# US 10,369,566 B2 · Microfluidic device, composition and method of forming

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- Number: US 10,369,566 B2
- Document ID: US10369566B2
- Status: Granted
- Kind: B2
- Application number: 14/989,320
- Filed: 2016-01-06
- Published: 2016-09-01
- Granted: 2019-08-06
- Earliest claimed: 2009-10-08
- Assignees: National Research Council of Canada
- Applicants: National Research Council of Canada
- Inventors: Emmanuel Roy; Teodor Veres
- Web page: https://patentgrep.com/patent/US10369566B2

## CPC

- B01L 3/502707: {characterised by the manufacture of the container or its components}
- B01L 3/5027: {by integrated microfluidic structures, i.e. dimensions of channels and chambers are such that surface tension forces are important, e.g. lab-on-a-chip}
- B29C 41/045: {the axis being placed vertically, e.g. spin casting}
- B29C 59/02: by mechanical means, e.g. pressing {(B29C59/007 takes precedence; embossing expanded porous articles B29C44/5627)}
- B29C 65/02: by heating, with or without pressure
- B29C 71/02: Thermal after-treatment {(B29C71/0063 and B29C71/0072 take precedence)}
- B32B 3/30: characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)}
- B32B 25/04: comprising rubber as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a layer of a particular substance B32B9/043; next to a bituminous or tarry layer B32B11/044; next to a water setting substance layer B32B13/042; next to a metal layer B32B15/06; next to a glass layer B32B17/063; next to a layer formed of natural mineral fibres or particles B32B19/043; next to a wood layer B32B21/045; next to a cellulosic plastic layer B32B23/046)}
- B32B 25/14: comprising {synthetic rubber copolymers (B32B25/18 and B32B25/20 take precedence)}
- B32B 27/28: comprising synthetic resins not wholly covered by any one of the sub-groups {B32B27/30 - B32B27/42}
- B32B 27/302: {comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers}
- C08J 5/18: Manufacture of films or sheets
- B01L 2200/12: Specific details about manufacturing devices
- B01L 2300/0887: Laminated structure
- B01L 2300/12: Specific details about materials
- B01L 2300/123: Flexible; Elastomeric
- B29K 2019/00: Use of rubber not provided for in a single one of main groups {B29K2007/00 - B29K2011/00,} as moulding material
- B29K 2995/0026: Transparent
- B29K 2995/0046: Elastic
- B29K 2995/0056: Biocompatible, e.g. biopolymers or bioelastomers
- B29K 2995/007: Hardness
- B29L 2009/00: Layered products
- B32B 2270/00: Resin or rubber layer containing a blend of at least two different polymers
- B32B 2274/00: Thermoplastic elastomer material
- B32B 2307/306: Resistant to heat
- B32B 2307/536: Hardness
- B32B 2307/546: Flexural strength; Flexion stiffness
- C08J 2309/06: Copolymers with styrene
- C08J 2323/04: Homopolymers or copolymers of ethene
- C08J 2323/20: having four to nine carbon atoms
- C08J 2325/08: Copolymers of styrene (C08J2329/08, C08J2335/06, C08J2355/02 take precedence)
- C08J 2353/00: Characterised by the use of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives of such polymers
- Y10T 428/24802: Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- B01L: CHEMICAL OR PHYSICAL LABORATORY APPARATUS FOR GENERAL USE
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A composition made of at least 60 wt. % of a thermoplastic elastomer resin and additives that are solid at least from 0-50° C., that has a Shore A hardness that is less than about 50 bears a patterned surface, the pattern comprising at least one microfluidic channel having a cross-sectional dimension smaller than 100 microns is a substrate for forming a microfluidic device. The chief advantages of such compositions are: its ability to bond in a sealing manner to smooth surfaces of many different compositions, its ease of manufacture and microstructure patterning, and its general impermeability to liquids.

## Claims

### Claim 1

A method for forming a microfluidic device comprising:
providing a composition containing a thermoplastic elastomer (TPE) resin;
placing the composition onto a relief mold having at least one ridge defined thereon for molding a microfluidic channel;
heating the composition adjacent the mold to a temperature above a highest glass transition temperature of the TPE, for a pressure-time of less than 5 bars seconds per micron of depth of the relief mold;
cooling the composition to form a first part that is composed of at least 60 wt. % of the TPE and additives, and has a Shore A hardness that is less than 50, where each of the additives and the TPE is solid, at least from 0-50° C.;
and removing the first part having a patterned surface from the mold.

### Claim 2 (depends on 1)

The method of claim 1 wherein the composition provided is selected so that the first part:
is composed of at least 80 wt. % of the thermoplastic elastomer and additives;
is composed of at least 83.33 wt. % of the thermoplastic elastomer and additives;
is composed of at least 90 wt. % of the thermoplastic elastomer and additives;
is composed of at least 95 wt. % of the thermoplastic elastomer and additives;
is composed of at least 99 wt. % of the thermoplastic elastomer and additives;
is composed of at least 99.5 wt. % of the thermoplastic elastomer and additives; or
has a microfluidic channel defined by the at least one ridge of the relief mold that extends between two of the following: junctions with one or more other ridges, raised structural features of the mold, and a mold limit.

### Claim 3 (depends on 1)

The method of claim 1 wherein the composition provided is: solid; a film; liquid; or a solution.

### Claim 4 (depends on 1)

The method of claim 1 further comprising applying the first part onto a second part having a meeting surface, the meeting surface covering enough of the patterned surface of the first part to enclose at least a part of the microfluidic channel.

### Claim 5 (depends on 4)

The method of claim 4 wherein the second part:
is composed of a same or different thermoplastic elastomer as the first part; is composed of a hard thermoplastic;
is in the form of a film; or
is composed of a less flexible material than the first part, and provides support for the microfluidic device.

### Claim 6 (depends on 4)

The method of claim 4 wherein the second part has a second meeting surface bearing a pattern comprising at least one microfluidic channel having a cross-sectional dimension smaller than 100 microns.

### Claim 7 (depends on 4)

The method of claim 4 wherein applying the first part onto the second part comprises reversibly bonding the first and second parts at room temperature, without application of any persistent pressure other than ambient pressure to provide sealed contact with the meeting surface of the second part.

### Claim 8 (depends on 4)

The method of claim 4 wherein applying the first part onto the second part comprises irreversibly bonding the first and second parts to provide sealed contact with the meeting surface of the second part by applying a regime of:
less than 2 bars at a temperature below 150° C., for less than 10 min.;
atmospheric temperature and pressure;
thermal treatment for 3 minutes at 100° C. at atmospheric pressure; or
room temperature and atmospheric pressure for 4 days.

### Claim 9 (depends on 1)

The method of claim 1 wherein the thermoplastic elastomer resin provided has a viscoelastic phase.

### Claim 10 (depends on 9)

The method of claim 9 wherein the viscoelastic phase exhibits flow at temperatures: below 100° C.; below 30° C.; below 20° C.; below 0° C.; or below −15° C.

### Claim 11 (depends on 9)

The method of claim 9 wherein the viscoelastic phase exhibits flow at a bonding temperature at which the first part is bonded to a second part.

### Claim 12 (depends on 9)

The method of claim 9 wherein the viscoelastic phase exhibits flow throughout an intended operating temperature regime of the microfluidic device.

### Claim 13 (depends on 1)

The method of claim 1 wherein the thermoplastic elastomer resin provided has soft blocks and hard blocks, the soft blocks composing 85-90% of the TPE resin that has a viscoelastic phase.

### Claim 14 (depends on 13)

The method of claim 13 wherein the viscoelastic phase exhibits flow at temperatures below 20° C.; below 0° C.; or from 60 to −100° C.

### Claim 15 (depends on 1)

The method of claim 1 wherein the thermoplastic elastomer resin provided comprises a styrenic block polymer, an olefin vinyl polymer, a thermoplastic rubber, a copolyester, a polyurethane, a polyolefin blend, a polyolefin alloy, or a polyamide.

### Claim 16 (depends on 1)

The method of claim 1 wherein the thermoplastic elastomer resin provided comprises a styrenic block polymer, or an olefin vinyl polymer.

### Claim 17 (depends on 1)

The method of claim 1 wherein the thermoplastic elastomer resin provided comprises a styrenic block polymer.

### Claim 18 (depends on 1)

The method of claim 1 wherein the thermoplastic elastomer resin provided comprises SBS, SEBS, SEPS, SIS, SIBS, EVA, COPE, TPU, TPO, TPV, or PEBA.

### Claim 19 (depends on 1)

The method of claim 1 wherein the thermoplastic elastomer resin provided comprises SBS, SEBS, SEPS, SIS, SIBS, or EVA.

### Claim 20 (depends on 1)

The method of claim 1 wherein the thermoplastic elastomer resin provided comprises SBS, SEBS, SEPS, SIS, or SIBS.