Array plates and methods for making and using same

1. A method, comprising:

providing a first structure in a mold, the first structure including a sheet layer with a plurality of discrete through-holes, and the sheet layer having a first surface and a second surface that is opposite to the first surface;

providing a heated plastic material into the mold, wherein the heated plastic material has a lower glass transition temperature than the sheet layer;

cooling the plastic material to form a second structure so that the first structure and the second structure are coupled; and

releasing the first structure and the second structure that is coupled with the first structure,

wherein:

the second surface of the sheet layer is embedded in the second structure;

a top portion of the sheet layer, including a portion of the first surface of the sheet layer, includes fluorocarbon;

the second structure includes a material of a higher surface energy than the top portion of the sheet layer; and

the second structure extends at least partially into the plurality of discrete through-holes of the first structure.

2. The method of claim 1 , wherein:

at least 90% of the top portion of the first surface is covered by fluorocarbon.

3. The method of claim 1 , wherein the sheet layer includes at least 96 discrete through-holes.

4. The method of claim 1 , wherein the top portion of the sheet layer includes at least 95% of fluorocarbon by weight.

5. The method of claim 1 , wherein the top portion of the sheet layer includes at least 99% of fluorocarbon by weight.

6. The method of claim 1 , wherein the top portion of the sheet layer has a thickness less than 1 μm.

7. The method of claim 1 , wherein the top portion of the sheet layer has a thickness less than 100 nm.

8. The method of claim 1 , wherein at least 90% of the top portion of the first surface is covered by polytetrafluoroethylene.

9. The method of claim 1 , wherein the sheet layer includes at least 90% of polytetrafluoroethylene by weight.

10. The method of claim 1 , wherein the second structure includes poly carbonates.

11. The method of claim 1 , wherein the second structure includes cyclic olefin polymer or copolymer or polystyrene.

12. The method of claim 1 , wherein a top surface of the sheet layer of the first structure is aligned with a top surface of the second structure.

13. The method of claim 1 , wherein a top surface of the sheet layer of the first structure extends above a top surface of the second structure.

14. The method of claim 1 , wherein a top surface of the sheet layer of the first structure extends below a top surface of the second structure.

15. The method of claim 1 , wherein:

the second structure has a first surface and a second surface that is opposite to the first surface of the second structure;

the first surface of the second structure is adjacent to the first structure;

the first surface of the second structure has a plurality of protrusions; and

a respective protrusion of the plurality of protrusions extends into a respective discrete through-hole of the plurality of discrete through-holes.

16. The method of claim 1 , wherein at least a portion of the first surface of the sheet layer is embedded in the second structure.

17. The method of claim 1 , wherein the second structure includes a base layer and one or more vertical structures along a periphery of the base layer, adjacent to a first surface of the base layer.

18. The method of claim 17 , wherein the one or more vertical structures, the base layer, and the first structure define a reservoir.

19. The method of claim 1 , wherein the first structure includes a hydrophobic material.

20. The method of claim 1 , wherein:

the second structure has a first surface adjacent the first structure; and

the first surface of the second structure has one or more indentations and one or more protrusions in regions corresponding to the plurality of discrete through-holes defined in the sheet layer when the second structure is coupled to the first structure.