Design and High-Resolution Analysis of an Efficient Periodic Split-and-Recombination Microfluidic Mixer

We developed a highly efficient passive mixing device based on a split-and-recombine (SAR) configuration. This micromixer was constructed by simply bonding two identical microfluidic periodical open-trench patterns face to face. The structure parameters of periodical units were optimized through numerical simulation to facilitate the mixing efficiency. Despite the simplicity in design and fabrication, it provided rapid mixing performance in both experiment and simulation conditions. To better illustrate the mixing mechanism, we developed a novel scheme to achieve high-resolution confocal imaging of serial channel cross-sections to accurately characterize the mixing details and performance after each SAR cycle. Using fluorescent IgG as an indicator, nearly complete mixing was achieved using only four SAR cycles in an aqueous solution within a device's length of less than 10 mm for fluids with a Péclet number up to 8.7 × 10⁴. Trajectory analysis revealed that each SAR cycle transforms the input fluids using three synergetic effects: rotation, combination, and stretching to increase the interfaces exponentially. Furthermore, we identified that the pressure gradients in the parallel plane of the curved channel induced vertical convection, which is believed to be the driving force underlying these effects to accelerate the mixing process.