Microreactor Branch Flow Paths for Mixing Different Flow Rates
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Solution Overview
Problem
Existing microreactor technologies face challenges in achieving good mixing of raw materials with different flow rates, leading to insufficient interfacial area and inefficient mixing processes, especially when handling highly corrosive substances or dangerous synthesis reactions.
Innovation Solution
The microreactor design includes a high-flow-rate side flow path and a low-flow-rate side flow path, with the high-flow-rate side flow path being branched into multiple paths to merge with the low-flow-rate side flow path in a sandwich-like configuration, ensuring equal pressure losses and optimizing the flow path internal volumes to achieve effective mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If two types of raw materials are each branched into a plurality of parts and merged alternately in a radial manner, then the mixing speed is improved, but the flow rate ratio (volume ratio) cannot be adjusted sufficiently
Solution Approach 1:
The high-flow-rate side flow path is segmented into multiple branch flow paths (first branch flow path and second branch flow path). This segmentation allows the high-flow-rate raw material to be divided into multiple streams that can be merged alternately with the low-flow-rate raw material, increasing the interfacial area and mixing efficiency while maintaining adjustable flow rate ratios.
Solution Approach 2:
The patent transitions from a single radial merging approach to a multi-dimensional merging structure where branch flow paths are arranged in different spatial configurations. This allows for both rapid alternation (improving mixing speed) and independent flow rate control (improving adaptability) by utilizing spatial arrangement rather than relying solely on a single merging point.
2Productivity
If the flow path internal volumes are not optimized, then the device structure is simple, but the mixing efficiency is insufficient
Solution Approach 1:
The patent optimizes the flow path internal volumes by establishing specific relationships between the volumes of the high-flow-rate side flow path and low-flow-rate side flow path, and between branch flow paths. This parameter optimization ensures equal pressure losses and proper flow distribution, achieving high mixing efficiency without requiring complex additional structures.
3Ease of manufacture
If resins such as PDMS, ABS resin, or PC are used as the material, then the cost is reduced, but the microreactor becomes suitable only for single use
Solution Approach 1:
The patent employs resin materials (PDMS, ABS, or PC) that enable cost-effective manufacturing of disposable microreactors. This approach is particularly suitable for applications requiring handling of highly corrosive substances or dangerous synthesis reactions, where single-use devices eliminate contamination risks and maintenance requirements while maintaining acceptable cost structures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design achieves a good mixing effect for raw materials with different flow rates, improving the interfacial area and mixing efficiency, while also being suitable for handling highly corrosive substances and dangerous synthesis reactions.
Implementation Method 1
as the size of the reaction field in the microreactor decreases, fluids are mixed rapidly due to molecular diffusion
Data Source
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AI summary
In mixing of raw materials having different flow rate ratios (volume ratios) (different flow rates), in order to achieve a good mixing effect, the present invention includes: for raw materials having different flow rates, a high-flow-rate side flow path (102) through which a raw material on a high-flow-rate side flows; a low-flow-rate side flow path (103) through which a raw material on a low-flow-rate side flows; branch flow paths (102a, 102b) which are branched from the high-flow-rate side flow path; and a residence flow path (104) which is a flow path after the branch flow paths (102a, 102b) and the low-flow-rate side flow path (103) merge. The branch flow path (102a) and the branch flow path (102b) merge in a way of sandwiching the low-flow-rate side flow path (103).