Numerical investigation of multiscale lateral microstructures enhancing passive micromixing efficiency via secondary vortex flow

Passive micromixing can efficiently mix laminar flows through molecular and convective diffusion. Microstructures are expected to be efficient, easily integrated into micromixers, and suitable for micromixers over a wide range of Re. This paper presents the enhancement effects of the multiscale lateral microstructures on the flow field characteristics and mixing efficiency through numerical simulations at Re = 0.01–50. Inspired by the regulation of lateral microstructures on the local flow field, cross-scale staggered baffles (CSBs) were established and applied in typical passive micromixers. For low-Re conditions, the paired trapezoidal microstructures (PTMs) of the CSBs improved the mixing effect by increasing the local streamline tortuosity. For high-Re conditions, the PTMs of CSBs increased the number of expanding vortices in the microchannel, which could increase the size of the fluid interfaces, and an optimal mixing index with relatively little pressure drop was achieved. Moreover, the CSBs were applied to the serpentine curved channel, which caused large expanding vortices on the inner side of the curved channel, and then the state of the Dean vortices on the cross section of the curved channel changed. Therefore, compared with the conventional micromixer channel structure, lateral microstructures regulate the local flow field through the enhancement of the streamlines and the secondary flow effects, and lateral microstructures have great potential to improve the mixing efficiency over a wide range of Re.