Microchannel reactor

Abstract

The application provides a kind of microchannel reactor, it is related to microreactor technical field.The microchannel reactor includes a plurality of sequentially connected reaction monomers, each reaction monomer includes a reaction substrate, at least one temperature control unit and a vibration unit.The reaction substrate forms a containing cavity filled with acoustic medium inside, and at least one side of the reaction substrate forms a channel.The at least one temperature control unit covers the channel respectively to form a microchannel for mixture flow reaction, and the temperature control unit is configured to exchange heat with the mixture in the microchannel to adjust the reaction temperature.The vibration unit is configured to extend into the acoustic medium and release acoustic waves to reduce the accumulation of solids in the mixture in the microchannel.

Description

Technical Field

[0001] This invention relates to the field of microreactor technology, and more specifically, to a microchannel reactor. Background Technology

[0002] Dilution refrigerators are currently the core equipment for achieving extremely low temperature environments (millikelvin level) and are widely used in cutting-edge research fields such as quantum computing and condensed matter physics. In dilution refrigerators, the thermal conductivity of the heat exchange material directly affects the cooling efficiency and the lowest achievable temperature. Silver has excellent thermal conductivity and low specific heat capacity at low temperatures, making it the preferred material for heat exchangers. Nano-silver has an extremely high specific surface area, which can significantly increase the contact area with liquid helium, effectively reducing interfacial thermal resistance (Kapicha resistance) and improving the heat exchange efficiency of the refrigerator. Currently, the preparation of nano-silver powder usually uses reaction vessels or tubular reactors, but due to the inability to precisely control or adjust the production process, the final product quality cannot be consistently maintained at a high level.

[0003] A microchannel reactor is a continuous flow reaction device based on microfabrication technology, with internal feature dimensions typically ranging from micrometers to millimeters. Due to its tiny channel size, microreactors possess extremely high specific surface areas, significantly improving heat and mass transfer efficiency during the reaction process. Compared to traditional batch reactors, microchannel reactors enable rapid and uniform mixing of reactants and precise temperature control, and can also achieve continuous and automated production processes through modular assembly.

[0004] In related technologies, the design concept of microchannel reactors is "all-liquid phase" or "gas-liquid" reaction, which usually does not allow the presence of solids in reactants or products. This is because solid particles are very easy to deposit and grow on the walls of microchannels, eventually leading to channel blockage, increased pressure, and equipment failure in a short period of time. Therefore, how to improve microchannel reactors so that they can allow solids to exist as reactants or products within the expected maintenance cycle, thereby providing higher quality silver nanopowder and promoting the development and progress of dilution refrigeration technology, has become an urgent technical problem to be solved. Summary of the Invention

[0005] In view of this, the present invention provides a microchannel reactor that uses a vibration unit to generate sound waves, which are then uniformly diffused into the microchannels on the reaction substrate through an acoustic medium to continuously disperse solid particles and prevent them from accumulating in the microchannels.

[0006] To achieve the above objectives, the present invention provides a microchannel reactor comprising a plurality of sequentially connected reaction monomers, each of the reaction monomers comprising: a reaction substrate having an internally formed containment cavity filled with an acoustic medium, at least one side of the reaction substrate having a channel formed thereon; at least one temperature control unit, which respectively covers the channel to form a microchannel for the flow and reaction of the mixture, the temperature control unit being configured to contact the mixture within the microchannel for heat exchange to regulate the reaction temperature; and a vibration unit configured to extend into the acoustic medium and release sound waves to reduce solid accumulation in the mixture within the microchannel.

[0007] According to an embodiment of the present invention, the vibration unit includes: a sound wave generator; a support base disposed outside the side of the reaction substrate perpendicular to the side where the channel is formed, and supporting the sound wave transmitter; and a plurality of extension columns extending from the support base through the side to the receiving cavity and partially immersed in the acoustic medium to transmit sound waves from the sound wave generator to the acoustic medium.

[0008] According to an embodiment of the present invention, the receiving cavity includes: a plurality of main cavities adapted for insertion of the extension post; and a plurality of diffusion cavities extending along a direction perpendicular to the extension post and communicating with each of the main cavities.

[0009] According to an embodiment of the present invention, the main cavity has an open end for inserting the extension post and a closed end opposite to the open end, wherein a rubber pad is provided at the closed end for supporting the lower end of the extension post.

[0010] According to an embodiment of the present invention, the two opposite sides of the reaction substrate are each formed with channels, and the two ends of each channel are connected through an input hole and an output hole penetrating the reaction substrate in the thickness direction, so that the mixture from the input hole flows synchronously through the two channels and flows out through the output hole; the input hole is connected to the output hole of the reaction substrate located on the upstream side, and the output hole is connected to the input hole of the reaction substrate located on the downstream side, so that multiple reaction substrates are connected in series sequentially.

[0011] According to an embodiment of the present invention, the two temperature control units respectively cover the two channels. One temperature control unit is provided with a feed hole, and the other temperature control unit is provided with a discharge hole. The feed hole is adapted to connect the discharge hole of the temperature control unit located on the upstream side and the input hole. The discharge hole is adapted to connect the output hole and the feed hole of the temperature control unit located on the downstream side.

[0012] According to an embodiment of the present invention, each of the temperature control units includes: a support plate, wherein a receiving groove is formed on the surface of the support plate facing the reaction substrate; and a heat-conducting plate, sandwiched between the support plate and the reaction substrate, to form a receiving space suitable for filling a heat transfer medium in combination with the receiving groove and to form the microchannel in combination with the channel, wherein the feed hole penetrates the support plate and the heat-conducting plate of one temperature control unit in the thickness direction, and the discharge hole penetrates the support plate and the heat-conducting plate of another temperature control unit in the thickness direction.

[0013] According to an embodiment of the present invention, a plurality of support protrusions extending toward the reaction substrate and distributed at row and / or column intervals are formed in the aforementioned receiving groove.

[0014] According to an embodiment of the present invention, the channel is configured to be formed by a plurality of serpentine channels connected in sequence to extend the flow reaction path of the mixture.

[0015] According to an embodiment of the present invention, the device further includes: a base frame adapted to support a plurality of the aforementioned reactive monomers; two mounting plates disposed on the base frame, wherein the plurality of the aforementioned reactive monomers are sandwiched between the two mounting plates; and a fastening assembly adapted to clamp the two mounting plates along the thickness direction of the aforementioned reactive substrate to fix the relative positions between the plurality of the aforementioned reactive monomers.

[0016] According to an embodiment of the present invention, it further includes: an input pipe disposed on the base frame and configured to communicate with the temperature control unit of each of the above-mentioned reaction monomers, suitable for allowing the heat transfer medium of the external temperature control device to enter the temperature control unit; and an output pipe disposed on the base frame and configured to communicate with the temperature control unit of each of the above-mentioned reaction monomers, suitable for allowing the heat transfer medium of the temperature control unit to flow back to the external temperature control device.

[0017] The microchannel reactor provided by this invention features channels on a reaction substrate and a temperature control unit that together form a microchannel. The temperature control unit, acting as a sidewall, directly contacts the mixture, ensuring the temperature is consistently maintained within the optimal reaction range. The reaction substrate contains a cavity filled with an acoustic medium. A vibration unit converts electrical signals into high-frequency mechanical vibrations and transmits them to the acoustic medium. Sound waves are uniformly transmitted to the microchannel via the acoustic medium, effectively dispersing solid particles and preventing their accumulation and scaling on the inner wall, thus providing a cleaning effect. The acoustic medium, acting as an intermediate carrier, ensures the uniformity of sound wave diffusion, making the received sound wave parameters within the microchannel more consistent. Furthermore, the vibration unit does not directly contact the reaction substrate or the temperature control unit, avoiding localized stress concentration caused by vibration, preventing component damage due to vibration fatigue, and reducing sound wave transmission losses at the solid interface, significantly improving energy utilization efficiency. Attached Figure Description

[0018] Figure 1 This is a three-dimensional structural diagram of the microchannel reactor provided in the embodiments of the present invention;

[0019] Figure 2 This is an exploded view of the reactants in the microchannel reactor provided in the embodiments of the present invention;

[0020] Figure 3 This is a three-dimensional structural diagram of the vibration unit of the microchannel reactor provided in the embodiment of the present invention;

[0021] Figure 4 This is a cross-sectional view of the reaction substrate of the microchannel reactor provided in the embodiment of the present invention;

[0022] Figure 5 This is a cross-sectional view of the microchannel reactor provided in an embodiment of the present invention;

[0023] Figure 6 This is a simulation diagram of the flow path of the mixture in the microchannel reactor provided in the embodiments of the present invention;

[0024] Figure 7 This is a plan view of the microchannel reactor provided in an embodiment of the present invention.

[0025] In the accompanying drawings, the meanings of the reference numerals are as follows:

[0026] 1. Reaction substrate;

[0027] 11. Channel;

[0028] 12. Receiving cavity;

[0029] 121. Main cavity;

[0030] 122. Diffuser cavity;

[0031] 123. Rubber pad;

[0032] 13. Input hole;

[0033] 14. Output port;

[0034] 2. Temperature control unit;

[0035] 21. Feed port;

[0036] 22. Discharge hole;

[0037] 23. Support plate;

[0038] 24. Heat-conducting plate;

[0039] 25. Support protrusion;

[0040] 3. Vibration unit;

[0041] 31. Sound wave generator;

[0042] 32. Support base;

[0043] 33. Extended column;

[0044] 4. Base frame;

[0045] 5. Mounting plate;

[0046] 51. Feed port;

[0047] 52. Discharge port;

[0048] 6. Fastening components;

[0049] 7. Input pipe;

[0050] 8. Output pipe. Detailed Implementation

[0051] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. However, it should be understood that these descriptions are exemplary only and are not intended to limit the scope of the invention. In the following detailed description, numerous specific details are set forth to provide a thorough understanding of the embodiments of the invention for ease of explanation. However, it will be apparent that one or more embodiments may be practiced without these specific details. Furthermore, descriptions of well-known structures and techniques are omitted in the following description to avoid unnecessarily obscuring the concept of the invention.

[0052] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the invention. The terms “comprising,” “including,” etc., as used herein indicate the presence of the stated features, steps, operations, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, or components.

[0053] All terms used herein (including technical and scientific terms) have the meanings commonly understood by those skilled in the art, unless otherwise defined. It should be noted that the terms used herein are to be interpreted in a manner consistent with the context of this specification, and not in an idealized or overly rigid way.

[0054] When using expressions such as "at least one of A, B and C", they should generally be interpreted in accordance with the meaning that is commonly understood by those skilled in the art (e.g., "a system having at least one of A, B and C" should include, but is not limited to, a system having A alone, a system having B alone, a system having C alone, a system having A and B, a system having A and C, a system having B and C, and / or a system having A, B and C, etc.).

[0055] Figure 1 This is a three-dimensional structural diagram of the microchannel reactor provided in an embodiment of the present invention. Figure 2 This is an exploded view of the reactants in the microchannel reactor provided in the embodiments of the present invention.

[0056] Embodiments of the present invention provide a microchannel reactor, such as Figure 1 and Figure 2 As shown, the reaction includes multiple sequentially connected reaction monomers. Each reaction monomer includes a reaction substrate 1, at least one temperature control unit 2, and a vibration unit 3. A cavity 12 filled with an acoustic medium is formed inside the reaction substrate 1, and a channel 11 is formed on at least one side of the reaction substrate 1. At least one temperature control unit 2 covers the channel 11 to form a microchannel for the flow and reaction of the mixture. The temperature control unit 2 is configured to contact the mixture within the microchannel for heat exchange to regulate the reaction temperature. The vibration unit 3 is configured to extend into the acoustic medium and release sound waves to reduce solid accumulation in the mixture within the microchannel.

[0057] In this embodiment, the reaction substrate 1 is the basic support component for the reaction monomer. The channel 11 on the reaction substrate 1 and the temperature control unit 2 together form a microchannel. Since the temperature control unit 2 serves as part of the sidewall of the microchannel, it facilitates contact heat exchange with the mixture in the microchannel, so as to keep the temperature of the mixture always within the temperature range with high reaction efficiency.

[0058] An acoustic medium is injected into the internal cavity of the reaction substrate 1 to form a receiving cavity 12. The vibration unit 3 converts electrical signals into high-frequency mechanical vibrations. One end of the vibration unit extends into the acoustic medium and releases sound waves to the surrounding area. These sound waves are transmitted through the acoustic medium to the microchannel, dispersing solid particles in the mixture and preventing them from accumulating on the inner wall of the microchannel. This also cleans the inner wall of the microchannel, preventing fouling. The mixture flows out after completing a full reaction within the continuous microchannel. Furthermore, the use of the acoustic medium as an intermediate carrier ensures more uniform diffusion and transmission of sound waves, allowing the entire microchannel to receive sound waves with approximately the same parameters (especially frequency). The vibration unit 3 does not directly contact the reaction substrate 1 or the temperature control unit 2, avoiding localized stress and preventing damage to the reaction substrate 1 or temperature control unit 2 due to vibration fatigue. It also reduces sound wave transmission loss at the solid contact surface, improving energy utilization.

[0059] Such microchannel reactors have a certain anti-clogging function, and at least within a proven and feasible maintenance cycle, there will be no serious clogging or even scrapping problems. The application scenarios are further expanded, for example, they can be used to produce nano silver powder and improve the refrigeration performance of dilution refrigerators.

[0060] In some alternative embodiments, the reaction substrate 1 is made of polytetrafluoroethylene, which has high corrosion resistance and can adapt to a variety of mixtures.

[0061] In some preferred embodiments, the reaction substrate 1 is made of reinforced polytetrafluoroethylene (PTFE) to improve creep resistance. The filler material includes, but is not limited to, carbon fiber or metal powder.

[0062] In some alternative embodiments, the vibration unit 3 is configured to emit ultrasonic waves with a frequency higher than 20,000 Hz.

[0063] In some optional embodiments, the temperature control unit 2 is made of a metal material that is both thermally conductive and corrosion-resistant, such as Monel alloy, Hastelloy, titanium alloy, etc., which can be selected according to the composition of the mixture to avoid the mixture reacting with the temperature control unit 2.

[0064] In some preferred embodiments, channels 11 are formed on both opposite sides of the reaction substrate 1. Accordingly, two temperature control units 2 are provided, respectively attached to these two sides, to form microchannels on both sides of the reaction substrate 1.

[0065] Figure 3 This is a three-dimensional structural diagram of the vibration unit of the microchannel reactor provided in the embodiment of the present invention.

[0066] In one exemplary embodiment, such as Figures 1 to 3 As shown, the vibration unit 3 includes a sound wave generator 31, a support base 32, and a plurality of extension columns 33. As described above, the sound wave generator 31 is capable of converting electrical signals into mechanical vibrations. The support base 32 is disposed on the exterior of the side perpendicular to the side where the channel 11 is formed on the reaction substrate 1, and forms the sound wave generator 31. The plurality of extension columns 33 extend from the support base 32 through the side to the receiving cavity 12 and are partially immersed in the acoustic medium to transmit the sound waves from the sound wave generator 31 to the acoustic medium.

[0067] In this embodiment, the support 32 is installed between the sound wave generator 31 and the plurality of extension posts 33, for distributing the sound waves from the sound wave generator 31 to each extension post 33. Figure 1 and Figure 2 As shown, the side or both sides of the reaction substrate 1 where the channel 11 is formed are the left and / or right sides. With this as a reference, the support base 32 is located above the upper side of the reaction substrate 1, with a predetermined distance between them. An acoustic generator 31 is mounted on the upper surface of the support base 32, and multiple extension pillars 33 extend from the lower surface of the support base 32 into the receiving cavity 12, such that the extension pillars 33 are partially immersed in the acoustic medium. The acoustic waves emitted by the acoustic generator 31 pass sequentially through the support base 32, the extension pillars 33, and the acoustic medium before acting on the reaction substrate 1, thereby clearing the solid particles that gradually accumulate within the microchannels.

[0068] Multiple extension columns 33 can transmit the sound waves from the sound wave generator 31 more evenly into the acoustic medium, making the sound waves diffuse more evenly in the receiving cavity 12, thereby ensuring that the entire microchannel area can receive sound waves with basically the same parameters, ensuring that solid particles at various locations in the microchannel can be effectively dispersed, and improving the consistency of the anti-clogging effect.

[0069] In some alternative embodiments, every two reactants share one acoustic generator 31 and one support 32. Multiple extension columns 33 are arranged in an array, such as... Figure 3 As shown, four columns are arranged at intervals along the length of the reaction substrate 1, and two rows are arranged along the thickness of the reaction substrate 1. Multiple extension columns 33 in each row extend into the receiving cavity 12 of the same reaction substrate 1.

[0070] In some alternative embodiments, the acoustic generator 31 can be suspended above the reaction substrate 1 by a mounting assembly. For example, the reaction substrate 1 is placed on a test bench, and a mounting assembly with a certain height is provided on the test bench. The acoustic generator 31 is connected to the mounting assembly and thus suspended above the reaction substrate 1. By setting the height of the mounting assembly or the length of the extension column 33, the extension column 33 can be made to have no direct contact with the reaction substrate 1 or the temperature control unit 2.

[0071] In some other embodiments, vibration-damping material can be placed at the bottom of the receiving cavity 12, and the end of the extension column 33 away from the sound wave generator 31 can be placed directly on the vibration-damping material. This simplifies the installation structure while avoiding direct contact. It should be understood that the arrangement of the vibration unit 3 is not limited to this, and the arrangement should be as simple as possible to avoid direct contact.

[0072] In some alternative embodiments, the acoustic generator 31 may be a piezoelectric ceramic transducer, a magnetostrictive transducer, or other types of ultrasonic transducers, the specific form of which may be selected according to the required frequency and power.

[0073] In some alternative embodiments, the support base 32 and the extension column 33 are integrally formed, or assembled by welding, bolting or other methods.

[0074] In some alternative embodiments, the extension column 33 may be made of a material whose acoustic impedance matches that of the acoustic medium, such as titanium alloy, aluminum alloy or specific polymer materials, to reduce reflection loss of sound waves during transmission at the solid-liquid interface and improve transmittance.

[0075] In some alternative embodiments, the acoustic medium includes, but is not limited to, heat-conducting oil, acoustic coupling agent, or silicone oil.

[0076] Figure 4 This is a cross-sectional view of the reaction substrate of the microchannel reactor provided in an embodiment of the present invention.

[0077] In one exemplary embodiment, such as Figures 2 to 4As shown, the receiving cavity 12 includes multiple main cavities 121 and multiple diffusion cavities 122. The main cavities 121 are adapted for insertion of the extension post 33, and the multiple diffusion cavities 122 extend along a direction perpendicular to the extension post 33 and are respectively connected to each main cavity 121.

[0078] In this method, the extension direction of the extension column 33 is the height direction of the reaction substrate 1. Multiple main cavities 121 and multiple diffusion cavities 122 form a mesh-like interconnected structure in the length and height directions of the reaction substrate 1, so that the sound wave can be rapidly diffused from the main cavity 121 to the entire receiving cavity 12. This solves the problem of uneven sound wave transmission in a single cavity, ensures that each area of ​​the microchannel can receive sound waves with basically the same parameters, further improves the uniformity of the anti-blocking effect, and avoids solid accumulation in local areas due to insufficient sound wave intensity.

[0079] Furthermore, the main cavity 121 and the diffusion cavity 122 can be directly formed on the reaction substrate 1, and the cleaning and maintenance of the mesh-like interconnected structure is relatively easy. Specifically, a first channel for the main cavity 121 and a second channel for the diffusion cavity 122 can be machined on the reaction substrate 1. The lower end of the first channel is machined with internal threads and fitted with a plugging screw, while the upper end can remain untreated for the extension post 33 to extend into. Both ends of the diffusion cavity 122 are machined with internal threads and fitted with plugging screws, thus effectively sealing and accommodating the acoustic medium while maintaining low structural complexity.

[0080] In some alternative embodiments, the cross-sectional area of ​​the main cavity 121 is larger than that of the diffuser cavity 122, which facilitates the insertion and positioning of the extension post 33. The narrower diffuser cavity 122 can reduce the amount of acoustic medium filling, thereby reducing costs, and utilizes the conduction characteristics of sound waves in a narrow channel to increase sound pressure intensity.

[0081] Figure 5 This is a cross-sectional structural diagram of the microchannel reactor provided in an embodiment of the present invention.

[0082] According to embodiments of the present invention, such as Figure 2 , Figure 3 and Figure 5 As shown, the main cavity 121 has an open end for inserting the extension post 33 and a closed end opposite to the open end. A rubber pad 123 is provided at the closed end to support the lower end of the extension post 33.

[0083] In this implementation, the open end faces the support base 32, while the closed end provides stable support for the extension column 33 and the entire vibration unit 3, even when the acoustic medium leaks. Specifically, a rubber pad 123 is provided at the closed end to support the lower end of the extension column 33, preventing the extension column 33 from being suspended and causing swaying during vibration. At the same time, the rubber pad 123 also has a buffering and vibration isolation function, preventing the extension column 33 from directly contacting the closed end (such as the aforementioned sealing screw), which would affect the sound wave transmission effect.

[0084] In some optional embodiments, the rubber pad 123 is a sheet-like structure adapted to the closed end of the main cavity 121, and is made of a rubber material that is elastic, wear-resistant, resistant to acoustic medium corrosion and does not affect sound wave transmission, such as fluororubber, silicone rubber, etc.

[0085] In some optional embodiments, the upper surface of the rubber pad 123 is formed with a groove to accommodate the lower end of the extension column 33, which serves as a lateral auxiliary positioning to prevent the extension column 33, along with the support base 32 and the acoustic generator 31, from slipping.

[0086] In some optional embodiments, an annular sealing ring is provided at the opening end of the main cavity 121, and an extension post 33 passes through the annular sealing ring. The diameter of the extension post 33 is less than or equal to the inner diameter of the annular sealing ring, so as to prevent the acoustic medium from leaking from the opening end or impurities from entering the receiving cavity 12 from the opening end and contaminating the acoustic medium.

[0087] Figure 6 This is a simulation diagram of the flow path of the mixture in the microchannel reactor provided in the embodiments of the present invention.

[0088] In one exemplary embodiment, such as Figure 2 and Figure 6 As shown, channels 11 are formed on two opposite sides of the reaction substrate 1, and the two ends of each channel 11 are connected through an input hole 13 and an output hole 14 that penetrate the reaction substrate 1 in the thickness direction, respectively, so that the mixture from the input hole 13 flows through the two channels 11 simultaneously and flows out through the output hole 14. The input hole 13 is connected to the output hole 14 of the reaction substrate 1 located on the upstream side, and the output hole 14 is connected to the input hole 13 of the reaction substrate 1 located on the downstream side, so that multiple reaction substrates 1 are connected in series.

[0089] In this embodiment, channels 11 are formed on two opposite sides of the reaction substrate 1. The two ends of each channel 11 are connected through an inlet hole 13 and an outlet hole 14 penetrating the reaction substrate 1 in the thickness direction, respectively. After the mixture enters the inlet hole 13, it flows synchronously through the microchannels corresponding to the two channels 11, and then converges to the outlet hole 14 and flows out. In the entire microchannel reactor, after the mixture flows out of the outlet hole 14 of the upstream reaction substrate 1, it flows to the inlet hole 13 of the downstream reaction substrate 1, and so on, so that the mixture flows in series through the entire microchannel reactor, eliminating the need for complex external connection pipelines, simplifying the assembly process, and reducing the risk of leakage that may occur at the external pipeline connection points.

[0090] The reaction substrate 1 has channels 11 on both opposite sides, which, together with the input port 13 and the output port 14, enable simultaneous flow splitting of the mixture. This effectively increases the reaction contact area and the number of reaction channels, improving reaction efficiency while reducing the flow pressure of individual microchannels and preventing incomplete reactions caused by excessively high local flow rates. Multiple reaction substrates 1 are connected in series via an "upstream output port 14 - downstream input port 13" configuration, achieving continuous extension of the reaction channels. This allows for continuous reaction of the mixture and avoids the potential for excessive pressure and excessively long reaction paths that might occur when the mixture flows sequentially through the microchannels corresponding to two channels 11 on a single reaction substrate 1. Each reaction substrate 1 is equipped with two temperature control units 2, making the reaction temperature more stable and ensuring reaction efficiency.

[0091] According to embodiments of the present invention, such as Figure 2 As shown, two temperature control units 2 respectively cover two channels 11. One temperature control unit 2 is provided with a feed hole 21, and the other temperature control unit 2 is provided with a discharge hole 22. The feed hole 21 is suitable for connecting the discharge hole and the input hole 13 of the temperature control unit 2 located on the upstream side, and the discharge hole 22 is suitable for connecting the output hole 14 and the feed hole 21 of the temperature control unit located on the downstream side.

[0092] In this embodiment, the two temperature control units 2 correspond to the two channels 11 of the reaction substrate 1 respectively, that is, each temperature control unit 2 is attached to one side of the reaction substrate 1 to form a double-layer microchannel reaction structure.

[0093] When multiple reactants are stacked, the feed port 21 receives the mixture flowing out of the reactant (or temperature control unit 2) located on the upstream side and guides it to the input port 13 of the current reaction substrate 1. The mixture is then diverted into the channels 11 on both sides for reaction.

[0094] The mixture is gathered through channel 11 to output port 14, then enters discharge port 22, and flows through discharge port 22 to feed port 21 of temperature control unit 2 in downstream reaction monomer, and then enters input port 13 of reaction substrate 1 in downstream reaction monomer, thereby realizing series connection between multiple reaction monomers.

[0095] By directly machining the feed hole 21 and the discharge hole 22 on the temperature control unit 2, and utilizing the thickness space of the temperature control unit itself to construct a fluid transfer channel, the adjacent reactants do not need to be connected by additional complex external bends or hoses, simplifying the assembly structure of the microchannel reactor, reducing the risk of external pipeline leakage, and making the equipment more compact.

[0096] When multiple reactants are stacked, the outlet holes 22 and inlet holes 21 of two adjacent reactants are directly connected in the thickness direction. The "hole-to-hole" stacking design not only facilitates assembly and positioning, but also ensures the smoothness of fluid transition between stages, reduces dead zones where fluid stagnates at the connection, and improves the continuity and uniformity of the reaction.

[0097] In some optional embodiments, an annular sealing groove is provided around the ports of the feed hole 21 and the discharge hole 22 on the mating surfaces of two adjacent temperature control units 2 (or the temperature control unit 2 and the reaction substrate 1), and a sealing ring (such as an O-ring) is installed in the sealing groove. When the reactants are compressed, the sealing ring is deformed by the pressure, sealing the gaps around the channels and ensuring that the mixture does not leak or flow during the flow process.

[0098] In some optional embodiments, the feed port 21 and the discharge port 22 are respectively disposed on both sides of the reaction substrate 1 along its length.

[0099] In some alternative embodiments, among the plurality of reactive monomers, at least the first reactive monomer has two feed ports 21 and two input ports 13 for different feedstocks to enter.

[0100] In some preferred embodiments, each reactant monomer has two feed ports 21 and two input ports 13, and correspondingly, two output ports 14 and two discharge ports 22.

[0101] In one exemplary embodiment, such as Figure 2 As shown, each temperature control unit 2 includes a support plate 23 and a heat-conducting plate 24. A receiving groove is formed on the surface of the support plate 23 facing the reaction substrate 1. The heat-conducting plate 24 is sandwiched between the support plate 23 and the reaction substrate 1 to form a receiving space suitable for filling a heat transfer medium in combination with the receiving groove, and to form a microchannel in combination with the channel 11. The feed hole 21 penetrates the support plate 23 and the heat-conducting plate 24 of one temperature control unit 2 in the thickness direction, and the discharge hole 22 penetrates the support plate 23 and the heat-conducting plate 24 of another temperature control unit 2 in the thickness direction.

[0102] In this embodiment, each temperature control unit 2 adopts a split composite structure. The support plate 23 serves as the main supporting component of the temperature control unit 2, and a receiving groove is formed on its surface facing the reaction substrate 1. The heat-conducting plate 24 is sandwiched between the support plate 23 and the reaction substrate 1. In the assembled state, the heat-conducting plate 24 covers the receiving groove, and the two combine to form a closed receiving space suitable for filling the heat transfer medium. At the same time, the heat-conducting plate 24 covers the channel 11 on the reaction substrate 1, and combines with the channel 11 to form a microchannel for the flow of the mixture.

[0103] like Figure 2 As shown, channels 11 are formed on both sides of the reaction substrate 1, and two temperature control units 2 are respectively arranged on both sides of the reaction substrate 1 facing each other. To facilitate positioning and installation, the outer contours of the reaction substrate 1, the heat-conducting plate 24 and the support plate 23 are exactly the same, which facilitates the processing of the feed hole 21, the input hole 13, the output hole 14 and the discharge hole 22.

[0104] The heat-conducting plate 24 serves as a common wall between the microchannel and the containment space. It ensures rapid heat exchange between the heat transfer medium and the mixture, while also physically isolating the two fluids to prevent leakage of the heat transfer medium and contamination of the reactants, thus guaranteeing the safety and purity of the reaction process.

[0105] The temperature control unit 2 is divided into a support plate 23 and a heat-conducting plate 24 for ease of manufacturing. The support plate 23 can be made of high-strength but relatively low-cost or easily machinable materials. It is machined into a receiving groove through milling, casting, or other methods, primarily for bearing pressure and constructing heat transfer medium channels. Since the type of heat transfer medium is relatively fixed, the support plate 23 is highly versatile; as long as its strength meets the requirements and it is resistant to heat transfer medium corrosion, it generally does not need to be replaced. The heat-conducting plate 24, however, needs to come into contact with mixtures of different components, requiring consideration of corrosion effects and replacement with different materials. Therefore, it can be made of thin-walled, high-thermal-conductivity materials, requiring only stamping or etching for molding, resulting in low production costs and easy replacement.

[0106] In some alternative embodiments, the support plate 23 may be made of reinforced polytetrafluoroethylene (PTFE) that can withstand most of the temperatures required for the reaction, and the filler material may include, but is not limited to, graphite, carbon fiber, or bronze.

[0107] In some alternative embodiments, the heat-conducting plate 24 may be made of materials including but not limited to copper, aluminum alloy or graphene composite material, as long as it has good thermal conductivity and does not have a significant interaction with the mixture to be in contact with.

[0108] In some alternative embodiments, the heat transfer medium includes, but is not limited to, heat transfer oil.

[0109] According to embodiments of the present invention, such as Figure 2As shown, a plurality of support protrusions 25 are formed in the receiving groove, extending toward the reaction substrate 1 and distributed along row and / or column intervals.

[0110] In this implementation, the support protrusion 25 extends to contact or abut against the heat-conducting plate 24. When the temperature control unit 2 is operating, the containment space is always filled with heat transfer medium, and the flow rate is typically slow. To ensure effective temperature control, the containment space needs to be as large as possible to accommodate more heat transfer medium. When both the bottom area and depth of the containment tank are large, it is difficult to maintain the strength of the support plate 23. By setting multiple arrayed support protrusions 25, the strength of the support plate 23 is effectively improved by occupying less space, and it also provides support for the heat-conducting plate 24.

[0111] Furthermore, the presence of the support protrusions 25 alters the flow field of the heat transfer medium within the containment space. As the heat transfer medium flows through the spaced support protrusions 25, the flow path becomes tortuous, generating turbulence and boundary layer separation. This turbulence effect disrupts the stability of the laminar sublayer, promotes fluid mixing, and thus increases the convective heat transfer coefficient between the heat transfer medium and the heat-conducting plate 24, further enhancing the temperature control unit 2's ability to regulate the temperature of the mixture within the microchannel.

[0112] In one exemplary embodiment, such as Figure 2 As shown, the channel 11 is constructed by connecting multiple serpentine channels in sequence to extend the flow reaction path of the mixture.

[0113] In this implementation, by designing the channels 11 as a serpentine series structure, the flow path of the mixture is increased within the limited space of the reaction substrate 1, thereby increasing the residence time of the mixture in the microchannel and ensuring that the reactants have sufficient time for mass transfer and reaction, thus improving the reaction conversion rate. Simultaneously, it facilitates the reduction of the volume of the reaction substrate 1 and the reactants, enabling the miniaturization and integration of the microchannel reactor and reducing the space required.

[0114] In addition, the serpentine channel design causes secondary flow when the mixture flows through the bends, which can disrupt the boundary layer and cause radial movement of fluid particles, thereby enhancing radial mixing between reactants.

[0115] In some preferred embodiments, the cross-section of the serpentine groove is semi-circular or arc-shaped to match the sound wave transmission of the vibration unit 3, reduce the scattering loss of sound waves at sharp corners, avoid the formation of flow dead zones in the mixture at the corners, and facilitate cleaning and maintenance.

[0116] In some other embodiments, the cross-section of the serpentine groove can also be rectangular, trapezoidal, or triangular.

[0117] Figure 7 This is a plan view of the microchannel reactor provided in an embodiment of the present invention.

[0118] In one exemplary embodiment, such as Figure 1 , Figure 2 and Figure 7 As shown, the microchannel reactor also includes a base frame 4, two mounting plates 5, and a fastening assembly 6. The base frame 4 is suitable for supporting multiple reactants. The two mounting plates 5 are disposed on the base frame 4, and the multiple reactants are sandwiched between the two mounting plates 5. One mounting plate 5 has a feed port 51 communicating with the feed hole 21 of the first reactant, and the other mounting plate 5 has a discharge port 52 communicating with the discharge hole 22 of the last reactant. The fastening assembly 6 is suitable for clamping the two mounting plates 5 along the thickness direction of the reaction substrate 1 to fix the relative position between the multiple reactants.

[0119] In this embodiment, the base frame 4 serves as the supporting foundation for the entire reactor and is constructed to support multiple sequentially stacked reaction monomers. Two mounting plates 5 are positioned opposite each other on the base frame 4, with the multiple reaction monomers sandwiched between the two mounting plates 5. One mounting plate 5, located at the beginning of the reaction monomer stack, has two feed ports 51, each connected to one of the two feed holes 21 of the first reaction monomer, allowing reactants to enter the microchannels and form a mixture. The other mounting plate 5, located at the end of the reaction monomer stack, has two discharge ports 52, each connected to one of the two discharge holes 22 of the last reaction monomer.

[0120] The fastening assembly 6 applies a clamping force along the thickness direction of the reaction substrate 1 (i.e. the stacking direction of the reaction monomers) to tighten the two mounting plates 5, thereby fixing the relative positions between the multiple reaction monomers.

[0121] By integrating multiple reactants into a single reactor assembly, the structure is simple and reliable. Operators can quickly load, replace, or clean and maintain the reactants by disassembling and fastening assembly 6, improving the maintainability and ease of use of the equipment. As mentioned earlier, adjacent reactants are fluidly connected through inlet 21 and outlet 22. The clamping force provided by fastening assembly 6 forces virtually no gaps between adjacent reactants and between the reactants and the mounting plate. Combined with the compression deformation of the aforementioned sealing ring, this effectively prevents leakage or cross-flow of the mixture during interstage transfer, ensuring the safety and stability of the reaction process.

[0122] In some alternative embodiments, the mounting plate 5 is made of stainless steel.

[0123] In some alternative embodiments, multiple sets of fastening components 6 are spaced apart along the edge of the mounting plate 5 to avoid structures such as the channel 11 and the receiving groove.

[0124] According to an embodiment of the present invention, each fastening assembly 6 includes a positioning rod and two fastening nuts. The positioning rod extends along the thickness direction of the reaction substrate 1, passing through the two mounting plates 5 and multiple reaction monomers. The two fastening nuts are threaded to both ends of the positioning rod and press against the surface of each mounting plate 5 opposite to the reaction monomer.

[0125] According to embodiments of the present invention, such as Figure 1 As shown, the microchannel reactor also includes an input pipe 7 and an output pipe 8, both of which are mounted on the base frame 4. The input pipe 7 is configured to connect to the temperature control unit 2 of each reaction cell, allowing the heat transfer medium from an external temperature control device to enter the temperature control unit 2. The output pipe 8 is configured to connect to the temperature control unit 2 of each reaction cell, allowing the heat transfer medium from the temperature control unit 2 to flow back to the external temperature control device.

[0126] In this implementation, the input pipe 7 serves as the main distribution pipe for the heat transfer medium, delivering the heat transfer medium from external temperature control equipment (such as a refrigerator or heater) to each reaction unit. The output pipe 8 serves as the main collection pipe for the heat transfer medium, collecting the heat transfer medium that has flowed through the temperature control unit 2 and completed heat exchange before returning it to the external temperature control equipment.

[0127] This allows the heat transfer medium to flow simultaneously and independently through the temperature control unit 2 of each reactant. The parallel connection effectively avoids the problem of excessive temperature change of the heat transfer medium after flowing through the upstream reactant, which would lead to a decrease in the temperature control accuracy of the downstream reactant. This ensures that each reactant can obtain a heat transfer medium with uniform temperature and sufficient flow.

[0128] In some alternative embodiments, such as Figure 1 As shown, the input pipe 7 and the output pipe 8 are integrated on the base frame 4, and together with the base frame 4, they support multiple reaction monomers.

[0129] In some alternative embodiments, the external temperature control device includes, but is not limited to, a thermostat.

[0130] Those skilled in the art will understand that the features described in the various embodiments of the present invention can be combined and / or combined in various ways, even if such combinations or combinations are not explicitly described in the present invention. In particular, the features described in the various embodiments of the present invention can be combined and / or combined in various ways without departing from the spirit and teachings of the present invention. All such combinations and / or combinations fall within the scope of the present invention.

[0131] The embodiments of the present invention have been described above. However, these embodiments are merely illustrative and not intended to limit the scope of the invention. Although various embodiments have been described above, this does not mean that the measures in the various embodiments cannot be used advantageously in combination. Various substitutions and modifications can be made by those skilled in the art without departing from the scope of the invention, and all such substitutions and modifications should fall within the scope of the invention.

Claims

1. A microchannel reactor, characterized in that, It includes a plurality of sequentially linked reactive monomers, each of which comprises: The reaction substrate has an internal cavity filled with an acoustic medium, and at least one side of the reaction substrate has a channel. At least one temperature control unit, each sealing one of the channels to form a microchannel for the flow and reaction of the mixture, wherein the temperature control unit is configured to contact the mixture within the microchannel for heat exchange to regulate the reaction temperature; and A vibrating unit, configured to extend into an acoustic medium and release sound waves to reduce solid buildup in the mixture within the microchannel, and comprising: Sound wave generator; A support base is disposed on the exterior of the side of the reaction substrate perpendicular to the side where the channel is formed, and supports the acoustic wave generator; and Multiple extension columns extend from the support base through the side into the receiving cavity and are partially immersed in the acoustic medium to transmit sound waves from the sound generator to the acoustic medium.

2. The microchannel reactor according to claim 1, characterized in that, The receiving cavity includes: Multiple main cavities are provided for insertion of the extension post; and Multiple diffusion cavities extend along a direction perpendicular to the extension column and are respectively connected to each of the main cavities.

3. The microchannel reactor according to claim 2, characterized in that, The main cavity has an open end for inserting the extension column and a closed end opposite to the open end. A rubber pad is provided at the closed end to support the lower end of the extension column.

4. The microchannel reactor according to claim 1, characterized in that, The reaction substrate has channels formed on two opposite sides, and the two ends of each channel are connected through an input hole and an output hole that penetrate the reaction substrate in the thickness direction, so that the mixture from the input hole flows through the two channels simultaneously and flows out through the output hole. The input hole is connected to the output hole of the reaction substrate located on the upstream side, and the output hole is connected to the input hole of the reaction substrate located on the downstream side, so that multiple reaction substrates are connected in series.

5. The microchannel reactor according to claim 4, characterized in that, The two temperature control units respectively cover the two channels. One temperature control unit is provided with a feed port, and the other temperature control unit is provided with a discharge port. The feed port is adapted to connect the discharge port of the temperature control unit located upstream and the input port, and the discharge port is adapted to connect the output port and the feed port of the temperature control unit located downstream.

6. The microchannel reactor according to claim 5, characterized in that, Each of the temperature control units includes: A support plate, wherein a receiving groove is formed on the surface of the support plate facing the reaction substrate; and A heat-conducting plate is sandwiched between the support plate and the reaction substrate to form a receiving space suitable for filling a heat transfer medium in combination with the receiving groove and to form the microchannel in combination with the channel. The feed hole penetrates the support plate and heat-conducting plate of one temperature control unit in the thickness direction, and the discharge hole penetrates the support plate and heat-conducting plate of another temperature control unit in the thickness direction.

7. The microchannel reactor according to claim 6, characterized in that, Multiple support protrusions are formed within the receiving groove, extending toward the reaction substrate and distributed at row and / or column intervals.

8. The microchannel reactor according to claim 1, characterized in that, The channel is constructed by sequentially connecting multiple serpentine channels to extend the flow reaction path of the mixture.

9. The microchannel reactor according to any one of claims 1-8, characterized in that, Also includes: The base frame is suitable for carrying multiple of the aforementioned reaction monomers; Two mounting plates are disposed on the base frame, and a plurality of the reaction monomers are sandwiched between the two mounting plates; A fastening assembly adapted to clamp two mounting plates along the thickness direction of the reaction substrate to fix the relative positions between a plurality of reaction monomers.

10. The microchannel reactor according to claim 9, characterized in that, Also includes: An input pipe, located on the base frame, is configured to communicate with the temperature control unit of each of the reaction monomers, and is suitable for supplying the heat transfer medium of an external temperature control device into the temperature control unit; An output pipe, located on the base frame, is configured to communicate with the temperature control unit of each of the reaction monomers, and is suitable for supplying the heat transfer medium of the temperature control unit to the external temperature control equipment.

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