Microreactor architectures for mixing, reactions, and/or heat exchange
Background Microfluidic systems and micro-reactors have emerged as promising platforms for precise, small-scale fluid processing. Microfluidic systems offer reduced reagent use, enhanced control over reaction kinetics, and improved safety through process intensification. However, efficient mixing of immiscible fluids or fluids of differing viscosities remains challenging. Conventional micromixers often fail to achieve sufficient mass transfer across fluid interfaces—particularly when mixing liquids with contrasting viscosities or differing phases (i.e., gas and liquids). Additionally, many designs are difficult to scale, limited in throughput, or require external energy inputs which introduce complexity and cost. There is a need for scalable micro‑mixing solutions that enable rapid, repeatable, and energy-efficient mixing for continuous-flow chemical processing. These systems must handle a variety of fluid combinations, maintain thermal stability, and support modular integration for broader process engineering.
Technology Description Described in two issued patents, this technology is a class of laminated microchannel-based mixers and reactors designed to overcome the limitations of conventional microfluidic mixing and reactor systems. These devices leverage a modular, stacked architecture composed of precisely patterned laminae (thin plates), which, when bonded together, define a network of micro-channels that guide and mix fluid streams with high precision. Fluids enter through inlets and are distributed into parallel micro-channels formed between adjacent laminae. These channels are designed to achieve mixing through both interface disruption and volumetric convergence, tailored as needed to the application. The layered format enables handling of diverse fluid properties—low and high viscosity, immiscible liquid–liquid systems, and gas–liquid combinations—without requiring active mixing components. Some designs may further include an inter‑digitated structure and/or multiple split-and-recombine stages within a single reactor unit. Fluids are split into sub-streams, passed through multiple recombination zones, and mixed progressively layer-by-layer. This boosts mixing efficiency and also allows for integrated heat exchange within the same module, essential for exothermic, endothermic, or temperature-sensitive reactions. The architectures are modular, compact, and tunable. The precise patterning of each lamina can be adjusted for specific process needs, enabling bespoke reactor configurations.
Features & Benefits
Applications
Opportunity OSU is seeking commercial development partners.
Status Patented US8622606B2, US9421507B2