Fully integrated three-dimensional electrodes for electrochemical detection in microchips: fabrication, characterization, and applications.

A scalable and rather inexpensive solution to producing microanalytical systems with "on-chip" three-dimensional (3D) microelectrodes is presented in this study, along with applicability to practical electrochemical (EC) detection scenarios such as preconcentration and interferant removal. This technique to create high-aspect-ratio (as much as 4:1) gold microstructures in constrained areas involved the modification of stud bump geometry with microfabricated silicon molds via an optimized combination of temperature, pressure, and time. The microelectrodes that resulted consisted of an array of square pillars approximately 18 microm tall and 20 microm wide on each side, placed at the end of a microfabricated electrophoresis channel. This technique increased the active surface area of the microelectrodes by as much as a factor of 50, while mass transfer and, consequently, preconcentration collection efficiencies were increased to approximately 100%, compared to approximately 30% efficiency for planar nonmodified microelectrodes (samples that were used included the neurotransmitters dopamine and catechol). The 3D microelectrodes were used both in a stand-alone configuration, for direct EC detection of model catecholamine analytes, and, more interestingly, in dual electrode configurations for EC sample processing prior to detection downstream at a second planar electrode. In particular, the 3D electrodes were shown to be capable of performing coulometry or complete (100%) redox conversion of analyte species over a wide range of concentrations, from 4.3 microM to 4.4 mM, in either plug-flow or continuous-flow formats.

Room temperature UV adhesive bonding of CE devices.

A simple low temperature adhesive 'stamp-and-stick' bonding procedure for lab-on-a-chip glass devices has been tested for capillary electrophoresis applications. This technique involves use of a mask aligner to transfer a UV-curable adhesive selectively onto the top CE substrate which is then aligned with and bonded to the bottom CE wafer. The entire bonding process can be carried out at room temperature in less than 30 minutes, involved only user-friendly laboratory operations, and provided a near 100% success rate. CE microchips made in this manner exhibited similar electroosmotic flow and separation characteristics as ones made via conventional high temperature thermal bonding. Equally important, the devices provided stable long-term performance over weeks of use, encompassing hundreds of individual CE runs without structural failure or any apparent change in operating characteristics. Finally, these devices exhibited excellent chip-to-chip reproducibility. Successful adaptation of the stamp-and-stick approach did require the development and testing of new but easily implemented structural features which were incorporated into the chip design and whose nature is described in detail.

Fabrication of a glass capillary electrophoresis microchip with integrated electrodes.

In this chapter, a detailed outline delineating the processing steps for microfabricating capillary electrophoresis (CE) with integrated electrochemical detection (ECD) platforms for performing analyte separation and detection is presented to enable persons familiar with microfabrication to enter a cleanroom and fabricate a fully functional Lab-on-a-Chip (LOC) microdevice. The processing steps outlined are appropriate for the production of LOC prototypes using easily obtained glass substrates and common microfabrication techniques. Microfabrication provides a major advantage over existing macro-scale systems by enabling precise control over electrode placement, and integration of all required CE and ECD electrodes directly onto a single substrate with a small footprint. In the processing sequences presented, top and bottom glass substrates are photolithographically patterned and etched using wet chemical processing techniques. The bottom substrate contains seven electrodes required for CE/ECD operation, whereas the top substrate contains the microchannel network. The flush planar electrodes are created using sputter deposition and lift-off processing techniques. Finally, the two glass substrates are thermally bonded to create the final LOC device.

Chemiresistive vapor sensing with microscale films of gold monolayer protected clusters.

Here we report the stability, conductivity, and vapor-sensing properties of microcontact-printed films of 1.6-nm average diameter hexanethiolate-coated gold monolayer protected clusters (C6 Au MPCs). The C6 Au MPCs were stamped into parallel lines (approximately 1.2 microm wide and 400 nm thick) across two Au electrodes separated by a 1-microm gap. The chemiresistive vapor-sensing properties were measured for saturated toluene and 2-propanol vapors. As-prepared patterned Au MPC films were unstable in the presence of saturated toluene vapor, and their current response was irreversible. Chemically linking the films with vapor-phase hexanedithiol greatly improves their stability and leads to reversible responses. The extent of Au MPC cross-linking and vapor response to organic vapors varies with different exposure times to dithiol vapor. The response to toluene changed from 61 to 8% for exposures of 1 and 60 min, respectively, which is likely due to greater film flexibility with less dithiol exposure. The current measured through the films varies from 10(-11) to 10(-3) Angstroms as a function of the temperature between 250 and 320 degrees C, which correlates with the loss of organic material as measured by FT-IR spectroscopy and the change in thickness and width of the film as measured by atomic force microscopy. The vapor-sensing properties vary with temperature, current, and organic content in the film, which are all interrelated. Response to toluene decreased with increasing temperature and conductivity, while the response to 2-propanol was less predictable. Reducing the size of vapor-sensing devices based on Au MPCs is important for creating highly portable devices that can simultaneously detect multiple analytes. This work demonstrates a simple method for reducing the size of such devices down to the microscale and describes methods for maximizing response, stability, and reversibility.

Portable high-voltage power supply and electrochemical detection circuits for microchip capillary electrophoresis.

Miniaturized, battery-powered, high-voltage power supply, electrochemical (EC) detection, and interface circuits designed for microchip capillary electrophoresis (CE) are described. The dual source CE power supply provides +/- 1 kVDC at 380 microA and can operate continuously for 15 h without recharging. The amperometric EC detection circuit provides electrode potentials of +/-2 VDC and gains of 1, 10, and 100 nA/V. The CE power supply power is connected to the microchip through an interface circuit consisting of two miniature relays, diodes, and resistors. The microchip has equal length buffer and separation channels. This geometry allows the microchip to be controlled from only two reservoirs using fixed dc sources while providing a consistent and stable sample injection volume. The interface circuit also maintains the detection reservoir at ground potential and allows channel currents to be measured likewise. Data are recorded, and the circuits are controlled by a National Instruments signal interface card and software installed in a notebook computer. The combined size (4 in. x 6 in. x 1 in.) and weight (0.35 kg) of the circuits make them ideal for lab-on-a-chip applications. The circuits were tested electrically, by performing separations of dopamine and catechol EC and by laser-induced fluorescence visualization.

Fully integrated on-chip electrochemical detection for capillary electrophoresis in a microfabricated device.

Microfabricated lab-on-a-chip devices employing a fully integrated electrochemical (EC) detection system have been developed and evaluated. Both capillary electrophoresis (CE) channels and all CE/EC electrodes were incorporated directly onto glass substrates via traditional microfabrication techniques, including photolithographic patterning, wet chemical etching, DC sputtering, and thermal wafer bonding. Unlike analogous CE/EC devices previously reported, no external electrodes were required, and critical electrode characteristics, including size, shape, and placement on the microchip, were established absolutely by the photolithography process. For the model analytes dopamine and catechol, detection limits in the 4-5 microM range (approximately 200 amol injected) were obtained with the Pt EC electrodes employed here, and devices gave stable analytical performance over months of usage.