Laminar mixing in different interdigital micromixers: II. Numerical simulations

Sub-millisecond microfluidic mixers coupled to time-resolved in situ photonics to study ultra-fast reaction kinetics: the case of ultra-small gold nanoparticle synthesis

We report a continuous microreactor platform achieving sub-millisecond homogeneous reagent mixing (∼300 μs) for a time-resolved study on the synthesis of ultra-small gold nanoparticles (NPs). The microreactor (coupled with small angle X-ray scattering, UV-vis, and X-ray absorption spectroscopy for in situ and in operando characterizations), operates within mixing time frames below system characteristic times, providing a unique opportunity to deepen the comprehension of reaction and phase transition pathways with unprecedented details. The microreactor channel length can be approximated to a given reaction time when operated in continuous mode and steady state. As a result, the system can be statically investigated, eliminating technique-dependent probing time constraints and local inhomogeneities caused by mixing issues. We have studied Au(0) NP formation kinetics from Au(III) precursors complexed with oleylamine in organic media, using triisopropylsilane as a reducing agent. The existence of Au(III)/Au(I) prenucleation clusters and the formation of a transient Au(I) lamellar phase under certain conditions, before the onset of Au(0) formation, have been observed. Taking advantage of the high frequency time-resolved information, we propose and model two different reaction pathways associated with the presence or absence of the Au(I) lamellar phase. In both cases, non-classical pathways leading to the formation of NPs are discussed.

A Digital Twin of the Coaxial Lamination Mixer for the Systematic Study of Mixing Performance and the Prediction of Precipitated Nanoparticle Properties

The synthesis of nanoparticles in microchannels promises the advantages of small size, uniform shape and narrow size distribution. However, only with insights into the mixing processes can the most suitable designs and operating conditions be systematically determined. Coaxial lamination mixers (CLM) built by 2-photon polymerization can operate long-term stable nanoparticle precipitation without fouling issues. Contact of the organic phase with the microchannel walls is prevented while mixing with the aqueous phase is intensified. A coaxial nozzle allows 3D hydrodynamic focusing followed by a sequence of stretch-and-fold units. By means of a digital twin based on computational fluid dynamics (CFD) and numerical evaluation of mixing progression, the influences of operation conditions are now studied in detail. As a measure for homogenization, the mixing index (MI) was extracted as a function of microchannel position for different operating parameters such as the total flow rate and the share of solvent flow. As an exemplary result, behind a third stretch-and-fold unit, practically perfect mixing (MI>0.9) is predicted at total flow rates between 50 µL/min and 400 µL/min and up to 20% solvent flow share. Based on MI values, the mixing time, which is decisive for the size and dispersity of the nanoparticles, can be determined. Under the conditions considered, it ranges from 5 ms to 54 ms. A good correlation between the predicted mixing time and nanoparticle properties, as experimentally observed in earlier work, could be confirmed. The digital twin combining CFD with the MI methodology can in the future be used to adjust the design of a CLM or other micromixers to the desired total flow rates and flow rate ratios and to provide valuable predictions for the mixing time and even the properties of nanoparticles produced by microfluidic antisolvent precipitation.

Wide and continuous dynamic tuning of period, modulation depth and duty cycle of a laminar-flow-based microfluidic grating

Flexible diffraction gratings that can be dynamically tuned in terms of both diffraction efficiency and diffraction angles are very important components for various applications, and fundamentally can be tuned through varying the modulation depth, duty cycle and grating period. However, dynamic and continuous tuning of a grating in all three aspects is difficult and has never been demonstrated hitherto. We propose and successfully fabricate a laminar-flow-based microfluidic grating in which all the three parameters can be dynamically tuned by simply varying flow rates into several liquid inlets. A 32-period liquid grating is generated by using ethanol and benzyl alcohol as alternate liquid lamellae. The total diffraction efficiency is tuned between 0 and 99%, and the maximum diffraction efficiency of the first order is ∼27%. The duty cycle of the grating is dynamically tuned from 7.6% to 91.5%. The grating period is compressed from more than 22 μm to less than 4 μm, leading to tuning of the first order diffraction angle from 1.7° to 9.2°.

Toward the Next Generation of Passive Micromixers: A Novel 3-D Design Approach

Passive micromixers are miniaturized instruments that are used to mix fluids in microfluidic systems. In microchannels, combination of laminar flows and small diffusion constants of mixing liquids produce a difficult mixing environment. In particular, in very low Reynolds number flows, e.g., Re < 10, diffusive mixing cannot be promoted unless a large interfacial area is formed between the fluids to be mixed. Therefore, the mixing distance increases substantially due to a slow diffusion process that governs fluid mixing. In this article, a novel 3-D passive micromixer design is developed to improve fluid mixing over a short distance. Computational Fluid Dynamics (CFD) simulations are used to investigate the performance of the micromixer numerically. The circular-shaped fluid overlapping (CSFO) micromixer design proposed is examined in several fluid flow, diffusivity, and injection conditions. The outcomes show that the CSFO geometry develops a large interfacial area between the fluid bodies. Thus, fluid mixing is accelerated in vertical and/or horizontal directions depending on the injection type applied. For the smallest molecular diffusion constant tested, the CSFO micromixer design provides more than 90% mixing efficiency in a distance between 260 and 470 µm. The maximum pressure drop in the micromixer is found to be less than 1.4 kPa in the highest flow conditioned examined.

Enhancement of Mixing Performance of Two-Layer Crossing Micromixer through Surrogate-Based Optimization

Optimum configuration of a micromixer with two-layer crossing microstructure was performed using mixing analysis, surrogate modeling, along with an optimization algorithm. Mixing performance was used to determine the optimum designs at Reynolds number 40. A surrogate modeling method based on a radial basis neural network (RBNN) was used to approximate the value of the objective function. The optimization study was carried out with three design variables; viz., the ratio of the main channel thickness to the pitch length (H/PI), the ratio of the thickness of the diagonal channel to the pitch length (W/PI), and the ratio of the depth of the channel to the pitch length (d/PI). Through a primary parametric study, the design space was constrained. The design points surrounded by the design constraints were chosen using a well-known technique called Latin hypercube sampling (LHS). The optimal design confirmed a 32.0% enhancement of the mixing index as compared to the reference design.

A 3D Printed Jet Mixer for Centrifugal Microfluidic Platforms

Homogeneous mixing of microscopic volume fluids at low Reynolds number is of great significance for a wide range of chemical, biological, and medical applications. An efficient jet mixer with arrays of micronozzles was designed and fabricated using additive manufacturing (three-dimensional (3D) printing) technology for applications in centrifugal microfluidic platforms. The contact surface of miscible liquids was enhanced significantly by impinging plumes from two opposite arrays of micronozzles to improve mixing performance. The mixing efficiency was evaluated and compared with the commonly used Y-shaped micromixer. Effective mixing in the jet mixer was achieved within a very short timescale (3s). This 3D printed jet mixer has great potential to be implemented in applications by being incorporated into multifarious 3D printing devices in microfluidic platforms.

Continuous flow synthesis of ordered porous materials: from zeolites to metal–organic frameworks and mesoporous silica

Herein we review the concepts, challenges and recent developments on the continuous flow synthesis of ordered porous materials.

Numerical and Experimental Study on Mixing Performances of Simple and Vortex Micro T-Mixers

Vortex flow increases the interface area of fluid streams by stretching along with providing continuous stirring action to the fluids in micromixers. In this study, experimental and numerical analyses on a design of micromixer that creates vortex flow were carried out, and the mixing performance was compared with a simple micro T-mixer. In the vortex micro T-mixer, the height of the inlet channels is half of the height of the main mixing channel. The inlet channel connects to the main mixing channel (micromixer) at the one end at an offset position in a fashion that creates vortex flow. In the simple micro T-mixer, the height of the inlet channels is equal to the height of the channel after connection (main mixing channel). Mixing of fluids and flow field have been analyzed for Reynolds numbers in a range from 1–80. The study has been further extended to planar serpentine microchannels, which were combined with a simple and a vortex T-junction, to evaluate and verify their mixing performances. The mixing performance of the vortex T-mixer is higher than the simple T-mixer and significantly increases with the Reynolds number. The design is promising for efficiently increasing mixing simply at the T-junction and can be applied to all micromixers.

Analysis of Passive Mixing in a Serpentine Microchannel with Sinusoidal Side Walls

Sample mixing is difficult in microfluidic devices because of laminar flow. Micromixers are designed to ensure the optimal use of miniaturized devices. The present study aims to design a chaotic-advection-based passive micromixer with enhanced mixing efficiency. A serpentine-shaped microchannel with sinusoidal side walls was designed, and three cases, with amplitude to wavelength (A/λ) ratios of 0.1, 0.15, and 0.2 were investigated. Numerical simulations were conducted using the Navier⁻Stokes equations, to determine the flow field. The flow was then coupled with the convection⁻diffusion equation to obtain the species concentration distribution. The mixing performance of sinusoidal walled channels was compared with that of a simple serpentine channel for Reynolds numbers ranging from 0.1 to 50. Secondary flows were observed at high Reynolds numbers that mixed the fluid streams. These flows were dominant in the proposed sinusoidal walled channels, thereby showing better mixing performance than the simple serpentine channel at similar or less mixing cost. Higher mixing efficiency was obtained by increasing the A/λ ratio.

Modeling size controlled nanoparticle precipitation with the co-solvency method by spinodal decomposition

The co-solvency method is a method for the size controlled preparation of nanoparticles like polymersomes, where a poor co-solvent is mixed into a homogeneous copolymer solution to trigger precipitation of the polymer. The size of the resulting particles is determined by the rate of co-solvent addition. We use the Cahn-Hilliard equation with a Flory-Huggins free energy model to describe the precipitation of a polymer under changing solvent quality by applying a time dependent Flory-Huggins interaction parameter. The analysis focuses on the characteristic size R of polymer aggregates that form during the initial spinodal decomposition stage, and especially on how R depends on the rate s of solvent quality change. Both numerical results and a perturbation analysis predict a power law dependence R∼s(-⅙), which is in agreement with power laws for the final particle sizes that have been reported from experiments and molecular dynamics simulations. Hence, our model results suggest that the nanoparticle size in size-controlled precipitation is essentially determined during the spinodal decomposition stage.

Design and Simulation of a Chaotic Micromixer with Diamond-Like Micropillar Based on Artificial Neural Network

Microfluidic mixing is an essential part of the process of microfluidic chip technology in the analysis, and micromixer has also become the key components of microfluidic chip analysis system. For DNA hybridization, protein folding and enzyme reaction, some biochemical processes need to react quickly to achieve on analysis and research has the vital significance. A simple, rapid and low-cost passive micromixer is presented in this paper. In order to improve the mixing efficiency of the species, the concept of a splitting and recombination (SAR) was used to shorten the mixing time of the species. This study simulated the species mixing in a micromixer with traditional T-type micromixer and diamond-like micropillar in laminar flow state through COMSOL multiphysics 3.5a to computational fluid dynamics (CFD). Linking artificial neural network (ANN) and CFD was used to optimize the diamond-like micropillar. Finally, simulation results proved that the micromixer with SAR diamond-like concept achieves a high-efficiency mixing than T-type micromixer. Numerical results also show that the mixing efficiency of the SAR micromixer with diamond-like micropillar can be up to 99 %, and that efficiency can reach rapidly 90 % in a short channel distance.

Parametric investigation on mixing in a micromixer with two-layer crossing channels

This work presents a parametric investigation on flow and mixing in a chaotic micromixer consisting of two-layer crossing channels proposed by Xia et al. (Lab Chip 5: 748–755, 2005). The flow and mixing performance were numerically analyzed using commercially available software ANSYS CFX-15.0, which solves the Navier–Stokes and mass conservation equations with a diffusion–convection model in a Reynolds number range from 0.2 to 40. A mixing index based on the variance of the mass fraction of the mixture was employed to evaluate the mixing performance of the micromixer. The flow structure in the channel was also investigated to identify the relationship with mixing performance. The mixing performance and pressure-drop were evaluated with two dimensionless geometric parameters, i.e., ratios of the sub-channel width to the main channel width and the channels depth to the main channel width. The results revealed that the mixing index at the exit of the micromixer increases with increase in the channel depth-to-width ratio, but decreases with increase in the sub-channel width to main channel width ratio. And, it was found that the mixing index could be increased up to 0.90 with variations of the geometric parameters at Re = 0.2, and the pressure drop was very sensitive to the geometric parameters.

Mechanism of co-nanoprecipitation of organic actives and block copolymers in a microfluidic environment

Microreactors have been shown to be a powerful tool for the production of nanoparticles (NPs); however, there is still a lack of understanding of the role that the microfluidic environment plays in directing the nanoprecipitation process. Here we investigate the mechanism of nanoprecipitation of block copolymer stabilized organic NPs using a microfluidic-based reactor in combination with computational fluid dynamics (CFD) modelling of the microfluidic implementation. The latter also accounts for the complex interplay between molecular and hydrodynamic phenomena during the nanoprecipitation process, in order to understand the hydrodynamics and its influence on the NP formation process. It is demonstrated that the competitive reactions result in the formation of two types of NPs, i.e., either with or without loading organic actives. The obtained results are interpreted by taking into consideration a new parameter representing the mismatching between the aggregations of the polymers and actives, which plays a decisive role in determining the size and polydispersity of the prepared hybrid NPs. These results expand the current understanding of the co-nanoprecipitation mechanism of active and block copolymer stabilizer, and on the role exerted by the microfluidic environment, giving information that could be translated to the emerging fields of microfluidic formation of NPs and nanomedicine.

A hydrodynamic focusing microchannel based on micro-weir shear lift force

A novel microflow cytometer is proposed in which the particles are focused in the horizontal and vertical directions by means of the Saffman shear lift force generated within a micro-weir microchannel. The proposed device is fabricated on stress-relieved glass substrates and is characterized both numerically and experimentally using fluorescent particles with diameters of 5 μm and 10 μm, respectively. The numerical results show that the micro-weir structures confine the particle stream to the center of the microchannel without the need for a shear flow. Moreover, the experimental results show that the particles emerging from the micro-weir microchannel pass through the detection region in a one-by-one fashion. The focusing effect of the micro-weir microchannel is quantified by computing the normalized variance of the optical detection signal intensity. It is shown that the focusing performance of the micro-weir structure is equal to 99.76% and 99.57% for the 5-μm and 10-μm beads, respectively. Overall, the results presented in this study confirm that the proposed microcytometer enables the reliable sorting and counting of particles with different diameters.

Production of polymeric micelles by microfluidic technology for combined drug delivery: application to osteogenic differentiation of human periodontal ligament mesenchymal stem cells (hPDLSCs)

The current paper reports the production of polymeric micelles (PMs), based on pluronic block-copolymers, as drug carriers, precisely controlling the cellular delivery of drugs with various physico-chemical characteristics. PMs were produced with a microfluidic platform to exploit further control on the size characteristic of the PMs. PMs were designed for the co-delivery of dexamethasone (Dex) and ascorbyl-palmitate (AP) to in vitro cultured human periodontal ligament mesenchymal stem cells (hPDLSCs) for the combined induction of osteogenic differentiation. Mixtures of block-copolymers and drugs in organic, water miscible solvent, were conveniently converted in PMs within microfluidic channel leveraging the fast mixing at the microscale. Our results demonstrated that the drugs can be efficiently co-encapsulated in PMs and that different production parameters can be adjusted in order to modulate the PM characteristics. The comparative analysis of PM produced by microfluidic and conventional procedures confirmed that the use of microfluidics platforms allowed the production of PMs in a robust manner with improved controllability, reproducibility, smaller size and polydispersity. Finally, the analysis of the effect of PMs, containing Dex and AP, on the osteogenic differentiation of hPDLSCs is reported. The data demonstrated the effectiveness and safety of PM treatment on hPDLSC. In conclusion, this report indicates that microfluidic approach represents an innovative and useful method for PM controlled preparation, warrant further evaluation as general methodology for the production of colloidal systems for the simultaneous drug delivery.

Continuous-flow production of polymeric micelles in microreactors: experimental and computational analysis

We report the development of a microfluidic-based process for the production of polymeric micelles (PMs) in continuous-flow microreactors where Pluronic® tri-block copolymer is used as model polymeric biomaterial relating to drug delivery applications. A flow focusing configuration is used enabling a controllable, and fast mixing process to assist the formation of polymeric micelles through nanoprecipitation which is triggered by a solvent exchange process when organic solutions of the polymer mixed with a non-solvent. We experientially investigate the effect of polymer concentration, flow rate ratio and microreactor dimension on the PMs size characteristics. The mixing process within the microfluidic reactors is further analyzed by computational modeling in order to understand the hydrodynamic process and its implication for the polymeric micelles formation process. The results obtained show that besides the effect of the flow rate ratio, the chemical environment in which the aggregation takes place plays an important role in determining the dimensional characteristics of the produced polymeric micelles. It is demonstrated that microfluidic reactors provide a useful platform for the continuous-flow production of polymeric micelles with improved controllability, reproducibility, and homogeneity of the size characteristics.

Micromixing within microfluidic devices

Micromixing is a crucial process within microfluidic systems such as micro total analysis systems (μTAS). A state-of-art review on microstructured mixing devices and their mixing phenomena is given. The review first presents an overview of the characteristics of fluidic behavior at the microscale and their implications in microfluidic mixing processes. According to the two basic principles exploited to induce mixing at the microscale, micromixers are generally classified as being passive or active. Passive mixers solely rely on pumping energy, whereas active mixers rely on an external energy source to achieve mixing. Typical types of passive micromixers are discussed, including T- or Y-shaped, parallel lamination, sequential, focusing enhanced mixers, and droplet micromixers. Examples of active mixers using external forces such as pressure field, electrokinetic, dielectrophoretic, electrowetting, magneto-hydrodynamic, and ultrasound to assist mixing are presented. Finally, the advantages and disadvantages of mixing in a microfluidic environment are discussed.

Investigations of mixing process in microfluidic manifold designed according to biomimetic rule

The paper is focused on the mechanism of mixing process in a manifold which mimics the geometrical properties of vascular systems. The relationship governing the optimum ratio between the diameters of the parent and daughter branches in vascular systems was first discovered by Murray using the principle of minimum work. However, in contrast to biological vascular networks, which are composed of circular pipes, microfluidic manifolds are fabricated using a range of processes (photolithography, wet or dry etching, surface micromachining), which result in channels of rectangular or trapezoidal sections and constant depth throughout the device. The paper focuses on constant-depth rectangular channels often employed in lab-on-a-chip systems and provides comprehensive numerical studies of mixing in such geometry. It also presents simplified analytical estimation on how the coefficient of mixing depends on the number of generations and Reynolds number. The main goal of the paper is to describe the concept of a mixer which provides almost perfect mixing at the outlet regardless of the value of Re and for a minimal number of manifold's generations.