Search Results (42)

This study investigates the continuous-flow hydrolysis reaction of propylene oxide (PO) in a spiral microchannel reactor, integrating experiments, computational fluid dynamics (CFD) simulations, and response surface methodology (RSM). To the best of our knowledge, experimentally determined apparent Arrhenius parameters for PO hydrolysis under microscale continuous-flow conditions remain rarely reported, and afterwards they were incorporated into CFD-based numerical simulations. This combined experimental–numerical framework provides a robust methodology for quantifying and optimizing liquid-phase kinetics in microscale flow environments. Subsequently, CFD simulations were employed to examine key process parameters, including reaction system temperature, inlet flow rate, and reactor length. Finally, RSM was utilized to identify the optimal process conditions (reaction system temperature of 298.15 K, inlet flow rate of 6 × 10⁻³ m·s⁻¹, and reactor length of 4 m), achieving a predicted PO conversion rate of 81.68%. The study provides a reference for designing and optimizing spiral microchannel reactors for PO hydrolysis. Full article

Inertial microfluidics is promising for the high throughput, label-free continuous separation of multicomponent microparticles. However, conventional single spiral microchannels struggle to separate three or more particle types, while traditional cascaded systems relying on sheath fluids or multiple pumps suffer from increased operational complexity. To address this, we propose a cascaded dual spiral microfluidic chip based on passive flow resistance matching. Driven by a single syringe pump without sheath flow, it achieves continuous sorting of three particle types. An adaptive flow resistance network is incorporated: the first stage channel maintains high velocity to preferentially extract large particles via strong inertial lift forces. The fluid then enters the second stage through a predetermined geometric resistance for automatic deceleration. Experiments demonstrate that at 1.6 mL/min, the system achieves continuous separation of a 1:10:10 mixture of 15, 10, and 5 µm microparticles. The 15 µm target recovery rate reaches 92%, while the collection purities for 10 µm and 5 µm particles exceed 98% and 99%, respectively. This purely passive fluidic architecture simplifies cascaded sorting, providing a robust engineering solution for complex multicomponent sample preprocessing. Full article

Spiral inertial microfluidic devices provide a simple, high-throughput approach for size-based particle separation; however, translating PDMS-optimized designs into monolithic, fully enclosed 3D-printed channels is often limited by printability and post-print channel clearing. In our previous PDMS study, a $400\times 120\mu \mathrm{m}$ spiral achieved high separation performance after computational optimization and experimental validation. To translate this high-performing PDMS concept into a faster and more cost-effective manufacturing approach, the same separation principle is transferred to a fully 3D-printed, closed-channel spiral device, and the geometry is re-optimized around manufacturability constraints. Printing trials showed that enclosed channels at $400\times 120\mu \mathrm{m}$ and $600\times 180\mu \mathrm{m}$ could not be cleared reliably due to trapped resin and frequent blockage, most often near the inner-outlet region. In contrast, $800\times 240\mu \mathrm{m}$ and $1200\times 360\mu \mathrm{m}$ channels were printed and flushed successfully, and $800\times 240\mu \mathrm{m}$ was selected as the smallest reproducibly functional cross-section. Particle-tracking simulations were then used to re-optimize spiral development length, showing that a 4-turn device provides limited collection for $12\mu \mathrm{m}$ targets (10%), intermediate lengths (5–7 turns) improve collection to 50%, and an 8-turn spiral achieves complete large-particle collection (100%) across tested target sizes (12–$24\mu \mathrm{m}$) while reducing small-particle crossover. Experimental validation of the 8-turn $800\times 240\mu \mathrm{m}$ device at $Q=6\mathrm{m}\mathrm{L} {\min }^{-1}$ using fluorescent polystyrene particles ($18\mu \mathrm{m}$ target; $6\mu \mathrm{m}$ background) yielded an average collection efficiency of 84% and an inner-outlet purity of 92%. Overall, these results demonstrate that spiral inertial separation can be retained in a monolithic 3D-printed format when the design is re-optimized around the smallest reliably clearable enclosed cross-section and sufficient spiral development length. Full article

Thermal runaway accidents in lithium batteries necessitate effective thermal management. This study proposes a liquid cooling plate with internal spiral-array fins and investigates its performance under electrochemically coupled temperature-dependent heat generation conditions. A pseudo-two-dimensional (P2D) electrochemical model simulates battery discharge at 0.5C–2C rates to obtain heat generation characteristics, which serve as inputs for a fluid–solid coupled heat transfer model. The effects of spiral fin parameters—pitch (S) and height (h)—are systematically analyzed. Three main contributions are presented: spiral fins induce secondary flow that disrupts thermal boundary layer development and enhances fluid mixing, with smaller pitch extending the flow path and increasing radial velocity; a performance evaluation criterion (PEC)-based analysis identifies the optimal parameter range that balances heat transfer enhancement and pressure drop penalty; and increasing the fin height raises the finned area proportion and swirl intensity, suppressing bypass flow and strengthening heat transfer, with effects more pronounced at higher discharge rates. Key quantitative findings show that at 2C discharge, the optimized configuration (S = 3 mm, h = 0.5 mm) achieves a comprehensive performance index of 2.19 and reduces the maximum temperature by 25.32% compared to smooth channels. This work integrates electrochemical and thermal models to provide a new approach for optimizing spiral fin microchannels tailored to lithium battery operation. Full article

This study explores the passive separation of solid particles from liquid suspensions in spiral separators fabricated using fused filament fabrication (FFF) and stereolithography (SLA). Building on prior work, we investigate the effect of microchannel geometry, circular vs. square cross-sections of equal area, and printing method on separation performance. Devices were tested across a wider range of flow rates (150 mL min⁻¹–350 mL min⁻¹), extending into transitional regimes, to examine geometry-induced inertial effects. Separation performance was quantified using the normalized outlet mass difference (Δ) for talc, precipitated calcium carbonate, and quartz. Maximum separation was obtained for quartz sand in the SLA separator at 250 mL min⁻¹ (Δ = 0.2175 g per 100 mL), while talc showed the highest mass difference in the square FFF separator at 300 mL min⁻¹ (Δ = 0.1196 g per 100 mL). For calcium carbonate, the highest separation occurred in the SLA device at 250 mL min⁻¹ (Δ = 0.1721 g per 100 mL), though performance was limited by agglomeration and clogging in FFF devices. Overall, separation was predominantly mass-based rather than strictly size-selective, with channel geometry, flow regime, and fabrication method jointly governing performance. Full article

Owing to their superior mass and heat transfer performance, microreactors have emerged as a research hotspot in novel intensified equipment in recent years. This study experimentally investigates the gas–liquid flow behavior and mass transfer characteristics in microchannel reactors for viscous systems, focusing on the effects of superficial gas and liquid velocities, viscosity, and spiral turbulence elements on T-type microchannel reactors (T-MCRs). Four flow regimes are identified in the T-MCR, where viscosity significantly influences regime distribution and Taylor bubble morphology. In contrast, the spiral-wired T-MCR (T-MCR-SW) is dominated by “serpentine Taylor flow”. Increased viscosity leads to elevated pressure drop and reduced CO₂ saturation in both reactors, with the T-MCR-SW exhibiting a notably higher pressure drop. The impact of gas–liquid flow rates on CO₂ saturation varies with reactor type and viscosity. The total volumetric mass transfer coefficient (K_La) of the T-MCR-SW is substantially higher than that of the T-MCR, but its pressure drop is nearly doubled. Thus, a balance between mass transfer efficiency and energy consumption must be considered for practical applications. This work provides valuable insights for the design and optimization of microreactors in viscous systems. Full article

To enhance passive mixing in microchannels, T-shaped double-spiral and serpentine microchannels with identical curvature radii were designed and numerically analyzed across a Reynolds number (Re) range of 1 to 300. The double-spiral microchannel exhibited superior mixing performance at Re ≤ 200, which is primarily attributed to the efficient utilization of Dean vortices. In contrast, the serpentine microchannel showed better performance at Re ≥ 250, benefiting from the early formation of four-vortex structures induced by periodic curvature reversals. To further enhance the performance of the serpentine microchannel at low Re, groove structures with varying orientation angles were incorporated. The introduction of the groove structures generated lateral secondary flows that not only increased flow disturbances but also disrupted the symmetry of the Dean vortices. Among these configurations, Structure 2, with a 45° angle between the groove direction and centrifugal force, exhibited the most pronounced enhancement in vortex intensity, as the secondary flows induced by the grooves synergistically interacted with the Dean vortices. This configuration resulted in the highest mixing enhancement (>50%). This study provides valuable insights into geometry-driven mixing mechanisms and offers design guidelines for high-efficiency micromixers across a wide range of Re. Full article

This study presents an innovative wedge-shaped inlet weir-type microfluidic chip designed to address common issues of clogging and inefficiency in microfiltration processes. Driven solely by centrifugal force, the chip integrates a crossflow separation mechanism and enables selective droplet sorting based on size, without the need for external pumps. Fabricated from PMMA, the device features a central elliptical chamber, a wedge-shaped inlet, and spiral microchannels. These structures leverage shear stress and Dean vortices under centrifugal fields to achieve high-throughput separation of droplets with different diameters. Using water-in-oil emulsions as a model system, we systematically investigated the effects of geometric parameters and rotational speed on separation performance. A theoretical model was developed to derive the critical droplet size based on force balance, accounting for centrifugal force, viscous drag, pressure differentials, and surface tension. Experimental results demonstrate that the chip can effectively separate droplets ranging from 0 to 400 μm in diameter at 200 rpm, achieving a sorting efficiency of up to 72% and a separation threshold (cutoff accuracy) of 98.2%. Fluorescence analysis confirmed the absence of cross-contamination during single-chip operation. This work offers a structure-guided, efficient, and contamination-free droplet sorting strategy with broad potential applications in biomedical diagnostics and drug screening. Full article

A spiral microfluidic chip (SMC) and multi-spiral microfluidic chip (MSMC) for lipid nanoparticle (LNP) production were fabricated using a CO₂ laser engraving method, using perfluoropolyether (PFPE) and poly(ethylene glycol) diacrylate as photopolymerizable base materials. The SMC includes a spiral microchannel that enables rapid fluid mixing, thereby facilitating the production of small and uniform LNPs with a size of 72.82 ± 24.14 nm and a PDI of 0.111 ± 0.011. The MSMC integrates multiple parallel SMC structures, which enables high-throughput LNP production without compromising quality and achieves a maximum production capacity of 960 mL per hour. The LNP fabrication technology using SMC and MSMC has potential applications in the pharmaceutical field due to the ease of chip fabrication, the simplicity and cost-effectiveness of the process, and the ability to produce high-quality LNPs. Full article

Accurate separation in microfluidic devices is crucial for biomedical applications; however, enhancing their performance remains challenging due to computational and experimental constraints. This study aims to optimize microfluidic devices by systematically refining spiral microchannel configurations for the segregation of circulating tumor cells (CTCs) and red blood cells (RBCs) through detailed variable analysis and resource-efficient techniques. The spiral design was developed into six variations, considering loop numbers (2, 3, and 4), aspect ratios (2.333, 3.333, and 5), spiral radii (5, 6, and 7 mm), flow rates (1.5, 2, and 3 mL/min), surface roughness levels (0, 0.5, and 1 μm), and particle sizes (12, 18, and 24 μm). Simulations were conducted in COMSOL Multiphysics and evaluated using the Taguchi method to determine the optimal configuration, reducing the analysis set from 216 to 27 through an efficient experimental design approach. The results identified the optimal structure as having an aspect ratio of 3.333, four loops, a spiral radius of 6–7 mm, a flow rate of 3 mL/min, a surface roughness of 1 μm, and a particle diameter of 24 μm. Among the evaluated parameters, aspect ratio (61.2%) had the most significant impact, followed by the number of loops (13.9%) and flow rate (9.4%). The optimized design demonstrated high separation efficiency and purity, achieving 97.5% and 97.6%, respectively. The fabrication process involved 3D-printing the channel mold, followed by polydimethylsiloxane (PDMS) casting, validating the durability and scalability of the proposed design. This study integrates simulation and experimental results, providing a robust framework for developing next-generation microfluidic devices and advancing diagnostic and targeted therapeutic applications. Full article

The microchannel plate (MCP) is susceptible to the adsorption of substantial amounts of gas during its fabrication process. To mitigate this, a uniform electron source is essential for effective electron scrubbing and gas removal. Thermionic emission, a method of electron generation, can be employed to create the electron source. In this study, a flat spiral filament was designed and simulated using the CST Studio Suite electron simulation software to assess the cleaning performance of the electron gun. The impact of variations in electron gun parameters on the uniformity of the electron beam and current density was systematically analysed. The simulation results show that, with filament, grid, focusing sleeve, and anode voltages set to 200 V, 500 V, 250 V, and 300 V, respectively, a uniform electron beam with a diameter exceeding 30 mm can be achieved. In order to obtain the current density (5~50 nA/mm²) required for the MCP, the temperature of the filament should be 1800–2000 K through theoretical calculation. These findings offer valuable insights for designing a more efficient electron gun for MCP scrubbing. Full article

In microfluidic chips, glass free-form microchannels have obvious advantages in thermochemical stability and biocompatibility compared to polymer-based channels, but they face challenges in processing morphology and quality. Hence, picosecond laser etching with galvanometer scanning is proposed to machine spiral microfluidic channels on a glass substrate. The objective is to disperse and sort microparticles from a glass microchip that is difficult to cut. First, the micropillar array and the spiral microchannel were designed to disperse and sort the particles in microchips, respectively; then, a scanning path with a scanning interval of 5 μm was designed according to the spot diameter in picosecond laser etching; next, the effects of laser power, scanning speed and accumulation times were experimentally investigated regarding the morphology of spiral microchannels; finally, the microfluidic flowing test with 5 μm and 10 μm microparticles was performed to analyze the dispersing and sorting performance. It was shown that reducing the laser power and accumulation times alongside increasing the scanning speed effectively reduced the channel depth and surface roughness. The channel surface roughness reached about 500 nm or less when the laser power was 9 W, the scanning speed was 1000 mm/s, and the cumulative number was 4. The etched micropillar array, with a width of 89 μm and an interval of 97 μm, was able to disperse the different microparticles into the spiral microchannel. Moreover, the spiral-structured channel, with an aspect ratio of 0.51, significantly influenced the velocity gradient distribution, particle focusing, and stratification. At flow rates of 300–600 μL/min, the microparticles produced stable focusing bands. Through the etched microchip, mixed 5 μm and 10 μm microparticles were sorted by stable laminar flow at flow rates of 400–500 μL/min. These findings contribute to the design and processing of high-performance glass microfluidic chips for dispersion and sorting. Full article

Inertial focusing-based Lab-on-Chip systems represent a promising technology for cell sorting in various applications, thanks to their alignment with the ASSURED criteria recommended by the World Health Organization: Affordable, Sensitive, Specific, User-friendly, Rapid and Robust, Equipment-free, and Delivered. Inertial focusing techniques using spiral microchannels offer a rapid, portable, and easy-to-prototype solution for cell sorting. Various microfluidic devices have been investigated in the literature to understand how hydrodynamic forces influence particle focusing in spiral microchannels. This is crucial for the effective prototyping of devices that allow for high-throughput and efficient filtration of particles of different sizes. However, a clear, comprehensive, and organized overview of current research in this area is lacking. This review aims to fill this gap by offering a thorough summary of the existing literature, thereby guiding future experimentation and facilitating the selection of spiral geometries and materials for cell sorting in microchannels. To this end, we begin with a detailed theoretical introduction to the physical mechanisms underlying particle separation in spiral microfluidic channels. We also dedicate a section to the materials and prototyping techniques most commonly used for spiral microchannels, highlighting and discussing their respective advantages and disadvantages. Subsequently, we provide a critical examination of the key details of inertial focusing across various cross-sections (rectangular, trapezoidal, triangular, hybrid) in spiral devices as reported in the literature. Full article

Microchannels with curved geometries have been employed for many applications in microfluidic devices in the past decades. The Dean vortices generated in such geometries have been manipulated using different methods to enhance the performance of devices in applications such as mixing, droplet sorting, and particle/cell separation. Understanding the effect of the manipulation method on the Dean vortices in different geometries can provide crucial information to be employed in designing high-efficiency microfluidic devices. In this review, the physics of Dean vortices and the affecting parameters are summarized. Various Dean number calculation methods are collected and represented to minimize the misinterpretation of published information due to the lack of a unified defining formula for the Dean dimensionless number. Consequently, all Dean number values reported in the references are recalculated to the most common method to facilitate comprehension of the phenomena. Based on the converted information gathered from previous numerical and experimental studies, it is concluded that the length of the channel and the channel pathline, e.g., spiral, serpentine, or helix, also affect the flow state. This review also provides a detailed summery on the effect of other geometric parameters, such as cross-section shape, aspect ratio, and radius of curvature, on the Dean vortices’ number and arrangement. Finally, considering the importance of droplet microfluidics, the effect of curved geometry on the shape, trajectory, and internal flow organization of the droplets passing through a curved channel has been reviewed. Full article

The isolation of circulating tumor cells (CTCs) and their analysis are crucial for the preliminary identification of invasive cancer. One of the effective properties that can be utilized to isolate CTCs is their deformability. In this paper, inertial-based spiral microchannels with various numbers of loops are employed to sort deformable CTCs using the finite element method (FEM) and an arbitrary Lagrangian–Eulerian (ALE) approach. The influences of cell deformability, cell size, number of loops, and channel depth on the hydrodynamic behavior of CTCs are discussed. The results demonstrate that the trajectory of cells is affected by the above factors when passing through the spiral channel. This approach can be utilized for sorting and isolating label-free deformable biological cells at large scales in clinical systems. Full article