A pressure-tolerant polymer microfluidic device fabricated by the simultaneous solidification-bonding method and...

Area of Science:

• Materials Science
• Chemical Engineering
• Microfluidics

Background:

• Microfluidic devices are crucial for chemical synthesis and analysis.
• Conventional fabrication methods often result in microchannels with limited pressure tolerance.
• There is a need for advanced microfluidic reactors capable of withstanding high pressures.

Purpose of the Study:

• To develop a novel fabrication method for high-pressure tolerant polymer-glass microfluidic reactors.
• To investigate the interfacial chemistry for strong bonding between polymers and glass.
• To demonstrate the versatility and performance of the fabricated microreactors.

Main Methods:

• Simultaneous Solidification-Bonding (SSB) method using a sacrificial wax template.
• Casting a reactive polymer matrix onto a functionalized glass substrate.
• UV or mild thermal curing for solidification and bonding.
• Complete removal of the wax template at elevated temperatures.

Main Results:

• Fabricated polymer-glass microfluidic reactors with excellent bonding strength.
• Achieved high pressure tolerance, with channels stable at 1000 psi and a burst pressure up to 2000 psi.
• Demonstrated superior pressure resistance in fluoropolymer-glass reactors compared to conventional methods.
• Successfully synthesized tryptanthrin using flash chemistry under high pressure in the microreactor.

Conclusions:

• The SSB method offers a versatile and effective approach for fabricating high-pressure tolerant polymer-glass microfluidic devices.
• These microreactors are suitable for high-pressure chemical synthesis and can be integrated with spectroscopic tools for analysis.
• The developed technology significantly enhances the performance of microfluidic systems for demanding applications.