Monolithic and Flexible Polyimide Film Microreactors for Organic Microchemical Applications Fabricated by Laser Ablation

Compact reaction-module on a pad for scalable flow-production of organophosphates as drug scaffolds

Continuous pharmaceutical manufacturing receives intense attention as an alternative way to meet flexible market needs with the assurance of higher safety and quality control. Here, we report a compact reaction-module on a pad (CRP, 170 × 170 × 1.2 mm) for scale-up production of drug precursors in a continuous-flow. The CRP system was devised by stacking 9 films of the patterned polyimide to integrate micro-flow circuits, combining the functions of the even distribution of feeds, being completely mixed in less than a few milliseconds. A methodology of using a highly reactive species for the single-step synthesis of α-phosphonyloxy ketone, a drug scaffold, required the synthesis time of a few seconds in microfluidics. The fast reaction in the single CRP was capable of producing 19.2 g h-1 drug precursor, which indicates a solid step toward kilogram-scale pharmaceutical manufacturing in small footage.

Integrated CO2 capture-fixation chemistry via interfacial ionic liquid catalyst in laminar gas/liquid flow

Simultaneous capture of carbon dioxide (CO₂) and its utilization with subsequent work-up would significantly enhance the competitiveness of CO₂-based sustainable chemistry over petroleum-based chemistry. Here we report an interfacial catalytic reaction platform for an integrated autonomous process of simultaneously capturing/fixing CO₂ in gas–liquid laminar flow with subsequently providing a work-up step. The continuous-flow microreactor has built-in silicon nanowires (SiNWs) with immobilized ionic liquid catalysts on tips of cone-shaped nanowire bundles. Because of the superamphiphobic SiNWs, a stable gas–liquid interface maintains between liquid flow of organoamines in upper part and gas flow of CO₂ in bottom part of channel. The intimate and direct contact of the binary reagents leads to enhanced mass transfer and facilitating reactions. The autonomous integrated platform produces and isolates 2-oxazolidinones and quinazolines-2,4(1H,3H)-diones with 81–97% yields under mild conditions. The platform would enable direct CO₂ utilization to produce high-valued specialty chemicals from flue gases without pre-separation and work-up steps.

Microfluidics is an attractive route for synthesis, but can suffer from poor reactivity with gaseous reagents. Here the authors report a microfluidic system catalysing an interfacial reaction between CO₂ and liquid phase reagents by modifying silicon nanowires with immobilized ionic liquid catalysts.

A monolithic and flexible fluoropolymer film microreactor for organic synthesis applications

A photocurable and viscous fluoropolymer with chemical stability is a highly desirable material for fabrication of microchemical devices. Lack of a reliable fabrication method, however, limits actual applications for organic reactions. Herein, we report fabrication of a monolithic and flexible fluoropolymer film microreactor and its use as a new microfluidic platform. The fabrication involves facile soft lithography techniques that enable partial curing of thin laminates, which can be readily bonded by conformal contact without any external forces. We demonstrate fabrication of various functional channels (~300 μm thick) such as those embedded with either a herringbone micromixer pattern or a droplet generator. Organic reactions under strongly acidic and basic conditions can be carried out in this film microreactor even at elevated temperature with excellent reproducibility. In particular, the transparent film microreactor with good deformability could be wrapped around a light-emitting lamp for close contact with the light source for efficient photochemical reactions with visible light, which demonstrates easy integration with optical components for functional miniaturized systems.

Catalytic conversion of γ-valerolactone to ε-caprolactam: towards nylon from renewable feedstock

The conversion of γ-valerolactone (GVL) in three atom-efficient steps to the important polymer precursor ε-caprolactam is reported. The bio-based GVL can be converted to a mixture of isomeric methyl pentenoates (MP) via trans-esterification with methanol with 94% yield (ratio of 3-MP/4-MP=3:1); subsequent aminolysis with ammonia leads to a mixture of pentenamides (PA) almost quantitatively (99% conversion). The resulting pentenamides are ultimately converted into ε-caprolactam via a rhodium-catalyzed intramolecular hydroamidomethylation reaction, comprising an initial hydroformylation of the alkene moiety of PA and subsequent ring-closing reductive amidation of the resulting aldehyde with the amide functionality. A promising yield of caprolactam of about 90% can be obtained with a Rh/xantphos catalyst system in a two-stage hydroformylation-reductive amidation using pure 4-PA as feedstock. The use of 3-PA as a substrate not only results in a significantly lower regioselectivity for the 7-membered lactam, but also in the formation of high amounts of valeramide (VA). Consequently, a best overall yield of caprolactam of nearly 40% could be demonstrated with a Rh/POP-xantphos [POP-xantphos=4,5-bis(2,8-dimethyl-10-phenoxaphosphino)-9,9,-dimethylxanthene] catalyst system based on the 3:1 mixture of 3-PA/4-PA directly obtainable from GVL.