U.S. patent application number 11/973266 was filed with the patent office on 2008-04-17 for latching micro-regulator.
This patent application is currently assigned to Cytonome, Inc.. Invention is credited to Sebastian Bohm, Bernard Bunner, Manish Deshpande, John Richard Gilbert.
Application Number | 20080086885 11/973266 |
Document ID | / |
Family ID | 28044409 |
Filed Date | 2008-04-17 |
United States Patent
Application |
20080086885 |
Kind Code |
A1 |
Gilbert; John Richard ; et
al. |
April 17, 2008 |
Latching micro-regulator
Abstract
A latching microregulator for regulating liquid flow on
micro-scale levels comprises a substrate having an inlet port and
an outlet port, a valve element defining a valve chamber for
opening and closing the inlet port, and an actuator assembly for
actuating the valve element. The valve chamber is configured to
contain a volume of fluid, and the inlet port and the outlet port
are in fluid communication with the valve chamber to provide a
liquid flow path through the chamber. The actuator assembly
comprises a cantilever beam for moving the valve element between an
open position and a closed position, an actuator, such as a
piezoelectric element, for moving the cantilever beam, and a latch,
such as a permanent magnet, for securing the cantilever beam in the
closed position. A flow regulation system comprises a plurality of
fluid channels of varied flow conductance and a plurality of
latching microregulators for selectively blocking or allowing flow
through each of the fluid channels.
Inventors: |
Gilbert; John Richard;
(Brookline, MA) ; Bunner; Bernard; (Watertown,
MA) ; Bohm; Sebastian; (Bloemendaal, NL) ;
Deshpande; Manish; (Canton, MA) |
Correspondence
Address: |
LAHIVE & COCKFIELD, LLP
ONE POST OFFICE SQUARE
BOSTON
MA
02109-2127
US
|
Assignee: |
Cytonome, Inc.
Boston
MA
|
Family ID: |
28044409 |
Appl. No.: |
11/973266 |
Filed: |
October 5, 2007 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
11591213 |
Nov 1, 2006 |
7293581 |
|
|
11973266 |
Oct 5, 2007 |
|
|
|
11099014 |
Apr 4, 2005 |
7134639 |
|
|
11591213 |
Nov 1, 2006 |
|
|
|
10179537 |
Jun 24, 2002 |
6981518 |
|
|
11099014 |
Apr 4, 2005 |
|
|
|
60364803 |
Mar 15, 2002 |
|
|
|
Current U.S.
Class: |
29/890.124 |
Current CPC
Class: |
Y10T 29/49412 20150115;
F16K 99/0009 20130101; F16K 99/0005 20130101; F16K 99/0001
20130101; F16K 2099/0069 20130101; G05D 7/0694 20130101; F15C 5/00
20130101; F16K 2099/0071 20130101; F16K 2099/0074 20130101; F16K
2099/0076 20130101; F16K 99/0007 20130101; Y10T 137/87314 20150401;
F16K 99/0046 20130101; F16K 2099/0084 20130101; F16K 99/0015
20130101; F16K 2099/008 20130101; F16K 99/0048 20130101 |
Class at
Publication: |
029/890.124 |
International
Class: |
B21K 1/20 20060101
B21K001/20 |
Claims
1. A method of manufacturing a valve for controlling fluid flow
through a channel, comprising the steps of: providing a substrate
having an inlet port extending to a surface of the substrate in
communication with the channel and an outlet port extending to the
surface of the substrate in communication with the channel; and
coupling an actuator assembly having a valve seat to the surface of
the substrate, wherein the valve seat includes a first protrusion
for selectively blocking one of said inlet ports and said outlet
ports.
2. The method of claim 1, wherein the valve seat comprises a
flexible membrane portion having a rim that sealingly contacts the
substrate to define a valve chamber in communication with the inlet
port and the outlet port for containing a volume of fluid.
3. The method of claim 1, wherein step of coupling an actuator
assembly comprises attaching and hinging a first end of a
cantilever beam to the substrate.
4. The method of claim 3, further comprising the step of coupling a
latching mechanism to at least one of the substrate and the
actuator assembly.
5. The method of claim 4, wherein the step of coupling the latching
mechanism comprises coupling one of a magnet and a permalloy
element to the surface of the substrate and the other of the magnet
and the permalloy element to a second end of the cantilever beam,
such that the magnet and permalloy element mate when the second end
of the cantilever beam is brought into proximity with the surface
of the substrate.
6. The method of claim 3, further comprising the step of coupling
an actuator to the cantilever beam.
7. The method of claim 6, wherein the actuator comprises a
piezoelectric element.
8. The method of claim 3, wherein the valve seat includes a second
protrusion external to the valve chamber for contacting the
cantilever beam, wherein the cantilever beam pushes on the second
protrusion to move the valve seat to a closed position.
9. A method of manufacturing a valve for controlling fluid flow
through a channel, comprising the steps of: providing a substrate
having an inlet port extending to a surface of the substrate in
communication with the channel and an outlet port extending to the
surface of the substrate in communication with the channel; and
coupling a valve seat to the surface of the substrate, wherein the
valve seat defines a valve chamber exterior to the substrate in
communication with the inlet port and the outlet port for
containing a volume of fluid.
10. The method of claim 9, wherein the valve seat comprises a
flexible membrane portion having a rim that sealingly contacts the
substrate to define the valve chamber.
11. The method of claim 10, wherein the valve seat includes a first
protrusion extending from the membrane portion into the valve
chamber to selectively block one of the inlet port and the outlet
port.
12. The method of claim 11, wherein the valve seat includes a
second protrusion external to the valve chamber.
13. The method of claim 12, further comprising the step of
attaching and hinging a cantilever beam to the substrate, with the
hinge spaced from the valve seat such that the cantilever beam
selectively pushes on the second protrusion to move the valve seat
to a closed position.
14. The method of claim 13, further comprising the step of coupling
a piezoelectric actuator to the cantilever beam.
15. The method of claim 9, further comprising the step of coupling
an actuator assembly for selectively moving the valve seat between
an open position, in which liquid flows through the valve chamber,
and a closed position, in which the valve seat blocks liquid from
flowing through the valve chamber.
16. The method of claim 15, further comprising the step of coupling
a latching mechanism to at least one of the substrate and the
actuator assembly.
17. The method of claim 16, wherein the step of coupling the
latching mechanism comprises coupling one of a magnet and a
permalloy element to the surface of the substrate and the other of
the magnet and the permalloy element to an end of the actuator
assembly.
18. A method of manufacturing a valve for controlling fluid flow
through a channel, comprising the steps of: providing a substrate
having an inlet port extending to a surface of the substrate in
communication with the channel and an outlet port extending to the
surface of the substrate in communication with the channel and a
magnet coupled to the exterior surface spaced from the inlet port
and outlet port; and attaching a first end of a cantilever beam to
the exterior surface of the substrate, such that a second end of
the cantilever beam is brought into proximity with the magnet when
the cantilever beam is lowered towards the substrate.
19. The method of claim 18, further comprising the step of coupling
a valve seat to the exterior surface of the substrate, wherein the
valve seat includes a first protrusion for selectively blocking one
of said inlet ports and said outlet ports and the cantilever beam
selectively moves the valve seat between an open position and a
closed position.
20. The method of claim 18, further comprising the step of coupling
a permalloy element to the second end of the cantilever beam.
Description
RELATED APPLICATION
[0001] The present invention is a continuation of U.S. patent
application Ser. No. 11/591,213 filed Nov. 1, 2006 entitled
"Latching Micro-Regulator", which is a continuation patent
application of U.S. patent application Ser. No. 11/099,014 filed
Apr. 4, 2005 entitled "Latching Micro-Regulator", which is a
divisional patent application of U.S. patent application Ser. No.
10/179,537 filed Jun. 24, 2002 entitled "Latching Micro-Regulator"
now U.S. Pat. No. 6,981,518 which, in turn, claims priority to U.S.
Provisional Patent Application No. 60/364,803 filed Mar. 15, 2002
entitled "Latching Micro-Regulator", the contents of which are
herein incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a micro-regulator and a
bi-stable latching valve for regulating fluid flow on micro-scale
dimensions.
BACKGROUND OF THE INVENTION
[0003] In the chemical, biomedical, bioscience and pharmaceutical
industries, it has become increasingly desirable to perform large
numbers of chemical operations, such as reactions, separations and
subsequent detection steps, in a highly parallel fashion. The high
throughput synthesis, screening and analysis of (bio)chemical
compounds, enables the economic discovery of new drugs and drug
candidates, and the implementation of sophisticated medical
diagnostic equipment. Of key importance for the improvement of the
chemical operations required in these applications are an increased
speed, enhanced reproducibility, decreased consumption of expensive
samples and reagents, and the reduction of waste materials.
[0004] Microfluidic devices and systems provide improved methods of
performing chemical, biochemical and biological analysis and
synthesis. Microfluidic devices and systems allow for the
performance of multi-step, multi-species chemical operations in
chip-based micro chemical analysis systems. Chip-based microfluidic
systems generally comprise conventional `microfluidic` elements,
particularly capable of handling and analyzing chemical and
biological specimens. Typically, the term microfluidic in the art
refers to systems or devices having a network of processing nodes,
chambers and reservoirs connected by channels, in which the
channels have typical cross-sectional dimensions in the range
between about 1.0 .mu.m and about 500 .mu.m. In the art, channels
having these cross-sectional dimensions are referred to as
`microchannels`.
[0005] By performing the chemical operations in a microfluidic
system, potentially a number of the above-mentioned desirable
improvements can be realized. Downscaling dimensions allows for
diffusional processes, such as heating, cooling and passive
transport of species (diffusional mass-transport), to proceed
faster. One example is the thermal processing of liquids, which is
typically a required step in chemical synthesis and analysis. In
comparison with the heating and cooling of liquids in beakers as
performed in a conventional laboratory setting, the thermal
processing of liquids is accelerated in a microchannel due to
reduced diffusional distances. Another example of the efficiency of
microfluidic systems is the mixing of dissolved species in a
liquid, a process that is also diffusion limited. Downscaling the
typical dimensions of the mixing chamber thereby reduces the
typical distance to be overcome by diffusional mass-transport, and
consequently results in a reduction of mixing times. Like thermal
processing, the mixing of dissolved chemical species, such as
reagents, with a sample or precursors for a synthesis step, is an
operation that is required in virtually all chemical synthesis and
analysis processes. Therefore, the ability to reduce the time
involved in mixing provides significant advantages to most chemical
synthesis and analysis processes.
[0006] Another aspect of the reduction of dimensions is the
reduction of required volumes of sample, reagents, precursors and
other often very expensive chemical substances. Milliliter-sized
systems typically require milliliter volumes of these substances,
while microliter sized microfluidic systems only require microliter
volumes. The ability to perform these processes using smaller
volumes results in significant cost savings, allowing the economic
operation of chemical synthesis and analysis operations. As a
consequence of the reduced volume requirement, the amount of
chemical waste produced during the chemical operations is
correspondingly reduced.
[0007] In microfluidic systems, regulation of minute fluid flows
through a microchannel is of prime importance, as the processes
performed in these systems highly depend on the delivery and
movement of various liquids such as sample and reagents. A flow
control device may be used to regulate, allow or halt the flow of
liquid through a microchannel, either manually or automatically.
Regulation includes control of flow rate, impeding of flow,
switching of flows between various input channels and output
channels, as well as volumetric dosing. It is generally desirable
that flow control devices, such as valves, precisely and accurately
regulates fluid flow, while being economical to manufacture.
SUMMARY OF THE INVENTION
[0008] The present invention provides a latching micro-regulator
for regulating liquid flow on micro-scale levels. The latching
micro-regulator provides binary addressable flow control using
digital latching. The latching micro-regulator includes a bi-stable
latching valve comprising a substrate having an inlet port and an
outlet port, a valve seat defining a valve chamber for opening and
closing the inlet port, and an actuator assembly for actuating the
valve element. The valve chamber is configured to contain a volume
of fluid, and the inlet port and the outlet port are in fluid
communication with the valve chamber to provide a liquid flow path
through the chamber. The actuator assembly comprises a cantilever
beam for moving the valve seat between an open position and a
closed position, an actuator, such as a piezoelectric element, for
moving the cantilever beam, and a latch, such as a permanent
magnet, for securing the cantilever beam in the closed
position.
[0009] According to a first aspect of the invention, a bi-stable
latching valve for controlling fluid flow through a channel is
provided. The bi-stable latching valve comprises a substrate
defining an inlet port and an outlet port in communication with the
channel, a valve seat, an actuator assembly for selectively moving
the valve seat between the open position and the closed position
and a latching mechanism. The valve seat defines a valve chamber in
communication with the inlet port and the outlet port for
containing a volume of fluid and the valve seat moves between a
closed position wherein the valve seat blocks one of said inlet
port and said outlet port and an open position to allow fluid flow
through the valve chamber to regulate fluid flow through the
chamber. The latching mechanism latches the valve seat in one of
said open position and closed position.
[0010] According to another aspect, a flow regulating system is
provided. The flow regulating system comprises a first flow channel
for conveying liquids having a first flow resistance, a first
bi-stable valve in communication with the first flow channel for
selectively blocking liquid flow through the first flow channel, a
second flow channel for conveying liquids having a second flow
resistance and a second bi-stable valve in communication with the
second flow channel for selectively blocking liquid flow through
the second flow channel.
[0011] According to yet another aspect, a flow regulating system is
provided. The flow regulating system comprises a first flow channel
for conveying liquids having a first flow resistance, a first
bi-stable latching valve in communication with the first flow
channel for selectively blocking liquid flow through the first flow
channel, a second flow channel for conveying liquids having a
second flow resistance and a second bi-stable latching valve in
communication with the second flow channel for selectively blocking
liquid flow through the second flow channel. The first and second
bi-stable latching valve each comprise a piezoelectric actuator for
selectively opening and blocking the flow channel, and a magnetic
latch for locking the valve in a closed position.
BRIEF DESCRIPTION OF THE FIGURES
[0012] FIG. 1 is a cross-sectional side view of an embodiment of
the bi-stable latching valve of the present invention.
[0013] FIG. 2a is a detailed side view of the bi-stable latching
valve of FIG. 1 in an open position.
[0014] FIG. 2b is a top view of the bi-stable latching valve of
FIG. 2a.
[0015] FIGS. 3a and 3b illustrate the bi-stable latching valve
switching from a closed position to an open position.
[0016] FIGS. 4a and 4b illustrate the bi-stable latching valve
switching from an open position to a closed position.
[0017] FIG. 5 is a schematic diagram of a flow regulating system
for a microfluidic system implementing a plurality of bi-stable
latching valves according to an illustrative embodiment of the
invention to provide variable control of fluid flow.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The present invention provides a digital latching
micro-regulator including a bi-stable latching valve for accurately
controlling fluid flow on demand. The present invention will be
described below relative to an illustrative embodiment. Those
skilled in the art will appreciate that the present invention may
be implemented in a number of different applications and
embodiments and is not specifically limited in its application to
the particular embodiments depicted herein.
[0019] The present invention provides a bi-stable latching valve
for selectively blocking fluid flow through a channel. The valve is
positioned in a channel to selectively block liquid flow through
the channel. As shown in FIG. 1, the bi-stable latching valve 10 of
the present invention comprises a substrate 20 having an inlet port
22 and an outlet port 24 formed therein in fluid communication with
a channel through which liquid flows. The substrate 20 is
preferably formed of glass or plastic, though other materials may
be used. The bi-stable latching valve 10 further includes a valve
seat 30 cooperating with the substrate to define a valve chamber 26
in communication with the inlet port 22 and the outlet port 24 for
containing a volume of fluid. The valve seat 30 selectively blocks
the inlet port 22 to regulate the flow of fluid into the chamber
26. The position of the valve seat 30 controls the fluid flow into
the chamber 26. The position of the valve seat 30 is controlled by
an actuator assembly 50. The actuator assembly can comprise any
suitable structure for selectively operating or moving the valve
seat 30 to block the inlet port 22 or the outlet port 24. According
to one embodiment, the actuator assembly includes a cantilever beam
40 hinged to the substrate 20, an actuator 52, and a latching
mechanism 60.
[0020] The position of the valve seat 30 is determined by the
position of the cantilever beam 40. The valve seat 30 is connected
to the cantilever beam 40, which is in turn connected to the
actuator 52. The actuator 52 can comprise any suitable structure
for moving the valve seat 30 between an open position for allowing
fluid to enter or exit the chamber, and a closed position. Examples
of suitable actuators include mechanical, electrical,
electro-mechanical, and magnetic devices. According to a preferred
embodiment, the actuator 52 is a piezoelectric element. The
cantilever beam 40 is hinged at a first end 41 to the glass
substrate 20 and rotates about the fixed hinge under the control of
the actuator 52 to move the valve seat 30 between the open and
closed positions. When the cantilever beam 40 is lowered, the beam
pushes the valve seat 30 into a closed position, thereby blocking
the inlet port and preventing fluid flow into the chamber. When the
cantilever beam 40 is raised, the valve 30 is moved to an open
position to allow fluid flow through the chamber 26. The cantilever
beam 40 is driven by the piezoelectric element 52, which
selectively applies a driving force to the beam 40.
[0021] The bi-stable latching valve 10 further includes a latching
mechanism 60 for selectively latching or holding the beam 40 in a
selected position. The latching mechanism can include any suitable
mechanical, electrical, electro-mechanical or magnetic structure
suitable for latching the beam 40. The latching mechanism 60,
according to a preferred embodiment, comprises a permanent magnet
62 and a permalloy element 46 disposed on a free end 44 of the beam
40. The permanent magnet 62 is attached to the glass substrate 20
opposite the permalloy element 46 and is configured to attract the
permalloy element 46. The magnetic attraction between the permanent
magnet and the permalloy element is effective to latch, i.e. to
retain, the valve element in a closed position to prevent fluid
flow through the bi-stable latching valve 10.
[0022] As shown in FIGS. 2a and 2b, the valve seat 30 is
cylindrical in shape and includes a rim 38 about the circumference
of the valve seat 30, which defines the valve chamber 26. The rim
38 cooperates with the glass substrate 20 to fluidly seal the valve
chamber 26. The valve chamber communicates with the inlet port 22
and the outlet port 24. The valve seat 30 is preferably formed of a
flexible material, such as silicone rubber, though one skilled the
art will recognize that alternate materials may be used. The valve
seat 30 further comprises a membrane portion 32, a first protrusion
34 for contacting the cantilever beam 40 and second protrusion 36
for selectively blocking the inlet port 22 to prevent the flow of
fluid through the valve chamber 26, thereby blocking fluid flow
through the associated channel. The second protrusion blocks the
inlet port 22 when the cantilever beam depresses the valve seat 30
by pushing on the first protrusion 34. One skilled in the art will
recognize that the valve seat 30 is not limited to a cylindrical
shape, and that any suitable shape may be utilized.
[0023] The operation of the bi-stable latching valve 10 is
illustrated in FIGS. 3a-3b and FIGS. 4a-4b. The bi-stable latching
valve 10 switches between two stable states: an ON state, which
allows the flow of liquid through the valve chamber and an OFF
state, which prevents the flow of liquid through the valve chamber.
The state of the bi-stable latching valve 10 is controlled by the
driving force on the cantilever beam 40 by the actuator 52 and the
magnetic latching force created by the permanent magnet 62 on the
beam free end. According to the illustrative embodiment, the
bi-stable latching valve only requires power to switch between the
two stable states and does not otherwise require power to
operate.
[0024] FIG. 3a illustrates the bi-stable latching valve 10 in an
OFF state, where the second protrusion 36 of the valve seat 30
blocks the inlet port 22 so that fluid is prevented from flowing
through the valve chamber 26. In the OFF state, the latching
mechanism 60 latches the cantilever beam 40 in the closed position
by securing the permalloy element 46 to the permanent magnet 60. As
shown, when the attractive force of the magnet pulls the cantilever
beam towards the magnet, causing the cantilever beam to push the
valve into the closed position, such that the first protrusion
blocks the inlet port. The valve maintains the closed position
until activated.
[0025] To open the bi-stable latching valve and allow fluid flow, a
voltage is applied to the piezoelectric element 52 using a
controller (not shown). The applied voltage causes the
piezoelectric element to compress, applying an opposite force on
the cantilever beam in the direction away from the magnet. If the
force generated is sufficient to overcome the magnetic attraction
between the magnet and the permalloy, the magnet releases the
permalloy element and the cantilever beam raises, pulling the valve
seat 30 clear of the inlet port 22. As shown in FIG. 3b, fluid
flows through unobstructed inlet port 22 into the valve chamber and
out of the valve chamber via the outlet port.
[0026] The bi-stable latching valve 10 remains in the ON state, as
shown in FIG. 4a, until the controller subsequently actuates the
piezoelectric element 52 by applying a second voltage. The second
voltage causes the piezoelectric element to expand, which applies a
driving force on the cantilever beam 40, pushing the beam towards
the magnet 60. The lowered beam in turn applies a force to the
valve seat 30, which shifts into a closed position, blocking the
inlet port. When the permalloy element 46 is brought close to the
magnet 62, a magnetic latching force generated by the magnet
latches the beam 40 into the closed position until a subsequent
actuation of the piezoelectric element 52.
[0027] The bi-stable latching valve 10 may be employed in a valve
architecture to provide binary addressable flow control using
digital latching. As shown in FIG. 5, multiple bi-stable latching
valves may be connected to channels 550 of specific flow
conductance that vary according to a pre-determined ratio to
provide a micro-regulator 500. Each bi-stable latching valve 10 can
be set to an on or off state as described previously, allowing or
blocking flow through its associated flow channel 550. The
bi-stable latching valves are selectively activated in various
combinations to provide a number of discrete flow conductance
states through the micro-regulator 500. The net flow through the
micro-regulator is therefore determined by the sum of the flows
through the open bi-stable latching valves 10. The number of
discrete flow conductance states is determined by the number of
bi-stable latching valves in the system and the flow conductance
ratios between the channels.
[0028] A typical example of a 4-bit micro-regulator system is
illustrated in FIG. 5. The individual channels 550a, 550b, 550c and
550d in the system have flow conductance ratios of 1:2:4:8, thus
providing 16 discrete net flow conductance states. For example, a
first flow conductance state may be provided by opening all of the
bi-stable latching valves 10a-10d to allow flow through all of the
channels 550a, 550b, 550c and 550d. A second flow conductance state
is achieved by closing the first bi-stable latching valve 10a,
while leaving the remaining bi-stable latching valves 10b, 10c, 10d
open, allowing fluid flow through the channels 550b, 550c and 550d
only. A third conductance state is achieved by closing the first
and second bi-stable latching valves 10a, 10b while leaving the
remaining bi-stable latching valves 10c, 10d to allow flow through
the associated channels 550c and 550d, and so on. This allows flow
rates to be controlled to a 6.67% precision. Higher precision can
be obtained by increasing the number of bits in the system--for
example an 8-bit system has 128 discrete states, achieving less
than 1% precision in the flow rate control.
[0029] One skilled in the art will recognize that any suitable
bi-stable valve for selectively blocking liquid flow through a
channel may be used in the flow regulating system 500 of FIG. 5 to
provide variable flow resistance. The micro-regulator 500 may have
any suitable number of channels arranged in any suitable
configuration and having any suitable flow resistance to achieve a
system having variable flow resistance, wherein the flow resistance
depends on the state of the bi-stable valves.
[0030] The manufacturing process for the bi-stable latching valve
10 of an illustrative embodiment of the present invention is
efficient, economical and simplified. The valve seat 30 may be
formed by surface micromachining of a substrate, followed by
deposition of silicone rubber, the permalloy element 46 and
polysilicon. The substrate 20 is etched to form a channel and then
drilled to form the inlet port 22 and the outlet port 24. The
cantilever beam 40 may be attached and hinged to the glass
substrate through means known in the art. The permalloy element may
be bonded to the beam and the permanent magnet 62 may be bonded to
the substrate through means known in the art. The piezoelectric
element 52 or other actuator for driving the cantilever beam 40 may
be attached to the beam through any suitable means.
[0031] The present invention has been described relative to an
illustrative embodiment. Since certain changes may be made in the
above constructions without departing from the scope of the
invention, it is intended that all matter contained in the above
description or shown in the accompanying drawings be interpreted as
illustrative and not in a limiting sense.
[0032] It is also to be understood that the following claims are to
cover all generic and specific features of the invention described
herein, and all statements of the scope of the invention which, as
a matter of language, might be said to fall therebetween.
* * * * *