Stem-well films for sample partitioning

1. A sample partitioning device, comprising:

a first film comprising an array of discrete stems each extending from a base to an upper surface thereof, the base being connected to a first major surface of the first film; and

a second film comprising an array of discrete wells formed into a second major surface thereof, each well including a sidewall and a bottom,

the first major surface of the first film and the second major surface of the second film being in direct physical contact and conformal with each other, and an outer surface of each stem being in direct physical contact and conformal with the sidewall of the respective wells, and the upper surface of each stem being in direct physical contact and conformal with the bottom of the respective wells such that the stems of the first film and the wells of the second film being mated with each other, and at least one of the stems completely filling the respective well,

wherein the mated stems and wells are separable from each other, the stems are flexible and have a molecular orientation with a birefringence value of at least 0.001, and during the removal of the stems from the wells, one or more voids are created inside the wells to suction an aqueous test sample into the wells.

2. The device of claim 1 , wherein the first major surface of the first film and the second major surface of the second film are in direct physical contact with each other, and the first and second major surfaces are separable from each other to provide a space therebetween allowing the aqueous test sample to flow.

3. The device of claim 1 , wherein at least one of the stems has a shape of conical post that is tapered away from the first major surface with a draft angle between 1 and 30 degrees.

4. The device of claim 1 , wherein the second major surface of the second film is hydrophobic.

5. The device of claim 1 , wherein the wells have an average volume of 1 to 500 nanoliters.

6. The device of claim 1 , wherein the array of stems has a density between 100 and 10,000 pins/inch 2 (ppi).

7. The device of claim 1 , wherein the first film comprises one or more of olefin polymer including polypropylene, polyethylene and copolymer, silicone polymer, polyurethane, polyvinyl chloride, ethylene-vinyl acetate polymer, (meth)acrylic polymer, polyamide, polyester, poly(styrene-acrylonitrile), and poly(acrylonitrile-butadiene-styrene).

8. The device of claim 1 , wherein the second film comprises one or more of (meth)acrylic polymer, polyvinyl acetal resin, polyvinylchloride, polyurethane, silicone polymer, styrenic polymer, vinyl ether polymer, vinylpyrrolidone polymer, polyester including lactone-based polymer, cyclic ether-based polymer including epoxy resin, and ring-opening metathesis polymer.

9. The device of claim 1 , wherein at least one of the first and second films comprises polydimethylsiloxane (PDMS).

10. The device of claim 1 , wherein at least one of the first and second films comprises a cured acrylate polymer.

11. The device of claim 1 , further comprising a cover film that is configured to laminate over the wells on the second major surface of the second film after the wells are filled with the aqueous test sample.

12. A method comprising:

providing a first film comprising an array of discrete stems each extending from a base to an upper surface thereof, the base being connected to a first major surface of the first film, wherein the stems are flexible and have a molecular orientation with a birefringence value of at least 0.001;

providing a second film comprising an array of wells that are mated with the stems of the first film, each well including a sidewall and a bottom;

submerging the mated stems and wells in an aqueous test sample;

separating the first film from the second film to remove the stems from the wells; and

during the removal of the stems, creating one or more voids inside the wells to suction the aqueous test sample into the wells and fill the wells,

wherein the first major surface of the first film and the second major surface of the second film are in direct physical contact and conformal with each other, and an outer surface of each stem is in direct physical contact and conformal with the sidewall of the respective wells, and the upper surface of each stem being in direct physical contact and conformal with the bottom of the respective wells such that the stems of the first film and the wells of the second film being mated with each other, and at least one of the stems completely filling the respective well.

13. The method of claim 12 , further comprising laminating over the wells on the second major surface of the second film with a cover film after filling the wells.

14. The method of claim 12 , wherein providing the second film comprises applying a film making material to the first major surface of the first film to form the wells mated with the stems.

15. The method of claim 14 , wherein the film making material comprises a curable polymeric material that is applied in a viscous or fluid state, and the method further comprises curing or drying the film making material.

16. The method of claim 12 , wherein the first film comprises one or more of olefin polymer including polypropylene, polyethylene and copolymer, silicone polymer, polyurethane, polyvinyl chloride, ethylene-vinyl acetate polymer, (meth)acrylic polymer, polyamide, polyester, poly(styrene-acrylonitrile), and poly(acrylonitrile-butadiene-styrene).

17. The method of claim 12 , wherein the second film comprises one or more of (meth)acrylic polymer, polyvinyl acetal resin, polyvinylchloride, polyurethane, silicone polymer, styrenic polymer, vinyl ether polymer, vinylpyrrolidone polymer, polyester including lactone-based polymer, cyclic ether-based polymer including epoxy resin, and ring-opening metathesis polymer.

18. The method of claim 12 , wherein separating the first film from the second film comprises applying a separation force at a peripheral edge of the first film and peeling the first film away from the second film.