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Experimental optimization of flow distributors for pressure-driven separations and reactions in flat-rectangular microchannels.

We report on the results of an experimental study established to optimize the design of microfabricated flow distributors for use in pressure-driven separations and reactions in flat-rectangular channels. For this purpose, the performance of a wide variety of possible flow distributor designs etched in glass/silicon wafers was compared, using CCD camera detection to study the shape and variance of the bands eluting from them. The best performance was obtained with radially interconnected distributors with a diverging inlet section and filled with diamond-shaped pillars, oriented perpendicular to the main flow direction and with a high transversal over axial aspect ratio. It was found that the best distributor designs start with a diverging section containing some 10-12 subsequent rows of high aspect ratio pillars (with a transversal width making up 10-15% of the final channel width) and with a divergence angle selected such that the sloped side-walls run parallel with the sides of the diamond-shaped pillars. After this zone, one or more regions with pillars with a smaller aspect ratio should be provided to increase the number of exit points. To prevent the formation of dead zones in these subsequent zones, so-called distributor wedges can be used to prevent the formation of any dead zones in the wake of the large aspect ratio pillars of the preceding section.