Is condensation the cause of plasma leakage in microporous hollow fiber membrane oxygenators

Extracorporeal membrane oxygenators are comprised of large bundles of microporous hollow fiber membranes (HFMs) across which oxygen and carbon dioxide are transferred to and from blood. Long term use of extracorporeal oxygenators is limited by plasma leakage through the pores of the HFM walls, requiring replacement of the oxygenator. Condensation of water vapor on the pore walls is thought to be a possible precursor to plasma leakage. To explore this mechanism, a simple theoretical analysis is used to examine the temperature of the gas flow through the HFMs. For conditions representative of two commercially available oxygenators, the analysis predicts that the gas heats up to the temperature of blood flow outside of the fibers after passing through less than 0.5% of the fiber lengths. Once the gas temperature and hence the fiber wall temperature equilibrates with the blood, condensation of water vapor is no longer possible. In vitro testing of microporous HFMs under gas flow rates and temperature conditions similar to those of extracorporeal oxygenators but with the fibers submerged in water is also presented. The fibers showed negligible degradation in carbon dioxide transfer over a four-day period. These results of both the theoretical and experimental analyses indicate that the condensation of water vapor within the pores of the HFMs is unlikely to be the cause of plasma leakage in clinically used extracorporeal oxygenators.     

Oxygen radical-driven surface modification of polycaprolactone-filled glass microfiber media: Probing the surface chemistry of wicking microfluidic devices

Cost and complexity are key factors in designing microfluidic devices for broad application. Therefore, the development of a simple, inexpensive, and easily manufactured fabrication technique that does not require expensive chemicals or instruments is necessary. We have successfully demonstrated the use of long-lived oxygen radicals for the fabrication of membrane-based microfluidic devices on polycaprolactone (PCL)-filled glass microfiber (GMF) membranes. These devices may incorporate complex multidimensional (2D and 3D) microfluidic pathways on a single PCL-filled GMF membrane. Selective exposure to oxygen radicals generated in a homebuilt oxygen plasma exposure system was employed to pattern the flow path; radical exposure of the polymer-filled substrate altered the physical and chemical properties of the surface, affecting wettability. To the best of our knowledge, this is the only wicking microfluidic device fabrication technology that is capable of generating both 2D and 3D microfluidic pathways in a single membrane; hence, it has many potential applications. Investigations were conducted to probe the effects of oxygen radical exposure in order to provide a more quantitative understanding of the process. These findings will help expand the utility of the selective oxygen radical exposure–driven fabrication technology.     

Lung assist device technology with physiologic blood flow developed on a tissue engineered scaffold platform

There is no technology available to support failing lung function for patients outside the hospital. An implantable lung assist device would augment lung function as a bridge to transplant or possible destination therapy. Utilizing biomimetic design principles, a microfluidic vascular network was developed for blood inflow from the pulmonary artery and blood return to the left atrium. Computational fluid dynamics analysis was used to optimize blood flow within the vascular network. A micro milled variable depth mold with 3D features was created to achieve both physiologic blood flow and shear stress. Gas exchange occurs across a thin silicone membrane between the vascular network and adjacent alveolar chamber with flowing oxygen. The device had a surface area of 23.1 cm(2) and respiratory membrane thickness of 8.7 ± 1.2 μm. Carbon dioxide transfer within the device was 156 ml min(-1) m(-2) and the oxygen transfer was 34 ml min(-1) m(-2). A lung assist device based on tissue engineering architecture achieves gas exchange comparable to hollow fiber oxygenators yet does so while maintaining physiologic blood flow. This device may be scaled up to create an implantable ambulatory lung assist device.     

Development of an integrated microfluidic platform for dynamic oxygen sensing and delivery in a flowing medium

This paper describes a platform for real-time sensing of dissolved oxygen in a flowing microfluidic environment using an oxygen-sensitive luminescent dye (platinum octaethylporphyrin ketone) integrated into a micro-oxygenator device. Using a phase-based detection method, the luminescent decay lifetime of the dye was consistent with the linear Stern-Volmer relationship using both gaseous and aqueous samples. Maximum sensor resolution varied between 120-780 ppb across a range of dissolved oxygen (DO) concentrations ranging from 0-42.5 ppm. The sensor was subsequently used to determine the convective mass-transfer characteristics of a multi-layer polydimethylsiloxane (PDMS) microfluidic oxygenator. The membrane-based oxygenator showed excellent agreement with an analytical convection model, and the integrated oxygen sensor was accurate across a wide range of tested flow rates (0.05-5 mL min(-1)). The device is unique for its ease of fabrication and highly flexible configuration, as well as the novel incorporation of oxygen delivery and detection in a single micro-device. Potential applications include tissue engineering, cell culturing, and miniaturized bio-assays that require the delivery and/or detection of precise quantities of oxygen within a microfluidic construct.     

Flexible microfluidic devices with three-dimensional interconnected microporous walls for gas and liquid applications

This article presents a simple, low-cost method of fabrication and the applications of flexible polystyrene microfluidic devices with three-dimensional (3D) interconnected microporous walls based on treatment using a solvent/non-solvent mixture at room temperature. The complete fabrication process from device design concept to working device can be completed in less than an hour in a regular laboratory setting, without the need for expensive equipment. Microfluidic devices were used to demonstrate gas generation and absorption reactions by acidifying water with carbon dioxide (CO(2)) gas. By selectively treating the microporous structures with oxygen plasma, acidification of water by acetic acid (distilled white vinegar) perfusion was also demonstrated with the same device design.     

Phase-changing sacrificial layers in microfluidic devices: adding another dimension to separations

The use of polymers in microchip fabrication affords new opportunities for the development of powerful, miniaturized separation techniques. One method in particular, the use of phase-changing sacrificial layers, allows for simplified designs and many additional features to the now standard fabrication of microchips. With the possibility of adding a third dimension to the design of separation devices, various means of enhancing analysis now become possible. The application of phase-changing sacrificial layers in microchip analysis systems is discussed, both in terms of current uses and future possibilities. Figure Phase-changing sacrificial materials enable multilayer microfluidic device layouts     

Design and fabrication of chemically robust three-dimensional microfluidic valves

A current problem in microfluidics is that poly(dimethylsiloxane) (PDMS), used to fabricate many microfluidic devices, is not compatible with most organic solvents. Fluorinated compounds are more chemically robust than PDMS but, historically, it has been nearly impossible to construct valves out of them by multilayer soft lithography (MSL) due to the difficulty of bonding layers made of "non-stick" fluoropolymers necessary to create traditional microfluidic valves. With our new three-dimensional (3D) valve design we can fabricate microfluidic devices from fluorinated compounds in a single monolithic layer that is resistant to most organic solvents with minimal swelling. This paper describes the design and development of 3D microfluidic valves by molding of a perfluoropolyether, termed Sifel, onto printed wax molds. The fabrication of Sifel-based microfluidic devices using this technique has great potential in chemical synthesis and analysis.     

Blood flow and oxygen transfer rate of an outside blood flow membrane oxygenator

We evaluated effects of the number of tied hollow fibers of an outside blood flow membrane oxygenator with cross-wound hollow fibers on the blood flow pattern and oxygen transfer rate. The number of tied hollow fibers in a bundle was varied from one to six, and the blood flow pattern was observed by X-ray computed tomography. The oxygen transfer rate and blood pressure drop were measured by in vitro experiments using bovine blood. Uniform blood flow patterns were obtained for each number of tied hollow fibers. A decrease in the number of tied hollow fibers caused more effective contact of blood with the tied hollow fibers and oxygen transfer rate was enhanced, demonstrating that single hollow fiber was the most effective. Empirical equations were obtained based on these results and optimum structure parameters of the membrane oxygenator were determined by simulation analysis. Optimum membrane surface area and axial jacket length of the oxygenator were 3.0 m² and 320 mm, respectively, at a hollow fiber outside diameter of 250 μm.     

In situ fabrication of macroporous polymer networks within microfluidic devices by living radical photopolymerization and leaching

Novel fabrication techniques and polymer systems are being explored to enable mass production of low cost microfluidic devices. In this contribution we discuss a new fabrication scheme for making microfluidic devices containing porous polymer components in situ. Contact lithography, a living radical photopolymer (LRPP) system and salt leaching were used to fabricate multilayer microfluidic devices rapidly with various channel geometries and covalently attached porous polymer plugs made of various photopolymerizable substrates. LRPP systems offer the advantages of covalent attachment of microfluidic device layers and facile surface modification via grafting. Several applications of the porous plugs are also explored, including a static mixer, a high surface area-to-volume reactor and a rapidly responding hydrogel valve. Quantitative and qualitative data show an increase in mixing of a fluorescein and a water stream for channels containing porous plugs relative to channels with no porous plugs. Confocal laser scanning microscopy images demonstrate the ability to graft a functional material onto porous plug surfaces. A reaction was carried out on the grafted pore surfaces, which resulted in fluorescent labelling of the grafted material throughout the pores of the plug. Homogenous fluorescence throughout the depth of the porous plug and along pore surfaces indicated that the porous plugs were surface modified by grafting and that reactions can be carried out on the pore surfaces. Finally, porous hydrogel valves were fabricated which swelled in response to contact with various pH solutions. Results indicate that a porous hydrogel valve will swell and close more rapidly than other valve geometries made with the same polymer formulation. The LRPP-salt leaching method provides a means for rapidly incorporating porous polymer components into microfluidic devices, which can be utilized for a variety of pertinent applications upon appropriate selection of porous plug materials and surface treatments.     

Fabrication of silver-coated silica microspheres through mussel-inspired surface functionalization

This paper reports a droplet-based microfluidic device composed of patterned co-planar electrodes in an all-in-a-single-plate arrangement and coated with dielectric layers for electrowetting-on-dielectric (EWOD) actuation of discrete droplets. The co-planar arrangement is preferred over conventional two-plate electrowetting devices because it provides simpler manufacturing process, reduced viscous drag, and easier liquid-handling procedures. These advantages lead to more versatile and efficient microfluidic devices capable of generating higher droplet speed and can incorporate various other droplet manipulation functions into the system for biological, sensing, and other microfluidic applications. We have designed, fabricated, and tested the devices using an insulating layer with materials having relatively high dielectric constant (SiO(2)) and compared the results with polymer coatings (Cytop) with low dielectric constant. Results show that the device with high dielectric layer generates more reproducible droplet transfer over a longer distance with a 25% reduction in the actuation voltage with respect to the polymer coatings, leading to more energy efficient microfluidic applications. We can generate droplet speeds as high as 26 cm/s using materials with high dielectric constant such as SiO(2).     

Patterning, integration and characterisation of polymer optical oxygen sensors for microfluidic devices

This paper describes a process for the layer-by-layer fabrication and integration of luminescent dye-based optical oxygen sensors into microfluidic devices. Application of oxygen-sensitive platinum(ii) octaethylporphyrin ketone fluorescent dye dissolved in polystyrene onto glass substrates by spin-coating was studied. Soft lithography with polydimethylsiloxane (PDMS) stamps and reactive ion etching in oxygen plasma were used to produce sensor patterns with a minimum feature size of 25 microm. Sensors patterns were integrated into a PDMS microfluidic device by plasma bonding. No degradation of the sensor response as a result of the lithography and pattern-transfer processes was detected. Gaseous and dissolved oxygen (DO) detection was characterised using fluorescence microscopy. The intensity signal ratio of the sensor films was found to increase almost two-fold from 3.6 to 6.8 by reducing film thickness from 1.3 microm to 0.6 microm. Calibration of DO measurement showed linear Stern-Volmer behaviour that was constant for flow rates from 0.5 to 2 mL min(-1). The calibrated sensors were subsequently used to demonstrate laterally resolved detection of oxygen inside a microfluidic channel. The fabrication process provides a novel, easy to use method for the repeatable integration of optical oxygen sensors into cell-culture and lab-on-a-chip devices.     

Thermoplastic elastomers for microfluidics: towards a high-throughput fabrication method of multilayered microfluidic devices

Multilayer soft lithography of polydimethylsiloxane (PDMS) is a well-known method for the fabrication of complex fluidic functions. With advantages and drawbacks, this technique allows fabrication of valves, pumps and micro-mixers. However, the process is inadequate for industrial applications. Here, we report a rapid prototyping technique for the fabrication of multilayer microfluidic devices, using a different and promising class of polymers. Using styrenic thermoplastic elastomers (TPE), we demonstrate a rapid technique for the fabrication and assembly of pneumatically driven valves in a multilayer microfluidic device made completely from thermoplastics. This material solution is transparent, biocompatible and as flexible as PDMS, and has high throughput thermoforming processing characteristics. We established a proof of principle for valving and mixing with three different grades of TPE using an SU-8 master mold. Specific viscoelastic properties of each grade allow us to report enhanced bonding capabilities from room temperature bonding to free pressure thermally assisted bonding. In terms of microfabrication, beyond classically embossing means, we demonstrate a high-throughput thermoforming method, where TPE molding experiments have been carried out without applied pressure and vacuum assistance within an overall cycle time of 180 s. The quality of the obtained thermoplastic systems show robust behavior and an opening/closing frequency of 5 Hz.     

Microfluidic tectonics platform: A colorimetric, disposable botulinum toxin enzyme-linked immunosorbent assay system

A fabrication platform for realizing integrated microfluidic devices is discussed. The platform allows for creating specific microsystems for multistep assays in an ad hoc manner as the components that perform the assay steps can be created at any location inside the device via in situ fabrication. The platform was utilized to create a prototype microsystem for detecting botulinum neurotoxin directly from whole blood. Process steps such as sample preparation by filtration, mixing and incubation with reagents was carried out on the device. Various microfluidic components such as channel network, valves and porous filter were fabricated from prepolymer mixture consisting of monomer, cross-linker and a photoinitiator. For detection of the toxoid, biotinylated antibodies were immobilized on streptavidin-functionalized agarose gel beads. The gel beads were introduced into the device and were used as readouts. Enzymatic reaction between alkaline phosphatase (on secondary antibody) and substrate produced an insoluble, colored precipitate that coated the beads thus making the readout visible to the naked eye. Clinically relevant amounts of the toxin can be detected from whole blood using the portable enzyme-linked immunosorbent assay (ELISA) system. Multiple layers can be realized for effective space utilization and creating a three-dimensional (3-D) chaotic mixer. In addition, external materials such as membranes can be incorporated into the device as components. Individual components that were necessary to perform these steps were characterized, and their mutual compatibility is also discussed.     

Three-dimensional interconnected microporous poly(dimethylsiloxane) microfluidic devices

This technical note presents a fabrication method and applications of three-dimensional (3D) interconnected microporous poly(dimethylsiloxane) (PDMS) microfluidic devices. Based on soft lithography, the microporous PDMS microfluidic devices were fabricated by molding a mixture of PDMS pre-polymer and sugar particles in a microstructured mold. After curing and demolding, the sugar particles were dissolved and washed away from the microstructured PDMS replica revealing 3D interconnected microporous structures. Other than introducing microporous structures into the PDMS replica, different sizes of sugar particles can be used to alter the surface wettability of the microporous PDMS replica. Oxygen plasma assisted bonding was used to enclose the microstructured microporous PDMS replica using a non-porous PDMS with inlet and outlet holes. A gas absorption reaction using carbon dioxide (CO(2)) gas acidified water was used to demonstrate the advantages and potential applications of the microporous PDMS microfluidic devices. We demonstrated that the acidification rate in the microporous PDMS microfluidic device was approximately 10 times faster than the non-porous PDMS microfluidic device under similar experimental conditions. The microporous PDMS microfluidic devices can also be used in cell culture applications where gas perfusion can improve cell survival and functions.     

Multilayer soft lithography of perfluoropolyether based elastomer for microfluidic device fabrication

The compatibility of microfluidic devices with solvents and other chemicals is extremely important for many applications such as organic synthesis in microreactors and drug screening. We report the successful fabrication of microfluidic devices from a novel perfluoropolyether based polymer utilizing the Multilayer Soft Lithography? (MSL) technique with simple, straightforward processing. The perfluorinated polymer SIFEL X-71 8115 is a highly chemically resistant elastomeric material. We demonstrate fabrication of a microfluidic device using an off-ratio bonding technique to bond multiple SIFEL layers, each patterned lithographically. The mechanical properties of the SIFEL MSL valves (including actuation pressures) are similar to PDMS MSL valves of the same geometry. Chemical compatibility tests highlight SIFEL's remarkable resistance to organic solvents, acids and alkalis.     

Mass and momentum transport in extra-luminal flow (ELF) membrane devices for blood oxygenation

In this paper, we report on the characterisation of transport in membrane modules for blood oxygenation where blood is circulated outside hollow fibre membranes arranged in double layer cross-laid mats at an angle with respect to the main direction of blood flow. The effect of design and operating variables on module performance was investigated with respect to oxygen transfer into water, as gaseous oxygen and water are circulated counter-currently, respectively inside the membrane lumen and through the membrane assembly.Increasing water flow rates and membrane angles enhanced oxygen transfer across the membrane and resulted in robust operation but also in high pressure drops.Module pressure drop and oxygen transfer rate were correlated to module geometry, fibre packing density, water flow rate and membrane angle with respect to the main direction of the liquid flow in non-dimensional equations that can be used by membrane module manufacturers for the design of optimal ELF blood oxygenators. The results suggest that an optimum membrane angle exists, beyond which module operation is not convenient in terms of energy.     

Continuous and reversible mixing or demixing of nanoparticles by dielectrophoresis

Mixing and demixing (separation) are essential tasks in microfluidic devices, which seem to be contrary in nature. Accordingly, completely different strategies and devices are usually employed for their realization. We here present a microfluidic device which is capable of performing both these tasks as it can be operated in either mixing or demixing mode. The mixing and demixing processes are reversible and are accomplished by continuous operation of the device. An asymmetric S-shaped ridge extends over the full width of a microfluidic channel (200 μm) creating a constriction of 620 nm in height with an aspect ratio of 1 : 500. Appropriate AC and DC voltages generate electrodeless dielectrophoresis at the constriction as well as (linear) electrokinetic driving forces along the channel. These de/mixing parameters can be adapted in real time in such a way that continuous separation and mixing efficiencies of 85-100% can be achieved. As a proof of concept we demonstrate continuous mixing and demixing of polystyrene nanoparticles (20 and 100 nm). The experimental results are complemented by numerical simulations illustrating the particles' motion under the influence of the electrokinetic effects and thermal noise (diffusion). The monolithic one-step fabrication process by soft lithography (with PDMS in our case) will make integration and combination of several mixing and demixing functions into a more complex lab-on-a-chip device possible.     

Use of axial membrane vibrations to enhance mass transfer in a hollow tube oxygenator

Membrane-oxygenator performance is limited by the mass-transfer resistance on the blood side. The most successful techniques thus far for enhancing oxygenator performance have employed liquid-side pressure pulsations. However, this technique is limited since it causes the least relative motion near the membrane. In this study we explore the use of axial vibrations of a membrane tube bundle to increase oxygen transfer to the intralumenal liquid flow. An analytical solution is first developed for the hydrodynamics of laminar flow through a sinusoidally vibrated straight cylindrical tube. This indicates that the effect of the tube vibrations is characterized by a dimensionless velocity and frequency. A novel oxygenator is designed that permits vibrating a parallel membrane hollow tube bundle without directly pulsing the intralumenal liquid flow. An embodiment of this design employing 41 silicone rubber tubes is used to study the oxygenation of water. A tuned response is observed in that the maximum enhancement in mass transfer for a fixed dimensionless vibration velocity occurs at a specific dimensionless frequency. These experiments demonstrate that axial membrane vibrations can increase the mass-transfer coefficient by at least a factor of 2.65. Even greater enhancement may be possible for systems characterized by larger Schmidt or Graetz numbers for which diffusive mass transfer is more limiting. Employing membrane vibrations may offer the additional advantage of minimizing fouling in blood oxygenator as well as other applications.     

Microfluidic Device： A Miniaturized Platform for Chemical Reactions

Microfluidic devices, as a new miniaturized platform stemming from the field of micro-electromechanical sys-tems, have been used in many disciplines. In the field of chemical reactions, microfluidic device-based microreac-tors have shown great promise in building new chemical technologies and processes with increased speed and reli- ability and reduced sample consumption and cost. This technology has also become a new and effective tool for precise, high-throughput, and automatic analysis of chemical synthesis processes. Compared with conventional chemical laboratory batch methodologies, microfluidic reactors have a number of features, such as high mixing ef- ficiency, short reaction time, high heat-transfer coefficient, small reactant volume, controllable residence time, and high surface-to-volume ratio, among others. Combined with recent advances in microfluidic devices for chemical reactions, this review aims to give an overview of the features and applications of microfluidic devices in the field of chemical synthesis. It also aims to stimulate the development of microfluidic device applications in the field of chemical reactions.     

Design and fabrication of a multilayered polymer microfluidic chip with nanofluidic interconnects via adhesive contact printing

The design and fabrication of a multilayered polymer micro-nanofluidic chip is described that consists of poly(methylmethacrylate) (PMMA) layers that contain microfluidic channels separated in the vertical direction by polycarbonate (PC) membranes that incorporate an array of nanometre diameter cylindrical pores. The materials are optically transparent to allow inspection of the fluids within the channels in the near UV and visible spectrum. The design architecture enables nanofluidic interconnections to be placed in the vertical direction between microfluidic channels. Such an architecture allows microchannel separations within the chip, as well as allowing unique operations that utilize nanocapillary interconnects: the separation of analytes based on molecular size, channel isolation, enhanced mixing, and sample concentration. Device fabrication is made possible by a transfer process of labile membranes and the development of a contact printing method for a thermally curable epoxy based adhesive. This adhesive is shown to have bond strengths that prevent leakage and delamination and channel rupture tests exceed 6 atm (0.6 MPa) under applied pressure. Channels 100 microm in width and 20 microm in depth are contact printed without the adhesive entering the microchannel. The chip is characterized in terms of resistivity measurements along the microfluidic channels, electroosmotic flow (EOF) measurements at different pH values and laser-induced-fluorescence (LIF) detection of green-fluorescent protein (GFP) plugs injected across the nanocapillary membrane and into a microfluidic channel. The results indicate that the mixed polymer micro-nanofluidic multilayer chip has electrical characteristics needed for use in microanalytical systems.