WO2009063380A1 - Method for structuring a ptfe layer - Google Patents

Method for structuring a ptfe layer Download PDF

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Publication number
WO2009063380A1
WO2009063380A1 PCT/IB2008/054687 IB2008054687W WO2009063380A1 WO 2009063380 A1 WO2009063380 A1 WO 2009063380A1 IB 2008054687 W IB2008054687 W IB 2008054687W WO 2009063380 A1 WO2009063380 A1 WO 2009063380A1
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WO
WIPO (PCT)
Prior art keywords
polymer layer
substrate
layer
light
diagnostics
Prior art date
Application number
PCT/IB2008/054687
Other languages
French (fr)
Inventor
Johan Bosman
Lucas J. A. M. Beckers
Original Assignee
Koninklijke Philips Electronics N. V.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Koninklijke Philips Electronics N. V. filed Critical Koninklijke Philips Electronics N. V.
Publication of WO2009063380A1 publication Critical patent/WO2009063380A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/16—Surface shaping of articles, e.g. embossing; Apparatus therefor by wave energy or particle radiation, e.g. infrared heating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B81—MICROSTRUCTURAL TECHNOLOGY
    • B81C—PROCESSES OR APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OR TREATMENT OF MICROSTRUCTURAL DEVICES OR SYSTEMS
    • B81C1/00—Manufacture or treatment of devices or systems in or on a substrate
    • B81C1/00015—Manufacture or treatment of devices or systems in or on a substrate for manufacturing microsystems
    • B81C1/00023—Manufacture or treatment of devices or systems in or on a substrate for manufacturing microsystems without movable or flexible elements
    • B81C1/00119—Arrangement of basic structures like cavities or channels, e.g. suitable for microfluidic systems
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B81—MICROSTRUCTURAL TECHNOLOGY
    • B81C—PROCESSES OR APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OR TREATMENT OF MICROSTRUCTURAL DEVICES OR SYSTEMS
    • B81C1/00—Manufacture or treatment of devices or systems in or on a substrate
    • B81C1/00436—Shaping materials, i.e. techniques for structuring the substrate or the layers on the substrate
    • B81C1/00555—Achieving a desired geometry, i.e. controlling etch rates, anisotropy or selectivity
    • B81C1/00595—Control etch selectivity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/30—Organic material
    • B23K2103/42—Plastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/50—Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/009—Using laser
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29K2027/00—Use of polyvinylhalogenides or derivatives thereof as moulding material
    • B29K2027/12—Use of polyvinylhalogenides or derivatives thereof as moulding material containing fluorine
    • B29K2027/18—PTFE, i.e. polytetrafluorethene, e.g. ePTFE, i.e. expanded polytetrafluorethene

Definitions

  • the invention relates to a method for imparting a structure or a pattern in a material layer, in particular in a polytetrafluoroethylene (PTFE) layer, to a device obtainable by the method, and to the use of such a device.
  • PTFE polytetrafluoroethylene
  • Structuring layers of various materials is used in different fields of technology. For example, in the semiconductor industry, processes such as embossing, imprinting or optical lithography are used for forming a structure. Similar techniques are also used in the production of optical media. Furthermore, in the production of fluidic devices for molecular diagnostics, structures, through which an analyte flows, are formed using the above techniques. In these structures, the analyte to be detected comes into contact with capture probes for detecting the analyte.
  • PTFE Polytetrafluoroethylene
  • a synthetic fluoropolymer which has a low coff ⁇ cient of friction and is very non-reactive may be advantageously used for fluidic or micro-fluidic diagnostic devices.
  • the use of PTFE is associated with the problem that its structuring with a laser proved to be impossible or at least difficult.
  • the absorption of PTFE is lower than the absorption of glass on which the PTFE layer is usually coated, i.e., the ablation threshold for PTFE is higher than the threshold for glass for typical laser light wavelengths between around 355 and 1064 nm. This means that when a PTFE coating is applied to a glass substrate, the glass is ablated when subjected to a laser beam without removal of the PTFE coating.
  • a known solution to this problem is to include a dye in the PTFE prior to coating the glass substrate in order to increase the absorption of the PTFE-dye mixture and to be able to forsee a structure in the PTFE coating using a laser.
  • the dye which has a notable effect on the hydrophobic behaviour of the PTFE remains in the coating of the structuring, which often is not wanted.
  • the PTFE layer comprising the dye is thin and can be removed by rubbing or solvent cleaning.
  • a laser may be used which scans the entire surface of the PTFE layer.
  • a conventional high-energy light source may be used.
  • the invention further provides a device including a structured polymer layer.
  • the PTFE is selectively doped using laser back transfer of a carbon containing polymer.
  • the PTFE layer is brought into contact with a carbon- filled black rubber.
  • Predetermined portions of the PTFE layer are selectively illuminated with a laser through the transparent substrate on which the PTFE layer is arranged, to transfer carbon-filled polymer material from the black rubber layer to the selected portions of the PTFE layer.
  • the intensities are selected to be below the damage threshold of the substrate.
  • the surface of the PTFE layer may be cleaned.
  • the laser may be further used to ablate holes, alignment patterns or to engrave the sample.
  • any suitable polymer layer may be used in conjunction with a suitable doping material which allows the selective transfer and subsequent removal of the doped areas in the polymer layer.
  • Figure 1 schematically illustrates different method steps of the method according to an embodiment of the invention.
  • Figure 2 shows a photograph of a drop of water on a PTFE layer before and after laser ablation.
  • Figure 3 is a photograph showing a top view of a micro fluidic device at the left side without water and at the right side with water.
  • FIG. 1 shows the different steps of a method according to a preferred embodiment of the invention using laser back transfer of a carbon containing polymer for selectively doping a PTFE layer.
  • Figure l(a) illustrates a PTFE layer or coating 1 on a transparent substrate 2, preferably a glass substrate.
  • known coating processes may be used, such as spin coating or a dipping process.
  • the PTFE layer 1 is brought into contact with a black rubber layer 3, as illustrated in Fig. l(b).
  • the substrate 2 with the PTFE layer 1 including the doped areas 5 is separated from the black rubber layer 3 ( Figure l(d)), and in the next step (see Figure l(e)) the PTFE layer 1 is illuminated using a laser beam 6 or another suitable light source.
  • the wavelength and intensity of the light source 6 should be selected to efficiently remove the doped areas 5 but not the non-doped ("white") areas 7 of the PTFE layer 1, which are between the doped areas 5.
  • the wavelength may be the same or different to the wavelength which is used to dope the PTFE layer 1.
  • the illumination during the removal step does not have to be selective because the non-doped areas 7 of the PTFE layer 1 do not absorb enough laser energy to show ablation as the doped areas 5 do. Areas 5 being doped as described and non-doped areas 7 which are areas unmodified to the original PTFE layer 1 have different ablation properties.
  • the PTFE layer 1 may be illuminated by scanning an appropriate laser beam 6 over the entire surface of the PTFE layer 1. Subsequently, the surface may be cleaned, preferably dry cleaned.
  • the method according to the invention may be used to manufacture fluidic or micro-fluidic devices.
  • Figure 2 shows a picture of a water drop on a glass substrate 2 which was coated with Teflon (AF 1600) by dip coating. The measured contact angle of the surface 2 with water was between 110° and 140°, as can be seen on the left side of Figure 2. On the left side of Fig. 2 the form of the water drop is thus nearly spherical, whereby the sphere of the water drop is truncated by the surface
  • the contact angle of the water drop dropped to 10° to 40°, as shown on the right side of Figure 2, where the water drop shows a rather flat form with regard to the substrate 2.
  • the form of the water drop is that of a lens, compared to the form without laser ablation the contact area between the water drop and the surface 2 has increased significantly.
  • Figure 3 shows a top view of a surface of a micro-fluidic device into which four elongate rectangular structures have been imparted. The structures on the surface are visible as dark areas, whereby two structures are each in parallel to each other and two strutures are each perpendicular to each other. As shown on the right side of Figure
  • water which has been applied to the surface of the micro-fluidic device is present only in the four areas which have been structured.
  • the structured areas show are highly hydrophilic behaviour, the water applied to the surface is attracted to these areas.

Abstract

A method for imparting a structure in a PTFE layer as provided. The structure is imparted in the PTFE layer by removing predetermined portions of the PTFE layer. The predetermined portions are selectively doped with a carbon-filled polymer and subsequently removed by illuminating the PTFE layer.

Description

METHOD FOR STRUCTURING A PTFE LAYER
FIELD OF THE INVENTION
The invention relates to a method for imparting a structure or a pattern in a material layer, in particular in a polytetrafluoroethylene (PTFE) layer, to a device obtainable by the method, and to the use of such a device. BACKGROUND OF THE INVENTION
Structuring layers of various materials is used in different fields of technology. For example, in the semiconductor industry, processes such as embossing, imprinting or optical lithography are used for forming a structure. Similar techniques are also used in the production of optical media. Furthermore, in the production of fluidic devices for molecular diagnostics, structures, through which an analyte flows, are formed using the above techniques. In these structures, the analyte to be detected comes into contact with capture probes for detecting the analyte.
Polytetrafluoroethylene (PTFE), a synthetic fluoropolymer which has a low coffϊcient of friction and is very non-reactive, may be advantageously used for fluidic or micro-fluidic diagnostic devices. However, the use of PTFE is associated with the problem that its structuring with a laser proved to be impossible or at least difficult. In particular, the absorption of PTFE is lower than the absorption of glass on which the PTFE layer is usually coated, i.e., the ablation threshold for PTFE is higher than the threshold for glass for typical laser light wavelengths between around 355 and 1064 nm. This means that when a PTFE coating is applied to a glass substrate, the glass is ablated when subjected to a laser beam without removal of the PTFE coating.
A known solution to this problem is to include a dye in the PTFE prior to coating the glass substrate in order to increase the absorption of the PTFE-dye mixture and to be able to forsee a structure in the PTFE coating using a laser. However, the dye which has a notable effect on the hydrophobic behaviour of the PTFE remains in the coating of the structuring, which often is not wanted. Furthermore, the PTFE layer comprising the dye is thin and can be removed by rubbing or solvent cleaning. SUMMARY OF THE INVENTION
There is a need for an improved method for structuring a PTFE layer which overcomes the problems associated with the above described known solution. The method according to the invention should further allow for a flexible production of different structures within a short time.
With the method of the present invention for imparting a structure in a polymer layer, in particular a PTFE layer, applied to a substrate, only those portions of the PTFE layer which are to be removed to form the structure are selectively doped with a carbon- filled polymer. The doped portions of the PTFE layer are subsequently removed by illuminating the PTFE layer. For removing the doped portions, the layer does not have to be selectively illuminated since the portions of the PTFE layer which are not doped do not show enough absorption of the laser energy to be removed. Therefore, for removing the doped portions, a laser may be used which scans the entire surface of the PTFE layer. Alternatively, also a conventional high-energy light source may be used. The invention further provides a device including a structured polymer layer.
In an embodiment of the invention, the PTFE is selectively doped using laser back transfer of a carbon containing polymer. To this end, the PTFE layer is brought into contact with a carbon- filled black rubber. Predetermined portions of the PTFE layer are selectively illuminated with a laser through the transparent substrate on which the PTFE layer is arranged, to transfer carbon-filled polymer material from the black rubber layer to the selected portions of the PTFE layer. In both laser processes, the laser back transfer and the subsequent removal of the doped portions, the intensities are selected to be below the damage threshold of the substrate.
Upon removing the doped portions, the surface of the PTFE layer may be cleaned. In case a laser is used to remove the doped portions, the laser may be further used to ablate holes, alignment patterns or to engrave the sample.
Although the invention is described in detail in conjunction with the structuring of a PTFE layer by means of doping using a carbon- filled polymer, other combinations of suitable materials are also possible within the scope of the invention. In particular, instead of the PTFE layer, any suitable polymer layer may be used in conjunction with a suitable doping material which allows the selective transfer and subsequent removal of the doped areas in the polymer layer.
These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereafter.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 schematically illustrates different method steps of the method according to an embodiment of the invention. Figure 2 shows a photograph of a drop of water on a PTFE layer before and after laser ablation.
Figure 3 is a photograph showing a top view of a micro fluidic device at the left side without water and at the right side with water.
DETAILED DESCRIPTION OF EMBODIMENTS
Fig. 1 shows the different steps of a method according to a preferred embodiment of the invention using laser back transfer of a carbon containing polymer for selectively doping a PTFE layer. Figure l(a) illustrates a PTFE layer or coating 1 on a transparent substrate 2, preferably a glass substrate. For applying the PTFE layer 1 on the substrate 2, known coating processes may be used, such as spin coating or a dipping process. In a second method step, the PTFE layer 1 is brought into contact with a black rubber layer 3, as illustrated in Fig. l(b). By directing a laser beam 4 through the transparent substrate 2 and the PTFE layer 1 onto the black rubber layer 3, as shown in Figure l(c), the rubber layer 3 is ablated in the illuminated areas and the carbon- filled polymer of the rubber is transferred to the PTFE layer 1. With other words by illuminating areas 5 carbon of the rubber layer 3 diffuses into the PTFE layer 1. In this way, the areas 5 of the PTFE layer 1 adjacent to the illuminated portions of the black rubber layer 3 are doped. This doping of the PTFE layer 1 with carbon is depicted in Fig. l(d) by the areas 5 being dark colored in the contrary to the non-doped areas 7 depicted in white which are not illuminated and consequently do not comprise transferred carbon from the rubber layer 3. Subsequently, the substrate 2 with the PTFE layer 1 including the doped areas 5 is separated from the black rubber layer 3 (Figure l(d)), and in the next step (see Figure l(e)) the PTFE layer 1 is illuminated using a laser beam 6 or another suitable light source.
For removing doped areas 5 (Fig. l(e)), the wavelength and intensity of the light source 6 should be selected to efficiently remove the doped areas 5 but not the non-doped ("white") areas 7 of the PTFE layer 1, which are between the doped areas 5. The wavelength may be the same or different to the wavelength which is used to dope the PTFE layer 1. The illumination during the removal step does not have to be selective because the non-doped areas 7 of the PTFE layer 1 do not absorb enough laser energy to show ablation as the doped areas 5 do. Areas 5 being doped as described and non-doped areas 7 which are areas unmodified to the original PTFE layer 1 have different ablation properties. Thus, the PTFE layer 1 may be illuminated by scanning an appropriate laser beam 6 over the entire surface of the PTFE layer 1. Subsequently, the surface may be cleaned, preferably dry cleaned. The method according to the invention may be used to manufacture fluidic or micro-fluidic devices. As an example, Figure 2 shows a picture of a water drop on a glass substrate 2 which was coated with Teflon (AF 1600) by dip coating. The measured contact angle of the surface 2 with water was between 110° and 140°, as can be seen on the left side of Figure 2. On the left side of Fig. 2 the form of the water drop is thus nearly spherical, whereby the sphere of the water drop is truncated by the surface
2. After laser ablation, the contact angle of the water drop dropped to 10° to 40°, as shown on the right side of Figure 2, where the water drop shows a rather flat form with regard to the substrate 2. On the right side of Fig. 2 the form of the water drop is that of a lens, compared to the form without laser ablation the contact area between the water drop and the surface 2 has increased significantly.
A further example of a micro-fluidic device into which a structure has been imparted using an embodiment of the method according to the invention is shown in Figure 3. Figure 3 shows a top view of a surface of a micro-fluidic device into which four elongate rectangular structures have been imparted. The structures on the surface are visible as dark areas, whereby two structures are each in parallel to each other and two strutures are each perpendicular to each other. As shown on the right side of Figure
3, water which has been applied to the surface of the micro-fluidic device is present only in the four areas which have been structured. The structured areas show are highly hydrophilic behaviour, the water applied to the surface is attracted to these areas.
While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and non-restrictive; the invention is thus not limited to the disclosed embodiments. Variations to the disclosed embodiments can be understood and effected by those skilled in the art and practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. A single processor or other unit may fulfill the functions of several items recited in the claims. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures can not be used to advantage. Any reference signs in the claims should not be considered as limiting the scope.

Claims

CLAIMS:
1. A method for imparting a structure in a polymer layer (1), comprising the steps:
(a) applying the polymer layer (1) on a substrate (2);
(b) selectively doping predetermined areas (5) of the polymer layer (1) with a light-absorbent material; and
(c) removing the doped areas (5) by illuminating the polymer layer (1) in order to form the structure.
2. The method according to claim 1, wherein the substrate (2) is a transparent substrate, preferably a glass substrate.
3. The method according to claim 1, wherein the polymer layer (1) is applied to the substrate (2) using spin-coating or dipping.
4. The method according to claim 2, wherein step (b) of selectively doping is done using laser back transfer.
5. The method according to claim 4, wherein step (b) comprises the steps of
(b 1 ) providing a layer of light-absorbent material (3), (b2) contacting the polymer layer (1) with the light-absorbent material layer (3),
(b3) illuminating the light-absorbent layer (3) adjacent to said predetermined areas (5) of the polymer layer (1) with a laser (4) through the transparent substrate (2) and the polymer layer (1) to ablate light- absorbent material and to dope the predetermined areas (5) of the polymer layer (1).
6. The method according to claim 1, wherein in step (c) the polymer layer
(1) is illuminated using a high energy light source, preferably a laser.
7. The method according to claim 1, further including the step of cleaning the surface of the polymer layer (1) after removing the doped portions.
8. The method of claim 1, wherein the polymer layer (1) comprises PTFE.
9. The method of claim 1 , wherein the light-absorbent material comprises a carbon-filled polymer.
10. A device comprising a substrate (2) and a polymer layer (1) applied on the substrate (2), said structure being obtainable with the method according to claim 1.
11. The device according to claim 10, wherein the polymer layer (1) comprises PTFE.
12. The device according to claim 10, wherein the substrate (2) is a transparent substrate, preferably a glass substrate.
13. The device according to claim 10, wherein the device is a micro-fluidic diagnostic device.
14. Use of the device according to one of claims 10 to 13 in one or more of the following applications: microfluidic biosensors for molecular diagnostics; integrated part of microfluidic biosensors, especially for pre-amplification or amplification, filtering, mixing and/or detection; - detection of proteins and nucleic acids in complex biological mixtures, especially for on-site testing and/or for diagnostics in centralized laboratories; medical diagnostics, especially protein diagnostics for cardiology, infectious diseases and/or oncology; food diagnostics; environmental diagnostics; metabolomics; and flow control.
PCT/IB2008/054687 2007-11-12 2008-11-10 Method for structuring a ptfe layer WO2009063380A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP07120474.7 2007-11-12
EP07120474 2007-11-12

Publications (1)

Publication Number Publication Date
WO2009063380A1 true WO2009063380A1 (en) 2009-05-22

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4816374A (en) * 1985-04-12 1989-03-28 Societe D'applications Plastiques Rhone-Alpes (Sapra) Method of making a plastic material sensitive to laser radiation and enabling it to be marked by a laser, and articles obtained thereby
US5320789A (en) * 1991-11-06 1994-06-14 Japan Atomic Energy Research Institute Surface modification of fluorine resin with laser light
DE10354341A1 (en) * 2002-11-21 2004-06-03 Heidelberger Druckmaschinen Ag To structure the surface of a printing plate, for offset printing, the hydrophilic polymer layer is heated locally to melt and form hydrophobic zones without material removal
US20060024504A1 (en) * 2004-08-02 2006-02-02 Nelson Curtis L Methods of controlling flow

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4816374A (en) * 1985-04-12 1989-03-28 Societe D'applications Plastiques Rhone-Alpes (Sapra) Method of making a plastic material sensitive to laser radiation and enabling it to be marked by a laser, and articles obtained thereby
US5320789A (en) * 1991-11-06 1994-06-14 Japan Atomic Energy Research Institute Surface modification of fluorine resin with laser light
DE10354341A1 (en) * 2002-11-21 2004-06-03 Heidelberger Druckmaschinen Ag To structure the surface of a printing plate, for offset printing, the hydrophilic polymer layer is heated locally to melt and form hydrophobic zones without material removal
US20060024504A1 (en) * 2004-08-02 2006-02-02 Nelson Curtis L Methods of controlling flow

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