CN104159863A - 用于对齐结构层上的覆盖物的方法以及所得到的装置 - Google Patents

用于对齐结构层上的覆盖物的方法以及所得到的装置 Download PDF

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CN104159863A
CN104159863A CN201280066772.4A CN201280066772A CN104159863A CN 104159863 A CN104159863 A CN 104159863A CN 201280066772 A CN201280066772 A CN 201280066772A CN 104159863 A CN104159863 A CN 104159863A
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sheet
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S·波尔赛
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Corning Inc
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Abstract

一种形成用于连续流反应器的流体模块的方法，所述方法包括：提供至少一块具有一个或多个通孔的平坦玻璃或陶瓷片，形成至少一层具有至少一个图案化表面的图案化玻璃或陶瓷层，使得所述图案化表面包括限定在具有上表面的壁之间的通道，所述上表面位于常规高度(common height)，将所述至少一块玻璃或陶瓷片与所述至少一层图案化玻璃或陶瓷层堆叠在一起，所述片与壁在常规高度接触，使得通道被封在片和图案化层之间，所述片与图案化层对齐，使得一个或多个通孔分别与图案化层的壁之间的各个空间对齐，以提供到达所述各个空间的流体可及性，以及通过将片和图案化层压制在一起同时对所述片和图案化层进行加热来将所述片和图案化层接合在一起；其中，所述图案化玻璃或陶瓷层还包括一个或多个提升的结构，所述提升的结构在常规高度上方延伸，并且所述堆叠的步骤包括将片堆叠到位于常规高度的壁的上表面上，该位置使得所述一个或多个提升的结构将片限制在所需的位置或者将片对齐到图案化层上。

Description

用于对齐结构层上的覆盖物的方法以及所得到的装置
本申请根据35U.S.C.§119，要求2011年11月30日提交的美国临时申请系列第61/565013号的优先权，本文以该申请为基础并将其全文通过引用结合于此。
领域
本发明一般地涉及用于形成微流体模块的方法，具体地，涉及用于对齐微流体模块的结构层上的覆盖物的方法以及所得到的装置。
背景和概述
微反应器，或者具有最小尺寸为微米至最高至数十毫米规格的通道的连续流反应器，相对于常规间歇式反应器具有许多优点，包括能效、反应条件控制、安全性、可靠性、生产力、可量测性和便携性的非常明显的提升。在此类微反应器中，化学反应通常被限制在此类通道中连续进行，因而称作术语“连续流反应器”。微反应器可以由进行一个或多个特定功能(例如，混合、停留时间(以完成反应或其他工艺)和分离等)的微流体模块构建。
根据本发明的一个实施方式，形成用于连续流反应器的流体模块的方法包括：提供至少一块具有一个或多个通孔的平坦玻璃或陶瓷片，形成至少一层具有至少一个图案化表面的图案化玻璃或陶瓷层，使得所述图案化表面包括限定在具有上表面的壁之间的通道，所述上表面位于常规高度(common height)，将所述至少一块玻璃或陶瓷片与所述至少一层图案化玻璃或陶瓷层堆叠在一起，所述片与壁在常规高度接触，使得通道被封在片和图案化层之间，片与图案化层对齐，使得一个或多个通孔分别与图案化层的壁之间的各个空间对齐，以提供到达所述各个空间的流体可及性，以及通过将片和图案化层压制在一起同时对所述片和图案化层进行加热来将所述片和图案化层接合在一起；其中，所述图案化玻璃或陶瓷层还包括一个或多个提升的结构，所述提升的结构在常规高度上方延伸，并且所述堆叠的步骤包括将片堆叠到位于常规高度的壁的上表面上，该位置使得所述一个或多个提升的结构将片限制在所需的位置或者将片对齐到图案化层上。
在下文参考附图描述了本发明方法的某些变化形式和实施方式，紧接下来对所述附图作简要描述。
附图简要说明
当结合以下附图阅读下面对本发明的具体实施方式的详细描述时，可对其形成最好的理解，附图中相同的结构用相同的附图标记表示，其中：
图1和2显示组装形成微流体模块的结构层上的覆盖物的现有技术布置的正视截面图；
图3显示根据本发明的一个实施方式，在结构层上的覆盖物布置的正视截面图；
图4是根据图3的实施方式的结构层上的覆盖物布置的平面图；
图5显示根据本发明的另一个实施方式，在结构层上的覆盖物布置的正视截面图；以及
图6-9是图5的实施方式的结构层上的覆盖层布置的各种替代形式的平面图。
发明详述
参见图1和2，在本发明的发明人和/或其同事的先前工作中，用于微反应器(由多个模块组装的、具有亚毫米至十多微米规格的通道的流反应器)的流体模块100通常形成作为两个结构层104a、104b和两个平坦覆盖物106a、106b的组件102，然后在高温下密封到一起。从特定设计的模具复制得到结构层104a、104b。
得益于卯榫型结构(未示出)，可以容易地将两个结构层104a、104b相互对齐，所述卯榫型结构理想地形成在两个结构层104a、104b的相对表面上。
对齐覆盖物的一种方法是通过视觉检查，将对齐的覆盖物粘合到位。但是，一旦流体模块部件组装到了一起，它们的堆叠在高温下密封，该温度远高于胶能够耐受的温度。如果在烧炉中产生一些振动，则会失去良好的对齐。当覆盖没有良好地对齐时，覆盖孔110就不在结构层104a、104b的孔108的前方，并且当流体通过这些孔或者通过这些孔的接合所形成的“端口”20时，可能会产生额外的压降。此外，在烧制过程中，模块中的胶可能产生污染。
根据本发明，提供了一种形成用于连续流反应器的流体模块的方法，所述方法包括以下步骤：(1)提供至少一块具有一个或多个通孔的平坦玻璃或陶瓷片；(2)形成至少一层具有至少一个图案化表面的图案化玻璃或陶瓷层，使得所述图案化表面包括限定在具有上表面的壁之间的通道，所述上表面位于常规高度；(3)将所述至少一块玻璃或陶瓷片与所述至少一层图案化玻璃或陶瓷层堆叠在一起，所述片与壁在常规高度接触，使得通道被封在片和图案化层之间，片与图案化层对齐，使得一个或多个通孔分别与图案化层的壁之间的各个空间对齐，以提供到达所述各个空间的流体可及性；以及(4)通过将片和图案化层压制在一起同时对所述片和图案化层进行加热来将所述片和图案化层接合在一起，其中所述图案化玻璃或陶瓷层还包括一个或多个提升的结构，所述提升的结构在常规高度上方延伸，并且所述堆叠的步骤包括将片堆叠到位于常规高度的壁的上表面上，该位置使得所述一个或多个提升的结构将片限制在所需的位置或者将片对齐到图案化层上。下面结合图3-9中所示的具体变化形式更详细地描述该方法。
3.根据权利要求1所述的方法，其中片106具有至少两个通孔110，并且一个或多个提升的结构120位于所述至少两个通孔110的至少两个内。在图3的截面图中，仅一个此类通孔是可见的，位于附图的左侧。
图4是根据图3的实施方式的结构层上的覆盖物布置的平面图，其中片106中的四个通孔110分别包括位于所述通孔110内的提升的结构120。(为了清楚起见，遮掉了提升的结构120中的一个)。理想地，至少两个通孔具有此类提升的结构120，从而当片106置于结构层104上的时候，它们一起可以确定片106的对齐(位置和角度)。在该实施方式中，提升的结构还表现为围绕着通孔110的内侧的连续边沿110的形式。
图5显示根据本发明的另一个实施方式的结构层104上的片106的形式的覆盖物的截面图，其中一个或多个提升的结构120表现为位于片106的最外边缘的提升的结构的形式。
图6-9是图5的实施方式的结构层上的覆盖层布置的各种替代形式的平面图。在图6中，一个或多个提升的结构120包括围绕着片106的连续边沿120。在图7中，一个或多个提升的结构120包括围绕片106的边沿的不连续或离散部分，为了更容易识别，遮住了其中一个离散部分。在图8中，一个或多个提升的结构120表现为一个或多个柱120的形式。在图9的实施方式中，不连续件(broken)和柱的组合用作提升的结构120。
本发明所揭示的方法及其产生的装置通常可用来进行任何工艺，所述工艺包括在微型结构中对流体或流体混合物，包括多相流体混合物进行混合、分离、萃取、结晶、沉淀或其他的工艺过程——包括含有多相流体混合物而该多相流体混合物还含有固体的流体或流体混合物。所述加工可以包括物理加工、化学反应、生物化学加工或者任意其他形式的加工过程，所述化学反应被定义为导致有机物、无机物或者有机物和无机物都发生相互转化的加工。以下列出了可以通过所揭示的方法和/或装置进行的反应的非限制性例子：氧化；还原；取代；消除；加成；配体交换；金属交换；以及离子交换。更具体地，以下列出了可以通过所揭示的方法和/或装置进行的反应的任意非限制性例子：聚合；烷基化；脱烷基化；硝化；过氧化；磺化氧化；环氧化；氨氧化；氢化；脱氢；有机金属反应；贵金属化学/均相催化剂反应；羰基化；硫羰基化；烷氧基化；卤化；脱氢卤化；脱卤化；加氢甲酰化；羧化；脱羧；胺化；芳基化；肽偶联；醇醛缩合；环化缩合；脱氢环化；酯化；酰胺化；杂环合成；脱水；醇解；水解；氨解；醚化；酶合成；缩酮化(ketalization)；皂化；异构化；季铵化；甲酰化；相转移反应；甲硅烷化；腈合成；磷酸化；臭氧分解；叠氮化物化学；复分解；氢化硅烷化；偶联反应；以及酶反应。
应当指出，本文所用的诸如“优选”、“常用”和“通常”之类的术语不是用来限制本发明要求保护的范围，也不表示某些特征对本发明要求保护的结构或者功能来说是重要的、关键的、或者甚至是必不可少的。相反地，这些术语仅仅用来表明本发明实施方式的特定方面，或者强调可以用于或者可以不用于本发明特定实施方式的可选或附加的特征。
以上结合具体实施方式详细描述了本发明的主题内容，显而易见的是，在不背离所附权利要求书限定的本发明范围的前提下可以有一些改良和变化。更具体的，尽管本发明的一些方面在本文中被认为是优选的或者特别有益的，但应考虑到本发明不一定限于这些方面。
应注意，以下权利要求书中的一项或多项权利要求使用术语“其特征在于”作为过渡语。出于限定本发明的目的，应当指出，在权利要求中用该术语作为开放式过渡短语来引出对一系列结构特征的描述，应当对其作出与更常用的开放式引导语“包括”类似的解释。

Claims (6)

1.一种形成用于连续流反应器的流体模块的方法，所述方法包括：
提供至少一块具有一个或多个通孔的平坦玻璃或陶瓷片；
形成至少一层具有至少一个图案化表面的图案化玻璃或陶瓷层，使得所述图案化表面包括限定在具有上表面的壁之间的通道，所述上表面位于常规高度；
将所述至少一块玻璃或陶瓷片与所述至少一层图案化玻璃或陶瓷层堆叠在一起，所述片与壁在常规高度接触，使得通道被封在片和图案化层之间，片与图案化层对齐，使得一个或多个通孔分别与图案化层的壁之间的各个空间对齐，以提供到达所述各个空间的流体可及性；以及
通过将片和图案化层压制在一起同时对所述片和图案化层进行加热来将所述片和图案化层接合在一起；
其中，所述图案化玻璃或陶瓷层还包括一个或多个提升的结构，所述提升的结构在常规高度上方延伸，并且
所述堆叠的步骤包括将片堆叠到位于常规高度的壁的上表面上，该位置使得所述一个或多个提升的结构将片限制在所需的位置或者将片对齐到图案化层上。
2.如权利要求1所述的方法，其特征在于，所述一个或多个提升的结构位于片的最外边缘。
3.如权利要求1所述的方法，其中所述片具有至少两个通孔，并且所述一个或多个提升的结构位于所述至少两个通孔的至少两个内。
4.如权利要求2或3所述的方法，其特征在于，所述一个或多个提升的结构包括绕着片的连续边沿或者绕着片中的通孔的边沿。
5.如权利要求2或3所述的方法，其特征在于，所述一个或多个提升的结构包括绕着片或绕着片中通孔的不连续边沿或边沿的离散部分。
6.如权利要求2或3所述的方法，其特征在于，所述一个或多个提升的结构包括图案化层上的柱，所述柱在常规高度上方延伸。
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