A mesh microcontactor for 2-phase reactions

The design, fabrication and use of mesh microcontactor structures is described. These allow contact between immiscible fluid phases (liquid/liquid or gas/liquid) enabling mass transfer and reaction between and within the phases. The phases are not mixed and are removed separately for subsequent use or analysis. The structures were designed for kinetic studies on biphasic reactions with the ability to handle sequential samples without excessive sample dispersion. Mass transport conditions are defined by fluid layer depths of 100 microm and the volume for each phase contacting in the reaction region was selected at 100 microl as sufficient for a range of analytical techniques. Micromeshes with pore diameter, depth, and spacing each of approximately 5 microm were formed by electrodeposition of nickel onto substrates with defined photoresist layers, and released by etching a copper sub-layer. Reactor enclosures defining chambers on each side of the mesh were formed from milled glass and metal components. The assembled structures have been used in flow-through and static fluid modes. System function has been demonstrated for both liquid/liquid and gas/liquid reactions. Test chemistries selected for ease of optical monitoring were hydrolysis of colourless fluorescein diacetate in toluene with transfer as fluorescein anion to aqueous alkali, and oxygen absorption into aqueous alkaline pyrogallol solution generating a coloured product, purpurogallin.