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We propose a novel passive micromixer leveraging STC (split-to-circulate) flow characteristics and analyze its mixing performance comprehensively. Three distinct designs incorporating submerged circular walls were explored to achieve STC flow characteristics, facilitating flow along a convex surface and flow impingement on a concave surface. Across a broad Reynolds number range (0.1 to 80), the present micromixer substantially enhances mixing, with a degree of mixing (DOM) consistently exceeding 0.84. Particularly, the mixing enhancement is prominent within the low and intermediate range of Reynolds numbers (0.1

A novel passive micromixer equipped with circulation promoters is proposed, and its mixing performance is simulated over a broad range of Reynolds numbers (0.1≤Re≤100). To evaluate the effectiveness of the circulation promoters, three different configurations are analyzed in terms of the degree of mixing (DOM) at the outlet and the associated pressure drop. Compared to other typical passive micromixers, the circulation promoter is shown to significantly enhance mixing performance. Among the three configurations of circulation promoters, Case 3 demonstrates the best performance, with a DOM exceeding 0.96 across the entire range of Reynolds numbers. At Re = 1, the DOM of Case 3 is 3.7 times larger than that of a modified Tesla micromixer, while maintaining a comparable pressure drop. The mixing enhancement of the present micromixer is particularly significant in the low and intermediate ranges of Reynolds numbers (Re<40). In the low range of Reynolds numbers (Re≤1), the mixing enhancement is primarily due to circulation promoters directing fluid flow from a concave wall to the opposite convex wall. In the intermediate range of Reynolds numbers (2≤Re<40), the mixing enhancement results from fluid flowing from one concave wall to another concave wall on the opposite side.

A novel passive micromixer based on curly baffles is proposed and optimized through the signal-to-noise analysis of various design parameters. The mixing performance of the proposed design was evaluated across a wide Reynolds number range, from 0.1 to 80. Through the analysis, the most influential parameter was identified, and its value was found to be constant regardless of the mixing mechanism. The optimized design, refined using the signal-to-noise analysis, demonstrated a significant enhancement of mixing performance, particularly in the low Reynolds number range (Re< 10). The design set obtained at the diffusion dominance range shows the highest degree of mixing (DOM) in the low Reynolds number range of Re< 10, while the design set optimized for the convection dominance range exhibited the least pressure drop across the entire Reynolds number spectrum (Re< 80). The present design approach proved to be a practical tool for identifying the most influential design parameter and achieving excellent mixing and pressure drop characteristics. The enhancement is mainly due to the curvature of the most influential design parameter.

A novel passive micromixer based on multiple baffles and a submergence scheme was designed, and its mixing performance was simulated over a wide range of Reynolds numbers ranging from 0.1 to 80. The degree of mixing (DOM) at the outlet and the pressure drop between the inlets and outlet were used to assess the mixing performance of the present micromixer. The mixing performance of the present micromixer showed a significant enhancement over a wide range of Reynolds numbers (0.1 ≤ Re ≤ 80). The DOM was further enhanced by using a specific submergence scheme. At low Reynolds numbers (Re < 5), submergence scheme Sub24 produced the highest DOM, approximately 0.57, which was 1.38 times higher than the case with no submergence. This enhancement was due to the fluid flowing from or toward the submerged space, creating strong upward or downward flow at the cross-section. At high Reynolds numbers (Re > 10), the DOM of Sub1234 became the highest, reaching approximately 0.93 for Re = 20, which was 2.75 times higher than the case with no submergence. This enhancement was caused by a large vortex formed across the whole cross-section, causing vigorous mixing between the two fluids. The large vortex dragged the interface between the two fluids along the vortex perimeter, elongating the interface. The amount of submergence was optimized in terms of DOM, and it was independent of the number of mixing units. The optimum submergence values were 90 μm for Sub24 and Re = 1, 100 μm for Sub234 and Re = 5, and 70 μm for Sub1234 and Re = 20.

A passive micromixer based on the modified Tesla mixing unit was designed by embedding tip clearance above the wedge-shape divider, and its mixing performance was simulated over a wider range of the Reynolds numbers from 0.1 to 80. The mixing performance was evaluated in terms of the degree of mixing (DOM) at the outlet and the required pressure load between inlet and outlet. The height of tip clearance was varied from 40 μm to 80 μm, corresponding to 25% to 33% of the micromixer depth. The numerical results show that the mixing enhancement by the tip clearance is noticeable over a wide range of the Reynolds numbers Re < 50. The height of tip clearance is optimized in terms of the DOM, and the optimum value is roughly h = 60 μm. It corresponds to 33% of the present micromixer depth. The mixing enhancement in the molecular diffusion regime of mixing, Re ≤ 1, is obtained by drag and connection of the interface in the two sub-streams of each Tesla mixing unit. It appears as a wider interface in the tip clearance zone. In the intermediate range of the Reynolds number, 1 < Re ≤ 50, the mixing enhancement is attributed to the interaction of the flow through the tip clearance and the secondary flow in the vortex zone of each Tesla mixing unit. When the Reynolds number is larger than about 50, vortices are formed at various locations and drive the mixing in the modified Tesla micromixer. For the Reynolds number of Re = 80, a pair of vortices is formed around the inlet and outlet of each Tesla mixing unit, and it plays a role as a governing mechanism in the convection-dominant regime of mixing. This vortex pattern is little affected as long as the tip clearance remains smaller than about h = 70 μm. The DOM at the outlet is little enhanced by the presence of tip clearance for the Reynolds numbers Re ≥ 50. The tip clearance contributes to reducing the required pressure load for the same value of the DOM.

A new passive micro-mixer with mixing units stacked in the cross flow direction was proposed, and its performance was evaluated numerically. The present micro-mixer consisted of eight mixing units. Each mixing unit had four baffles, and they were arranged alternatively in the cross flow and transverse direction. The mixing units were stacked in four different ways: one step, two step, four step, and eight step stacking. A numerical study was carried out for the Reynolds numbers from 0.5 to 50. The corresponding volume flow rate ranged from 6.33 μL/min to 633 μL/min. The mixing performance was analyzed in terms of the degree of mixing (DOM) and relative mixing energy cost (MEC). The numerical results showed a noticeable enhancement of the mixing performance compared with other micromixers. The mixing enhancement was achieved by two flow characteristics: baffle wall impingement by a stream of high concentration and swirl motion within the mixing unit. The baffle wall impingement by a stream of high concentration was observed throughout all Reynolds numbers. The swirl motion inside the mixing unit was observed in the cross flow direction, and became significant as the Reynolds number increased to larger than about five. The eight step stacking showed the best performance for Reynolds numbers larger than about two, while the two step stacking was better for Reynolds numbers less than about two.

A passive micromixer was designed by combining two mixing units: the cross-channel split and recombined (CC-SAR) and a mixing cell with baffles (MC-B). The passive micromixer was comprised of eight mixing slots that corresponded to four combination units; two mixing slots were grouped as one combination unit. The combination of the two mixing units was based on four combination schemes: (A) first mixing unit, (B) first combination unit, (C) first combination module, and (D) second combination module. The statistical significance of the four combination schemes was analyzed using analysis of variance (ANOVA) in terms of the degree of mixing (DOM) and mixing energy cost (MEC). The DOM and MEC were simulated numerically for three Reynolds numbers (Re = 0.5, 2, and 50), representing three mixing regimes. The combination scheme (B), using different mixing units in the first two mixing slots, was significant for Re = 2 and 50. The four combination schemes had little effect on the mixing performance of a passive micromixer operating in the mixing regime of molecular dominance. The combination scheme (B) was generalized to arbitrary mixing slots, and its significance was analyzed for Re = 2 and 50. The general combination scheme meant two different mixing units in two consecutive mixing slots. The numerical simulation results showed that the general combination scheme was statistically significant in the first three combination units for Re = 2, and significant in the first two combination units for Re = 50. The combined micromixer based on the general combination scheme throughout the entire micromixer showed the best mixing performance over a wide range of Reynolds numbers, compared to other micromixers that did not adopt completely the general combination scheme. The most significant enhancement due to the general combination scheme was observed in the transition mixing scheme and was negligible in the molecular dominance scheme. The combination order was less significant after three combination units.

A new cross-channel split-and-recombine (CC-SAR) micro-mixer was proposed, and its performance was demonstrated numerically. A numerical study was carried out over a wide range of volume flow rates from 3.1 μL/min to 826.8 μL/min. The corresponding Reynolds number ranges from 0.3 to 80. The present micro-mixer consists of four mixing units. Each mixing unit is constructed by combining one split-and-recombine (SAR) unit with a mixing cell. The mixing performance was analyzed in terms of the degree of mixing and relative mixing cost. All numerical results show that the present micro-mixer performs better than other micro-mixers based on SARs over a wide range of volume flow rate. The mixing enhancement is realized by a particular motion of vortex flow: the Dean vortex in the circular sub-channel and another vortex inside the mixing cell. The two vortex flows are generated on the different planes perpendicular to each other. They cause the two fluids to change their relative position as the fluids flow into the circular sub-channel of the SAR, eventually promoting violent mixing. High vorticity in the mixing cell elongates the flow interface between two fluids, and promotes mixing in the flow regime of molecular diffusion dominance.