Methods and materials for fabricating microfluidic devices

Abstract

Materials and methods are provided for fabricating microfluidic devices. The materials include low surface energy fluoropolymer compositions having multiple cure functional groups. The materials can include multiple photocurable and/or thermal-curable functional groups such that laminate devices can be fabricated. The materials also substantially do not swell in the presence of hydrocarbon solvents.

That which is claimed: 
     
         1 . A method for pattern transfer of a micro-scale or nano-scale pattern, comprising:
 contacting a fluoropolymer with a master template, wherein the master template includes a dimensional pattern;   curing the fluoropolymer such that the cured fluoropolymer has a dimensional pattern that substantially corresponds to the dimensional pattern of the master template;   removing the cured fluoropolymer from the master template;   contacting a silicone with the dimensional pattern of the cured fluoropolymer;   curing the silicone such that the cured silicone is a substantial replicate of the dimensional pattern of the master template; and   removing the cured silicone from the fluoropolymer.   
     
     
         2 . The method of  claim 1 , further comprising:
 after removing the cured silicone, using the cured silicone as a mold.   
     
     
         3 . The method of  claim 1 , wherein the dimensional pattern of the cured silicone comprises at least one cavity. 
     
     
         4 . The method of  claim 2 , wherein using the cured silicone as a mold comprises:
 introducing a substance to the dimensional pattern of the cured silicone;   curing the substance while in contact with the dimensional pattern of the cured silicone; and,   removing the cured substance whereby the cured substance has a dimensional pattern that substantially corresponds to the dimensional pattern of the cured silicone.   
     
     
         5 . The method of  claim 1 , wherein the dimensional pattern comprises a plurality of structures, wherein each structure has a broadest dimension of less than 1000 micrometers. 
     
     
         6 . The method of  claim 3 , wherein the cavity has a broadest dimension of less than 1000 micrometers. 
     
     
         7 . The method of  claim 1 , wherein the fluoropolymer comprises perfluoropolyether. 
     
     
         8 . The method of  claim 1 , wherein the silicone comprises poly(dimethylsiloxane). 
     
     
         9 . A method for making a mold, comprising:
 contacting a silicone with a polymer layer defining a dimensional pattern;   curing the silicone while in contact with the dimensional pattern of the polymer layer to form a silicone layer that has a dimensional pattern that substantially corresponds to the dimensional pattern of the polymer; and,   removing the silicone layer from the polymer layer.   
     
     
         10 . The method of  claim 9 , wherein the dimensional pattern of the silicone layer comprises a plurality of structures, wherein each structure has a broadest dimension of less than 1000 micrometers. 
     
     
         11 . The method of  claim 9 , further comprising, after removing the silicone layer, using the silicone layer as a mold. 
     
     
         12 . The method of  claim 9 , wherein the dimensional pattern of the silicone layer comprises at least one cavity. 
     
     
         13 . The method of  claim 11 , wherein using the silicone layer as a mold comprises:
 introducing a substance to the dimensional pattern of the silicone layer;   curing the substance while in contact with the dimensional pattern of the silicone layer; and,   removing the cured substance whereby the cured substance has a dimensional pattern that substantially corresponds to the dimensional pattern of the silicone layer.   
     
     
         14 . The method of  claim 12 , wherein the cavity has a broadest dimension of less than 1000 micrometers. 
     
     
         15 . The method of  claim 9 , wherein the polymer comprises a fluoropolymer. 
     
     
         16 . The method of  claim 15 , wherein the fluoropolymer comprises a perfluoropolyether. 
     
     
         17 . The method of  claim 9 , wherein the silicone comprises poly(dimethylsiloxane).