Fluid processing cassettes incorporating micro- and macrofluidic channels

1. A fluid processing cassette comprising:

first and second covers; and

an interior wall positioned between the first and second covers, wherein

the interior wall includes

a first surface facing a substantially planar surface of the first cover and defining a portion of a plurality of macrofluidic channels, and

a second surface facing the second cover and defining a portion of a plurality of microfluidic channels, with at least one of the microfluidic channels being configured to separate a fluid into two or more fluid components and including a first outlet port for at least a portion of a first separated fluid component and a second outlet port for at least a portion of a second separated fluid component fluid component,

the interior wall defines at least one opening providing fluid communication between at least one of the plurality of microfluidic channels and at least one of the macrofluidic channels, and

side walls of the microfluidic channels are at least partially defined by projections extending from a surface of the second cover facing the second surface of the interior wall.

2. The fluid processing cassette of claim 1 , wherein the first cover is flexible.

3. The fluid processing cassette of claim 1 , wherein the first cover is rigid.

4. The fluid processing cassette of claim 1 , wherein the interior wall is secured to one of the covers by an adhesive.

5. The fluid processing cassette of claim 1 , wherein the interior wall is secured to one of the covers by a weld.

6. The fluid processing cassette of claim 5 , wherein the weld comprises a hot plate weld.

7. The fluid processing cassette of claim 5 , wherein the weld comprises a laser weld.

8. The fluid processing cassette of claim 5 , wherein the weld comprises an ultrasonic weld.

9. The fluid processing cassette of claim 1 , wherein

the second cover defines one end and the projections extending from the second cover entirely define the sidewalls of each microfluidic channel, and

the second surface of the interior wall defines a second end of each microfluidic channel.

10. The fluid processing cassette of claim 1 , wherein the first cover is configured to be placed against a complementary surface of a fluid processing system configured to convey fluid into and through the fluid processing cassette.

11. The fluid processing cassette of claim 1 , wherein at least one of the covers includes a port configured to accommodate a conduit for conveying fluid into and/or out of the fluid processing cassette.

12. The fluid processing cassette of claim 1 , further comprising an additional interior wall, wherein

the additional interior wall is secured to the first cover,

the interior wall is secured to the additional interior wall and to the second cover,

a first surface of the additional interior wall faces the first cover and cooperates with the first cover to define a plurality of macrofluidic channels,

a second surface of the additional interior wall faces the interior wall and cooperates with the first surface of the interior wall to define a plurality of macrofluidic channels, and

the second surface of the interior wall cooperates with the second cover to define said plurality of microfluidic channels.

13. A fluid processing cassette comprising:

first and second covers;

a first interior wall secured to the first cover; and

a second interior wall secured to the first interior wall and to the second cover, wherein

the first interior wall includes

a first surface facing a substantially planar surface of the first cover and cooperating with the first cover to define a plurality of macrofluidic channels, and

a second surface facing the second interior wall,

the second interior wall includes

a first surface facing the first interior wall and cooperating with the second surface of the first interior wall to define a plurality of macrofluidic channels,

a second surface facing a surface of the second cover and cooperating with the second cover to define a plurality of microfluidic channels, with at least one of the microfluidic channels being configured to separate a fluid into two or more fluid components and including a first outlet port for at least a portion of a first separated fluid component and a second outlet port for at least a portion of a second separated fluid component fluid component,

side walls of the microfluidic channels are at least partially defined by projections extending from the surface of the second cover, and

the second interior wall defines at least one opening providing fluid communication between at least one of the plurality of microfluidic channels and at least one of the macrofluidic channels defined by the first and second interior walls.

14. The fluid processing cassette of claim 13 , wherein

the first interior wall is secured to the first cover by an adhesive,

the second interior wall is secured to the second cover by an adhesive, and/or

the first interior wall is secured to the second interior wall by an adhesive.

15. The fluid processing cassette of claim 13 , wherein

the first interior wall is secured to the first cover by a weld,

the second interior wall is secured to the second cover by a weld, and/or

the first interior wall is secured to the second interior wall by a weld.

16. The fluid processing cassette of claim 13 , wherein

the second surface of the first interior wall defines one end and a sidewall of each macrofluidic channel defined between the first and second interior walls, and

the first surface of the second interior wall defines a second end of each macrofluidic channel defined between the first and second interior walls.

17. The fluid processing cassette of claim 1 , wherein said at least one of the microfluidic channels is configured to separate said fluid into two or more fluid components via an electric separation field.

18. The fluid processing cassette of claim 1 , wherein said at least one of the microfluidic channels is configured to separate said fluid into two or more fluid components via a gravitational separation field.

19. The fluid processing cassette of claim 1 , wherein said at least one of the microfluidic channels is configured to separate said fluid into two or more fluid components via a centrifugal separation field.

20. The fluid processing cassette of claim 1 , wherein said at least one of the microfluidic channels is configured to separate said fluid into two or more fluid components via a magnetic separation field.

21. The fluid processing cassette of claim 1 , wherein said at least one of the microfluidic channels is configured to separate said fluid into two or more fluid components via an acoustic separation field.