged soft baking is done at lower temperatures, where the wafer is heated to about 50° C. for about 4 minutes (202); about 70° C. for about 4 minutes (204); and about 90° C. for about 4 minutes (206). Following the soft baking, the wafer is rinsed and air dried. Hard baking is then done for about 3 minutes at about 95° C. (208). The baked PDMS layer is removed from the silicon wafer.
(39) In another embodiment, to assemble a 3D electrode assembly, two coplanar electrodes are fabricated on a thin PDMS layer, as has been described earlier. In another embodiment, the first coplanar electrode (254) is aligned with the SU8 channel (256) and placed on it. The PDMS layer behind the SU8 is peeled off. The thin layer of SU8 from the coplanar electrode forms a seal with the PDMS without application of any external pressure.
(40) In another embodiment, alignment of the second layer of coplanar electrodes (258) onto the existing assembly requires higher precision as the electrodes of the two coplanar layers must align with one another.
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(43) In an embodiment, the fluidic device can be decoupled for cleaning the fluidic channels in case of clogging. In an exemplary embodiment, the final modular assembly comprises a 20 μm wide microchannel crossing between two coplanar electrodes arrays orthogonally, each containing three 20 μm wide electrodes each. Each electrode is analogous to three parallel plate capacitors of area 20×20 μm.sup.2.
(44) In an embodiment, the coplanar “in-contact” electrodes are characterised by measuring their response to varying input frequencies (0.1 to 10 MHz) and peak-to-peak source voltage (0.2 to 2 V) at different electrolyte concentrations (0 to 10×; concentration with respect to Phosphate Buffer Saline (PBS)). The characterisation is performed in the given sequence to determine an optimum configuration for peak-to peak voltage (V.sub.p-p), source frequency and electrolyte concentration.
(45) In another embodiment, the FM is prone to electrolysis at high currents, and therefore, a linear response from the electrodes with varying electrical parameters is not as accurate as in the case of Platinum electrodes.
(46) In another embodiment, in order to overcome this limitation, the mean output voltage (V.sub.RMS) response of the electrodes is measured at different electrolyte concentrations averaged over an excitation frequency range (0.5 to 10 MHz).
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(50) In an embodiment, to establish the proposed candidates as a potential candidate for MIC, it is compared against standard Platinum (Pt) electrodes in a set-up to detect erythrocytes from a sample of erythrocyte-enriched human blood. In another embodiment, the frequency dependence of the erythrocyte signals is explored at the parameters optimised during characterisation as previously described, i.e., at 10×PBS and 2 V.sub.p-p.
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(53) In another embodiment, the highest peaks obtained for the proposed electrode is at 0.5 MHz and 3 MHz source, and for Pt electrodes is at 0.5 MHz and 1 MHz source.
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(55) In another embodiment, it can be observed from
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(61) In an aspect, signals taken from fusible alloy (FA) micro-electrodes show discrete frequency dependent characteristics when compared to those taken by standard Platinum electrodes. At low frequencies, Pt electrodes give a higher signal, but as the frequency shifts to above 2 MHz, the FM electrodes give a higher signal.
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Z.sub.sys is the impedance of the system:
C.sub.DL is the double layer capacitance;
R.sub.i and R.sub.m are the resistances provided by the medium and the cell's cytoplasm respectively:
C.sub.in and C.sub.mem are the capacitances provided by the medium and cell membrane respectively:
ω is the frequency of the excitation signal.
(63) According to the above equation (1), double layer capacitance (C.sub.DL) dominates the impedance (Z.sub.sys) of the system at lower frequency regime. Higher the double layer, lower is the Impedance in this regime. In another aspect, the surface roughness is proportional to the double layer capacitance at the electrode-electrolyte interface partly due to the high effective area of rough surfaces. A higher surface roughness for FM electrode in comparison to the Pt electrode can explain its behavior at low frequencies.
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(67) In another aspect, as the particle moving across a region over the FM electrode has to cut through more electric field lines (flux is proportional to charge density) and this results in higher differential current (and thus voltage) as compared to Pt electrode.
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(69) It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive patient matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “includes” and “including” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refer to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N. or B plus N, etc. The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practised with modification within the spirit and scope of the appended claims.
(70) While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.
ADVANTAGES
(71) The present disclosure provides a fluidic device for the detection of single cells in a sample.
(72) The present disclosure provides design and fabrication of micro-structured electrodes in 3D for the device.
(73) The present disclosure provides a device that shows enhanced sensitivity at bio-compatible frequencies.
(74) The present disclosure provides a 3D microfluidic device.
(75) The present disclosure provides a method to fabricate a microfluidic device that can be performed outside of a clean room.