CN109847819B - Nanofiber self-supporting additive manufacturing method containing multi-stage micro-nano structure device - Google Patents
Nanofiber self-supporting additive manufacturing method containing multi-stage micro-nano structure device Download PDFInfo
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- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
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Abstract
The invention relates to the field of microfluidic device manufacturing. The invention provides a manufacturing method of a microfluidic device, which comprises the following steps: depositing a micro/nano fiber film layer by a printing mode, then spraying and printing building fluid to the micro/nano fiber film layer according to a set pattern and curing to form basic units containing the building pattern and the micro/nano fiber film, and constructing at least one layer of the basic units according to the process. The invention can greatly save the manufacturing cost of the micro-flow controller and provides a new technical approach for manufacturing macro devices with embedded multi-stage micro-nano structures such as membrane-cavity, column-cavity, ultra-thin pore channels (through holes/blind holes) and the like.
Description
Technical Field
The invention relates to the technical field of micro-nano 3D printing and microfluidic devices, in particular to a microfluidic device based on micro/nano fiber printing, a manufacturing method and a manufacturing device thereof.
Background
Efficient microfluidic systems are evolving towards three-dimensional stacked structures. Various basic elements (micropumps, microvalves, micromixers, microelectrodes and the like) in the microfluidic system present 3D (Three-dimension) geometrical characteristics, and the method is the key for realizing the Three-dimensional, large-scale and integrated microfluidic system. The functional area in the 3D microfluidic device used by the microfluidic system can be provided with a micro-channel basic unit or a micro-valve basic unit according to different functional purposes.
The 3D paper-based microfluidic device is a typical 3D microfluidic device with a microfluidic basic unit, and two preparation methods, namely a paper folding method and a paper folding method, are mainly adopted at present. The paper-stacking method (a.w. martinez, s.t. phillips, z.nie, c.m. cheng, e.carrilho, b.j.4wiley and g.m.whitetides, Lab on a chip,2010,10,2499-2504.) is a 3D structure formed by stacking multiple layers of paper with double-sided adhesive layer by layer, and the alignment of upper and lower chips on a micrometer scale channel needs to be very precise and cumbersome; in addition, the use of laser cutting of the pre-formed attachment holes increases the steps and cost of manufacture. The manufacturing process of the paper folding method is very tedious and time-consuming, and limits mass production and application.
The paper folding method (H.Liu and R.M. Crooks, Journal of the American Chemical Society,2011,133,17564-17566.D.Sechi, B.Greer, J.Johnson and N.Hashmemi, analytical chemistry,2013,85,10733 and 10737.) folds a piece of paper into multiple layers according to a designed procedure, and finally fixes the chip using an aluminum clip to complete the entire 3D chip assembly. The method does not need adhesive tape sticking, avoids pollution and nonspecific adsorption, and avoids the use of cellulose powder. However, this method only uses an aluminum clip for fixation and may cause leakage of the reagent.
In 2012, the Lewis group (g.g.lewis, m.j.ditucci, m.s.baker and s.t.phillips, Labon a chip,2012,12, 2630-. This method requires additional pressure to compress the layers during assembly, which may cause the chip to deform or damage the microfluidic pattern.
The above methods are all manufactured by patterning paper in advance by photolithography or wax printing, and then performing subsequent assembly and assembly by means of additional equipment or processes. Therefore, based on the complexity of the current 3D paper-based microfluidic device manufacturing methods, it is a very significant and challenging task to develop a flexible, simple and automated one-step manufacturing method of microfluidic devices.
However, the above-described method for manufacturing 3D paper-based microfluidic devices is not feasible for some other microfluidic devices with a microvalve base unit. In the microfluidic device, a typical three-dimensional structure-micro valve basic unit is basically characterized by a micro-scale actuating film-micro cavity (the film thickness is 10-100 μm, the micro cavity depth is about 300 μm, and the pressure is about 500kPa), and is the basis for constructing a microfluidic control element system. The microvalve is widely used as a pressure driving basic unit of microfluid, and avoids electric heating, electromagnetic and other effects brought by electric driving when carrying out fluid transportation. The micro-scale actuating film-micro cavity structure is the core structure of a micro pump or a micro valve and is a manufacturing difficulty.
For the microfluidic devices with the movable thin film-microcavity structure, the prior art adopts MEMS technology to realize micropumps and microvalves based on silicon and glass materials, and although the technology is mature, the application in a large-scale microfluidic system is difficult. Compared with silicon, glass and the like, the polymer material has the advantages of low cost, simple process, good biocompatibility, relatively easy surface modification and wide application.
There are various effective methods for processing the micro-nano structure on the single-layer polymer plane, such as hot pressing, injection molding, casting, nano imprinting, micro milling, laser ablation and the like. Hot pressing and micro injection molding are most commonly used. For structures with more than two layers, Quake and the like form films and flow channels by using a soft etching technology based on PDMS materials, and an on-chip air/hydraulic micro-valve array is manufactured on a polymer. Weaver et al design three-layer membrane-cavity structure microvalves, and cascade of multiple microvalves constructs an integrated microfluidic system. The traditional processes of hot pressing, bonding and the like for manufacturing micropumps and microvalves with actuating films and micro-cavity structures have many problems, such as incapability of manufacturing true three-dimensional structures, difficulty in controlling consistency of large-area bonding rates, deformation and collapse of movable films, insufficient rigidity, difficulty in compatibility with manufacturing processes of sensing unit structures and the like. These inherent problems make the process difficult to use in industrial production.
Reference documents:
1、A.W.Martinez,S.T.Phillips and G.M.Whitesides,Proceedings of theNational Academy of Sciences of the United States of America,2008,105,19606-19611。
2、A.W.Martinez,S.T.Phillips,Z.Nie,C.M.Cheng,E.Carrilho,B.J.4Wiley andG.M.Whitesides,Lab on a chip,2010,10,2499-2504。
3、H.Liu and R.M.Crooks,Journal of the American Chemical Society,2011,133,17564-17566.D.Sechi,B.Greer,J.Johnson and N.Hashemi,Analytical chemistry,2013,85,10733-10737。
4、G.G.Lewis,M.J.Ditucci,M.S.Baker and S.T.Phillips,Lab on a chip,2012,12,2630-2633。
5、Weaver J A,Melin J,Stark D,et al.Static control logic formicrofluidic devices using pressure-gain valves[J].Nature Physics,2010,6(3):218-223。
6、Unger,M.A.Monolithic Microfabricated Valves and Pumps by MultilayerSoft Lithography[J].Science,2000,288(5463):113-116。
disclosure of Invention
Therefore, in order to solve the above problems, the present invention provides a micro-fluidic device based on micro/nano fiber printing, and a manufacturing method and a manufacturing apparatus thereof.
The invention aims to provide a nanofiber self-supporting additive manufacturing method containing a multi-level micro-nano structure device, which specifically comprises the following steps: depositing a micro/nano fiber film layer by a printing mode, then spraying and printing building fluid to the micro/nano fiber film layer according to a set pattern and curing to form basic units containing the building pattern and the micro/nano fiber film, and constructing at least one layer of the basic units according to the process.
The technical scheme of the invention has the following beneficial technical effects:
the invention not only can greatly save the manufacturing cost of the micro-flow controller, but also has simple and flexible method and simple and quick process, thereby having wide application prospect in large-scale device integration and large-batch device manufacturing.
In addition, the invention can realize mixed printing of various materials, has controllable material components, controllable thickness, controllable density and high flexibility, and can meet the requirements and performances of different microfluidic devices. The invention provides a new technical approach for manufacturing macro devices with embedded multistage micro-nano structures, such as membrane-cavity, column-cavity, ultra-thin pore canal (through hole/blind hole) and the like.
Drawings
FIG. 1 is a flow chart of example 1;
FIG. 2 is a flow chart of the steps added in example 3;
FIG. 3 is a flowchart of example 5;
FIG. 4 is a flowchart of an alternative procedure in embodiment 7;
FIG. 5 is a schematic structural view of example 9;
FIG. 6 is a schematic structural view of example 10.
Detailed Description
The invention provides a technical scheme for manufacturing a micro-fluidic device by micro-nano 3D printing, and particularly relates to a technical scheme for manufacturing a 3D micro-fluidic device based on self-supporting additive printing of micro/nano fibers, which is different from a 3D paper-based micro-fluidic device manufacturing method in the prior art and a micro-fluidic device manufacturing method for manufacturing micro pumps and micro valves with actuating thin film-micro cavity structures by adopting traditional processes of hot pressing, bonding and the like.
The invention will now be further described with reference to the accompanying drawings and detailed description.
To further illustrate the various embodiments, the invention provides the accompanying drawings. The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the embodiments. Those skilled in the art will appreciate still other possible embodiments and advantages of the present invention with reference to these figures. Elements in the figures are not drawn to scale and like reference numerals are generally used to indicate like elements.
Example 1:
the present embodiment provides a method for manufacturing a microfluidic device, which is mainly used for manufacturing a microfluidic device having a basic unit of a microchannel, and is shown in fig. 1 as a schematic working flow diagram of the present embodiment.
S1, referring to fig. 1 (a), a base material film sheet with a certain size is first prepared as the lower base layer 10 of the microfluidic device to be manufactured, and any one of the following examples without limitation can be selected as the base material film sheet of the lower base layer 10: a silicon substrate, a PDMS (polydimethylsiloxane) substrate, a glass substrate, a polymer film substrate, etc., and the examples are illustrated and described below with reference to the PDMS substrate, but the scope of the invention is not limited thereto. In this embodiment, the lower substrate layer 10 of PDMS is first fixed during the manufacturing process.
S2, referring to fig. 1 (b), then depositing a first micro/nano fiber film 201 on the lower substrate layer 10 of PDMS by printing, the printing material as the micro/nano fiber film 201 may be selected from any one of the following list without limitation: examples of the nano-scale fibers include, but are not limited to, PI (Polyimide), PVDF (poly (vinylidene fluoride), PVDF), PCL (Polycaprolactone), PLA (polylactic acid), PLGA (poly-co-glycolic acid), poly (lactic-co-glycolic acid), PVA (polyvinyl alcohol), and the like, and the examples are illustrated and described below using PVA (polyvinyl alcohol) nano-scale fibers, but are not intended to limit the scope of the present invention While the technical content that the operator can grasp, the present invention will be described later in conjunction with the manufacturing equipment, and will not be developed in detail herein.
S3, referring to fig. 1 (c), printing a casting fluid material (hydrophobic material is selected as the casting fluid material in this embodiment) on the first micro/nano fiber membrane 201 according to a casting pattern, transferring the casting fluid material onto the first micro/nano fiber membrane 201, and curing the casting fluid material, wherein the hydrophobic material penetrates into the micro/nano fiber membrane 201 due to the micro/nano fiber membrane 201 having a plurality of micro pores, fills the pores of the micro pores in the micro/nano fiber membrane 201, and after curing the hydrophobic material, the microfluidic hydrophobic barrier with the design requirement can be constructed. The hydrophobic material may be selected from any one of the following illustrative without limitation: paraffin, PDMS or surfactant, and the corresponding curing mode is also adaptively selected and adjusted according to the selected material of the micro/nano fiber membrane and the hydrophobic material. The following examples are shown and described by taking PDMS as the hydrophobic material, and the curing method thereof is thermal curing, and the curing temperature is selected to be between 100 ℃ and 120 ℃, but the above hydrophobic material and curing method are not used to limit the scope of the present invention. In the figure of this embodiment, after PDMS printing, a hydrophobic region 201A and a hydrophilic region 201B are formed on the first micro/nanofiber membrane 201 (the hydrophilic region 201B, i.e., the region where the hydrophobic material pattern is not printed, has a hydrophilic characteristic due to the existence of the microporous structure of the micro/nanofiber membrane 201 itself). As a preferable mode of this embodiment, a micro flow channel is formed by printing a hydrophobic material on the micro/nano fiber film 201 by using a melting electrostatic direct writing printing technology or an electrostatic spray printing technology, and a specific implementation manner of the melting electrostatic direct writing printing technology and the electrostatic spray printing technology is within a technical content that can be grasped by those skilled in the art, and meanwhile, the present invention will be described in conjunction with a manufacturing apparatus hereinafter, and will not be expanded in detail herein.
S4, since the micro flow channels in the micro flow control device to be manufactured are usually 3D distributed, it is usually constructed by stacking multiple layers of printing. Specifically, referring to fig. 1 (d), on the basis of the first micro/nanofiber membrane 201 (which may be referred to as a basic unit containing a building pattern and a micro/nanofiber membrane, or a micro/nanofiber membrane functional layer) printed in the above step S3, a second micro/nanofiber membrane 202 is printed on the first micro/nanofiber membrane 201 in the same manner as in step S2, and referring to fig. 1 (e), in the same manner as in step S3, a hydrophobic material PDMS is jet-printed on the second micro/nanofiber membrane 202 in the set building pattern. Referring to fig. 1 (f) to 1 (i), a third micro/nanofiber membrane 203 (basic unit) and a fourth micro/nanofiber membrane 204 (basic unit) are sequentially printed on the second micro/nanofiber membrane 202 (basic unit) in the same manner as in steps S2 and S3. It should be noted that the number of layers of the micro/nanofiber membrane printed in the microfluidic device and the shape of the hydrophobic material pattern on each layer are related to the structural design of the micro channel in the device, and those skilled in the art can adjust the number according to actual needs without limitation.
In this embodiment, PVA nanofibers are used as the base material for the first micro/nanofiber membrane 201, the second micro/nanofiber membrane 202, the third micro/nanofiber membrane 203 and the fourth micro/nanofiber membrane 204, and are used as the printing material (i.e. the deposition material for the micro/nanofiber membrane base layer); however, in other implementation applications, the PVA nanofibers are not necessarily used as the base materials of the basic units of the first micro/nanofiber membrane 201, the second micro/nanofiber membrane 202, the third micro/nanofiber membrane 203, and the fourth micro/nanofiber membrane 204, and different nanofiber materials may be used for the mixed printing of the lamination.
S5, referring to (j) of fig. 1, finally, on the basis of sequentially printing and overlapping the functional region 20 formed by the first micro/nano fiber film 201, the second micro/nano fiber film 202, the third micro/nano fiber film 203 and the fourth micro/nano fiber film 204, the upper substrate layer 30 is bonded, thereby forming a complete microfluidic device. The upper substrate layer 30 may be made of the same material as the lower substrate layer 10, and any one of the following may be selected without limitation: a silicon substrate, a PDMS (polydimethylsiloxane) substrate, a glass substrate, a polymer film substrate, etc., and the examples are illustrated and described below with reference to the PDMS substrate, but the scope of the invention is not limited thereto.
As can be seen from the above, the 3D microfluidic device manufacturing method of this embodiment may be implemented by printing and depositing a micro/nanofiber membrane with a certain thickness as a micro/nanofiber membrane base layer, and then constructing a microfluidic hydrophobic barrier on the micro/nanofiber membrane layer by combining with a building-type fluid material (in this embodiment, a hydrophobic material) printing technology, so that the manufacturing of the entire micro/nanofiber-based 2D or 3D microfluidic device may be completed at one time by controlling continuous operations with a computer automation system. Compared with the 3D paper-based microfluidic device manufacturing method in the prior art, the embodiment can reduce the manufacturing steps of the paper-based 3D microfluidic device, thereby reducing the manufacturing cost, improving the manufacturing efficiency, and having wide application prospects in large-scale device integration and large-batch device manufacturing. In addition, the structure used as the micro/nano fiber membrane base layer can be mixed printing of various materials, has controllable material components, controllable thickness, controllable density and high flexibility, and can meet the requirements and performances of different microfluidic devices.
Example 2:
in this embodiment, a microfluidic device manufactured by the manufacturing method of the above embodiment 1 is also provided, as shown in (j) of fig. 1, the microfluidic device includes a lower substrate layer 10, an upper substrate layer 30, and a functional region 20 disposed therebetween, where the functional region 20 is formed by printing at least one, and preferably two or more, micro/nanofiber membranes in a lamination manner, and a building fluid material is infiltrated and cured in at least one of the micro/nanofiber membranes, and the hydrophobic material is formed according to a set building pattern to construct a microfluidic hydrophobic barrier, so that micro channels with 2D (planar) distribution or 3D distribution are constructed in the functional region 20. In this embodiment, the micro flow channel in the functional region 20 is also filled with micro/nano fiber material (hydrophilic).
Example 3:
referring to fig. 1 again, and also referring to fig. 2, in the embodiment 2, a step S6 is added on the basis of the embodiment 1 to remove the micro/nano fiber material in the functional region 20. Specifically, in this embodiment, the micro/nanofiber materials of the base layers of the first micro/nanofiber membrane 201, the second micro/nanofiber membrane 202, the third micro/nanofiber membrane 203, and the fourth micro/nanofiber membrane 204 in the functional region 20 all adopt PVA nanofibers as printing materials and can be dissolved in water, so that the step (j) of fig. 2 can be implemented by only placing the whole microfluidic device in water for soaking, or by using an injector to suck a certain amount of water and using an injection pump to pump in for dissolution at a certain speed and time, wherein the inlet and outlet of the microfluidic device are connected by using PEEK and are connected by using a silicone tube and the injector. It should be noted that the specific implementation manner of step S6 is to select different removing manners according to different characteristics of the micro/nano fiber material in the functional region 20, which is known to those skilled in the art or can be found in the literature of the prior art, and is not illustrated herein.
Example 4:
in this embodiment, a microfluidic device manufactured by the manufacturing method of the above embodiment 3 is also provided, as shown in fig. 2 (k), the microfluidic device includes a lower substrate layer 10, an upper substrate layer 30, and a functional region 20 disposed therebetween, where the functional region 20 is formed by printing at least one layer, and preferably two or more layers of micro/nanofiber membranes in a lamination manner, and at least one layer of micro/nanofiber membrane is penetrated and solidified with a building fluid material (such as a hydrophobic material), and the building fluid material is formed according to a set building pattern to construct a microfluidic hydrophobic barrier, so that micro channels with 2D distribution or 3D distribution are constructed in the functional region 20. In this embodiment, the micro flow channel in the functional region 20 is hollow.
Example 5:
the embodiment provides a method for manufacturing a microfluidic device, which is mainly used for manufacturing a microfluidic device with a microvalve basic unit, and reference is made to fig. 3, which is a schematic working flow diagram of the embodiment.
S1, referring to fig. 3 (a), a base material film sheet with a certain size is first prepared as the lower base layer 10 of the microfluidic device to be manufactured, and any one of the following examples without limitation can be selected as the base material film sheet of the lower base layer 10: a silicon substrate, a PDMS (polydimethylsiloxane) substrate, a glass substrate, a polymer film substrate, etc., and the examples are illustrated and described below with reference to the PDMS substrate, but the scope of the invention is not limited thereto. In this embodiment, the lower substrate layer 10 of PDMS is first fixed during the manufacturing process.
S2, referring to fig. 3 (b), then depositing a first micro/nano fiber film 201 on the lower substrate layer 10 of PDMS by printing, the printing material as the micro/nano fiber film 201 may be selected from any one of the following list without limitation: polymer nanometer fiber, polymer composite nanometer fiber, nanometer modified fiber of natural fiber, etc., such as PI, PVDF, PCL, PLA, PLGA, PVA. This example is shown and described below with respect to a PVA (polyvinyl alcohol) nanofiber as an example, but is not intended to limit the scope of the present invention. As a preferred example of this embodiment, a micro/nano fiber membrane 201 with a certain thickness is prepared by using an electro-hydraulic coupling jet printing technology (such as electrospinning printing). In this embodiment, the thickness of each micro/nanofiber membrane is preferably 40 to 60 μm. While the specific implementation of electrospinning printing is within the skill of one skilled in the art, the present invention will be described below in conjunction with the manufacturing equipment and will not be described in detail herein.
S3, referring to fig. 3 (c), printing a building fluid material (in this embodiment, a hydrophobic material) on the first micro/nano fiber membrane 201 according to a set building pattern, and transferring the building fluid material onto the first micro/nano fiber membrane 201, and curing the building fluid material, wherein the hydrophobic material penetrates into the micro/nano fiber membrane 201 and fills pores of the micro/nano fiber membrane 201 due to the micro/nano fiber membrane 201 having a plurality of micro pores, and the micro-fluidic hydrophobic barrier required by the design can be constructed after the hydrophobic material is cured. The hydrophobic material as the building type fluid material in this embodiment may be selected from any one of the following illustrative examples without limitation: paraffin, PDMS or surfactant, and the corresponding curing mode is also adaptively selected and adjusted according to the selected material of the micro/nano fiber membrane and the hydrophobic material. The following examples are shown and described by taking PDMS as the hydrophobic material, and the curing method thereof is thermal curing, and the curing temperature is selected to be between 100 ℃ and 120 ℃, but the above hydrophobic material and curing method are not used to limit the scope of the present invention. In the figure of this embodiment, after PDMS printing, a hydrophobic region 201A and a hydrophilic region 201B are formed on the first micro/nanofiber membrane 201 (the hydrophilic region 201B, i.e., the region where the hydrophobic material pattern is not printed, has a hydrophilic characteristic due to the existence of the microporous structure of the micro/nanofiber membrane 201 itself). As a preferable mode of this embodiment, a micro flow channel is formed by printing a hydrophobic material on the micro/nano fiber film 201 by using a melting electrostatic direct writing printing technology or an electrostatic spray printing technology, and a specific implementation manner of the melting electrostatic direct writing printing technology and the electrostatic spray printing technology is within a technical content that can be grasped by those skilled in the art, and meanwhile, the present invention will be described in conjunction with a manufacturing apparatus hereinafter, and will not be expanded in detail herein.
S4, since the thin film-microcavity structure in the microfluidic device to be manufactured is a 3D structure, it is usually constructed by stacking multiple layers of printing. In this embodiment, referring to fig. 3 (d), on the basis of the first micro/nanofiber membrane 201 (including the building pattern and the basic unit of the micro/nanofiber membrane, or the functional layer of the micro/nanofiber membrane) printed in the above step S3, in the same manner as in step S2, a second micro/nanofiber membrane 202 is printed on the first micro/nanofiber membrane 201, see (e) of fig. 3, again in the same manner as in step S3, a hydrophobic material PDMS is transferred onto the second layer of micro/nanofiber membrane 202 by means of inkjet printing, but, in contrast, as the actuatable film portion constituting the film-microcavity structure, the printing of the hydrophobic material PDMS of the second micro/nanofiber membrane 202 is a full coverage, and it is not necessary to print according to a set micro channel pattern to form a micro channel like in the first micro/nanofiber membrane 201.
In the embodiment, the thickness of the actuatable film part can be 50 to 200 μm, and in the case that the printing thickness of each micro/nanofiber film layer is preferably 40 to 60 μm, one or more layers can be performed to perform overall covering printing of the hydrophobic material PDMS according to the film thickness requirement of the actuatable film. In this embodiment, the thickness of the actuating membrane is illustrated by a printing thickness of a micro/nano fiber membrane, that is, the thickness of the second micro/nano fiber membrane 202 is used as the actuating membrane, but the practical application is not limited thereto.
S5, referring to fig. 3 (f) and fig. 3 (g), the third micro/nanofiber membrane 203 is printed on the second micro/nanofiber membrane 202 to construct a micro flow channel on the third micro/nanofiber membrane 203, also in the same manner as in steps S2 and S3.
S6, referring to fig. 3 (h) and fig. 3 (i), the second layer of micro/nano fiber membrane 202 of the actuatable film part is constructed in a manner similar to the step S4, and the hydrophobic material PDMS and the fourth layer of micro/nano fiber membrane 204 are printed to cover the whole surface to close the micro flow channel on the third layer of micro/nano fiber membrane 203 constructed in the step S5, and the fourth layer of micro/nano fiber membrane 204 is also used for bonding with the upper substrate layer 30. It should be noted that the number of layers of the printed micro/nanofiber membrane in the microfluidic device and the shape of the hydrophobic material pattern on the micro/nanofiber membrane as the micro channel are related to the structural design of the micro channel in the device, and those skilled in the art can adjust the number according to actual needs without limitation.
In this embodiment, PVA nano-sized fibers are used as the base materials of the functional layers of the first micro/nano-fiber film 201, the second micro/nano-fiber film 202, the third micro/nano-fiber film 203 and the fourth micro/nano-fiber film 204 as the printing material (i.e., the deposition material of the micro/nano-fiber film base layer); however, in other implementation applications, the PVA nanofibers are not necessarily used as the base materials of the functional layers of the first micro/nanofiber membrane 201, the second micro/nanofiber membrane 202, the third micro/nanofiber membrane 203 and the fourth micro/nanofiber membrane 204, and different nanoscale fiber materials may be used for mixed printing of lamination.
S7, referring to (j) of fig. 3, on the basis of sequentially printing the functional region 20 formed by overlapping the first layer of the micro/nanofiber membrane 201 (the basic unit containing the building pattern and the micro/nanofiber membrane, or the micro/nanofiber membrane functional layer), the second layer of the micro/nanofiber membrane 202 (the basic unit), the third layer of the micro/nanofiber membrane 203 (the basic unit), and the fourth layer of the micro/nanofiber membrane 204 (the basic unit), the upper substrate layer 30 is bonded to the fourth layer of the micro/nanofiber membrane 204, thereby forming a complete microfluidic device. The upper substrate layer 30 may be made of the same material as the lower substrate layer 10, and any one of the following may be selected without limitation: a silicon substrate, a PDMS (polydimethylsiloxane) substrate, a glass substrate, a polymer film substrate, etc., and the examples are illustrated and described below with reference to the PDMS substrate, but the scope of the invention is not limited thereto.
S8, referring to fig. 3 (k), the micro/nano-fiber material in the device functional region 20 is finally removed. Specifically, in this embodiment, the micro/nanofiber materials of the base layers of the first micro/nanofiber membrane 201, the second micro/nanofiber membrane 202, the third micro/nanofiber membrane 203, and the fourth micro/nanofiber membrane 204 in the functional region 20 all adopt PVA nanofibers as printing materials, and can be dissolved in water, so that the step (j) of fig. 3 can be implemented by only placing the whole microfluidic device in water for soaking, or by using an injector to suck a certain amount of water, and using an injection pump to pump in for dissolving at a certain speed and time, wherein the inlet and outlet of the microfluidic device are connected by using PEEK, and are connected by using a silicone tube and the injector. It should be noted that the specific implementation manner of step S8 is to select different removing manners according to different characteristics of the micro/nano fiber material in the functional region 20, which is known to those skilled in the art or can be found in the literature of the prior art, and is not illustrated herein.
As can be seen from the above, the 3D microfluidic device manufacturing method of this embodiment prints and deposits a micro/nanofiber membrane with a certain thickness as the base material of the functional layer (i.e. the micro/nanofiber membrane base layer), then, combining with hydrophobic material printing technology to construct a microfluidic hydrophobic barrier on the functional layer substrate material so as to prepare a lower-layer microchannel structure with certain depth and width, then, an intermediate layer micro/nano fiber film with a certain depth is formed after deposition for a certain time, the intermediate layer micro/nano fiber film and PDMS can be compounded to be used as a movable film cavity structure of the micro valve basic unit, the same procedures of the lower layer micro channel structure are repeatedly executed, an upper layer micro channel structure with a certain depth and width is manufactured, the fabrication of the entire micro/nanofiber based 3D microfluidic device can be done at once with continuous operation controlled by a computer automated system. Compared with the prior art that the micro-fluidic device containing the actuating film-micro-cavity structure, such as a micro pump and a micro valve, is manufactured by adopting the traditional processes of hot pressing, bonding and the like, the embodiment can reduce the manufacturing cost and improve the manufacturing efficiency, and has wide application prospect in large-scale device integration and large-batch device manufacturing. In addition, the micro/nano fiber membrane body structure can be used for mixed printing of various materials, has controllable material components, controllable thickness, controllable density and high flexibility, and can meet the requirements and performances of different microfluidic devices.
In addition, in this embodiment, a method of performing layer-by-layer deposition printing on a micro/nanofiber material is preferably performed by using a technology that is performed in a micro/nanofiber self-supporting additive manufacturing manner, and compared with the existing commercial micro-nano 3D printing, the method also has a considerable technical advantage. The challenge encountered in current 3D printing technology to fabricate thin film-microcavity structures is that support material removal is very difficult, resulting in compromised microvalve/micropump performance. Also, materials for commercial 3D printing technology are limited and expensive. The micro valve mainly realizes the fluid shutoff function by means of deformation of a thin film structure, and due to different processes in the existing commercial micro-nano 3D printing, the elasticity (elastic modulus 1463MPA) and durability of a material (photosensitive resin material) for manufacturing the micro valve thin film structure are poor, and the material is easy to break to cause fluid leakage after long-term use. In this embodiment, it is preferable to use an electrostatic spinning printing technique (i.e., an electro-hydraulic coupling jet printing technique) to stretch the micro/nano fiber material solution by using an electric field force, so as to deform the micro/nano fiber material solution and overcome the surface tension, and finally deposit the micro/nano fiber material solution on the collecting plate to form a micro/nano fiber film or liquid drops or lines. And repeating the alternate jet printing to stack the three-dimensional structure of the device functional area. In addition, the technology of the embodiment adopts wide materials, and provides an effective method for manufacturing diversified microfluidic devices.
Example 6:
in this embodiment, a microfluidic device manufactured by the manufacturing method of the above embodiment 5 is also provided, as shown in fig. 3 (k), the microfluidic device includes a lower substrate layer 10, an upper substrate layer 30, and a functional region 20 disposed therebetween, where the functional region 20 is formed by printing at least three layers of micro/nanofiber films in a lamination manner, where: the middle layer at least comprises an actuatable film part of a film-microcavity structure, wherein the actuatable film part is formed by permeating and curing a hydrophobic material in a micro/nanofiber film layer, the upper layer and the lower layer of the middle layer are respectively provided with at least one layer of micro/nanofiber film layer, the hydrophobic material is permeated and cured in a micro/nanofiber film layer, and the hydrophobic material is formed according to a set pattern to construct a microfluidic hydrophobic barrier so as to construct a 2D distribution or 3D distribution micro-channel. In this embodiment, the micro flow channel in the functional region 20 is hollow.
Example 7:
referring to fig. 3 again and also to fig. 4, the embodiment 7 is improved based on the embodiment 5, specifically: the micro/nanofiber materials of the base layers of the first micro/nanofiber membrane 201, the second micro/nanofiber membrane 202, the third micro/nanofiber membrane 203 and the fourth micro/nanofiber membrane 204 in the functional region 20, which are different from those of the embodiment, are all PVA nanofibers, in this embodiment, PI (Polyimide) or other material difficult to degrade or dissolve is used as the printing material of the base layer of the first micro/nanofiber membrane 201, while the base layer printing material of the third micro/nanofiber membrane 203 is printed with PVA nanofibers or other material degradable or dissolve, and other embodiments and conditions are similar to those of embodiment 5, so that in step S8, referring to (k') of fig. 4, which is different from (k) of fig. 3, finally the micro/nanofiber material in the functional region 20 of the device is partially removed, that is, the micro/nanofiber material in the micro flow channel of the first layer of micro/nanofiber membrane 201 is not removed, while the micro/nanofiber material in the micro flow channel of the third layer of micro/nanofiber membrane 203 is removed.
Example 8:
in this embodiment, a microfluidic device manufactured by the manufacturing method of the above embodiment 7 is also provided, as shown in (k') of fig. 4, the microfluidic device includes a lower substrate layer 10, an upper substrate layer 30, and a functional region 20 disposed therebetween, where the functional region 20 is formed by printing at least three layers of micro/nanofiber films in a lamination manner, where: the middle layer at least comprises an actuatable film part of a film-microcavity structure, wherein the actuatable film part is formed by permeating and curing a hydrophobic material in a micro/nanofiber film layer, the upper layer and the lower layer of the middle layer are respectively provided with at least one layer of micro/nanofiber film layer, the hydrophobic material is permeated and cured in a micro/nanofiber film layer, and the hydrophobic material is formed according to a set pattern to construct a microfluidic hydrophobic barrier so as to construct a 2D distribution or 3D distribution micro-channel. In this embodiment, the micro flow channel in the functional region 20 is partially hollow, and partially filled with micro/nano fiber material (hydrophilic). The microfluidic device can be applied in some occasions; for example, the micro-fluidic device has wide application prospect in the occasions of fluid pumping, cooling and heat dissipation and the like.
For the manufacturing method of each embodiment described above, in order to control continuous operations by means of a computer automation system to achieve efficient manufacturing, the present invention also proposes the following manufacturing equipment.
Example 9:
referring to fig. 5, the embodiment proposes a manufacturing apparatus for scale-up manufacturing of the micro/nanofiber-based microfluidic device as described above, and specifically includes: the device comprises a high-voltage direct-current power supply 1, an injection pump system 2, a spray head module 3, a collecting plate 4, an X-axis moving platform 5, a Y-axis moving platform 6, a Z-axis moving platform 7, a printing industrial control system 8, a computer 9, a spray head installation module 11 and a CCD camera module 12.
In this embodiment, a three-dimensional displacement execution assembly is composed of the X-axis moving platform 5, the Y-axis moving platform 6, and the Z-axis moving platform 7, and is specifically controlled by the industrial printing control system 8. The embodiment is specific: the guide rail of the X-axis moving platform 5 is fixedly connected to the moving seat of the Y-axis moving platform 6, and the moving seat of the X-axis moving platform 5 is used for fixedly connecting the collecting plate 4, so that the X-axis moving platform 5 and the Y-axis moving platform 6 drive the collecting plate 4 to perform XY coordinate translation in the plane where the collecting plate is located, the relative transverse and longitudinal positions of the spray head module 3 and the collecting plate 4 are changed, and the lower basal layer fixed on the collecting plate 4 is sequentially printed and deposited with each layer of nano-scale fiber film layer and transferred hydrophobic material according to a printing path; the movable base of the Z-axis movable platform 7 is fixedly connected with the spray head module 3 through the spray head installation module 11, the spray head installation module 11 comprises a transition plate and a fixed base, the two ends of the transition plate are respectively and fixedly connected with the two movable bases of the Z-axis movable platform 7, the fixed base is arranged in the middle of the transition plate, the spray head module 3 is fixedly installed on the fixed base through a screw lock, and the transition plate is connected with the movable base of the Z-axis movable platform 7. In the illustration of the embodiment, the implementation structures of the mobile platforms are shown only in the manner of sliding rail pairs, but in practical application, different mobile platform structures can be adopted according to the structural design requirements.
In order to achieve faster printing and improve printing efficiency, the nozzle module 3 is designed to have three nozzles, and correspondingly, the fixing base of the nozzle mounting module 11 has three mounting positions for respectively mounting the three nozzles of the nozzle module 3; preferably, the three heads are an electrospinning head, a melt electrostatic direct writing head, and an electrostatic jet printing head. The spray head module 3 of the embodiment adopts a plurality of spray heads to rapidly switch different printing materials and printing modes, thereby greatly improving the printing efficiency. Of course, the head module 3 of this embodiment may be designed to adopt a single head structure without considering printing efficiency.
In this embodiment, a CCD camera module 12 is further mounted on the transition plate of the head mounting module 11 to capture images during a print job and feed back to the computer 9, and the computer 9 guides and corrects the print job of the head module 3 according to the image feedback.
the high-voltage direct-current power supply 1 is used for generating power supply required by printing operation (electro-hydraulic coupling jet printing technology), in the embodiment, the positive electrode of the high-voltage direct-current power supply 1 is electrically connected to the spray head module 3, and the negative electrode of the high-voltage direct-current power supply 1 is electrically connected to the collecting plate 4 (the polarity can be exchanged); meanwhile, the collecting plate 4 needs to be grounded to improve safety of electricity.
In this embodiment, the printing industrial control system 8 is electrically connected with the X-axis moving platform 5, the Y-axis moving platform 6 and the Z-axis moving platform 7 to control the specific execution of the displacement motion in the corresponding dimension;
in this embodiment, the computer 9 is connected to the print industrial control system 8, and since the print job in this embodiment usually needs a special upper computer program (print program) to calculate, and then transmits a specific displacement command and an injection on-off command to the print industrial control system 8, so as to drive the X-axis moving platform 5, the Y-axis moving platform 6, and the Z-axis moving platform 7 to perform the displacement motion in the corresponding dimension and control the motion of the syringe pump system 2.
The following description will be made by taking the manufacturing apparatus of this embodiment to perform the manufacturing method of the above embodiment 1 or 5 to manufacture a microfluidic device as an example, including the following operation processes:
1) and starting a temperature control unit on the collecting plate 4, and keeping the temperature of the collecting plate 4 between 100 and 120 ℃ so as to heat and solidify the polymer solution (such as PDMS) for subsequent printing.
2) Firstly, fixing a lower basal layer on a collecting plate 4 (the collecting plate 4 can further comprise an auxiliary fixing clamp), adjusting the heights of a spray head module 3 and the lower basal layer through a Z-axis moving platform 7, and then controlling to start an injection pump system 2 and a high-voltage direct-current power supply 1 and adjusting voltage; when the injection pump system 2 starts to work, the printing solution for forming the micro/nano fiber membrane material is conveyed to the electrostatic spinning nozzle according to the given spinning speed and time, and finally the printing solution is loaded into a printing program by the computer 9 and is transmitted to the printing industrial control system 8, so that the movement of the X-axis moving platform 5 and the movement of the Y-axis moving platform 6 are controlled according to the pre-designed program and path to perform electrostatic spinning printing, and then the micro/nano fiber membrane is deposited on the collecting plate 4 and the appearance is observed through the CCD camera module 12, so as to guide and correct the printing operation of the nozzle module 3 according to image feedback. In the process, the printed micro/nano fiber film layer is mainly carried out by using an electrostatic spinning printing technology, charged printing material solution (PVA) is stretched into micro/nano fiber substances under the action of a high-voltage electric field generated by a high-voltage direct-current power supply 1, a spinning needle head on a spray head module 3 (electrostatic spinning spray head) is firstly conveyed at a certain speed provided by an injection pump system 2, and the high-voltage direct-current power supply 1 is connected with the positive pole of the spray head module 3 (electrostatic spinning spray head) and the negative pole of the high-voltage direct-current power supply 1 is connected with a collecting plate 4, the high-voltage electric field is applied between the positive pole and the collecting plate, the printing material solution is promoted to be jetted downwards in a jet flow.
3) When the micro/nano fiber film reaches a certain thickness (such as 40-60 μm preferably), the injection pump system 2 is controlled to be closed; and controlling to regulate the distance between the spray head module 3 and the substrate again through the Z-axis moving platform 7, regulating the power supply voltage of the high-voltage direct-current power supply 1 again, and then controlling the injection pump system 2 to convey the PDMS hydrophobic material to the melting electrostatic direct-writing spray head or the electrostatic spray printing spray head.
4) The printing industrial control system 8 controls and adjusts the X-axis moving platform 5 and the Y-axis moving platform 6, and performs local printing or comprehensive coverage printing for constructing the microfluidic hydrophobic barrier according to the microfluidic pattern designed by the computer 9, wherein the printing mode is to select to perform melting electrostatic direct writing printing or electrostatic spray printing or perform melting electrostatic direct writing printing or electrostatic spray printing alternately according to one of the selected melting electrostatic direct writing nozzle or electrostatic spray printing nozzle. If the melting electrostatic direct writing printing is adopted, the spray head module 3 (melting electrostatic direct writing spray head) is heated and kept at a proper temperature, so that a printing material (PDMS hydrophobic material) in the spray head is kept in a molten state and has proper spray printing viscosity, the spray head is connected with the anode of the high-voltage direct current power supply 1 through a lead, the collecting plate 4 is connected with the cathode of the high-voltage direct current power supply 1, a high-voltage electrostatic field is formed between the spray head module 3 (melting electrostatic direct writing spray head) and the collecting plate 4 through the high-voltage direct current power supply 1, the hydrophobic material is sprayed on the micro/nano fiber membrane in a fog drop mode under the action of the electric field force, the moving speed of the collecting plate 4 is adjusted, the hydrophobic layer moves according to a specific path to construct hydrophobic layer patterns, and corresponding structures are formed on.
5) After the PDMS hydrophobic material is printed, the printed micro flow channel pattern or the full coverage pattern is thermally cured under the action of the temperature control unit of the collection plate 4 to form a hydrophobic barrier or an actuatable membrane portion.
6) The processes from 2) to 5) can be repeatedly and circularly executed according to the number of layers of the micro-fluidic device to be manufactured and the structural requirements of the micro-channel basic unit or the micro-valve basic unit in the functional area until the micro/nano-fiber-based 2D or 3D micro-fluidic device is manufactured.
In this embodiment, as the control for performing the electrospinning printing, the molten electrostatic direct writing printing, and the electrostatic jet printing, the control of the distance parameter between the head module 3 and the lower base layer on the collecting plate 4 is the key for effective implementation. In this embodiment, when electrostatic spinning printing is performed, the distance between the nozzle module 3 and the substrate should be set to be 1-200 mm; when electrostatic spray printing or fused electrostatic direct writing printing is performed, the distance between the nozzle module 3 and the substrate should be set to be 0-5 mm.
Example 10:
referring to fig. 6, this embodiment provides another manufacturing apparatus for manufacturing micro/nanofiber-based microfluidic devices as described above on a large scale, and specifically includes: the device comprises a high-voltage direct-current power supply 1, an injection pump system 2, a spray head module 3, a collecting plate 4, an X-axis moving platform 5, a Y-axis moving platform 6, a Z-axis moving platform 7, a printing industrial control system 8, a computer 9, a spray head installation module 11 and a CCD camera module 12.
This embodiment 10 is substantially the same as embodiment 9 above except that: in this embodiment, the nozzle module 3 is fixed on the fixed support, and a three-dimensional displacement executing assembly composed of the X-axis moving platform 5, the Y-axis moving platform 6, and the Z-axis moving platform 7 is used to drive the collecting plate 4 to make three-dimensional motion, so that the X-axis moving platform 5, the Y-axis moving platform 6, and the Z-axis moving platform 7 cooperate to drive the collecting plate 4 to make XY-axis planar coordinate translation and Z-axis height movement in the plane where the collecting plate is located, and change the relative position and height of the nozzle module 3 and the collecting plate 4. In this way, the same print job operation as in embodiment 9 described above can also be realized.
The operation of the manufacturing apparatus of this embodiment to perform the manufacturing method of embodiment 1 or 5 described above to manufacture a microfluidic device is substantially similar to that of embodiment 9 described above, including the following operation:
1) and starting a temperature control unit on the collecting plate 4, and keeping the temperature of the collecting plate 4 between 100 and 120 ℃ so as to heat and solidify the polymer solution (such as PDMS) for subsequent printing.
2) Firstly, fixing a lower substrate layer on a collecting plate 4 (the collecting plate 4 can further comprise a fixture for auxiliary fixing), adjusting the height of the lower substrate layer on the collecting plate 4 relative to a spray head module 3 through a Z-axis moving platform 7, and then controlling to start an injection pump system 2 and a high-voltage direct-current power supply 1 and adjusting voltage; when the injection pump system 2 starts to work, the printing solution for forming the micro/nano fiber membrane material is conveyed to the electrostatic spinning nozzle according to the given spinning speed and time, and finally the printing solution is loaded into a printing program by the computer 9 and is transmitted to the printing industrial control system 8, so that the movement of the X-axis moving platform 5 and the movement of the Y-axis moving platform 6 are controlled according to the pre-designed program and path to perform electrostatic spinning printing, and then the micro/nano fiber membrane is deposited on the collecting plate 4 and the appearance is observed through the CCD camera module 12, so as to guide and correct the printing operation of the nozzle module 3 according to image feedback.
3) When the micro/nano fiber film reaches a certain thickness (such as 40-60 μm preferably), the injection pump system 2 is controlled to be closed; and controlling to regulate the height of the lower substrate layer on the collecting plate 4 relative to the spray head module 3 through the Z-axis moving platform 7 again, regulating the power supply voltage of the high-voltage direct-current power supply 1 again, and then controlling the injection pump system 2 to convey the PDMS hydrophobic material to the melting electrostatic direct-writing spray head or the electrostatic spray printing spray head.
4) The printing industrial control system 8 controls and adjusts the X-axis moving platform 5 and the Y-axis moving platform 6, local printing of the microfluidic hydrophobic barrier is built or overall coverage printing is carried out according to microfluidic patterns designed by the computer 9, and the printing mode is that melting electrostatic direct-writing printing or electrostatic spray printing or alternative printing is carried out according to one of the selected melting electrostatic direct-writing nozzle or electrostatic spray printing nozzle.
5) After the PDMS hydrophobic material is printed, the printed micro flow channel pattern or the full coverage pattern is thermally cured under the action of the temperature control unit of the collection plate 4 to form a hydrophobic barrier or an actuatable membrane portion.
6) The processes from 2) to 5) can be repeatedly and circularly executed according to the number of layers of the micro-fluidic device to be manufactured and the structural requirements of the micro-channel basic unit or the micro-valve basic unit in the functional area until the micro/nano-fiber-based 2D or 3D micro-fluidic device is manufactured.
It should be noted that, in other application occasions, the collecting plate 4 may be fixedly installed in this embodiment, and the three-dimensional displacement executing assembly is connected to the nozzle module 3 in a driving manner, and drives the nozzle module 3 to make three-dimensional movement relative to the collecting plate 4 through the three-dimensional displacement executing assembly.
While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (6)
1. A nanofiber self-supporting additive manufacturing method containing a multi-level micro-nano structure device is characterized by comprising the following steps: depositing a micro/nano fiber film layer by a printing mode, then spraying and printing building fluid to the micro/nano fiber film layer according to a set pattern and curing to form a basic unit containing a building pattern and a micro/nano fiber film, and constructing a film-microcavity structure formed by at least three layers of the basic unit according to the process, wherein the film-microcavity structure at least comprises a first layer structure, a second layer structure and a third layer structure, the building pattern spraying and printing mode of the basic unit forming the first layer structure and the third layer structure is partially covered according to a micro-channel pattern, and the building pattern spraying and printing mode of the basic unit forming the second layer structure is fully covered; further comprising: and (3) completely removing or selectively removing the micro/nano fiber membrane which is not covered with the building type fluid part in the basic unit.
2. The manufacturing method according to claim 1, characterized in that: the printing is carried out in a self-supporting additive manufacturing mode of the micro/nano fibers.
3. The manufacturing method according to claim 2, characterized in that: the nanofiber self-supporting additive manufacturing mode is based on an electro-hydraulic coupling jet printing technology.
4. The manufacturing method according to claim 1, characterized in that: the micro/nano fiber film layer is made of the following materials: nanometer level modified fiber of nanometer level polymer fiber, nanometer level composite polymer fiber or natural fiber.
5. The manufacturing method according to claim 4, characterized in that: the material of the micro/nano fiber film layer includes, but is not limited to, PI, PVDF, PCL, PLA, PLGA, PVA.
6. The manufacturing method according to claim 1, characterized in that: the building fluids include, but are not limited to, paraffin, PDMS, or surfactants.
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| CN201910280944.1A CN109847819B (en) | 2019-04-09 | 2019-04-09 | Nanofiber self-supporting additive manufacturing method containing multi-stage micro-nano structure device |
| CN202010966487.4A CN112138731B (en) | 2019-04-09 | 2019-04-09 | Microfluidic device, and method and apparatus for manufacturing the same |
| PCT/CN2019/083760 WO2020206729A1 (en) | 2019-04-09 | 2019-04-23 | Manufacturing method for nano fiber self-supporting additive containing components having multistage micro-nano structure |
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| CN111569671A (en) * | 2020-04-17 | 2020-08-25 | 广东工业大学 | Oil-water separation filtering membrane with periphery sealed by wax and preparation method thereof |
| JP2021175970A (en) * | 2020-04-28 | 2021-11-04 | デクセリアルズ株式会社 | Testing chip and method for manufacturing same |
| EP4116405A1 (en) * | 2021-07-07 | 2023-01-11 | Koninklijke Philips N.V. | Fluidic device and method of manufacturing the same |
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| CN108715641A (en) * | 2018-05-25 | 2018-10-30 | 湖州斯蔓生物材料有限公司 | PVA hydrogels use its composite material, its manufacturing method and its application |
| CN108893411A (en) * | 2018-06-15 | 2018-11-27 | 杭州电子科技大学 | Micro-fluidic chip and its manufacturing method based on photocuring printing |
Also Published As
| Publication number | Publication date |
|---|---|
| CN109847819A (en) | 2019-06-07 |
| WO2020206729A1 (en) | 2020-10-15 |
| CN112138731B (en) | 2022-05-03 |
| CN112138731A (en) | 2020-12-29 |
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