CN106132690A - 通过连续施加真空和机械力来层压刚性基片的方法和设备 - Google Patents
通过连续施加真空和机械力来层压刚性基片的方法和设备 Download PDFInfo
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Abstract
用于层压基片(例如,刚性塑料层)以制造层压产品的方法和设备。所述方法包括通过具有产生一个或多个作用力的冲程的汽缸的层压设备执行的两个冲程过程相继施加真空和机械力。产生第一冲程的汽缸致动在所述设备内部形成了封装待被层压的基片堆垛的密封室。密封室可能通过施加真空而被排出空气。汽缸产生第二冲程的随后的致动向密封室应用机械力,其将所述基片压成基本上无气泡或者空穴的层压产品。
Description
技术领域
本发明的实施例总体上涉及用于层压刚性基片的方法和设备,更具体地涉及用于制造层压的微流体装置的方法和设备。
背景技术
操作微小体积的生物和化学流体的技术被广泛地称为微流体技术。微流体技术的已实现和潜在的应用包括疾病诊断、生命科学研究、生物和/或化学传感器研制以及其他由本领域技术人员所领会的。
包括具有一个或者更多个微流体孔道或通道的基片和盖板或者包括具有可能互连或可能不互连的流体通道的第二或更多个基片的微流体结构可能通常被称为微流体芯片(chip)或者芯(cartridge)。高度集成的微流体芯片有时被称为“芯片上的实验室”。
微流体结构或装置通常是由聚合物、“塑料”材料制成的。聚合物的微流体结构具有有利的低材料成本和大规模生产的潜力。然而,聚合物的微流体芯片的构造提出了各种挑战。例如,微流体芯片可能包含密封的微观结构。这可通过以薄盖板或者以一个或多个附加基片封装具有预制流体通道或者其他微特征的基片以便形成三维流体网络来形成。通道或者其他微观结构具有在微米到毫米范围内的典型尺寸。该多层的微流体结构通过多种传统技术被集成或者联接到一起。这些技术包括热、超声波和溶剂粘合。不幸地,例如由于聚合物材料在上述粘结状态下的低空间刚度,这些技术经常改变配合的表面并且产生扭曲的或者完全阻断的微流体通道。
胶粘层压的使用可通过避免使用过量的热能或者浓的有机溶剂而绕过一些潜在的困难。传统的层压系统应用对置的圆柱辊。用于层压的基片材料通过两个运动辊之间的间隙供给,所述运动辊当堆叠材料穿过系统时给堆叠材料的前缘施加压力并将其粘结到一起。该过程是在不圈闭气泡的情况下将柔性薄膜粘结到基片上而同时给层压产品提供最小变形的有效手段。然而,基于辊子的系统的弯曲表面对于刚性基片的层压不是最佳的。例如,所述基片可能缺乏按保持精确的基片对准极限以便确保集成的微流体特征的完整性的方式进给通过运动辊所需的柔韧性。
用于层压刚性基片的备选系统和方法包括其中在施加层压力之前基片被堆叠或者“夹”在上平台和下平台之间的平面压紧或者“铰链”系统。该方法在微流体装置的构造中的一个相当大的缺点是,在层压期间被堆叠基片之间圈闭空气,引起最终产品的变形,诸如气泡或者空穴。所述变形可能显著地损害了层压的微流体装置的功能,特别是当其出现在诸如流体孔道或者光学显示窗的特征中。因此,本发明的实施例涉及用于层压刚性结构的方法和设备,其解决了当前技术状态的那些公认的缺点并且进一步提供了如本领域的技术人员赏识的好处和优点。
发明内容
本发明提供了通过连续地施加真空和机械力来层压基片的方法和设备。所述方法和设备的优点包括制造基本上无气穴或者空穴的刚性的层压产品。
在一个方面,该方法包括:在层压设备的基座部分上提供刚性基片构件的堆垛;给层压设备的盖部分提供第一作用力以使盖部分与基座部分上的垫片密封地接触,以在基座部分和盖部分之间产生密封室;向密封室施加真空以从所述室排出空气;并且向设备的盖部分提供第二作用力以压缩垫片和基片堆垛,以生产出基本上无气泡或者空穴的层压产品。
在一个实施例中,第一作用力由长冲程汽缸(cylinder)提供并且第二作用力由短冲程汽缸提供。在备选实施例中,第一作用力和第二作用力由同一个汽缸提供。在又一实施例中,该方法还可包括为第一作用力提供阻力的步骤,其中所述阻力防止在给密封室施加真空的步骤之前压缩垫片。在某些实施例中,阻力是由弹簧提供的。
在其他实施例中,刚性基片构件是基本上扁平的并且可以是聚合物材料。在又一实施例中,刚性基片构件是多层微流体装置并且还可包括可以是粘结层的至少一个柔性层。
在又一实施例中,该方法还可以包括给密封室施加热的步骤。
本发明的另一实施例涉及一种层压刚性基片构件的设备,所述设备包括:配置成支撑刚性基片的堆垛的基座部分,其中基座部分包括可压缩的垫片和至少一个对准销;盖部分,所述盖部分配置成密封地接触可压缩的垫片以形成封装刚性基片构件的堆垛的密封室;至少一个产生冲程的汽缸,所述汽缸配置成伸展到所述盖部分并且施加第一作用力,以使盖部分与对准销和基座部分的垫片接触,以便形成密封室;以及配置成附接至真空源的真空端口。
在某些实施例中,该设备还包括第二产生冲程的汽缸,该第二产生冲程的汽缸被配置成伸展到密封室并且提供第二作用力来压缩垫片和刚性基片的堆垛,以生产出层压产品。在备选实施例中,该设备包括配置成向产生冲程的汽缸提供阻力的至少一个弹簧,并且所述产生冲程的汽缸还可被配置成在形成密封室之后克服阻力并且压缩垫片和刚性基片的堆垛,以生产出层压产品。
在又一实施例中,该设备还可以包括热源。
附图说明
图1A是处于汽缸被缩回的装载位置的本发明的层压设备的一个实施例的剖视图。
图1B是在长冲程汽缸朝向对准销和垫片伸展情况下的本发明的层压设备的一个实施例的近视图。
图2A是在长冲程汽缸伸展至垫片的情况下的本发明的层压设备的一个实施例的剖视图。
图2B是在长冲程汽缸伸展至垫片从而产生密封室的情况下的本发明的层压设备的一个实施例的近视图。
图2C是在短冲程汽缸伸展并压缩垫片的情况下的本发明的层压设备的一个实施例的近视图。
图3是在短冲程汽缸伸展并将堆叠的基片压缩成层压产品的情况下的本发明的层压设备的一个实施例的近视图。
图4是处于汽缸被缩回并且弹簧处于松驰配置的装载位置的本发明的层压设备的另一实施例的近视图。
图5是在弹簧提供阻力时汽缸伸展到对准销和垫片的情况下的本发明的层压设备的另一实施例的近视图。
图6是在克服弹簧阻力并且将基片堆垛压缩成层压产品的情况下的本发明的层压设备的另一实施例的近视图。
具体实施方式
图1A和1B分别显示了处于装载位置的本发明的层压设备100的一个实施例的剖视图和近视图。在该构造中,汽缸110和汽缸120处于缩回位置。在某些实施例中,汽缸110可以被称为“长冲程汽缸”并且汽缸120可以被称为“短冲程汽缸”。在该实施例中,该设备的上表面是由盖部分130提供的,其可以被称为“顶部真空吸盘”,并且下表面是由基座部分140提供的,其可以被称为“底部真空吸盘”。在本叙述中,该设备被配置成接收待被层压的基片堆垛。顶部真空吸盘可选择性地设有顺应的硅树脂压垫135。底部真空吸盘140可设有一个或多个对准销145,以在层压期间保持表面和基片的精确对齐和对准。垫片150允许在顶部真空吸盘130和底部真空吸盘140之间形成密封室。垫片150可以是由当受压缩时在顶部真空吸盘和底部真空吸盘之间保持空气密封的任何材料制成的。例证性的垫片材料包括任何橡胶或者PVC材料,例如,硅树脂、丁基、氯丁橡胶、腈类、乙烯树脂以及类似物。在操作中,当汽缸110和120缩回时用于层压的基片200和300放置在顶部真空吸盘130和底部真空吸盘140上。在其他实施例中,基片可以被直接堆叠在彼此上并且被放置在任一个真空吸盘上。在其他实施例中,设计成层压两个或更多个基片。在某些实施例中,设计成层压至少三个基片并且可包括柔性基片,诸如薄膜,其还可以包括如本文中进一步描述的粘合材料。
图2A和2B分别显示了在长冲程汽缸110处于伸展配置的本发明的层压设备100的一个实施例的剖视图和近视图。在操作中,第一汽缸冲程(本文中描述为“长冲程”)使汽缸110伸展以使顶部真空吸盘130与底部真空吸盘140的垫片150接触以形成密封室。顶部基片200和底部基片300在形成密封室期间由一个或多个对准销145保持精确对齐。短冲程汽缸120在形成密封室期间未被致动。密封室可通过从真空源施加真空而被排出空气。如与本发明结合使用时,术语“真空”描述了与环境压力相比的负压。该术语不需要被抽成或者保持成绝对或者极端的负压。虽然在有些情况下,实现与本发明有关的大负压是可能的和/或所希望的。在操作中,所述真空将足以基本上从密封室中的基片200和300之间移除所有的空气。如此,所有的空气在层压基片之前被移除,以防止在最终的层压产品中有问题地形成气泡或者空穴。图2C显示了受压缩的垫片150,其可能通过致动短冲程的汽缸120和/或通过降低密封室中的气压来完成。
图3描绘了短冲程汽缸120处于伸展配置的本发明的层压设备100的一个实施例的近视图。在操作中,第二冲程(在本文中被称为“短冲程”)致动短冲程汽缸120,其给顶部真空吸盘130和底部真空吸盘140施加伸展的机械力,以将基片压缩成层压产品500。为达到基片层压所必需的机械力的量取决于基片的物理性能,但对本领域普通技术人员来说是显而易见的。被应用于设备以完成层压过程的压力或者作用力的示例性的量达到大约10磅/平方英寸(psi),更特别地在0到2.5psi之间。层压过程的例证性的压缩时间是从数秒到数分钟。如本文所述的,长冲程和短冲程汽缸的相继致动能够开始形成密封室,该密封室可以被紧跟着由对层压基片的机械力压缩所述室的真空排出空气。如本文所描述的真空和机械力的相继施加防止圈闭气泡,该气泡在层压产品中产生空穴或者缺陷。
图4描绘了处于装载位置的本发明的层压设备600的备选实施例的近视图。汽缸610被缩回并且阻力弹簧615未被压缩。顶部真空吸盘630和底部真空吸盘640处于打开配置。底部真空吸盘640设有一个或多个真空对准销620和垫片645。在该实施例中,当汽缸610被缩回时待被层压的所有的基片被作为堆垛650放置在底部真空吸盘640上。
图5描绘了汽缸610处于伸展情况下的层压设备600的近视图。在该构造中,弹簧615未被压缩并且给汽缸610提供阻力。在操作中,汽缸610的伸展使顶部真空吸盘630与底部真空吸盘640上的垫片645接触,从而产生了密封室。顶部真空吸盘和底部真空吸盘由一个或多个对准销645定位,其在层压之前保持所堆垛的基片的适当对齐和对准。当顶部真空吸盘和底部真空吸盘之间发生接触时弹簧615给汽缸610提供阻力,其暂时停止汽缸610的向下运动以产生密封室。密封室然后可如本文所述地通过施加真空而被排出空气。
图6描绘了汽缸610处于完全伸展的情况下的层压设备600的近视图。在操作中,由弹簧615提供的阻力已经被汽缸610克服,该汽缸610向顶部真空吸盘630和底部真空吸盘640施加伸展力,以压缩密封室并且完成基片的层压。在汽缸610完全伸展之前从密封室排出空气防止在层压产品650中圈闭气泡,这是技术方面的明显进步。
本文所描述的方法和设备在由至少一个刚性基片层组成的任何产品的制造中是适合的。本发明的一个示例性实施例涉及一种用于制造层压的聚合物微流体结构的方法和设备。如本文所使用的,术语“微流体结构”通常指具有在大约0.1微米到大约1000微米范围内的至少一个尺寸的壁的微流体基片部件上的结构特征。这些特征可以是但不限于,微孔道、微流体通道、微储层、微阀或者微过滤器。
微流体结构(例如,微流体芯子或者卡片)是由通过将基片层粘合到一起的工艺制造的塑料本体组成的。在本发明的实施例中,通过层压实现各层的粘合。每个芯子可以是由一对基片构件或基片层或者粘合到一起的多个层所形成的。术语“层”是指包括芯子的一个或多个大致平面的、实心的基片构件中的任何一个。“层”或者“基片”是大致刚性结构但是还可以包括胶合层或者柔性片材、薄膜、压敏粘合剂(PSA)或者热粘合剂。
术语“聚合物”是指具有基本上高于组成单体的分子量并且通过聚合反应生产的大分子结构或者材料。通常并且在本文中被称为“塑料”材料的所有材料是聚合物材料。塑料是一种建造本发明的微流体装置的优选材料。可能使用的塑料包括烯烃、环状聚烯烃、环状烯烃共聚物、聚酯、聚对苯二甲酸乙二醇酯、聚对苯二甲酸丁二醇酯、聚苯乙烯、聚碳酸酯、聚丙烯、聚乙烯、聚氨基甲酸酯、聚醚砜、聚氯乙烯、聚醋酸乙烯酯、聚酰胺、聚酰亚胺、聚丙烯酸酯、聚甲基丙烯酸甲酯(PMMA)、聚四氟乙烯、聚二甲硅氧烷(PDMS)、聚硅烷、三醋酸纤维素、一般的热塑性塑料等。复合材料和共聚物也是经常被使用的。对于选择塑料或者其他固体基片和传统的粘合剂的知识在相关领域是众所周知的。
先前的具体实施例是本发明实践的说明。在不脱离本发明范围的情况下本发明的各种改进和改变对本领域普通技术人员是显而易见的,并且很清楚,本发明不局限于本文所阐述的例证性实施例。
Claims (16)
1.一种制造刚性基片构件的叠层的方法,包括:
a)在层压设备的基座部分上提供刚性基片构件的堆垛;
b)给所述层压设备的盖部分提供第一作用力,以使所述盖部分与所述基座部分上的垫片密封地接触,以便在所述基座部分和所述盖部分之间产生密封室;
c)给所述密封室施加真空,以从所述室排出空气;和
d)给所述层压设备的盖部分提供第二作用力,以压缩所述垫片和基片的堆垛,以便生产出基本上无气泡或者空穴的层压产品。
2.权利要求1所述的方法,其中第一作用力是由长冲程汽缸提供的,并且第二作用力是由短冲程汽缸提供的。
3.权利要求1所述的方法,其中第一作用力和第二作用力是由同一汽缸提供的。
4.权利要求3所述的方法,还包括给第一作用力提供阻力的步骤,其中所述阻力防止在给所述密封室施加真空的步骤之前压缩所述垫片。
5.权利要求4所述的方法,其中所述阻力是由弹簧提供的。
6.权利要求1所述的方法,其中所述刚性基片构件是基本上扁平的。
7.权利要求1所述的方法,其中所述刚性基片构件包括聚合物材料。
8.权利要求1所述的方法,其中所述刚性基片构件包括微流体装置的多个层。
9.权利要求8所述的方法,其中所述微流体装置的所述多个层还包括至少一个柔性层。
10.权利要求9所述的方法,其中所述至少一个柔性层包括粘结层。
11.权利要求1所述的方法,还包括给所述密封室施加热的步骤。
12.一种用于层压刚性基片构件的设备,所述设备包括:
a)基座部分,所述基座部分被配置成支撑刚性基片的堆垛,其中所述基座部分包括可压缩的垫片和至少一个对准销;
b)盖部分,所述盖部分被配置成密封地接触所述可压缩的垫片,以形成封装所述刚性基片构件的堆垛的密封室;
c)至少一个产生冲程的汽缸,所述至少一个产生冲程的汽缸被配置成伸展到所述盖部分并且施加第一作用力,以使所述盖部分与所述基座部分的对准销和垫片接触,以便形成所述密封室;和
d)真空端口,所述真空端口被配置成附接至真空源。
13.权利要求12所述的设备,还包括第二产生冲程的汽缸,所述第二产生冲程的汽缸被配置成伸展到所述密封室并且提供第二作用力,以压缩所述垫片和刚性基片的堆垛,以便生产出层压产品。
14.权利要求12所述的设备,还包括至少一个弹簧,所述弹簧被配置成给所述产生冲程的汽缸提供阻力。
15.权利要求14所述的设备,其中所述产生冲程的汽缸被配置成在形成所述密封室之后克服所述阻力并且压缩所述垫片和刚性基片的堆垛,以生产出层压产品。
16.权利要求12所述的设备,还包括热源。
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CN114471774B (zh) * | 2017-01-03 | 2023-08-22 | 伊鲁米那股份有限公司 | 具有浮动式密封支架的流动室匣 |
CN110605864A (zh) * | 2018-06-14 | 2019-12-24 | 台山市世昌纸业有限公司 | 一种纸板回收系统 |
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KR102332628B1 (ko) | 2021-11-30 |
WO2015148945A1 (en) | 2015-10-01 |
US20170182758A1 (en) | 2017-06-29 |
EP3122554A1 (en) | 2017-02-01 |
KR20160138237A (ko) | 2016-12-02 |
EP3620300B1 (en) | 2021-02-24 |
JP2017512664A (ja) | 2017-05-25 |
EP3122554A4 (en) | 2017-11-29 |
JP6629227B2 (ja) | 2020-01-15 |
EP3620300A1 (en) | 2020-03-11 |
CN106132690B (zh) | 2019-03-08 |
US10518517B2 (en) | 2019-12-31 |
EP3122554B1 (en) | 2020-03-18 |
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