Multi-layered micro-channel mixer and method for mixing fluids

A multi-layered micro-channel mixer, comprising:

• a base plate;
• and
• a cover plate;
• wherein two inlet fluid reservoirs, two inlet channels, two groups of fluid distribution channel networks, two groups of process fluid channels, an impinging stream mixing chamber, a fluid mixing intensification channel and an outlet buffer reservoir are provided on the base plate;
• the cover plate is provided with three through-holes;
• two of the three through-holes are connected with the two inlet fluid reservoirs, respectively, and used as inlets of fluid materials to be mixed;
• the another one of the three through-holes is connected with the outlet buffer reservoir and used as an outlet of mixed fluid material;
• one end of each of the two inlet fluid reservoirs is connected with an external feed tube via a corresponding through-hole in the cover plate, and the other end of each of the two inlet fluid reservoirs is connected with one of the two inlet channels;
• each of the two inlet channels is connected with one group of process fluid channels via one group of fluid distribution channel network;
• each of the two groups of fluid distribution channel networks is composed of N stages of fluid distribution channels with different hydraulic diameters, wherein N is an integer ranging from 1-10;
• the first stage fluid distribution channels are directly connected with the two inlet channels, respectively;
• the Nth stage fluid distribution channels have 2N branch channels that are connected with 2N next stage fluid distribution channels, or have 2(N+1) branch channels that are connected with 2(N+1) process fluid channels;
• each fluid distribution channel has two branch channels;
• each branch channel is connected with either a next stage fluid distribution channel or two process fluid channels;
• each branch channel of the last stage fluid distribution channels has two branches which are connected with two process fluid channels, respectively;
• one end of each of the process fluid distribution channels is connected with one branch channel of the last stage fluid distribution channels, and the other end of each of the process fluid channels is an outlet end and fixed inside the impinging stream mixing chamber;
• the two groups of process fluid channels are connected with the two inlet channels, respectively, and are symmetrically arranged on both sides of the impinging stream mixing chamber;
• the end of each of the process fluid channels inside the impinging stream mixing chamber is tapered;
• the impinging stream mixing chamber is directly connected with the fluid mixing intensification channel;
• internals or baffles are installed in the impinging stream mixing chamber;
• internals or baffles are installed in the fluid mixing intensification channel;
• the fluid mixing intensification channel is connected with the outlet buffer reservoir;
• and the outlet buffer reservoir is connected with an external discharge tube via the another one of the three through-holes;
• an angle α formed between each of the inlet channels and the corresponding first stage fluid distribution channel is 70°-130°;
• an angle β formed between each of the branch channels and the corresponding next stage fluid distribution channel is 70°-130°;
• an angle γ formed between two adjacent process fluid channels that are connected with the same branch channel is 95°-150°;
• each of the fluid distribution channels has a rectangular cross section;
• each of the first stage fluid distribution channels has a width of 0.1-30 mm, a depth of 0.1-15 mm and a length of 1-200 mm;
• the width, depth and length of the Nth stage fluid distribution channel are 40%-90%, 40%-90% and 20%-80% of those of the (N−1)th stage fluid distribution channel, respectively, where N is an integer greater than or equal to 2;
• the baffles are installed in interval arrangement at both side walls of the impinging stream mixing chamber;
• an angle θ formed between each of the baffles and the side wall of the impinging stream mixing chamber is 20°-160°;
• the internals or baffles in the impinging stream mixing chamber are fixed away from the central axes of the process fluid channels, and are not in the same horizontal planes with the central axes of the process fluid channels;
• the distance between the central axis of the process fluid channel and its neighboring baffle or internal is 50-800 μm;
• a distance between two adjacent baffles or internals in the impinging stream mixing chamber is 50 μm-5 mm;
• the baffles are installed in interval arrangement at both side walls of the fluid mixing intensification channel;
• an angle φ formed between the baffle and the side wall of the fluid mixing intensification channel is 20°-160°;
• a distance between two adjacent baffles or internals in the fluid mixing intensification channel is 50 μm-5 mm;
• an outlet of each of the process fluid channels inside the impinging stream mixing chamber is tapered, and has a width of 1-500 μm;
• the process fluid channels are symmetrically arranged on both sides of the impinging stream mixing chamber;
• and
• a distance between the two tapered outlets of two process fluid channels symmetrically arranged with respect to the impinging stream mixing chamber is 10-500 μm.