Microreactor systems and methods

Patent metadata

Field	Value
Publication number	US-10105671-B2
Application number	US-201514936916-A
Country	US
Kind code	B2
Filing date	Nov 10, 2015
Priority date	Nov 11, 2014
Publication date	Oct 23, 2018
Grant date	Oct 23, 2018

Abstract

In various embodiments, a microreactor features a corrosion-resistant microchannel network encased within a thermally conductive matrix material that may define therewithin one or more hollow heat-exchange conduits.

First claim

What is claimed is:

1. A method of fabricating a microreactor, the method comprising:
forming a network of hollow microchannel conduits from a corrosion-resistant material; and
thereduring, surrounding the network of microchannel conduits with a matrix material having a thermal conductivity larger than a thermal conductivity of the corrosion-resistant material.

2. The method of claim 1 , further comprising defining a plurality of hollow heat-exchange conduits within the matrix material, the heat-exchange conduits not intersecting the microchannel conduits.

3. The method of claim 1 , wherein the network of microchannel conduits is formed by an additive manufacturing technique.

4. The method of claim 3 , wherein the additive manufacturing technique comprises three-dimensional printing.

5. The method of claim 3 , wherein the matrix material is formed around the microchannel conduits via the additive manufacturing technique.

6. The method of claim 1 , wherein the corrosion-resistant material comprises at least one of niobium, molybdenum, tantalum, tungsten, rhenium, titanium, zirconium, glass, or stainless steel.

7. The method of claim 1 , wherein the matrix material comprises at least one of aluminum, gold, brass, silver, or copper.

8. The method of claim 1 , wherein a wall thickness of each of the microchannels ranges between 10 μm and 500 μm.

9. The method of claim 1 , wherein a portion of the matrix proximate at least a portion of at least one of the microchannel conduits has a mixed and/or graded composition comprising the corrosion-resistant material and the matrix material.

10. The method of claim 1 , wherein forming the network of microchannel conduits comprises forming at least one microchannel conduit with a sealed end, and further comprising unsealing the sealed end after the network of microchannel conduits and the matrix material are formed.

11. A method of fabricating a microreactor, the method comprising:
shaping and joining metal sheet into one or more microchannel conduits, the metal sheet comprising a corrosion-resistant material;
fabricating one or more microreactor parts each configured to interface with one or more of the microchannel conduits via an additive manufacturing technique utilizing a feedstock comprising the corrosion-resistant material;
joining the one or more microchannel conduits to the one or more microreactor parts, thereby forming a microchannel network of the microreactor; and
thereafter, encasing the microchannel network within a matrix material having a thermal conductivity larger than a thermal conductivity of the corrosion-resistant material.

12. The method of claim 11 , further comprising, during or after the encasing of the microchannel network within the matrix material, defining within the matrix material one or more hollow heat-exchange conduits, the one or more heat-exchange conduits not intersecting the microchannel network.

13. The method of claim 12 , wherein a diameter or lateral dimension of at least one heat-exchange channel is larger than a diameter or lateral dimension of at least one microchannel conduit.

14. The method of claim 11 , wherein the microchannel network is encased within the matrix material via an additive manufacturing technique.

15. The method of claim 11 , wherein the microchannel network is encased within the matrix material via at least one of casting or powder pressing.

16. The method of claim 11 , wherein the corrosion-resistant material comprises at least one of niobium, molybdenum, tantalum, tungsten, rhenium, titanium, zirconium, glass, or stainless steel.

17. The method of claim 11 , wherein the matrix material comprises at least one of aluminum, gold, brass, silver, or copper.

18. The method of claim 11 , wherein a portion of the matrix proximate at least a portion of the microchannel network has a mixed and/or graded composition comprising the corrosion-resistant material and the matrix material.

19. The method of claim 11 , further comprising:
sealing at least one opening in the microchannel network before encasing the microchannel network within the matrix material; and
unsealing the at least one sealed opening after encasing the microchannel network within the matrix material.

20. The method of claim 11 , wherein the microchannel network comprises two or more input conduits converging to a single reaction zone.

21. The method of claim 20 , wherein the microchannel network comprises an output conduit leading away from the reaction zone.

Assignees

• Aimone Paul R
• Abouaf Marc
• Hogan Patrick
• Starck H C Inc

Inventors

• Aimone Paul R
• Abouaf Marc
• Hogan Patrick

Classifications

• B22F5/10

  of articles with cavities or holes, not otherwise provided for in the preceding subgroups · CPC title

• B01J19/02

  Apparatus characterised by being constructed of material selected for its chemically-resistant properties · CPC title

• B01J2219/0277

  Metal based · CPC title

• B01J2219/0236

  Metal based · CPC title

• B01J19/2415

  Tubular reactors · CPC title