Method of producing a multi-microchannel, flow-through element and device using same

Abstract

A method of producing a multi-microchannel, flow-through element, including the steps of providing a body of material, and producing multiple microchannels within the body, wherein the microchannels extend through the body to produce a multi-microchannel, flow-through element. Such an element can be used as a micromixer, a sensor element, a filter, a fuel element or a chromatographic element.

1 . A method of producing and using a multi-microchannel, flow-through element, including the steps of: 
 providing a body of material;    producing multiple microchannels within said body, wherein said microchannels extend through said body to produce said multi-microchannel, flow-through element; and    using said element as a micromixer, sensor element, filter, fuel element or chromatographic element.    
     
     
         2 . The method of  claim 1 , wherein said producing step comprises the steps of: 
 melting said body of material in a gas atmosphere such that at least one gas in said gas atmosphere dissolves in the resulting melt to form a material/gas composition; and    cooling said melt, while controlling pressure thereon, to allow dissolved gas to escape said material/gas composition as it solidifies, thereby producing microchannels in the solidified material.    
     
     
         3 . The method of  claim 1 , wherein said producing step comprises producing microchannels such that walls of at least some of said microchannels have a non-uniform cross section, or a cylindrical shape.  
     
     
         4 . The method of  claim 3 , wherein said microchannels have a conical or ellipsoidal shape, or said walls of said microchannels contain ridges and grooves or protuberances, or have periodically or irregularly changing cross sections.  
     
     
         5 . The method of  claim 1 , wherein said multi-microchannel element contains a high density of microchannels that provide communication between opposite faces of said multi-microchannel element.  
     
     
         6 . The method of  claim 5 , wherein said microchannels have an average diameter or cross-section of 1 to 200 microns.  
     
     
         7 . The method of  claim 1 , wherein said material of said body is selected from the group consisting of Fe, Ni, Co, Cr, Cu, Mg, Mo, W, Al, Au, Ir, Ru, Pd, Pt, Zr, Ti, Rh, alloys thereof, ceramic and glass.  
     
     
         8 . The method of  claim 1 , wherein said element is used as a micromixer, and wherein walls of at least some of said microchannels have a non-uniform cross section.  
     
     
         9 . The micromixer of  claim 8 , wherein several of said microchannels merge into a single, larger microchannel having a non-uniform cross section.  
     
     
         10 . The method of  claim 1 , wherein at least one of said elements is provided for use in an electrochemical sensor, and wherein said at least one element is provided as a transducer and is an electrically conductive, metallic element.  
     
     
         11 . The electrochemical sensor of  claim 10 , wherein walls of said microchannels of said at least one element have a mirrored and smooth, yet not polished, surface.  
     
     
         12 . The electrochemical sensor of  claim 10 , wherein said multi-microchannel element has a ceramic base and an electroconductive coating of material selected from the group consisting of Fe, Ni, Co, Cr, Cu, Mg, Mo, W, Al, Au, Ir, Ru, Pd, Pt, Zr, Ti, Rh and alloys thereof.  
     
     
         13 . The electrochemical sensor of  claim 10 , wherein chemical or biological recognition agent is immobilized on at least some of the walls of said microchannels of said multi-microchannel element.  
     
     
         14 . The electrochemical sensor of  claim 13 , wherein said chemical or biological recognition agent is effective for carrying out binding reactions involving small molecules, macromolecules, particles or cellular systems.  
     
     
         15 . The electrochemical sensor of  claim 14 , wherein said chemical or biological recognition agents are selected from the group consisting of polypeptides, proteins, nucleic acids, receptors, polysaccharides, phospholipids, cells, tissue, nano-particles, selected from the group consisting of Au, Ag, Mi, GIS, and carbon nanotubes, with immobilized biological recognition agent, and related unnatural polymers of biological relevance.  
     
     
         16 . An electrochemical sensor according to  claim 10 , in the form of a flow-through amperometric detector coupled with a micropipette, wherein said multi-microchannel element is disposed in said amperometric detector.  
     
     
         17 . An electrochemical sensor according to  claim 10 , in the form of a flow-through micro-array chip that includes a carrier for said at least one multi-microchannel element, and a respective contact pad disposed on said carrier and electrically connected to said at least one multi-microchannel element.  
     
     
         18 . An electrochemical sensor according to  claim 17 , wherein a plate is disposed on at least part of said carrier and is provided with holes to receive a portion of said at least one multi-microchannel element that extends beyond a surface of said carrier.  
     
     
         19 . An electrochemical sensor according to  claim 17 , wherein at least one cap is provided on said carrier for distributing said sample to said at least one multi-microchannel element.