Microreactor Plate Design for Contamination-Free Temperature Control
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Solution Overview
Problem
Increasing production volume in microreactors while maintaining residence time and temperature control becomes complex, leading to potential contamination from temperature control liquids and increased operator workload due to the need for multiple reaction channel plates and complicated handling.
Innovation Solution
A microreactor design where all inlets, outlets, and temperature control liquid inlets/outlets are located on the same face of the plates, allowing for simplified handling and reduced risk of contamination by integrating temperature control within the plate structure, eliminating the need for external joints and tubes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple reaction channel plates are used to increase production volume, then productivity is improved, but device complexity increases and operator workload increases
Solution Approach 1:
The patent combines multiple functions (reaction channels, temperature control channels, inlets, and outlets) into a single integrated plate structure. The plate contains both reaction channels for fluid flow and temperature control channels for heating/cooling, with all inlets and outlets positioned on one face. This merging eliminates the need for multiple separate plates and external connections, resolving the contradiction between increased productivity and device complexity.
2Temperature
If temperature control liquid channels are added for temperature control, then temperature control capability is improved, but reliability decreases due to potential contamination
Solution Approach 1:
The patent embeds the temperature control channels within the same plate structure as the reaction channels. The temperature control channels are positioned adjacent to the reaction channels, allowing thermal coupling for efficient temperature control. This nested arrangement eliminates the need for external temperature control plates and connections, reducing the risk of contamination while maintaining effective temperature control.
3Ease of operation
If all inlets and outlets are positioned on the same face, then ease of operation is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent positions all inlets and outlets on the same face (one dimension) of the plate, simplifying operation and installation. The channel design uses standard geometric shapes (rectangular or circular cross-sections) with consistent dimensions, making the positioning and alignment more predictable and manufacturable. The uniform channel geometry helps compensate for the challenge of positioning multiple openings on one face.
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 reduces operator workload and prevents contamination by foreign substances, simplifying the installation and operation of the microreactor while maintaining effective temperature control and residence time for reactions.
Implementation Method 1
a microchannel is used as a reaction field, making it possible to rapidly mix fluids by molecular diffusion
Implementation Method 2
the effect of the surface area relative to the volume of the fluid is relatively large. This allows for higher efficiency in heat transfer, heat conduction, reaction, and the like
Data Source
AI summary
A microreactor which reduces workload of an operator without risk of contamination by foreign substances such as a temperature control liquid. The microreactor produces a product by mixing at least two types of raw material and includes plates which are stacked on each other. One of the plates includes an inlet (first and second raw material inlets) which allows the raw material to be introduced into the inlet, a product outlet which allows a solution containing the product to be discharged from the outlet, a temperature control liquid inlet which allows a heat medium for temperature control to be introduced into the inlet, and a temperature control liquid outlet which allows the heat medium to be discharged from the outlet. The inlet, the product outlet, the temperature control liquid inlet, and the temperature control liquid outlet are located on the same face of the one of the plates.