PDMS-glass hybrid microreactor array with embedded temperature control device. Application to cell-free protein synthesis

A microreactor array was developed which enables high-throughput cell-free protein synthesis. The microreactor array is composed of a temperature control chip and a reaction chamber chip. The temperature control chip is a glass-made chip on which temperature control devices, heaters and temperature sensors, are fabricated with an ITO (indium tin oxide) resistive material. The reaction chamber chip is fabricated by micromolding of PDMS (polydimethylsiloxane), and is designed to have an array of reaction chambers and flow channels for liquid introduction. The microreactor array is assembled by placing the reaction chamber chip on the temperature control chip. The small thermal mass of the reaction chamber resulted in a short thermal time constant of 170 ms for heating and 3 s for cooling. The performance of the microreactor array was examined through the experiments of cell-free protein synthesis. By measuring the fluorescence emission from the products, it was confirmed that GFP (Green Fluorescent Protein) and BFP (Blue Fluorescent Protein) were successfully synthesized using Escherichia coli extract.     

Evaluation of cell-free protein synthesis using PDMS-based microreactor arrays.

A living cell has numerous proteins, only a few thousand of which have been identified to date. Cell-free protein synthesis is a useful and promising technique to discover and produce various proteins that might be beneficial for biotechnological, pharmaceutical, and medical applications. For this study, we evaluated the performance and the general applicability of our previously developed microreactor array chip to cell-free protein synthesis by comparisons with a commercially available system. The microreactor array chip comprises a temperature control chip made of glass and a disposable reaction chamber chip made of polydimethylsiloxane (PDMS). For evaluation of the microreactor array chip, rat adipose-type fatty acid binding protein, glyceraldehyde-3-phosphate dehydrogenase, cyclophilin, and firefly luciferase were synthesized from their respective DNA templates using a cell-free extract prepared from Escherichia coli. All these proteins were synthesized in the microreactor array chip, and their respective amounts and yields were investigated quantitatively.     

Design of a capillary-microreactor for efficient Suzuki coupling reactions

A Pyrex glass capillary (0.4 mm internal diameter) microreactor was developed and used for Suzuki coupling reactions. Capillary-microreactors are more attractive than photolithographic microfluidic devices in terms of simplicity, low cost and ease of handling. Compared with the conventional synthesis procedure, our approach of using a capillary-microreactor offers a convenient and highly efficient means to optimize reaction conditions and the performance of catalysts. The procedure exhibits good precision, reproducibility and high reaction yield for a range of reactants investigated.     

Microreactors as Tools for Synthetic Chemists—The Chemists' Round‐Bottomed Flask of the 21st Century?

Will microreactors replace the round‐bottomed flask to perform chemical reactions in the near future? Recent developments in the construction of microstructured reaction devices and their wide‐ranging applications in many different areas of chemistry suggest that they can have a significant impact on the way chemists conduct their experiments. Miniaturizing reactions offers many advantages for the synthetic organic chemist: high‐throughput scanning of reaction conditions, precise control of reaction variables, the use of small quantities of reagents, increased safety parameters, and ready scale‐up of synthetic procedures. A wide range of single‐ and multiphase reactions have now been performed in microfluidic‐based devices. Certainly, microreactors cannot be applied to all chemistries yet and microfluidic systems also have disadvantages. Limited reaction‐time range, high sensitivity to precipitating products, and new physical, chemical, and analytical challenges have to be overcome. This concept article presents an overview of microfluidic devices available for chemical synthesis and evaluates the potential of microreactor technology in organic synthesis.     

The synthesis of fluorinated materials in microreactors

Synthetic utilities of microreactor for the synthesis of fluorinated materials are described. In particular, synthesis of silylenol ether of 4,4,4-trifluorobutan-2-one and its synthetic application at room temperature. Further, nitroaldol reactions and Michael addition reaction in microreactor are convenient ways for the syntheses of difluoromethylated materials.     

Generation and reactions of oxiranyllithiums by use of a flow microreactor system

A flow microreactor system consisting of micromixers and microtubes provides an effective reactor for the generation and reactions of aryloxiranyllithiums without decomposition by virtue of short residence time and efficient temperature control. The deprotonation of styrene oxides with sBuLi can be conducted by using the flow microreactor system at -78 or -68 °C (whereas much lower temperatures (< -100 °C) are needed for the same reactions conducted under macrobatch conditions). The resulting α-aryloxiranyllithiums were allowed to react with electrophiles in the flow microreactor system at the same temperature. The sequential introduction of various electrophiles onto 2,3-diphenyloxiranes was also achieved by using an integrated flow microreactor, which serves as a powerful system for the stereoselective synthesis of tetrasubstituted epoxides.     

Controllable polymerization of N-carboxy anhydrides in a microreaction system

We have developed a microfluidic system for polymerization of amino acid N-carboxyanhydride and compared the properties of the products with those obtained by batchwise system under various experimental conditions. It was found that the microreactor produced polymers with narrower molecular weight distribution compared with polymers obtained by the batchwise system. Also, the molecular mass of the polymer produced using the microreactor was simply governed by the flow (pumping) rate. These results indicated that the microreactor could be a model for synthesis of amino acid polymer with highly controllable average molecular weight and molecular weight distribution.     

微流控芯片中高效合成苯基二吡咯-2-基甲烷的研究

微流控芯片是近年发展起来的一种新型的微反应器.在微流控芯片中以HCl为催化剂常温下合成了苯基二吡咯-2-基甲烷,考察了反应物流速、催化剂浓度、吡咯与苯甲醛的比例对苯基二吡咯-2-基甲烷产率的影响.通过在催化剂溶液中加入离子液体[bmim]BF4明显地提高了反应效率,苯基二吡咯-2-基甲烷的产率可以达到95%以上.采用本法大大减少了试剂用量和条件试验阶段的实验成本.     

Continuous‐Flow Technology—A Tool for the Safe Manufacturing of Active Pharmaceutical Ingredients

In the past few years, continuous‐flow reactors with channel dimensions in the micro‐ or millimeter region have found widespread application in organic synthesis. The characteristic properties of these reactors are their exceptionally fast heat and mass transfer. In microstructured devices of this type, virtually instantaneous mixing can be achieved for all but the fastest reactions. Similarly, the accumulation of heat, formation of hot spots, and dangers of thermal runaways can be prevented. As a result of the small reactor volumes, the overall safety of the process is significantly improved, even when harsh reaction conditions are used. Thus, microreactor technology offers a unique way to perform ultrafast, exothermic reactions, and allows the execution of reactions which proceed via highly unstable or even explosive intermediates. This Review discusses recent literature examples of continuous‐flow organic synthesis where hazardous reactions or extreme process windows have been employed, with a focus on applications of relevance to the preparation of pharmaceuticals.     

Microreactors for the synthesis of fluorinated materials

The utility of microreactor for the synthesis of α-fluoro-α,β-unsaturated esters, trifluoromethylation and Michael addition reaction, is described.     

Pigments with improved properties – microreaction technology as a new approach for synthesis of pigments –

Clariant, as an important pigment producer forces the investigation of new pigments with improved qualities and properties to fulfill the rising tomorrow's demands of customers. For these reasons, new production ways like microreaction technology are included. This paper focuses on results obtained in manufacturing pigments in a lab-scale microreactor as well as in a microreactor pilot plant. Investigations of the diazotation, azo-coupling and laking steps of pigments have shown not only the principle feasibility of these reactions in laboratory microreactors but also significant improvement of coloristic properties. The microreactor pilot plant, realized by the concept of numbering-up instead of conventional scaling-up process, allowed more detailed investigations of the complete azo-pigments synthesis under production conditions.     

Catalysis of hydrosilylation. XV. A poly(phosphino-organosiloxanyl)silicate-supported rhodium(I) catalyst for gas-phase hydrosilylation of acetylene

Wilkinson's complex [RhCl(PPh₃)₃], anchored to phosphino-organosiloxane macromolecules grafted onto chrysotile asbestos, appeared to be an unusually effective and selective catalyst for the synthesis of vinylsilanes via gas-phase hydrosilylation of acetylene, particularly by methyldichlorosilane in a continuous-flow microreactor as well as in a laboratory reactor. Catalytic and kinetic parameters show an advantage for the catalyst based on the chrysotile-polyorganosiloxane support (catalyst CHR–Rh) over the phosphinated silica (catalyst A).     

Rapid multistep synthesis of 1,2,4-oxadiazoles in a single continuous microreactor sequence

A general method for the synthesis of bis-substituted 1,2,4-oxadiazoles from readily available arylnitriles and activated carbonyls in a single continuous microreactor sequence is described. The synthesis incorporates three sequential microreactors to produce 1,2,4-oxadiazoles in approximately 30 min in quantities (40-80 mg) sufficient for full characterization and rapid library supply.     

Fabrication of a Flexible and Disposable Microreactor Using a Dry Film Photoresist

In this paper, we demonstrate that a low‐cost flexible microreactor can be manufactured using a dry film photoresist in conjunction with photolithographic and hot roll lamination techniques. A microfluidic flow path and sample reservoir patterns were prefabricated in a dry film photoresist tape using traditional photolithographic methods. This tape was sandwiched between two plastic films ‐ wells were prepouched on the cover film — that were bonded upon passage through a hot roll laminator. A simple Plexiglas reactor holder was designed and constructed to use in evaluating the flexible microchip reactor. We demonstrate a chemical synthesis of polyaniline that was performed with this polymeric microreactor using a hydrodynamic flow control system. The fabrication of this microreactor suggests that there is great potential for designing and prototyping disposable microscale reaction systems using dry film photoresist for a range of chemical and biochemical syntheses.     

TS-1 zeolite microengineered reactors for 1-pentene epoxidation

A zeolite-based microengineered reactor was fabricated and tested for 1-pentene epoxidation over titanium silicalite-1 (TS-1) catalyst, which has been selectively incorporated within the microreactor channel using a new synthesis procedure.     

Continuous synthesis of dolutegravir sodium crystals using liquid-gas heterogeneous microreactor

In this work, a liquid-gas heterogeneous microreactor was developed for investigating continuous crystallization of dolutegravir sodium (DTG), as well as revealing reaction kinetics and mixing mechanism with 3-min data acquisition. The reaction kinetics models were established by visually recording the concentration variation of reactants over time in the microchannel via adding pH-sensitive fluorescent dye. The mixing intensification mechanism of liquid-gas flow was quantified through the fluorescent signal to indicate mixing process, demonstrating an outstanding mixing performance with a mixing time less than 0.1 s. Compared with batch crystallization, continuous synthesis of dolutegravir sodium using liquid-gas heterogenous microreactor optimizes crystal distribution size, and successfully modifies the crystal morphology in needle-like habit instead of rod-like habit. The microreactor continuous crystallization can run for 5 h without crystal blockage and achieve D90 of DTG less than 30 µm. This work provides a feasible approach for continuously synthesizing dolutegravir sodium, and can optimize the existing pharmaceutical crystallization.     

Microfluidic labeling of biomolecules with radiometals for use in nuclear medicine

Radiometal-based radiopharmaceuticals, used as imaging and therapeutic agents in nuclear medicine, consist of a radiometal that is bound to a targeting biomolecule (BM) using a bifunctional chelator (BFC). Conventional, macroscale radiolabeling methods use an excess of the BFC-BM conjugate (ligand) to achieve high radiolabeling yields. Subsequently, to achieve maximal specific activity (minimal amount of unlabeled ligand), extensive chromatographic purification is required to remove unlabeled ligand, often resulting in longer synthesis times and loss of imaging sensitivity due to radioactive decay. Here we describe a microreactor that overcomes the above issues through integration of efficient mixing and heating strategies while working with small volumes of concentrated reagents. As a model reaction, we radiolabel 1,4,7,10-tetraazacyclododecane-1,4,7,10-tetraacetic acid (DOTA) conjugated to the peptide cyclo(Arg-Gly-Asp-DPhe-Lys) with (64)Cu(2+). We show that the microreactor (made from polydimethylsiloxane and glass) can withstand 260 mCi of activity over 720 hours and retains only minimal amounts of (64)Cu(2+) (<5%) upon repeated use. A direct comparison between the radiolabeling yields obtained using the microreactor and conventional radiolabeling methods shows that improved mixing and heat transfer in the microreactor leads to higher yields for identical reaction conditions. Most importantly, by using small volumes (~10 μL) of concentrated solutions of reagents (>50 μM), yields of over 90% can be achieved in the microreactor when using a 1:1 stoichiometry of radiometal to BFC-BM. These high yields eliminate the need for use of excess amounts of often precious BM and obviate the need for a chromatographic purification process to remove unlabeled ligand. The results reported here demonstrate the potential of microreactor technology to improve the production of patient-tailored doses of radiometal-based radiopharmaceuticals in the clinic.     

Droplet synthesis of well-defined block copolymers using solvent-resistant microfluidic device

Well-defined diblock copolymers were synthesized via an exothermic RAFT route by a droplet microfluidic process using a solvent-resistant and thermally stable fluoropolymer microreactor fabricated by a non-lithographic embedded template method. The resulting polymers were compared to products obtained from continuous flow capillary reactor and conventional bulk synthesis. The droplet based microreactor demonstrated superior molecular weight distribution control by synthesizing a higher molecular weight product with higher conversion and narrow polydispersity in a much shorter reaction time. The high quality of the as-synthesized block copolymer PMMA-b-PS led to a generation of micelles with a narrow size distribution that could be used as a template for well-ordered mesoporous silica with regular frameworks and high surface areas.     

A Teflon microreactor with integrated piezoelectric actuator to handle solid forming reactions

We present a general inexpensive method for realizing a Teflon stack microreactor with an integrated piezoelectric actuator for conducting chemical synthesis with solid products. The microreactors are demonstrated with palladium-catalyzed C-N cross-coupling reactions, which are prone to clogging microchannels by forming insoluble salts as by-products. Investigations of the ultrasonic waveform applied by the piezoelectric actuator reveal an optimal value of 50 kHz at a load power of 30 W. Operating the system at these conditions, the newly developed Teflon microreactor handles the insoluble solids formed and no clogging is observed. The investigated reactions reach full conversion in very short reaction times and high isolated yields are obtained (>95% yield).     

An enzyme-encapsulated microreactor for efficient theanine synthesis

A flow-type microreactor containing glutaminase-mesoporous silica composites with 10.6 nm pore diameter (TMPS10.6) was developed for the continuous synthesis of theanine, a unique amino acid. High enzymatic activity was exhibited by the local control of the reaction temperature.