Acoustic resonance and atomization for gas-liquid systems in microreactors

It is shown that a liquid slug in gas–liquid segmented flow in microchannels can act as an acoustic resonator to disperse large amounts of small liquid droplets, commonly referred to as atomization, into the gas phase. We investigate the principles of acoustic resonance within a liquid slug through experimental analysis and numerical simulation. A mechanism of atomization in the confined channels and a hypothesis based on high-speed image analysis that links acoustic resonance within a liquid slug with the observed atomization is proposed. The observed phenomenon provides a novel source of confined micro sprays and could be an avenue, amongst others, to overcome mass transfer limitations for gas–liquid processes in flow.     

Agglomeration of particles by a converging ultrasound field and their quantitative assessments

The acoustic radiation force resulting from acoustic waves have been extensively studied for the contact-free generation of organized patterning arrays. The precise arrangement of microscopic objects clustered at the pressure nodes is critical to the development of functional structures and patterned surfaces. However, the size of the clusters is restricted by the saturation limit of the acoustic nodes. Here, we present a bulk acoustic wave (BAW) platform, which employs a two-dimensional acoustic wave to propel particles of various sizes. Experimentally, when particles are large, significant acoustic energy is scattered and partly absorbed by the matched layers in front of the sensors. The acoustic radiation force from a convergent acoustic pressure field agglomerates the large polystyrene (PS) particles towards the central region instead of the pressure nodes. The parametric analysis has been performed to assess the transition in the particles from clustering at the organized nodal arrays to agglomerating in the central region, which is a function of particle size, particle concentration, and load voltage. Statistically, the particles can agglomerate with a cluster ratio greater than 70%, and this ratio can be improved by increasing the load power/voltage supplied to the transducers. With its ability to perform biocompatible, label-free, and contact-free self-assembly, this concept offers a new possibility in the fabrication of colloidal layers, the recreation of tissue microstructure, the development of organoid spheroid cultures, the migration of microorganisms, and the assembly of bioprinting materials.     

Particle separation in microfluidics using different modal ultrasonic standing waves

Microfluidic technology has great advantages in the precise manipulation of micro and nano particles, and the separation of micro and nano particles based on ultrasonic standing waves has attracted much attention for its high efficiency and simplicity of structure. This paper proposes a device that uses three modes of ultrasonic standing waves to continuously separate particles with positive acoustic contrast factor in microfluidics. Three modes of acoustic standing waves are used simultaneously in different parts of the microchannel. According to the different acoustic radiation force received by the particles, the particles are finally separated to the pressure node lines on both sides and the center of the microchannel. In this separation method, initial hydrodynamic focusing and satisfying various equilibrium constraints during the separation process are the key. Through numerical simulation, the resonance frequency of the interdigital transducer, the distribution of sound pressure in the liquid, and the relationship between the interdigital electrode voltage and the output sound pressure are obtained. Finally, the entire separation process in the microchannel was simulated, and the separation of the two particles was successfully achieved. This work has laid a certain theoretical foundation for the rapid diagnosis of diseases in practical applications.     

Control of the dynamics of a boiling vapour bubble using pressure-modulated high intensity focused ultrasound without the shock scattering effect: A first proof-of-concept study

Boiling histotripsy is a promising High-Intensity Focused Ultrasound (HIFU) technique that can be used to induce mechanical tissue fractionation at the HIFU focus via cavitation. Two different types of cavitation produced during boiling histotripsy exposure can contribute towards mechanical tissue destruction: (1) a boiling vapour bubble at the HIFU focus and (2) cavitation clouds in between the boiling bubble and the HIFU source. Control of the extent and degree of mechanical damage produced by boiling histotripsy is necessary when treating a solid tumour adjacent to normal tissue or major blood vessels. This is, however, difficult to achieve with boiling histotripsy due to the stochastic formation of the shock scattering-induced inertial cavitation clouds. In the present study, a new histotripsy method termed pressure-modulated shockwave histotripsy is proposed as an alternative to or in addition to boiling histotripsy without inducing the shock scattering effect. The proposed concept is (a) to generate a boiling vapour bubble via localised shockwave heating and (b) subsequently control its extent and lifetime through manipulating peak pressure magnitudes and a HIFU pulse length. To demonstrate the feasibility of the proposed method, bubble dynamics induced at the HIFU focus in an optically transparent liver tissue phantom were investigated using a high speed camera and a passive cavitation detection systems under a single 10, 50 or 100 ms-long 2, 3.5 or 5 MHz pressure-modulated HIFU pulse with varying peak positive and negative pressure amplitudes from 5 to 89 MPa and −3.7 to −14.6 MPa at the focus. Furthermore, a numerical simulation of 2D nonlinear wave propagation with the presence of a boiling bubble at the focus of a HIFU field was conducted by numerically solving the generalised Westervelt equation. The high speed camera experimental results showed that, with the proposed pressure-modulated shockwave histotripsy, boiling bubbles generated by shockwave heating merged together, forming a larger bubble (of the order of a few hundred micron) at the HIFU focus. This coalesced boiling bubble then persisted and maintained within the HIFU focal zone until the end of the exposure (10, 50, or 100 ms). Furthermore, and most importantly, no violent cavitation clouds which typically appear in boiling histotripsy occurred during the proposed histotripsy excitation (i.e. no shock scattering effect). This was likely because that the peak negative pressure magnitude of the backscattered acoustic field by the boiling bubble was below the cavitation cloud intrinsic threshold. The size of the coalesced boiling bubble gradually increased with the peak pressure magnitudes. In addition, with the proposed method, an oval shaped lesion with a length of 0.6 mm and a width of 0.1 mm appeared at the HIFU focus in the tissue phantom, whereas a larger lesion in the form of a tadpole (length: 2.7 mm, width: 0.3 mm) was produced by boiling histotripsy. Taken together, these results suggest that the proposed pressure-modulated shockwave histotripsy could potentially be used to induce a more spatially localised tissue destruction with a desired degree of mechanical damage through controlling the size and lifetime of a boiling bubble without the shock scattering effect.     

Wave mixing in coupled phononic crystals via a variable stiffness mechanism

We investigate wave mixing effects in a phononic crystal that couples the wave dynamics of two channels – primary and control ones – via a variable stiffness mechanism. We demonstrate analytically and numerically that the wave transmission in the primary channel can be manipulated by the control channel's signal. We show that the application of control waves allows the selection of a specific mode through the primary channel. We also demonstrate that the mixing of two wave modes is possible whereby a modulation effect is observed. A detailed study of the design parameters is also carried out to optimize the switching capabilities of the proposed system. Finally, we verify that the system can fulfill both switching and amplification functionalities, potentially enabling the realization of an acoustic transistor.     

Frequency-dependent acoustic energy focusing in hexagonal ceramic micro-scaffolds

Acoustic properties of an additive-manufactured SiC scaffold with hexagonal symmetry fabricated by the robocasting method are studied both numerically and experimentally. The numerical analysis is based on the finite element method (FEM) using Bloch boundary conditions. The calculations show both angular and frequency dispersion of the acoustic waves with wavelengths comparable to the spacing between the rods, i.e., on a millimeter scale, indicating interesting acoustic properties in the MHz range. The dispersion character leads to focusing of the energy propagation into the directions of the rods of the hexagonal structure. This is illustrated by modal-based calculations of the propagation of longitudinal and out-of-plane shear wave packets with a dominant wavelength. The experimental analysis consists of two steps, the measurement of the resonant spectrum and shear wave propagation character. The measured resonant spectrum is in good agreement with the one calculated using numerically obtained low-frequency properties of the structure, also showing the quality of the overall manufactured structure. The time-domain measurement shows significant changes in the energy propagation between low and high frequencies, as predicted by FEM calculations.     

Synergistic effects of the alternating application of low and high frequency ultrasound for particle synthesis in microreactors

Ultrasound (US) is a promising method to address clogging and mixing issues in microreactors (MR). So far, low frequency US (LFUS), pulsed LFUS and high frequency US (HFUS) have been used independently in MR for particle synthesis to achieve narrow particle size distributions (PSD). In this work, we critically assess the advantages and disadvantages of each US application method for the case study of calcium carbonate synthesis in an ultrasonic microreactor (USMR) setup operating at both LFUS (61.7 kHz, 8 W) and HFUS (1.24 MHz, 1.6 W). Furthermore, we have developed a novel approach to switch between LFUS and HFUS in an alternating manner, allowing us to quantify the synergistic effect of performing particle synthesis under two different US conditions. The reactor was fabricated by gluing a piezoelectric plate transducer to a silicon microfluidic chip. The results show that independently applying HFUS and LFUS produces a narrower PSD compared to silent conditions. However, at lower flow rates HFUS leads to agglomerate formation, while the reaction conversion is not enhanced due to weak mixing effects. LFUS on the other hand eliminates particle agglomerates and increases the conversion due to the strong cavitation effect. However, the required larger power input leads to a steep temperature rise in the reactor and the risk of reactor damage for long-term operation. While pulsed LFUS reduces the temperature rise, this application mode leads again to the formation of particle agglomerates, especially at low LFUS percentage. The proposed application mode of switching between LFUS and HFUS is proven to combine the advantages of both LFUS and HFUS, and results in particles with a unimodal narrow PSD (one order of magnitude reduction in the average size and span compared to silent conditions) and negligible rise of the reactor temperature.