Effects of Baffle Configuration on Mixing in a T-Shaped Micro-Channel

Design and Mixing Analysis of a Passive Micromixer with Circulation Promoters

A novel passive micromixer equipped with circulation promoters is proposed, and its mixing performance is simulated over a broad range of Reynolds numbers (0.1≤Re≤100). To evaluate the effectiveness of the circulation promoters, three different configurations are analyzed in terms of the degree of mixing (DOM) at the outlet and the associated pressure drop. Compared to other typical passive micromixers, the circulation promoter is shown to significantly enhance mixing performance. Among the three configurations of circulation promoters, Case 3 demonstrates the best performance, with a DOM exceeding 0.96 across the entire range of Reynolds numbers. At Re = 1, the DOM of Case 3 is 3.7 times larger than that of a modified Tesla micromixer, while maintaining a comparable pressure drop. The mixing enhancement of the present micromixer is particularly significant in the low and intermediate ranges of Reynolds numbers (Re<40). In the low range of Reynolds numbers (Re≤1), the mixing enhancement is primarily due to circulation promoters directing fluid flow from a concave wall to the opposite convex wall. In the intermediate range of Reynolds numbers (2≤Re<40), the mixing enhancement results from fluid flowing from one concave wall to another concave wall on the opposite side.

Mixing Performance of a Passive Micromixer Based on Split-to-Circulate (STC) Flow Characteristics

We propose a novel passive micromixer leveraging STC (split-to-circulate) flow characteristics and analyze its mixing performance comprehensively. Three distinct designs incorporating submerged circular walls were explored to achieve STC flow characteristics, facilitating flow along a convex surface and flow impingement on a concave surface. Across a broad Reynolds number range (0.1 to 80), the present micromixer substantially enhances mixing, with a degree of mixing (DOM) consistently exceeding 0.84. Particularly, the mixing enhancement is prominent within the low and intermediate range of Reynolds numbers (0.1 Collapse

Key Words

• concave wall
• convex wall
• degree of mixing (DOM)
• flow impingement
• saddle point
• split-to-circulate
• submerged circular wall

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Affiliation(s)

Makhsuda Juraeva
Dong-Jin Kang School of Mechanical Engineering, Yeungnam University, 280 Daehak-ro, Gyoungsan 38541, Republic of Korea;

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Design and Mixing Analysis of a Passive Micromixer Based on Curly Baffles

A novel passive micromixer based on curly baffles is proposed and optimized through the signal-to-noise analysis of various design parameters. The mixing performance of the proposed design was evaluated across a wide Reynolds number range, from 0.1 to 80. Through the analysis, the most influential parameter was identified, and its value was found to be constant regardless of the mixing mechanism. The optimized design, refined using the signal-to-noise analysis, demonstrated a significant enhancement of mixing performance, particularly in the low Reynolds number range (Re< 10). The design set obtained at the diffusion dominance range shows the highest degree of mixing (DOM) in the low Reynolds number range of Re< 10, while the design set optimized for the convection dominance range exhibited the least pressure drop across the entire Reynolds number spectrum (Re< 80). The present design approach proved to be a practical tool for identifying the most influential design parameter and achieving excellent mixing and pressure drop characteristics. The enhancement is mainly due to the curvature of the most influential design parameter.

Lipid nanoparticles for siRNA delivery in cancer treatment

RNA-based therapies, and siRNAs in particular, have attractive therapeutic potential for cancer treatment due to their ability to silence genes that are imperative for tumor progression. To be effective and solve issues related to their poor half-life and poor pharmacokinetic properties, siRNAs require adequate drug delivery systems that protect them from degradation and allow intracellular delivery. Among the various delivery vehicles available, lipid nanoparticles have emerged as the leading choice. These nanoparticles consist of cholesterol, phospholipids, PEG-lipids and most importantly ionizable cationic lipids. These ionizable lipids enable the binding of negatively charged siRNA, resulting in the formation of stable and neutral lipid nanoparticles with exceptionally high encapsulation efficiency. Lipid nanoparticles have demonstrated their effectiveness and versatility in delivering not only siRNAs but also multiple RNA molecules, contributing to their remarkable success. Furthermore, the advancement of efficient manufacturing techniques such as microfluidics, enables the rapid mixing of two miscible solvents without the need for shear forces. This facilitates the reproducible production of lipid nanoparticles and holds enormous potential for scalability. This is shown by the increasing number of preclinical and clinical trials evaluating the potential use of siRNA-LNPs for the treatment of solid and hematological tumors as well as in cancer immunotherapy. In this review, we provide an overview of the progress made on siRNA-LNP development for cancer treatment and outline the current preclinical and clinical landscape in this area. Finally, the translational challenges required to bring siRNA-LNPs further into the clinic are also discussed.

Mixing Performance of a Passive Micromixer Based on Multiple Baffles and Submergence Scheme

A novel passive micromixer based on multiple baffles and a submergence scheme was designed, and its mixing performance was simulated over a wide range of Reynolds numbers ranging from 0.1 to 80. The degree of mixing (DOM) at the outlet and the pressure drop between the inlets and outlet were used to assess the mixing performance of the present micromixer. The mixing performance of the present micromixer showed a significant enhancement over a wide range of Reynolds numbers (0.1 ≤ Re ≤ 80). The DOM was further enhanced by using a specific submergence scheme. At low Reynolds numbers (Re < 5), submergence scheme Sub24 produced the highest DOM, approximately 0.57, which was 1.38 times higher than the case with no submergence. This enhancement was due to the fluid flowing from or toward the submerged space, creating strong upward or downward flow at the cross-section. At high Reynolds numbers (Re > 10), the DOM of Sub1234 became the highest, reaching approximately 0.93 for Re = 20, which was 2.75 times higher than the case with no submergence. This enhancement was caused by a large vortex formed across the whole cross-section, causing vigorous mixing between the two fluids. The large vortex dragged the interface between the two fluids along the vortex perimeter, elongating the interface. The amount of submergence was optimized in terms of DOM, and it was independent of the number of mixing units. The optimum submergence values were 90 μm for Sub24 and Re = 1, 100 μm for Sub234 and Re = 5, and 70 μm for Sub1234 and Re = 20.

Mixing Performance of the Modified Tesla Micromixer with Tip Clearance

A passive micromixer based on the modified Tesla mixing unit was designed by embedding tip clearance above the wedge-shape divider, and its mixing performance was simulated over a wider range of the Reynolds numbers from 0.1 to 80. The mixing performance was evaluated in terms of the degree of mixing (DOM) at the outlet and the required pressure load between inlet and outlet. The height of tip clearance was varied from 40 μm to 80 μm, corresponding to 25% to 33% of the micromixer depth. The numerical results show that the mixing enhancement by the tip clearance is noticeable over a wide range of the Reynolds numbers Re < 50. The height of tip clearance is optimized in terms of the DOM, and the optimum value is roughly h = 60 μm. It corresponds to 33% of the present micromixer depth. The mixing enhancement in the molecular diffusion regime of mixing, Re ≤ 1, is obtained by drag and connection of the interface in the two sub-streams of each Tesla mixing unit. It appears as a wider interface in the tip clearance zone. In the intermediate range of the Reynolds number, 1 < Re ≤ 50, the mixing enhancement is attributed to the interaction of the flow through the tip clearance and the secondary flow in the vortex zone of each Tesla mixing unit. When the Reynolds number is larger than about 50, vortices are formed at various locations and drive the mixing in the modified Tesla micromixer. For the Reynolds number of Re = 80, a pair of vortices is formed around the inlet and outlet of each Tesla mixing unit, and it plays a role as a governing mechanism in the convection-dominant regime of mixing. This vortex pattern is little affected as long as the tip clearance remains smaller than about h = 70 μm. The DOM at the outlet is little enhanced by the presence of tip clearance for the Reynolds numbers Re ≥ 50. The tip clearance contributes to reducing the required pressure load for the same value of the DOM.

Mixing Enhancement of a Passive Micromixer with Submerged Structures

A passive micromixer combined with two different mixing units was designed by submerging planar structures, and its mixing performance was simulated over a wider range of the Reynolds numbers from 0.1 to 80. The two submerged structures are a Norman window and rectangular baffles. The mixing performance was evaluated in terms of the degree of mixing (DOM) at the outlet and the required pressure load between inlet and outlet. The amount of submergence was varied from 30 μm to 70 μm, corresponding to 25% to 58% of the micromixer depth. The enhancement of mixing performance is noticeable over a wide range of the Reynolds numbers. When the Reynolds number is 10, the DOM is improved by 182% from that of no submergence case, and the required pressure load is reduced by 44%. The amount of submergence is shown to be optimized in terms of the DOM, and the optimum value is about 40 μm. This corresponds to a third of the micromixer depth. The effects of the submerged structure are most significant in the mixing regime of convection dominance from Re = 5 to 80. In a circular passage along the Norman window, one of the two Dean vortices burst into the submerged space, promoting mixing in the cross-flow direction. The submerged baffles in the semi-circular mixing units generate a vortex behind the baffles that contributes to the mixing enhancement as well as reducing the required pressure load.

Mixing Performance of a Passive Micro-Mixer with Mixing Units Stacked in Cross Flow Direction

A new passive micro-mixer with mixing units stacked in the cross flow direction was proposed, and its performance was evaluated numerically. The present micro-mixer consisted of eight mixing units. Each mixing unit had four baffles, and they were arranged alternatively in the cross flow and transverse direction. The mixing units were stacked in four different ways: one step, two step, four step, and eight step stacking. A numerical study was carried out for the Reynolds numbers from 0.5 to 50. The corresponding volume flow rate ranged from 6.33 μL/min to 633 μL/min. The mixing performance was analyzed in terms of the degree of mixing (DOM) and relative mixing energy cost (MEC). The numerical results showed a noticeable enhancement of the mixing performance compared with other micromixers. The mixing enhancement was achieved by two flow characteristics: baffle wall impingement by a stream of high concentration and swirl motion within the mixing unit. The baffle wall impingement by a stream of high concentration was observed throughout all Reynolds numbers. The swirl motion inside the mixing unit was observed in the cross flow direction, and became significant as the Reynolds number increased to larger than about five. The eight step stacking showed the best performance for Reynolds numbers larger than about two, while the two step stacking was better for Reynolds numbers less than about two.

Optimal Combination of Mixing Units Using the Design of Experiments Method

A passive micromixer was designed by combining two mixing units: the cross-channel split and recombined (CC-SAR) and a mixing cell with baffles (MC-B). The passive micromixer was comprised of eight mixing slots that corresponded to four combination units; two mixing slots were grouped as one combination unit. The combination of the two mixing units was based on four combination schemes: (A) first mixing unit, (B) first combination unit, (C) first combination module, and (D) second combination module. The statistical significance of the four combination schemes was analyzed using analysis of variance (ANOVA) in terms of the degree of mixing (DOM) and mixing energy cost (MEC). The DOM and MEC were simulated numerically for three Reynolds numbers (Re = 0.5, 2, and 50), representing three mixing regimes. The combination scheme (B), using different mixing units in the first two mixing slots, was significant for Re = 2 and 50. The four combination schemes had little effect on the mixing performance of a passive micromixer operating in the mixing regime of molecular dominance. The combination scheme (B) was generalized to arbitrary mixing slots, and its significance was analyzed for Re = 2 and 50. The general combination scheme meant two different mixing units in two consecutive mixing slots. The numerical simulation results showed that the general combination scheme was statistically significant in the first three combination units for Re = 2, and significant in the first two combination units for Re = 50. The combined micromixer based on the general combination scheme throughout the entire micromixer showed the best mixing performance over a wide range of Reynolds numbers, compared to other micromixers that did not adopt completely the general combination scheme. The most significant enhancement due to the general combination scheme was observed in the transition mixing scheme and was negligible in the molecular dominance scheme. The combination order was less significant after three combination units.

Mixing Performance of a Cross-Channel Split-and-Recombine Micro-Mixer Combined with Mixing Cell

A new cross-channel split-and-recombine (CC-SAR) micro-mixer was proposed, and its performance was demonstrated numerically. A numerical study was carried out over a wide range of volume flow rates from 3.1 μL/min to 826.8 μL/min. The corresponding Reynolds number ranges from 0.3 to 80. The present micro-mixer consists of four mixing units. Each mixing unit is constructed by combining one split-and-recombine (SAR) unit with a mixing cell. The mixing performance was analyzed in terms of the degree of mixing and relative mixing cost. All numerical results show that the present micro-mixer performs better than other micro-mixers based on SARs over a wide range of volume flow rate. The mixing enhancement is realized by a particular motion of vortex flow: the Dean vortex in the circular sub-channel and another vortex inside the mixing cell. The two vortex flows are generated on the different planes perpendicular to each other. They cause the two fluids to change their relative position as the fluids flow into the circular sub-channel of the SAR, eventually promoting violent mixing. High vorticity in the mixing cell elongates the flow interface between two fluids, and promotes mixing in the flow regime of molecular diffusion dominance.

Integrated Immunomagnetic Bead-Based Microfluidic Chip for Exosomes Isolation

Exosomes are essential early biomarkers for health monitoring and cancer diagnosis. A prerequisite for further investigation of exosomes is the isolation, which is technically challenging due to the complexity of body fluids. This paper presents the development of an integrated microfluidic chip for exosomes isolation, which combines the traditional immunomagnetic bead-based protocol and the recently emerging microfluidic approach, resulting in benefits from both the high-purity of the former and the automated continuous superiority of the latter. The chip was designed based on an S-shaped micromixer with embedded baffle. The excellent mixing efficiency of this micromixer compared with Y-shaped and S-shaped micromixers was verified by simulation and experiments. The photolithography technique was employed to fabricate the integrated microfluidic chip, and the manufacturing process was elucidated. We finally established an experimental platform for exosomes isolation with the fabricated microfluidic chip built in. Exosomes isolation experiments were conducted using this platform. The distribution and morphology of the isolated exosomes were observed by transmission electron microscopy (TEM) and scanning electron microscopy (SEM). Quantitative size analyses based on transmission electron micrographs indicated that most of the obtained particles were between 30 and 150 nm. Western blot analyses of the isolated exosomes and the serum were conducted to verify the platform’s capability of isolating a certain subpopulation of exosomes corresponding to specified protein markers (CD63). The complete time for isolation of 150 μL serum samples was approximately 50 min, which was highly competitive with the reported existing protocols. Experimental results proved the capacity of the established integrated microfluidic chip for exosomes isolation with high purity, high integrity, and excellent efficiency. The platform can be further developed to make it possible for practical use in clinical applications as a universal exosomes isolation and characterization tool.

Effects of Channel Wall Twisting on the Mixing in a T-Shaped Micro-Channel

A new design scheme is proposed for twisting the walls of a microchannel, and its performance is demonstrated numerically. The numerical study was carried out for a T-shaped microchannel with twist angles in the range of 0 to 34π. The Reynolds number range was 0.15 to 6. The T-shaped microchannel consists of two inlet branches and an outlet branch. The mixing performance was analyzed in terms of the degree of mixing and relative mixing cost. All numerical results show that the twisting scheme is an effective way to enhance the mixing in a T-shaped microchannel. The mixing enhancement is realized by the swirling of two fluids in the cross section and is more prominent as the Reynolds number decreases. The twist angle was optimized to maximize the degree of mixing (DOM), which increases with the length of the outlet branch. The twist angle was also optimized in terms of the relative mixing cost (MC). The two optimum twisting angles are generally not coincident. The optimum twist angle shows a dependence on the length of the outlet branch but it is not affected much by the Reynolds number.

Wall-mounted flexible plates in a two-dimensional channel trigger early flow instabilities

A high level of mixing by passive means is a desirable feature in microchannels for various applications, and use of flexible obstacles (or plates) is one of the prime choices in that regard. To gain further insight, we carry out two-dimensional numerical simulations for flow past one or two flexible plates anchored to a channel's opposite walls using a fluid-structure interaction framework. For the inlet flow Reynolds number vs the Strouhal number plane, we observe a sudden flow change from a laminar to a time-periodic vortex shedding state when flexible plates are present in the channel. We found the critical Reynolds number to be Re_{cr}≈370 when a single plate is anchored on the channel wall and Re_{cr}≈290 or even lower when two plates are anchored. With an increase in the inlet flow Reynolds number (up to 3200), we found that vortices detach regularly at the plates' tips, which causes the flow to meander in the channel. In a two-plate anchored configuration, primary vortices generated at the first plate are constrained by the second plate and result in an energetic secondary vortex generation in the downstream side. The overall flow features and the energy dissipation in the channel are mainly controlled by the separation gap between the plates. At high-inlet-flow Reynolds numbers (≥1600), the probability density function (F) of the kinetic energy dissipation in a flexible plate configuration shows a stretched exponential shape in the form F(Z)∼1/sqrt[Z]e^{-pZ^{q}}, where Z is the normalized kinetic energy dissipation and the constants p=0.89 and q=0.86. The observed increase in energy dissipation comes at the cost of an increase in pressure loss in the channel, and we found that the loss is inversely related to the plates' separation gap. From our simulations, we found that if high mixing levels are desired, then two flexible plates anchored to the channel walls is a better choice than a channel flow without obstacles or flow past a single plate. The two-plate configuration with zero separation gap between the plates is best suited to achieve a high mixing level.

A 3D-printed flow distributor with uniform flow rate control for multi-stacked microfluidic systems

In the scale-up of chemical production in a microfluidic system, it is challenging to prevent flow maldistribution from a single inlet into stacked multiple microchannel exits. In the present study, a compact flow distributor equipped with a fluidic damper is developed by computational fluid dynamics (CFD) along with experimental validation. A microfluidic flow distributor, which is equipped with an optimized fluidic damper and consists of 25 exit channels, is fabricated as an integrated body using a digital light processing (DLP) type 3D printer. The 3D printed flow distributor with a CFD-optimized fluidic damper is found to achieve a low maldistribution factor (MF) of 2.2% for the average flow rate over 25 exit channels while inducing only a minor increment (<6%) in the pressure drop. A generalized manual is proposed for the design of optimal flow distributors with different scale-up dimensions. Using the manual, an optimal flow distributor with 625 stacked microchannels with a MF of only 1.2% is successfully designed. It is expected that the design manual and the rapid printing platform will allow the efficient development of multi-channel stacked micro-devices such as those in drug delivery and energy conversion systems where equidistribution of fluid flow is highly demanded.