Characterization of the Mixing Quality in Micromixers

Feasibility Analysis of Calcium Carbonate Particle Trajectory Simulation in a Dual Horizontal Shaft Mixer

This article aims to investigate the feasibility of using discrete element software EDEM 2022.0 to simulate the trajectory of artificial marble patterns in a dual horizontal shaft mixer. Research was conducted on the mixing uniformity of particles in the mixing chamber, and the optimal speed range for particle mixing was established. By simulating the trajectory of pigment particles, the trajectories of the particles at different positions of the stirring paddle were obtained, and the trajectories were compared with the measured results. In the study of uniform particle mixing, the Lacey index at different speeds was compared, and the optimal speed range was established between 40 RPM and 60 RPM. Based on this, the particle trajectory simulation found that the motion trajectories of particles at different positions of the stirring paddle varied significantly. The particles in the stirring paddle rod exhibit a gradual trend, in which they gradually decrease as they approach the head of the stirring paddle. Finally, the feasibility of this method was established by comparing the simulated and actual patterns through proportional replication of the mixing process, and it was discovered that the two were similar.

Herringbone micromixers for particle filtration

Herringbone micromixers are a powerful tool for introducing advection into microfluidic systems. While these mixers are typically used for mixing fluids faster than the rate of diffusion, there has been recent interest in using the device to enhance interactions between suspended particles and channel walls. We show how the common approximations applied to herringbone micromixer theory can have a significant impact on results. We show that the inclusion of gravity can greatly alter the interaction probability between suspended particles and channel walls. We also investigate the proposed impedance matching condition and the inclusion of imperfect binding using numerical methods, and investigate transient behaviors using an experimental system. These results indicate that while traditional methods, such as simple streamline analysis, remain powerful tools, it should not be considered predictive in the general case.

Ultrasensitive Analysis of Exosomes Using a 3D Self-Assembled Nanostructured SiO2 Microfluidic Chip

Conventional microfluidics with a solid mixer for exosome detection is constrained by the low binding efficiency of the solid-liquid boundary effects and reduced sensitivity of individual markers. Here, we report a 3D-SiO₂ porous chip that combines nanoscale porous characteristics and multiple exosome specific markers to greatly improve the sensitivity for biosensing. The lower limit of detection was 220 particles/μL exosomes in PBS. We applied the 3D-SiO₂ porous chip for prostate cancer (PCa) staging in mice and early detection of clinical PCa patients. The developed method could significantly differentiate the different stages of PCa in mice and improve the early detection rate in clinical patients. Expression of multiple specific markers in clinical serum samples identified disease fingerprints, alongside histological results, which supports the potential application of exosomes as a noninvasive surrogate biopsy for PCa.

Fouling Mitigation via Chaotic Advection in a Flat Membrane Module with a Patterned Surface

Fouling mitigation using chaotic advection caused by herringbone-shaped grooves in a flat membrane module is numerically investigated. The feed flow is laminar with the Reynolds number (Re) ranging from 50 to 500. In addition, we assume a constant permeate flux on the membrane surface. Typical flow characteristics include two counter-rotating flows and downwelling flows, which are highly influenced by the groove depth at each Re. Poincaré sections are plotted to represent the dynamical systems of the flows and to analyze mixing. The flow systems become globally chaotic as the groove depth increases above a threshold value. Fouling mitigation via chaotic advection is demonstrated using the dimensionless average concentration (c¯w*) on the membrane and its growth rate. When the flow system is chaotic, the growth rate of c¯w* drops significantly compared to that predicted from the film theory, demonstrating that chaotic advection is an attractive hydrodynamic technique that mitigates membrane fouling. At each Re, there exists an optimal groove depth minimizing c¯w* and the growth rate of c¯w*. Under the optimum groove geometry, foulants near the membrane are transported back to the bulk flow via the downwelling flows, distributed uniformly in the entire channel via chaotic advection.

Enhancement of Mixing Performance of Two-Layer Crossing Micromixer through Surrogate-Based Optimization

Optimum configuration of a micromixer with two-layer crossing microstructure was performed using mixing analysis, surrogate modeling, along with an optimization algorithm. Mixing performance was used to determine the optimum designs at Reynolds number 40. A surrogate modeling method based on a radial basis neural network (RBNN) was used to approximate the value of the objective function. The optimization study was carried out with three design variables; viz., the ratio of the main channel thickness to the pitch length (H/PI), the ratio of the thickness of the diagonal channel to the pitch length (W/PI), and the ratio of the depth of the channel to the pitch length (d/PI). Through a primary parametric study, the design space was constrained. The design points surrounded by the design constraints were chosen using a well-known technique called Latin hypercube sampling (LHS). The optimal design confirmed a 32.0% enhancement of the mixing index as compared to the reference design.

Microfluidic Mixer with Automated Electrode Switching for Sensing Applications

An electronic tongue (e-tongue) is a multisensory system usually applied to complex liquid media that uses computational/statistical tools to group information generated by sensing units into recognition patterns, which allow the identification/distinction of samples. Different types of e-tongues have been previously reported, including microfluidic devices. In this context, the integration of passive mixers inside microchannels is of great interest for the study of suppression/enhancement of sensorial/chemical effects in the pharmaceutical, food, and beverage industries. In this study, we present developments using a stereolithography technique to fabricate microfluidic devices using 3D-printed molds for elastomers exploring the staggered herringbone passive mixer geometry. The fabricated devices (microchannels plus mixer) are then integrated into an e-tongue system composed of four sensing units assembled on a single printed circuit board (PCB). Gold-plated electrodes are designed as an integral part of the PCB electronic circuitry for a highly automated platform by enabling faster analysis and increasing the potential for future use in commercial applications. Following previous work, the e-tongue sensing units are built functionalizing gold electrodes with layer-by-layer (LbL) films. Our results show that the system is capable of (i) covering basic tastes below the human gustative perception and (ii) distinguishing different suppression effects coming from the mixture of both strong and weak electrolytes. This setup allows for triplicate measurements in 12 electrodes, which represents four complete sensing units, by automatically switching all electrodes without any physical interaction with the sensor. The result is a fast and reliable data acquisition system, which comprises a suitable solution for monitoring, sequential measurements, and database formation, being less susceptible to human errors.

Development of small-volume, microfluidic chaotic mixers for future application in two-dimensional liquid chromatography

We report a microfluidic chaotic micromixer with staggered herringbone grooves having a geometry optimized for fast mobile-phase modification at the interface of a two-dimensional liquid chromatography system.

Convex Grooves in Staggered Herringbone Mixer Improve Mixing Efficiency of Laminar Flow in Microchannel

The liquid streams in a microchannel are hardly mixed to form laminar flow, and the mixing issue is well described by a low Reynolds number scheme. The staggered herringbone mixer (SHM) using repeated patterns of grooves in the microchannel have been proved to be an efficient passive micro-mixer. However, only a negative pattern of the staggered herringbone mixer has been used so far after it was first suggested, to the best of our knowledge. In this study, the mixing efficiencies from negative and positive staggered herringbone mixer patterns as well as from opposite flow directions were tested to investigate the effect of the micro-structure geometry on the surrounding laminar flow. The positive herringbone pattern showed better mixing efficiency than the conventionally used negative pattern. Also, generally used forward flow gives better mixing efficiency than reverse flow. The mixing was completed after two cycles of staggered herringbone mixer with both forward and reverse flow in a positive pattern. The traditional negative pattern showed complete mixing after four and five cycles in forward and reverse flow direction, respectively. The mixing effect in all geometries was numerically simulated, and the results confirmed more efficient mixing in the positive pattern than the negative. The results can further enable the design of a more efficient microfluidic mixer, as well as in depth understanding of the phenomena of positive and negative patterns existing in nature with regards to the surrounding fluids.

How a "pinch of salt" can tune chaotic mixing of colloidal suspensions

Efficient mixing of colloids, particles or molecules is a central issue in many processes. It results from the complex interplay between flow deformations and molecular diffusion, which is generally assumed to control the homogenization processes. In this work we demonstrate on the contrary that despite fixed flow and self-diffusion conditions, the chaotic mixing of colloidal suspensions can be either boosted or inhibited by the sole addition of a trace amount of salt as a co-mixing species. Indeed, this shows that local saline gradients can trigger a chemically driven transport phenomenon, diffusiophoresis, which controls the rate and direction of molecular transport far more efficiently than the usual Brownian diffusion. A simple model combining the elementary ingredients of chaotic mixing with diffusiophoretic transport of the colloids allows rationalization of our observations and highlights how small-scale out-of-equilibrium transport bridges to mixing at much larger scales in a very effective way. Considering chaotic mixing as a prototypal building block for turbulent mixing suggests that these phenomena, occurring whenever the chemical environment is inhomogeneous, might bring interesting perspectives from micro-systems to large-scale situations, with examples ranging from ecosystems to industrial contexts.

A simplified design of the staggered herringbone micromixer for practical applications

We demonstrated a simple method for the device design of a staggered herringbone micromixer (SHM) using numerical simulation. By correlating the simulated concentrations with channel length, we obtained a series of concentration versus channel length profiles, and used mixing completion length L(m) as the only parameter to evaluate the performance of device structure on mixing. Fluorescence quenching experiments were subsequently conducted to verify the optimized SHM structure for a specific application. Good agreement was found between the optimization and the experimental data. Since L(m) is straightforward, easily defined and calculated parameter for characterization of mixing performance, this method for designing micromixers is simple and effective for practical applications.

Miniaturization in biocatalysis

The use of biocatalysts for the production of both consumer goods and building blocks for chemical synthesis is consistently gaining relevance. A significant contribution for recent advances towards further implementation of enzymes and whole cells is related to the developments in miniature reactor technology and insights into flow behavior. Due to the high level of parallelization and reduced requirements of chemicals, intensive screening of biocatalysts and process variables has become more feasible and reproducibility of the bioconversion processes has been substantially improved. The present work aims to provide an overview of the applications of miniaturized reactors in bioconversion processes, considering multi-well plates and microfluidic devices, update information on the engineering characterization of the hardware used, and present perspective developments in this area of research.

Quantitative characterization of micromixing simulation

Micromixers with floor-grooved microfluidic channels have been successfully demonstrated in experiment. In this work, we numerically simulated the mixing within the devices and used the obtained concentration versus channel length profiles to quantitatively characterize the process. It was found that the concentration at any given cross-section location of the microfluidic channel periodically oscillates along the channel length, in coordination with the groove-caused helical flow during the mixing, and eventually converges to the neutral concentration value of two the mixing fluids. With these data, the specific channel length required for each helical flow to complete, the mixing efficiency of the devices, and the total channel length required to complete a mixing were easily defined and quantified, and were used to directly and comprehensively characterize the micromixing. This concentration versus channel length profile-based characterization method was also demonstrated in quantitatively analyzing the micromixing within a classic T mixer. It has clear advantages over the traditional concentration image-based characterization method that is only able to provide qualitative or semiquantitative information about a micromixing, and is expected to find an increasing use in studying mixing and optimizing device structure through numerical simulations.

Geometrical optimization of helical flow in grooved micromixers

Owing to the enhancement of surface effects at the micro-scale, patterned grooves on a micro-channel floor remain a powerful method to induce helical flows within a pressure driven system. Although there have been a number of numerical studies on geometrical effects concerning fluid mixing within the staggered herringbone mixer, all have focused mainly on the groove angle and depth, two factors that contribute greatly to the magnitude of helical flow. Here we present a new geometrical factor that significantly affects the generation of helical flow over patterned grooves. By varying the ratio of the length of the grooves to the neighboring ridges, helical flow can be optimized for a given groove depth and channel aspect ratio, with up to 50% increases in transverse flow possible. A thorough numerical study of over 700 cases details the magnitude of helical flow over unsymmetrical patterned grooves in a slanted groove micro-mixer, where the optimized parameters for the slanted groove mixer can be translated to the staggered herringbone mixer. The optimized groove geometries are shown to have a large dependence on the channel aspect ratio, the groove depth ratio, and the ridge length.

Geometric effects on fluid mixing in passive grooved micromixers

The effects of geometric parameters on the mixing performance of a staggered herringbone mixer (SHM) with patterned grooves are numerically investigated. Combining use of the software package CFD-ACE+ and the Taguchi method provides a powerful and systematic approach for research on microfluidics. An orthogonal array L9(3(4)) is established for parameters introduced by the groove geometry; in total 9 cases are simulated. Analyses of the mixing phenomena, geometric parameter, pressure loss and flow rate through grooves are conducted. The modes of fluid motion and dominant mechanisms of mixing within the SHM are observed and ascertained. Although the depth ratio and the asymmetry index of the groove are found to be dominant geometric parameters, the rate of flow within the groove is verified to be the most significant factor that affects the mixing performance of a SHM. To date, the effects of the parameters are evaluated within specified ranges, and the true optimum design has yet to be discovered.