Micro-total envelope system with silicon nanowire separator for safe carcinogenic chemistry

A single-particle mechanofluorescent sensor

Monitoring mechanical stresses in microchannels is challenging. Herein, we report the development of a mechanofluorescence sensor system featuring a fluorogenic single polydiacetylene (PDA) particle, fabricated using a co-flow microfluidic method. We construct a stenotic vessel-mimicking capillary channel, in which the hydrodynamically captured PDA particle is subjected to controlled fluid flows. Fluorescence responses of the PDA particle are directly monitored in real time using fluorescent microscopy. The PDA particle displays significant nonlinear fluorescence emissions influenced by fluid viscosity and the presence of nanoparticles and biomolecules in the fluid. This nonlinear response is likely attributed to the torsion energy along the PDA's main chain backbone. Computational fluid dynamic simulations indicate that the complete blue-to-red transition necessitates ~307 μJ, aligning with prior research. We believe this study offers a unique advantage for simulating specific problematic regions of the human body in an in vitro environment, potentially paving the way for future exploration of difficult-to-access areas within the body.

Particle Size-Dependent Component Separation Using Serially Arrayed Micro-Chambers

The purpose of this research was to enable component separation based on simple control of the flow rate. We investigated a method that eliminated the need for a centrifuge and enabled easy component separation on the spot without using a battery. Specifically, we adopted an approach that uses microfluidic devices, which are inexpensive and highly portable, and devised the channel within the fluidic device. The proposed design was a simple series of connection chambers of the same shape, connected via interconnecting channels. In this study, polystyrene particles with different sizes were used, and their behavior was evaluated by experimentally observing the flow in the chamber using a high-speed camera. It was found that the objects with larger particle diameters required more time to pass, whereas the objects with smaller particle diameters flowed in a short time; this implied that the particles with a smaller size could be extracted more rapidly from the outlet. By plotting the trajectories of the particles for each unit of time, the passing speed of the objects with large particle diameters was confirmed to be particularly low. It was also possible to trap the particles within the chamber if the flow rate was below a specific threshold. By applying this property to blood, for instance, we expected plasma components and red blood cells to be extracted first.

3D printed microfluidic mixer for real-time monitoring of organic reactions by direct infusion mass spectrometry

3D printing is a technology that has revolutionized traditional rapid prototyping methods due to its ability to build microscale structures with customized geometries in a simple, fast, and low-cost way. In this sense, this article describes the development of a microfluidic mixing device to monitor chemical reactions by mass spectrometry (MS). Microfluidic mixers were designed containing 3D serpentine and Y-shaped microchannels, both with a pointed end for facilitating the spray formation. The devices were fabricated entirely by 3D printing with fusion deposition modeling (FDM) technology. As proof-of-concept, micromixers were evaluated through monitoring the Katritzky reaction by injecting simultaneously 2,4,6-triphenylpropyllium (TPP) and amino acid (glycine or alanine) solutions, each through a different reactor inlet. Reaction product was monitored online by MS at different flow rates. Mass spectra showed that the relative abundances of the products obtained with the device containing the 3D serpentine channel were three times greater than those obtained with the Y-channel device due to the turbulence generated by the barriers created inside microchannels. In addition, when compared to the conventional electrospray ionization mass spectrometry (ESI-MS) technique, the 3D serpentine mixer offered better performance measured in relation to the relative abundance values for the reaction products. These results as well as the instrumental simplicity indicate that 3D printed microfluidic mixer is a promising tool for monitoring organic reactions via MS.

Sulphonated graphene oxide catalyzed continuous flow synthesis of pyrazolo pyrimidinones, sildenafil and other PDE-5 inhibitors

Sulphonated graphene oxide was used for cascade condensation and cyclization reactions towards accessing substituted pyrazolo pyrimidinones. Further, sulphonation and amination reactions were integrated through continuous flow chemistry to access PDE-5 inhibitors. Herein, we report a simple continuous synthetic platform that reduce tedious manual operations and accelerate the synthesis of several potent inhibitors of phosphodiesterase type-5. The developed platform enabled us to perform one-flow multi-step, multi-operational process to synthesize the PDE-5 inhibitors such as sildenafil and its analogues in 32.3 min of the reaction time, with minimal human intervention and single solvent.

The Concept of Chemical Generators: On-Site On-Demand Production of Hazardous Reagents in Continuous Flow

In recent years, a steadily growing number of chemists, from both academia and industry, have dedicated their research to the development of continuous flow processes performed in milli- or microreactors. The common availability of continuous flow equipment at virtually all scales and affordable cost has additionally impacted this trend. Furthermore, regulatory agencies such as the United States Food and Drug Administration actively encourage continuous manufacturing of active pharmaceutical ingredients (APIs) with the vision of quality and productivity improvements. That is why the pharmaceutical industry is progressively implementing continuous flow technologies. As a result of the exceptional characteristics of continuous flow reactors such as small reactor volumes and remarkably fast heat and mass transfer, process conditions which need to be avoided in conventional batch syntheses can be safely employed. Thus, continuous operation is particularly advantageous for reactions at high temperatures/pressures (novel process windows) and for ultrafast, exothermic reactions (flash chemistry).

In addition to conditions that are outside of the operation range of conventional stirred tank reactors, reagents possessing a high hazard potential and therefore not amenable to batch processing can be safely utilized (forbidden chemistry). Because of the small reactor volumes, risks in case of a failure are minimized. Such hazardous reagents often are low molecular weight compounds, leading generally to the most atom-, time-, and cost-efficient route toward the desired product. Ideally, they are generated from benign, readily available and cheap precursors within the closed environment of the flow reactor on-site on-demand. By doing so, the transport, storage, and handling of those compounds, which impose a certain safety risk especially on a large scale, are circumvented. This strategy also positively impacts the global supply chain dependency, which can be a severe issue, particularly in times of stricter safety regulations or an epidemic. The concept of the in situ production of a hazardous material is generally referred to as the “generator” of the material. Importantly, in an integrated flow process, multiple modules can be assembled consecutively, allowing not only an in-line purification/separation and quenching of the reagent, but also its downstream conversion to a nonhazardous product.

For the past decade, research in our group has focused on the continuous generation of hazardous reagents using a range of reactor designs and experimental techniques, particularly toward the synthesis of APIs. In this Account, we therefore introduce chemical generator concepts that have been developed in our laboratories for the production of toxic, explosive, and short-lived reagents. We have defined three different classes of generators depending on the reactivity/stability of the reagents, featuring reagents such as Br₂, HCN, peracids, diazomethane (CH₂N₂), or hydrazoic acid (HN₃). The various reactor designs, including in-line membrane separation techniques and real-time process analytical technologies for the generation, purification, and monitoring of those hazardous reagents, and also their downstream transformations are presented. This Account should serve as food for thought to extend the scope of chemical generators for accomplishing more efficient and more economic processes.

Hydrodynamic Characterization of Phase Separation in Devices with Microfabricated Capillaries

Capillary microseparators have been gaining interest in downstream unit operations, especially for pharmaceutical, space, and nuclear applications, offering efficient separation of two-phase flows. In this work, a detailed analysis of the dynamics of gas?liquid separation at the single meniscus level helped to formulate a model to map the operability region of microseparation devices. A water?nitrogen segmented flow was separated in a microfabricated silicon-glass device, with a main channel (width, W = 600 ?m; height, H = 120 ?m) leading into an array of 276 capillaries (100 ?m long; width = 5 ?m facing the main channel and 25 ?m facing the liquid outlet), on both sides of the channel. At optimal pressure differences, the wetting phase (water) flowed through the capillaries into the liquid outlet, whereas the nonwetting phase (nitrogen) flowed past the capillaries into the gas outlet. A high-speed imaging methodology aided by computational analysis was used to quantify the length of the liquid slugs and their positions in the separation zone. It was observed that during stable separation, the position of the leading edge of the liquid slugs (advancing meniscus), which became stationary in the separation zone, was dependent only on the outlet pressure difference. The trailing edge of the liquid slugs (receding meniscus) approached the advancing meniscus at a constant speed, thus leading to a linear decrease of the liquid slug length. Close to the liquid-to-gas breakthrough point, that is, when water exited through the gas outlet, the advancing meniscus was no longer stationary, and the slug lengths decreased exponentially. The rates of decrease of the liquid slug length during separation were accurately estimated by the model, and the calculated liquid-to-gas breakthrough pressures agreed with experimental measurements.

Micro-electro-flow reactor (μ-EFR) system for ultra-fast arene synthesis and manufacture of daclatasvir

Electro-micro flow reactor containing Pt@Ni@Cu anode materials for reductant free biaryl synthesis, further extended to daclatasvir synthesis.

Integrated continuous flow/batch protocol for the photoreduction of ortho-methyl phenyl ketones using water as the hydrogen source

The direct hydrogenation of ketones (RRCO) with water to secondary alcohols under catalyst-free, minimal risk conditions, through the light-driven transfer hydrogenation platform.

Flow-Assisted Switchable Catalysis of Metal Ions in a Microenvelope System Embedded with Core-Shell Polymers

Many efforts have been made on stimuli-responsive switchable catalysis to trigger catalytic activity over various chemical reactions. However, the reported light-, pH- or chemically responsive organocatalysts are mostly incomplete in the aspects of shielding efficiency and long-term performance. Here, we advance the flow-assisted switchable catalysis of metal ions in a microenvelope system that allows  the on-off catalysis mode on demand for long-lasting catalytic activity. Various metal-ion catalysts can be selectively embedded in a novel polymeric core-shell of the heteroarm star copolymer of poly(styrene) and poly(4-vinylpyridine) emanated from a polyhedral oligomeric silsesquioxane center. The immobilized core-shell polymer on the inner wall of a poly(dimethylsiloxane) envelope microreactor shows on-off switching catalysis between the expanded active mode and contracted protective mode under continuous flow of solvents or subsequent dry conditions. In particular, the preserved catalytic activity of toxic Hg²⁺ for oxymercuration was demonstrated even for 2 weeks without leaching, whereas the activity of moisture-sensitive Ru³⁺ ions for polymerization of methyl methacrylate was maintained even after 5 days from an open atmosphere. It is practical that the tight environment of the enveloped microfluidic system facilitates cyclic switching between the reaction-"on" and -"off" modes of such toxic, sensitive/expensive catalysts for long-term prevention and preservation.

Superamphiphobic coatings based on liquid-core microcapsules with engineered capsule walls and functionality

Microcapsules with specific functional properties, related to the capsule wall and core, are highly desired in a number of applications. In this study, hybrid cellulose microcapsules (1.2 ± 0.4 µm in diameter) were prepared by nanoengineering the outer walls of precursor capsules. Depending on the preparation route, capsules with different surface roughness (raspberry or broccoli-like), and thereby different wetting properties, could be obtained. The tunable surface roughness was achieved as a result of the chemical and structural properties of the outer wall of a precursor capsule, which combined with a new processing route allowed in-situ formation of silica nanoparticles (30–40 nm or 70 nm in diameter). By coating glass slides with “broccoli-like” microcapsules (30–40 nm silica nanoparticles), static contact angles above 150° and roll-off angles below 6° were obtained for both water and low surface-tension oil (hexadecane), rendering the substrate superamphiphobic. As a comparison, coatings from raspberry-like capsules were only strongly oleophobic and hydrophobic. The liquid-core of the capsules opens great opportunities to incorporate different functionalities and here hydrophobic superparamagnetic nanoparticles (SPIONs) were encapsulated. As a result, magnetic broccoli-like microcapsules formed an excellent superamphiphobic coating-layer on a curved geometry by simply applying an external magnetic field.

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.