3D Stacked Micro-Mixers for Rapid Fluid Interleaving
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Solution Overview
Problem
Current micro-fluid processing technologies face challenges in efficiently mixing reactants with different viscosities and immiscible liquids, as well as controlling the incremental introduction of limiting reagents, particularly due to high processing costs and workspace requirements associated with large volumes of reagents.
Innovation Solution
The development of interdigital micro-mixers and micro-reactors with micro-channels that utilize patterned laminae for rapid fluid layer interleave, allowing for efficient mixing through thin fluid layers and controlled incremental reagent introduction, achieved through techniques such as chemical etching, diffusion bonding, and embossing, with designs that reduce aspect ratios and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If molding and lithography techniques are used to construct planar micro-fluid devices, then single-layer mixing can be achieved, but processing time and workspace requirements become very large
Solution Approach 1:
The patent transitions from planar two-dimensional microfluidic devices to three-dimensional stacked devices with vertical channel interconnections. Multiple mixing layers are stacked vertically with micro-channels connecting corresponding channels across layers, enabling rapid mixing through vertical transport while maintaining a compact footprint and reducing processing time compared to planar designs.
2Quantity of substance
If large volumes of reagents are used for processing, then sufficient reactant supply is ensured, but workspace requirements and processing costs become very large
Solution Approach 1:
The stacked three-dimensional configuration allows multiple reaction and mixing chambers to be vertically arranged, significantly increasing the effective working volume within a small horizontal footprint. This vertical stacking enables sufficient reagent capacity without requiring large workspace area.
3Productivity
If traditional mixing methods are used for reactants with different viscosities, then mixing can be achieved, but mixing efficiency is reduced due to diffusion limitations
Solution Approach 1:
The invention introduces vertical micro-channels that connect corresponding channels in stacked layers, enabling rapid vertical transport and mixing of fluid streams. This three-dimensional mixing approach overcomes the diffusion limitations of planar mixing by creating multiple mixing interfaces and reducing diffusion distances through the vertical dimension.
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
These devices enable rapid and efficient mixing of reactants with different viscosities and immiscible liquids, reducing diffusion limitations and manufacturing costs, while allowing for controlled reagent introduction, thereby improving reaction control and reducing waste.
Implementation Method 1
rapid fluid layer interleave, allowing for efficient mixing through thin fluid layers
Implementation Method 2
achieved through techniques such as chemical etching, diffusion bonding, and embossing
Implementation Method 3
achieved through techniques such as chemical etching, diffusion bonding, and embossing
Data Source
AI summary
A fluid micro-mixer and micro-reactor array is provided having at least two bonded layers of micro-channels. The micro-mixer can include at least one input port and one output port, and a mixing and/or reaction port. At least one inlet stream separator layer can isolate the inlet ports from one another.