Multiple modular microfluidic (M3) reactors for the synthesis of polymer particles.

Area of Science:

• Polymer Science
• Microfluidics
• Materials Science

Background:

• Microfluidic reactors offer precise control over particle synthesis.
• Scaling up microfluidic particle production presents challenges in maintaining uniformity and productivity.

Purpose of the Study:

• To investigate the continuous generation of polymer particles in parallel multiple modular microfluidic (M3) reactors.
• To identify and mitigate factors affecting particle size distribution in M3 reactors.

Main Methods:

• Utilized sixteen parallel microfluidic reactors per module, including emulsification and polymerization compartments.
• Analyzed and minimized effects of fabrication fidelity, crosstalk, and droplet/particle coalescence.
• Optimized M3 reactor design for consistent particle generation.

Main Results:

• Successfully minimized factors causing broadened particle size distribution compared to individual reactors.
• Achieved production of polymer microgel particles with polydispersity not exceeding 5%.
• Demonstrated a productivity of approximately 50 g/h using the M3 reactor system.

Conclusions:

• M3 reactors enable continuous, high-throughput, and uniform polymer particle synthesis.
• The study provides a scalable approach for producing polymer microgels with controlled properties.
• Optimized M3 reactor design overcomes common challenges in parallel microfluidic systems.