Preparation of Metal-Immobilized Methacrylate-Based Monolithic Columns for Flow-Through Cross-Coupling Reactions

With the aim of developing efficient flow-through microreactors for high-throughput organic synthesis, in this work, microreactors were fabricated by chemically immobilizing palladium-, nickel-, iron-, and copper-based catalysts onto ligand-modified poly(glycidyl methacrylate-co-ethylene dimethacrylate) [poly(GMA-co-EDMA)] monoliths, which were prepared inside a silicosteel tubing (10 cm long with an inner diameter of 1.0 mm) and modified with several ligands including 5-amino-1,10-phenanthroline (APHEN), iminodiacetic acid (IDA), and iminodimethyl phosphonic acid (IDP). The performance of the resulting microreactors in Suzuki-Miyaura cross-coupling reactions was evaluated, finding that the poly(GMA-co-EDMA) monolith chemically modified with 5-amino-1,10-phenanthroline as a binding site for the palladium catalyst provided an excellent flow-through performance, enabling highly efficient and rapid reactions with high product yields. Moreover, this monolithic microreactor maintained its good activity and efficiency during prolonged use.

One-flow upscaling neutralization of an organophosphonate-derived pesticide/nerve agent simulant to value-added chemicals in a novel Teflon microreactor platform

Synthesizing value-added products from chemical warfare agents is a concept well beyond the usual notion of simply neutralizing the agents.

Flexible Microfluidics: Fundamentals, Recent Developments, and Applications

Miniaturization has been the driving force of scientific and technological advances over recent decades. Recently, flexibility has gained significant interest, particularly in miniaturization approaches for biomedical devices, wearable sensing technologies, and drug delivery. Flexible microfluidics is an emerging area that impacts upon a range of research areas including chemistry, electronics, biology, and medicine. Various materials with flexibility and stretchability have been used in flexible microfluidics. Flexible microchannels allow for strong fluid-structure interactions. Thus, they behave in a different way from rigid microchannels with fluid passing through them. This unique behaviour introduces new characteristics that can be deployed in microfluidic applications and functions such as valving, pumping, mixing, and separation. To date, a specialised review of flexible microfluidics that considers both the fundamentals and applications is missing in the literature. This review aims to provide a comprehensive summary including: (i) Materials used for fabrication of flexible microfluidics, (ii) basics and roles of flexibility on microfluidic functions, (iii) applications of flexible microfluidics in wearable electronics and biology, and (iv) future perspectives of flexible microfluidics. The review provides researchers and engineers with an extensive and updated understanding of the principles and applications of flexible microfluidics.

Chloroform compatible, thiol-ene based replica molded micro chemical devices as an alternative to glass microfluidic chips

Polymeric microfluidic chips offer a number of benefits compared to their glass equivalents, including lower material costs and ease and flexibility of fabrication. However, the main drawback of polymeric materials is often their limited resistance to (organic) solvents. Previously, thiol-ene materials were shown to be more solvent resistant than most other commonly used polymers; however, they still fall short in "harsh" chemical environments, such as when chlorinated solvents are present. Here, we show that a simple yet effective treatment of thiol-ene materials results in exceptional solvent compatibility, even for very challenging chemical environments. Our approach, based on a temperature treatment, results in a 50-fold increase in the chloroform compatibility of thiol-enes (in terms of longevity). We show that prolonged heat exposure allows for the operation of the microfluidic chips in chloroform for several days with no discernable deformation or solvent-induced swelling. The method is applicable to many different thiol-ene-based materials, including commercially available formulations, and also when using other commonly considered "harsh" solvents. To demonstrate the utility of the solvent compatible thiol-enes for applications where chloroform is frequently employed, we show the continuous and uniform production of polymeric microspheres for drug delivery purposes over a period of 8 hours. The material thus holds great promise as an alternative choice for microfluidic applications requiring harsh chemical environments, a domain so far mainly restricted to glass chips.

Microfluidic-Based Single-Cell Study: Current Status and Future Perspective

Investigation of cell behavior under different environments and manual operations can give information in specific cellular processes. Among all cell-based analysis, single-cell study occupies a peculiar position, while it can avoid the interaction effect within cell groups and provide more precise information. Microfluidic devices have played an increasingly important role in the field of single-cell study owing to their advantages: high efficiency, easy operation, and low cost. In this review, the applications of polymer-based microfluidics on cell manipulation, cell treatment, and cell analysis at single-cell level are detailed summarized. Moreover, three mainly types of manufacturing methods, i.e., replication, photodefining, and soft lithography methods for polymer-based microfluidics are also discussed.

Why microfluidics? Merits and trends in chemical synthesis

The intrinsic limitations of conventional batch synthesis have hindered its applications in both solving classical problems and exploiting new frontiers. Microfluidic technology offers a new platform for chemical synthesis toward either molecules or materials, which has promoted the progress of diverse fields such as organic chemistry, materials science, and biomedicine. In this review, we focus on the improved performance of microreactors in handling various situations, and outline the trend of microfluidic synthesis (microsynthesis, μSyn) from simple microreactors to integrated microsystems. Examples of synthesizing both chemical compounds and micro/nanomaterials show the flexible applications of this approach. We aim to provide strategic guidance for the rational design, fabrication, and integration of microdevices for synthetic use. We critically evaluate the existing challenges and future opportunities associated with this burgeoning field.

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.

On-chip integration of organic synthesis and HPLC/MS analysis for monitoring stereoselective transformations at the micro-scale

We present a microfluidic system, seamlessly integrating microflow and microbatch synthesis with a HPLC/nano-ESI-MS functionality on a single glass chip. The microfluidic approach allows to efficiently steer and dispense sample streams down to the nanoliter-range for studying reactions in quasi real-time. In a proof-of-concept study, the system was applied to explore amino-catalyzed reactions, including asymmetric iminium-catalyzed Friedel-Crafts alkylations in microflow and micro confined reaction vessels.

Scanning-SAXS of microfluidic flows: nanostructural mapping of soft matter

The determination of in situ structural information of soft matter under flow is challenging, as it depends on many factors, such as temperature, concentration, confinement, channel geometry, and type of imposed flow. Here, we combine microfluidics and scanning small-angle X-ray scattering (scanning-SAXS) to create a two-dimensional spatially resolved map, which represents quantitatively the variation of molecular properties under flow. As application examples, mappings of confined amyloid fibrils and wormlike micelles under flow into various channel geometries are compared. A simple process to fabricate X-rays resistant chips, based on polyimide and UV-curing resin, is discussed. During experiments, these chips remained in high-energy synchrotron radiation for more than 24 hours, causing constant low background scattering. Thus, sufficient statistics were obtained from sample scattering at exposure times as low as 0.1 s, even with the small scattering volumes in microfluidic channels. Scanning-SAXS of microfluidic flows has many potential applications from biology to fundamental soft matter physics. In general, any fluid which has enough contrast for X-ray scattering can be measured to obtain the dependence of molecular shape, conformation, alignment and size on the flow field. Besides, dynamic processes of soft matter caused by flow, temperature, concentration gradient, and confinement, for example self-assembling, aggregation, mixing, diffusion, and disintegration of macromolecules, can be quantified and visualized on a single image by this mapping technique.

Multilayered film microreactors fabricated by a one-step thermal bonding technique with high reproducibility and their applications

We report the versatile uses of multilayered polyimide (PI) film microreactors with various functions including pressure tolerance, three-dimensional mixing and multistep membrane emulsification. Such PI film microreactors were fabricated by a simple one-step thermal bonding technique with high reproducibility. Upon bonding at 300 °C for 1 hour, the thin and flexible film microdevices could withstand pressure up to 8.6 MPa and 16.3 MPa with PI adhesive film or fluoropolymer adhesive, respectively, due to differences in wettability. The hydrophilic and hydrophobic microchannel devices were used to generate monodisperse oil-in-water (O/W) and water-in-oil (W/O) droplets, and polymer micro/nanoparticles at a high generation frequency. A monolithic and chemical resistant film microreactor with a three-dimensional serpentine microchannel was used for the selective reduction of ester to aldehyde by efficient mixing and quenching in a flash chemistry manner, within a several 10(1) millisecond time scale. Furthermore, a novel multilayered film microreactor for organic-aqueous biphasic interfacial reactions was devised by embedding a membrane layer to induce chaotic mixing in both the interface and emulsified phase by flowing through multiple numbers of meshed structures along the hydrophobic channel. This simple and economic fabrication technique significantly facilitates mass production of multilayered film devices that could be useful as a platform for various microfluidic applications in chemistry and biology.

Stop flow lithography in perfluoropolyether (PFPE) microfluidic channels

Stop Flow Lithography (SFL) is a microfluidic-based particle synthesis method for creating anisotropic multifunctional particles with applications that range from MEMS to biomedical engineering. Polydimethylsiloxane (PDMS) has been typically used to construct SFL devices as the material enables rapid prototyping of channels with complex geometries, optical transparency, and oxygen permeability. However, PDMS is not compatible with most organic solvents which limit the current range of materials that can be synthesized with SFL. Here, we demonstrate that a fluorinated elastomer, called perfluoropolyether (PFPE), can be an alternative oxygen permeable elastomer for SFL microfluidic flow channels. We fabricate PFPE microfluidic devices with soft lithography and synthesize anisotropic multifunctional particles in the devices via the SFL process--this is the first demonstration of SFL with oxygen lubrication layers in a non-PDMS channel. We benchmark the SFL performance of the PFPE devices by comparing them to PDMS devices. We synthesized particles in both PFPE and PDMS devices under the same SFL conditions and found the difference of particle dimensions was less than a micron. PFPE devices can greatly expand the range of precursor materials that can be processed in SFL because the fluorinated devices are chemically resistant to most organic solvents, an inaccessible class of reagents in PDMS-based devices due to swelling.

A pressure-tolerant polymer microfluidic device fabricated by the simultaneous solidification-bonding method and flash chemistry application

Pressure-tolerant polymer-glass microfluidic reactors with excellent bonding strength have been fabricated by the simultaneous solidification-bonding (SSB) method, in which a viscous and reactive matrix polymer was cast on the glass substrate with pre-patterned wax as a sacrificial template. Elaborate interfacial chemistry between the matrix polymer and the functionalized glass surface was designed to achieve simultaneous solidification and chemical bonding under UV or/and mild thermal conditions (<200 °C with no pressure). Highly pressure-tolerant microchannels were obtained by complete removal of the liquid wax template at 80 °C. Versatility was demonstrated by fabricating microreactors from various polymers with different interfacial chemistry, which were all stable at 1000 psi with the highest burst pressure of 2000 psi. In particular, the fluoropolymer-glass microreactor can withstand a burst pressure that is two orders of magnitude higher than that of the microchannel made by the conventional method. Finally, the polymer-glass microfluidic device was used for the synthesis of a natural product, tryptanthrin, by flash chemistry under high pressure induced conditions (synthetic yield: 90%, flow rate: 10.5 mL min(-1), reaction time: 14 ms). The transparent microfluidic device can be used as a useful platform for miniaturizing spectroscopic tools for chemical analysis studies under high pressure conditions.

Fast diffusion-limited lyotropic phase transitions studied in situ using continuous flow microfluidics/microfocus-SAXS

Fast concentration-induced diffusion-limited lyotropic phase transitions can be studied in situ with millisecond time resolution using continuous flow microfluidics in combination with microfocus small-angle X-ray scattering. The method was applied to follow a classical self-assembly sequence where amphiphiles assemble into micelles, which subsequently assemble into an ordered lattice via a disorder/order transition. As a model system we selected the self-assembly of an amphiphilic block copolymer induced by the addition of a nonsolvent. Using microchannel hydrodynamic flow-focusing, large concentration gradients can be generated, leading to a deep quench from the miscible to the microphase-separated state. Within milliseconds the block copolymers assembly via a spinodal microphase separation into micelles, followed by a disorder/order transition into an FCC liquid-crystalline phase with late-stage domain growth and shear-induced domain orientation into a mesocrystal. A comparison with a slow macroscopic near-equilibrium kinetic experiment shows that the fast structural transitions follow a direct pathway to the equilibrium structure without the trapping of metastable states.

Three-dimensional flash flow microreactor for scale-up production of monodisperse PEG-PLGA nanoparticles

We present a pressure-tolerant 3D parallel polyimide (PI) film microreactor operating at up to ~160 bars with direct 3D flow focusing geometry for mass production of PEG-PLGA nanoparticles in a ~10(1) gram-scale (g h(-1)).

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.

Whole ceramic-like microreactors from inorganic polymers for high temperature or/and high pressure chemical syntheses

Two types of whole ceramic-like microreactors were fabricated from inorganic polymers, polysilsesquioxane (POSS) and polyvinylsilazane (PVSZ), that were embedded with either perfluoroalkoxy (PFA) tube or polystyrene (PS) film templates, and subsequently the templates were removed by physical removal (PFA tube) or thermal decomposition (PS). A POSS derived ceramic-like microreactor with a 10 cm long serpentine channel was obtained by an additional "selective blocking of microchannel" step and subsequent annealing at 300 °C for 1 h, while a PVSZ derived ceramic-like microreactor with a 14 cm long channel was yielded by a co-firing process of the PVSZ-PS composite at 500 °C for 2 h that led to complete decomposition of the film template leaving a microchannel behind. The obtained whole ceramic-like microfluidic devices revealed excellent chemical and thermal stabilities in various solvents, and they were able to demonstrate unique chemical performance at high temperature or/and high pressure conditions such as Michaelis-Arbuzov rearrangement at 150-170 °C, Wolff-Kishner reduction at 200 °C, synthesis of super-paramagnetic Fe3O4 nanoparticles at 320 °C and isomerisation of allyloxybenzene to 2-allylphenol (250 °C and 400 psi). These economic ceramic-like microreactors fabricated by a facile non-lithographic method displayed excellent utility under challenging conditions that is superior to any plastic microreactors and comparable to glass and metal microreactors with high cost.

A doubly cross-linked nano-adhesive for the reliable sealing of flexible microfluidic devices

Along with the expansion of microfluidics into many areas of applications such as sensors, microreactors and analytical tools, many other materials besides poly(dimethylsiloxane) (PDMS) have been suggested such as poly(imide) (PI) or poly(ethylene terephthalate) (PET). However, the sealing methods for these materials are not reliable in that many of the methods are specific to the substrate materials. Here, we report a novel robust doubly cross-linked nano-adhesive (DCNA) for bonding of various heterogeneous substrates. By depositing 200 nm of epoxy-containing polymer, poly(glycidyl methacrylate), via initiated chemical vapour deposition (iCVD) onto various substrates and cross-linking them with ethylenediamine, a strong adhesion was obtained between the substrates. This adhesive system was not only able to bond various difficult-to-bond substrates, such as PET or PI, but it could also preserve the complicated morphology of the surfaces owing to the thin nature of the DCNA system. The DCNA allowed fabrication of microfluidic devices using both rigid substrates, such as silicon wafer and glass, and flexible substrates, such as PDMS, PET and PI. The burst pressure of the devices sealed with DCNA exceeded 2.5 MPa, with a maximum burst pressure of 11.7 MPa. Furthermore, the adhesive system demonstrated an exceptional chemical and thermal resistance. The adhesion strength of the adhesive sandwiched between glass substrates remained the same even after a 10 day exposure to strong organic solvents such as toluene, acetone, and tetrahydrofuran (THF). Also, exposure to 200 °C for 15 h was not able to damage the adhesion strength. Using the high adhesive strength and flexibility of DCNA, flexible microfluidic devices that can be completely folded or rolled without any delamination during the operation were fabricated. The DCNA bonding is highly versatile in the sealing of microfluidic systems, and is compatible with a wide selection of materials, including flexible and foldable substrates, even upon sealing few-μm-sized channels.

Continuous-flow catalytic asymmetric hydrogenations: Reaction optimization using FTIR inline analysis

The asymmetric organocatalytic hydrogenation of benzoxazines, quinolines, quinoxalines and 3H-indoles in continuous-flow microreactors has been developed. Reaction monitoring was achieved by using an inline ReactIR flow cell, which allows fast and convenient optimization of reaction parameters. The reductions proceeded well, and the desired products were isolated in high yields and with excellent enantioselectivities.

Microfluidic approach for highly efficient synthesis of heparin-based bioconjugates for drug delivery

This paper demonstrates the highly efficient synthesis of amphiphilic heparin-folic acid-retinoic acid (HFR) bioconjugates with a high drug coupling ratio by a microfluidic approach. The microfluidic synthesis enabled the conjugation of 17 molecules of retinoic acid to each heparin chain with 21 possible groups for attachment after reacting for several minutes. In contrast, about 11 molecules of the drug were covalently conjugated to one heparin chain after 4 days in the bulk reaction. The microfluidic based-HFR bioconjugates readily self-assembled in aqueous media to form uniform nanoparticles, while the product from the bulk reaction formed non-uniform nanoparticles with broad size distribution. The HFR nanoparticles with high drug content effectively delivered the drug to folate receptor-positive cancer cells with superior cellular uptake and selective cytotoxicity in vitro compared to HFR nanoparticles synthesized in bulk reaction. With the ability to achieve high drug content in heparin carrier within a short reaction time, the microfluidic technique offers new alternatives for the efficient synthesis of polymer-based conjugates for drug delivery.

Facile fabrication of a rigid and chemically resistant micromixer system from photocurable inorganic polymer by static liquid photolithography (SLP)

Highly effective mixing in microchannels is important for most chemical reactions conducted in microfluidic chips. To obtain a rigid and chemically resistant micromixer system at low cost, we fabricated a Y-shaped microchannel with built-in mixer structures by static liquid photolithography (SLP) from methacrylated polyvinylsilazane (MPVSZ) as an inorganic polymer photoresist which was then converted to a silicate phase by hydrolysis in vaporized ammonia atmosphere at 80 °C. The microchannel incorporating herringbone mixer structures was bonded with a matching polydimethylsiloxane (PDMS) open channel which was pre-coated by perhydropolysilazane (PHPS)-based mixture, and finally treated by additional hydrolysis at room temperature to convert the PHPS layer to a silica phase. Finally, the chemical resistance of the microfluidic system with embedded micromixer was confirmed with various solvents, and the excellent mixing performance in a short mixing length of 2.3 cm was demonstrated by injecting two different colored fluids into the microchannel.

Micromolding of solvent resistant microfluidic devices

We demonstrate a rapid fabrication procedure for solvent-resistant microfluidic devices based on the perfluoropolyether (PFPE) SIFEL. We carefully modified the poly-dimethylsiloxane (PDMS) micromolding procedure, such that it can still be executed using the standard facilities for PDMS devices. Most importantly, devices with a thin SIFEL layer for the patterned channels and a PDMS support layer on top offered the best of two worlds in terms of chemical and mechanical stability during fabrication and use. Tests revealed that these devices overcome two important drawbacks of PDMS devices: (i) incompatibility with almost all non-aqueous solvents, and (ii) leaching of oligomer into solution. The potential of our device is shown by performing a relevant organic synthesis reaction with aggressive reactants and solvents. PFPE-PDMS devices will greatly expand the application window of micromolded devices.

Efficient photosensitized oxygenations in phase contact enhanced microreactors

A transparent dual-channel microreactor with highly enhanced contact area-to-volume ratio was fabricated for efficient photosensitized oxygenations. The dual-channel microreactor shielded with polyvinylsilazane (PVSZ) consisting of an upper channel for liquid flow and a lower channel for O(2) flow, allows sufficient phase contact along the parallel channels through a gas permeable PDMS membrane for maintaining the O(2) saturated solution. Under full exposure of reactants to light, the reactions in high concentration are completed in minutes rather than hours that it takes to complete in a batch reactor. Moreover, the scale-up process using the microreactor revealed higher productivity than the batch reactor, which would be valuable for the practical applications in a broad range of gas-liquid chemical reactions.