Patent Description:
In recent years, efforts have been actively made to apply a device which mixes fluids in a fine flow path prepared by a micro processing technique or the like, namely a microreactor, to biotechnology field, medical field, and chemical synthesis field of medicines, chemical products, or the like.

Synthesis reactions in a microreactor have the following features. That is, as the size of the reaction field in the microreactor decreases, fluids are mixed rapidly due to molecular diffusion. As a result, the effect of surface area on the volume of the fluid becomes relatively large, and the effect of heat transfer on the volume of the fluid becomes relatively large. Therefore, compared to general batch reactions, the production efficiency is expected to be improved by shortened reaction time and yield improvement.

Since the microreactor is a closed system which provides a small reaction field, the microreactor is suitable for handling highly corrosive substances and dangerous synthesis reactions. Even if the productivity of a single microreactor is small, the same product can be produced in large quantities by multiplying the number of the microreactors by N times, that is, so-called "numbering-up".

In addition, in the field of biotechnology or medicine synthesis, although the corrosiveness of the substance to be handled is relatively low, cross-contamination caused by inclusion of foreign matters from the outside is usually not preferred.

By using resins such as PDMS (polydimethylsiloxane), ABS resin, or PC (polycarbonate) as the material, the cost of material and molding process is reduced, so that the microreactor is for single use (disposable).

Various developments and studies have been carried out with respect to a flow path structure of a microreactor which is oriented for application to each of the fields mentioned above and in which two types of fluids are rapidly mixed.

As a first method, there has been known a technique in which two types of raw materials are each branched into a plurality of parts, and can be alternately introduced in a radial manner to form multilayer flows toward the center and merge with one another (refer to, for example, PTL <NUM> and PTL <NUM>).

PTL <NUM> (refer to claim <NUM>) describes a micro-device which "supplies two or more incoming fluids independently to a merging area and discharges the fluids from the merging area, comprising: supplying channels configured to supply each incoming fluid of the micro-device respectively to the merging area; and a discharging channel configured to discharge the merged fluids from the merging area to the outside of the micro-device, wherein the supplying channel, which supplies at least one fluid, has a plurality of sub-channels merging in the same merging area, the sub-channels and the supplying channels are configured such that a central axis of at least one of the plurality of sub-channels and a central axis of at least one of the supplying channels or the sub-channels supplying at least one of the fluids other than the fluid supplied by the above subchannel intersect with each other at a point" and a method for merging of fluids.

In addition, PTL <NUM> (refer to claim <NUM>) describes a method for producing organic pigment fine particles, comprising "allowing two or more solutions, at least one of which is an organic pigment solution in which an organic pigment is dissolved and at least one of which is a pH adjustor, to flow through a micro flow path in a non-laminar state; and depositing organic pigment fine particles from the organic pigment solution in a process of flowing, wherein the organic pigment solution is a solution in which an organic pigment is dissolved in an alkaline or acidic aqueous medium, the organic pigment fine particles are deposited by changing a hydrogen ion exponent (pH) of the organic pigment solution in the process of flowing in the micro flow path, and intersection angles α and β upon merging of solutions of the organic pigment solution and the pH adjustor are set to satisfy a relationship of S1>S2 if a sum of the cross-sectional areas of all of the merged solutions in the thickness direction is defined as S1 and the cross-sectional area of the micro flow path in the radial direction is defined as S2".

In addition, as a second method, there has been known a technique in which two types of raw materials are each branched into a plurality of parts, and one type of the branched raw materials merges in a way of being sandwiched by the other type of branched raw materials, so as to finally perform the merging (for example, refer to PTL <NUM>).

PTL <NUM> describes an emulsifying device "comprising an introducing member; a first member connected with the introducing member; a second member connected with the first member; a third member connected with the second member; and a discharge member connected with the third member, in a laminated manner. In each of a dispersion phase inflow path through which a first liquid flows and which penetrates the introducing member and the first member in a lamination direction; a continuous phase inflow path through which a second liquid which is dissoluble in the first liquid flows, and which is provided between the first member and the second member; a mixing flow path which penetrates the second member in the lamination direction and configured to form a sheath flow in which the first liquid flowing from the dispersion phase inflow path flows on an inner side, the second liquid flowing from the continuous phase inflow path flows on an outer side to form a mixed liquid; and an enlarged mixing flow path which penetrates the third member and the discharge member in the lamination direction and has a larger flow path width than the mixing flow path, the dispersion phase inflow path, the mixing flow path, and the enlarged mixing flow path are provided coaxially, the mixing flow path and the enlarged mixing flow path are formed on separate members respectively, the first liquid contained in the mixed liquid is divided while flowing in the mixing flow path and the enlarged mixing flow path so as to form emulsion particles, and thus emulsification is performed".

<CIT> discloses a reaction apparatus which has: a main flow channel having an inner diameter of <NUM>, in which a raw material flows; an introduction flow channel in which a raw material that causes a chemical reaction with the raw material flows; and five branch introduction flow channels which are branched from the introduction flow channel and introduce the raw material to the main flow channel.

<CIT> discloses a method for mixing fluids that can control mixing characteristics of fluids, a method for producing particulates that can provide desired particulates, and particulates produced thereby.

Here, in the technique of the flow path structure described in PTL <NUM>, two types of raw materials are each branched into a plurality of parts, and can be alternately introduced in a radial manner to form multilayer flows toward the center and merge with one another. In this technique, since the flow rate ratio (volume ratio) of the two types of raw materials does not change even when the raw materials are branched, a sufficient interfacial area between the raw materials may not be obtained if the flow rate ratio (volume ratio) is greatly biased. Here, the flow rate refers to the volume of a flowing fluid per unit time.

In addition, in the technique of the flow path structure described in PTL <NUM>, two types of raw materials are each branched into a plurality of parts, and one type of the branched raw materials merges in a state of being sandwiched by the other type of branched raw materials so as to finally perform the merging. In this technique, fine flow paths are required according to the number of the branches. However, since materials having high corrosion resistance are difficult to be finely processed, the technique may be difficult to be applied to highly corrosive substances or dangerous synthesis reactions.

Further, in the technique of the flow path structure described in PTL <NUM>, the flow path internal volume (internal capacity) of each raw material, from the introduction of the two types of raw materials to the merging thereof, are substantially the same. In this way, when the flow rate ratio (volume ratio) of the two types of raw materials is largely biased, more raw materials will flow on a high-flow-rate side. For this reason, the raw materials on the high-flow-rate side may flow into the flow path for raw materials on a low-flow-rate side at the beginning of the manufacture of chemical products.

The invention has been made in view of the above background. An object of the invention is to obtain good mixing effect when mixing raw materials having different flow rates.

The above cited problems are solved in accordance with the appended claims. In the following description, so-named "embodiments" which do not fall under the scope of the appended claims shall be considered examples useful for the understanding of the invention.

According to the invention, a good mixing effect can be obtained when mixing raw materials having different flow rates.

Next, embodiments for implementing the invention (referred to as "embodiments") will be appropriately described in detail with reference to the drawings.

Hereinafter, a first embodiment will be described with reference to <FIG>.

<FIG> is an external view of a microreactor according to the first embodiment.

A microreactor <NUM> of <FIG> includes a high-flow-rate side flow path <NUM>, a low-flow-rate side flow path <NUM>, a residence flow path <NUM>, a high-flow-rate side introduction port <NUM>, a low-flow-rate side introduction port <NUM>, and a discharge port <NUM>.

As shown in <FIG>, a raw material on the high-flow-rate side (a high-flow-rate raw material) is introduced from the high-flow-rate side introduction port <NUM>, and flows through the high-flow-rate side flow path <NUM> (the flow path for a high-flow-rate raw material) indicated by a one-dot chain line. In addition, a raw material on the low-flow-rate side (a low-flow-rate raw material) is introduced from the low-flow-rate side introduction port <NUM>, and flows through the low-flow-rate side flow path <NUM> (the flow path for a low-flow-rate raw material) indicated by a broken line. Here, at a branch point 111a, as the high-flow-rate side flow path <NUM> is branched into two paths: a branch flow path 102a and a branch flow path 102b indicated by one-dot chain lines, the raw material on the high-flow-rate side is also branched into two parts. At a merging point 111b, the raw material on the high-flow-rate side merges in a way of sandwiching the raw material on the low-flow-rate side. Here, the high-flow-rate raw material is mixed with the raw material on the low-flow-rate side. Hereinafter, the product obtained by mixing the raw material on the high-flow-rate side and the raw material on the low-flow-rate side is referred to as a mixture. The mixture finally flows through the residence flow path <NUM> indicated by a two-dot chain line and is discharged from the discharge port <NUM>. Here, the residence flow path <NUM> serves as a reaction field in a case where the flow rate of the mixture is small. However, in a case where the flow rate of the mixture is large, the mixture does not react in the residence flow path <NUM>, and is discharged from the discharge port <NUM> in the form of mixture. In this case, the residence flow path <NUM> serves as a mixing field.

The high-flow-rate side path <NUM> is branched into two branches, the branch flow path 102a and the branch flow path 102b, and thus the flow path internal volume (internal capacity) of the high-flow-rate side flow path <NUM> is larger than the flow path internal volume of the low-flow-rate side flow path <NUM>.

Here, it is desirable that the ratio between the flow path internal volume of the high-flow-rate side flow path <NUM> and the flow path internal volume of the low-flow-rate side flow path <NUM> is approximate to the flow rate ratio (volume ratio) between the two types of raw materials, but the invention is not limited thereto. The flow path internal volume of the high-flow-rate side flow path <NUM> and the flow path internal volume of the low-flow-rate side path <NUM> may be set such that the pressure losses during the flowing of the two types of raw materials are equal or approximate to each other.

Here, it is desirable that the cross-sectional areas of the high-flow-rate side flow path <NUM>, the branch flow paths 102a, 102b, the low-flow-rate side flow path <NUM> and the residence flow path <NUM> are the same from the viewpoint of the manufacturing method of the microreactor <NUM> to be described later in <FIG> (the cross-sectional area of the high-flow-rate side flow path <NUM> ≈ the total cross-sectional area of the branch flow paths 102a, 102b ≈ the cross-sectional areas of the low-flow-rate side flow path <NUM> ≈ the cross-sectional area of the residence flow path <NUM>). In this way, the cross-sectional area of the raw material on the high-flow-rate side in the residence flow path <NUM> is smaller than the total cross-sectional areas of the branch flow paths 102a and 102b. The cross-sectional area of the raw material on the low-flow-rate side in the residence flow path <NUM> is smaller than the cross-sectional area of the low-flow-rate side flow path <NUM>. For this reason, the raw material on the high-flow-rate side flowing from the high-flow-rate side flow path <NUM> and the raw material on the low-flow-rate side flowing from the low-flow-rate side flow path <NUM> are mixed satisfactorily. A pump <NUM> (refer to <FIG>) is connected to the high-flow-rate side introduction port <NUM> and the low-flow-rate side introduction port <NUM>. Since the raw materials on the high-flow-rate side and the low-flow-rate side are driven by a discharge force of the pump <NUM> to flow, the respective raw materials can flow into the residence flow path <NUM> even if the cross-sectional areas of the branch flow paths 102a, 102b and the low-flow-rate side flow path <NUM> are the same.

In the microreactor <NUM> shown in <FIG>, the lengths of the high-flow-rate side flow path <NUM> and the branch flow paths 102a, 102b are configured to be longer than the low-flow-rate side flow path <NUM>, so that the flow path internal volume of the high-flow-rate side flow path <NUM> is larger than the flow path internal volume of the low-flow-rate side flow path <NUM>, but the invention is not limited thereto. For example, the flow path internal volume of the high-flow-rate side flow path <NUM> may be larger than the flow path internal volume of the low-flow-rate side flow path <NUM> by making the cross-sectional area of the high-flow-rate side flow path <NUM> larger than the low-flow-rate side flow path <NUM>. The flow path internal volume of the high-flow-rate side flow path <NUM> may be larger than the flow path internal volume of the low-flow-rate side flow path <NUM> by both setting the lengths and cross-sectional areas of the high-flow-rate side flow path <NUM> and the branch flow paths 102a and 102b.

Further, it is desirable that the pressure loss in the flow path of the high-flow-rate side flow path <NUM> is substantially equal to the pressure loss in the low-flow-rate side flow path <NUM>.

Screw holes for fitting connection are formed in the high-flow-rate side introduction port <NUM>, the low-flow-rate side introduction port <NUM>, and the discharge port <NUM> (not shown). By using the fitting (not shown), tubes <NUM> (refer to <FIG>) can be connected to the high-flow-rate side introduction port <NUM>, the low-flow-rate side introduction port <NUM>, and the discharge port <NUM>.

The microreactor <NUM> is configured by two plates: an upper plate <NUM> and a lower plate <NUM>. The high-flow-rate side flow path <NUM>, the branch flow paths 102a, 102b, the low-flow-rate side flow path <NUM>, and the residence flow path <NUM> are formed on the upper plate <NUM>. The high-flow-rate side introduction port <NUM>, the low-flow-rate side introduction port <NUM>, and the discharge port <NUM> are formed on the lower plate <NUM>. The upper plate <NUM> and the lower plate <NUM> are integrated by welding. The welding method will be described later.

In order to obtain good mixing, it is desirable that representative diameters of the high-flow-rate side flow path <NUM>, the low-flow-rate side flow path <NUM> and the residence flow path <NUM> in the microreactor <NUM> are set to be <NUM> or less. In particular, in order to rapidly mix the two types of raw materials by molecular diffusion at the merging point 111b and in the residence flow path <NUM>, it is desirable that the representative diameters of the flow paths are set within a range from tens of µm to <NUM>. In addition, in the microreactor <NUM>, the two types of raw materials may be mixed uniformly, or may be non-uniform (in a so-called emulsified state) without being mixed.

Further, since the raw material on the high-flow-rate side are branched into two parts, the raw material on the high-flow-rate side is merged with the raw material on the low-flow-rate side from other directions at the merging point 111b, so that a good mixing can be realized. As a result, as shown in <FIG>, an interfacial area <NUM> of the two types of raw materials (the raw material <NUM> on the high-flow-rate side and the raw material <NUM> on the low-flow-rate side) is twice the interfacial area determined by the flow rate ratio (volume ratio), so that the mixing efficiency can be improved even if the structure is not such fine.

In the techniques disclosed in PTL <NUM> to PTL <NUM>, the cases where the raw materials have different flow rate ratios (flow rates) are not considered.

In particular, as in the microreactor <NUM> shown in <FIG>, at the merging point 111b, the branch flow path 102a and the branch flow path 102b merge with the low-flow-rate side flow path <NUM> at the same time, so that the raw material <NUM> on the high-flow-rate side merges in a way of sandwiching the raw material <NUM> on the low-flow-rate side, as shown in <FIG>. As a result, the interfacial area <NUM> of the two types of raw materials is twice the interfacial area determined by the flow rate ratio (volume ratio), so that the mixing efficiency can be improved even if the structure is not such fine.

In <FIG>, in order to make the merging state easily understood, an image in which the raw material <NUM> on the high-flow-rate side is not mixed with the raw material <NUM> on the low-flow-rate side is described in <FIG>. Actually, the raw material <NUM> on the high-flow-rate side and the raw material <NUM> on the low-flow-rate side are in a mixed state.

In addition, in the microreactor <NUM> according to the present embodiment, the raw material on the high-flow-rate side is branched into two parts, so that the flow path internal volume of the high-flow-rate side flow path <NUM> is larger than the flow path internal volume of the low-flow-rate side flow path <NUM>. For this reason, the raw material on the high-flow-rate side can be prevented from flowing into the low-flow-rate side flow path <NUM> at the beginning of chemical product manufacture.

That is, if the flow path internal volume of the high-flow-rate side flow path <NUM> and the flow path internal volume of the low-flow-rate side flow path <NUM> are the same, the raw material on the high-flow-rate side reaches the merging point 111b earlier, because the flow velocity of the raw material on the high-flow-rate side is faster. Then, the raw material on the high-flow-rate side, which has reached the merging point 111b earlier, flows into the low-flow-side flow path <NUM>, that is, reverse flowing.

In the present embodiment, the flow path internal volume of the high-flow-rate side flow path <NUM> is made larger than the flow path internal volume of the low-flow-rate side flow path <NUM>, thereby increasing the time for the raw material on the high-flow-rate side to reach the merging point 111b. Accordingly, the raw material on the high-flow rate side and the raw material on the low-flow-rate side can reach the merging point 111b at substantially the same time. One point of the present embodiment is that the flow path internal volume of the flow paths (the high-flow-rate side flow path <NUM> and the branch flow paths 102a, 102b) in which the raw material on the high-flow-rate side flows is made larger than the flow path internal volume of the flow path (the low-flow-rate side flow path <NUM>) in which the raw material on the low-flow-rate side flows.

<FIG> is a schematic view of a chemical product manufacturing system according to the first embodiment.

A chemical product manufacturing system <NUM> of <FIG> includes a high-flow-rate side raw material container <NUM>, a first low-flow-rate side raw material container <NUM>, a second low-flow-rate side raw material container <NUM>, pumps <NUM> (204a to 204c), a product container <NUM>, and a waste container <NUM>. Further, the chemical product manufacturing system <NUM> includes a switching valve <NUM>, a check valve <NUM>, thermostatic tanks <NUM> (209a and 209b), weight sensors <NUM>, pressure sensors <NUM>, temperature sensors <NUM>, tubes <NUM> (213a to 213e), and microreactors <NUM> (101A and 101B). Here, the microreactor 101A and the microreactor 101B have the same structure as the microreactor <NUM> shown in <FIG>.

A computer (not shown) is connected to the chemical product manufacturing system <NUM>. The computer obtains information from each weight sensor <NUM>, each pressure sensor <NUM>, each temperature sensor <NUM>, or the like. The computer controls each pump <NUM> (204a to 204c), the switching valve <NUM>, and heaters in the thermostatic tanks <NUM> based on the obtained information.

Here, the thermostatic tanks <NUM> keep each raw material and the mixture obtained by the microreactor <NUM> at an optimum temperature for the reaction, and hold the microreactor <NUM>. The tubes <NUM> include loops <NUM> (221a to 221e). The thermostatic tanks <NUM> and the loops <NUM> will be described later.

As shown in <FIG>, a raw material on the high-flow-rate side and a raw material on the first low-flow-rate side are introduced from the high-flow-rate side raw material container <NUM> and the first low-flow-rate side raw material container <NUM> into the first microreactor 101A through the respective tubes 213a and 213b by the respective pumps <NUM> (204a and 204b). A first mixture is obtained by mixing the raw material on the high-flow-rate side and the raw material on the first low-flow-rate side in the first microreactor 101A.

Meanwhile, a raw material on the second low-flow-rate side is introduced from the second low-flow-rate side raw material container <NUM> to the second microreactor 101B through the tube 213c by the pump 204c. The first mixture obtained in the first microreactor 101A is introduced into the second microreactor 101B through the tube 213d. The first mixture and the raw material on the second low-flow-rate side are mixed in the second microreactor 101B. An obtained second mixture is collected by the product container <NUM> or the waste container <NUM> via the switching valve <NUM> through the tube 213e.

At the beginning of the chemical product manufacture, firstly, the raw material on the high-flow-rate side and the raw material on the first low-flow-rate side are introduced nearly into the first microreactor 101A, respectively. Then, the raw material on the second low-flow-rate side is introduced nearly into the second microreactor 101B. Then, introduction of the raw material on the high-flow-rate side and the raw material on the first low-flow-rate side into the microreactor 101A begins.

When the first mixture obtained in the first microreactor 101A is introduced nearly into the second microreactor 101B, introduction of the raw material on the second low-flow-rate side to the microreactor 101B begins.

By stopping the pump <NUM>, the raw materials and the mixture are stopped before reaching the microreactor 101A or 101B.

In this way, the time for the introduction of each raw material into the microreactors 101A, 101B can be shortened, and the time spent from the beginning of the introduction of the raw materials to the obtaining of the product can be shortened. In addition, the waste of each raw material can be prevented, and the use of expensive raw materials can be minimized in this way.

Further, in the chemical product manufacturing system <NUM> shown in <FIG>, the check valve <NUM> is provided just before the introduction of the raw material side on the second low-flow-rate side into the second microreactor 101B. In this way, when only the raw materials on the high-flow-rate side and the raw material on the first low-flow-rate side are introduced, air inside the first microreactor 101A or the tube 213d can be prevented from flowing into the raw material side of second low-flow-rate side via the introduction flow path (the low-flow-rate side flow path <NUM> in the microreactor 101B (<FIG>)) for the raw material on the second low-flow-rate side in the second microreactor 101B.

The check valve <NUM> may also be provided just before the introduction of the raw material on the high-flow-rate side and the raw material on the first low-flow-rate side into the first microreactor 101A. In this way, when the raw material on the high-flow-rate side is not introduced, the raw material on the first low-flow-rate side can be prevented from flowing into the introduction flow path (the high-flow-rate side flow path <NUM> and the branch flow paths 102a, 102b in the microreactor 101A (<FIG>)) on the raw material side of the high-flow-rate side by capillary phenomenon or the like. When the raw material on the first low-flow-rate side is not introduced, the raw material on the high-flow-rate side can be prevented from flowing into the introduction flow path (the low-flow-rate side flow path <NUM> in the microreactor 101A (<FIG>)) on the raw material side of the first low-flow-rate side.

In the chemical product manufacturing system <NUM> shown in <FIG>, weights of the high-flow-rate side raw material container <NUM>, the first low-flow-rate side raw material container <NUM> and the second low-flow-rate side raw material container <NUM> are measured by each of the weight sensors <NUM>. Further, the computer (not shown) grasps the amounts of each of the raw material on the high-flow-rate side, the raw material on the first low-flow-rate side, and the raw material on the second low-flow-rate side introduced by the pumps <NUM> (204a to 204c). The computer may obtain time series of the weight data from the weight sensors <NUM> and combine the time series with time data (not shown) to calculate respective flow rate data of the raw material on the high-flow-rate side, the raw material on the first low-flow-rate side, and the raw material on the second low-flow-rate side. When the raw material on the high-flow-rate side, the raw material on the first low-flow-rate side, and raw material on the second low-flow-rate side are materials that can be cleaned after wetting from the viewpoint of chemical hazard, flow rate sensors (not shown) can be provided instead of the weight sensors <NUM> to measure the flow rate. Based on densities of the raw material on the high-flow-rate side, the raw material on the first low-flow-rate side and the raw material on the second low-flow-rate side, the time-series data of flow rate, and time data, the computer may calculate changes in weight to replace the weight sensors <NUM>.

In the chemical product manufacturing system <NUM> shown in <FIG>, the pressures (discharge pressures) of the raw material on the high-flow-rate side, the raw material on the first low-flow-rate side and the raw material on the second low-flow-rate side in the tubes <NUM> inside the chemical product manufacturing system <NUM> are measured by each of the pressure sensors <NUM>. Accordingly, precipitation of substances contained in the raw material, clogging caused by an unexpected increase in viscosity, or the like in the high-flow-rate side flow path <NUM>, the low-flow-rate side flow path <NUM>, the residence flow path <NUM> (<FIG>), and the tubes <NUM> in the microreactor <NUM> can be detected. The maximum pressure allowed by the chemical product manufacturing system <NUM> is determined in advance, and the computer may obtain time-series data of the pressure data from the pressure sensors <NUM> and stop the operation of the pumps <NUM> when the maximum pressure is reached. A relief valves or the like which detects a value of a certain pressure and release the pressure can be used as the pressure sensor <NUM>.

Further, in the chemical product manufacturing system <NUM> shown in <FIG>, the temperatures of the two microreactors 101A, 101B are adjusted by the thermostatic tanks 209a, 209b, respectively, and the temperatures are measured by each of the temperature sensors <NUM>. Accordingly, the raw materials introduced into each of the microreactors 101A, 101B can be mixed at a predetermined temperature. For example, the computer obtains time-series data of temperature data from the temperature sensors <NUM>, and switches on and off a heater (not shown) or a cooler (not shown) to perform temperature adjustment in the thermostatic tanks <NUM> so as to satisfy the set temperature.

At this time, the thermostatic tanks <NUM> may perform temperature adjustment for a necessary time period in the loops 221a, 221b and 221c in the tubes <NUM> on the upstream side of the microreactor <NUM> according to the flow rates and the thermal conductivities of the raw material on the high-flow-rate side, the raw material on the first low-flow-rate side and the raw material on the second low-flow-rate side, and the wall thicknesses or the thermal conductivities of the tubes <NUM>. In this way, the raw materials introduced into the microreactor <NUM> can be mixed at a more accurate predetermined temperature. When the raw materials introduced into the microreactor <NUM> are mixed to react with each other, the reaction is performed on the downstream side of the microreactor <NUM> if a residence time in the residence flow path <NUM> (refer to <FIG>) is shorter than the reaction time. In this case, the lengths of the tubes 213d, 213e may be adjusted so as to ensure an appropriate residence time. Then, the reaction can be performed at a more accurate predetermined temperature by performing temperature adjustment by the thermostatic tanks 209a, 209b for necessary time periods in the loops 221d, 221e in the tubes 213d, 213e on the downstream side of the microreactor <NUM> according to the flow rate, thermal conductivity, and reaction heat of the mixed liquid and the wall thicknesses and thermal conductivities of the tubes <NUM>.

In order to perform the mixing satisfactorily, it is desirable that the representative diameters of not only the flow paths in the microreactor <NUM> but also the flow paths of the tubes <NUM> (213d and 213e) on the downstream side of the microreactor <NUM> are set to be <NUM> or less.

In the chemical product manufacturing system <NUM> of <FIG>, the raw material on the high-flow-rate side, the raw material on the first low-flow-rate side and the raw material on the second low-flow-rate side are respectively introduced by the pumps <NUM>. Here, for example, tube pumps, syringe pumps, manual syringes, plunger pumps, diaphragm pumps, screw pumps, or the like can be used as the pumps <NUM>. Liquid sending units taking advantages of water head difference may be used to replace the pumps <NUM>.

Fluids such as water, water-ethanol mixed solvent and ethylene glycol, or a Peltier, a mantle heater or the like can be used as the temperature adjustment means of the thermostatic tanks <NUM>. If the reaction temperature is the room temperature, the thermostatic tanks <NUM> are not necessarily required depending on reaction heat and the heat controllability of the microreactor <NUM>.

Materials of liquid contacting portions in the microreactor <NUM>, the high-flow-rate side raw material container <NUM>, the first low-flow-rate side raw material container <NUM>, and the second low-flow-rate side raw material container <NUM> may be any materials which have no negative influence on the mixing and subsequent reactions. The material of the liquid contacting portions can be appropriately changed according to the types of the raw material on the high-flow-rate side, the raw material on the first low-flow-rate side, and the raw material on the second low-flow-rate side.

Similarly, the materials of the liquid contacting portions of the pumps <NUM>, the tubes <NUM>, and fittings (not shown) connecting the microreactor <NUM> and the tubes <NUM>, or the like may be any materials which have no negative influence on the mixing and subsequent reactions. The material of the liquid contacting portions can be appropriately changed according to the types of the raw material on the high-flow-rate side, the raw material on the first low-flow-rate side, and the raw material on the second low-flow-rate side. For example, stainless steel, silicon, gold, glass, Hastelloy, silicone resin, PP (polypropylene), TPX (polymethylpentene), PE (polyethylene), fluorine-based resin, or the like, which has high chemical resistance, can be used. Further, a glass lining, a material obtained by coating a surface of a metal with nickel or gold, a material obtained by oxidizing a surface of silicon, or the like, which has improved corrosion resistance, may be used.

Further, when tube pumps or syringe pumps are used as the pumps <NUM>, various resins such as silicone resin, PP (polypropylene), and fluorine-based resin can be used as the materials of the tubes <NUM> or syringes which serve as the liquid contacting portions in the pumps <NUM>. Further, various resins may be used for the high-flow-rate side raw material container <NUM>, the first low-flow-rate side raw material container <NUM>, the second low-flow-rate side raw material container <NUM>, the tubes <NUM>, and the fittings connecting the microreactor <NUM> and the tubes <NUM> (not shown). In this way, it is possible to use only the liquid contacting portions of the chemical product manufacturing system <NUM> as single use (disposable). The materials of the liquid contacting portions are not necessarily the same, and can be appropriately changed according to the processability of the microreactor <NUM> and the flexibility of the tube <NUM>.

In the chemical product manufacturing system <NUM> of <FIG>, two microreactors <NUM> are mounted for mixing the three types of raw materials including the raw material on the high-flow-rate side, the raw material on the first low-flow-rate side, and the raw material on the second low-flow-rate side in two stages. However, when the raw materials having two types of flow ratios are mixed, the mixing may be performed in one stage. In this case, the configuration related to the raw material on the second low-flow-rate side may be omitted from the chemical product manufacturing system <NUM>.

Further, although three types of raw materials are mixed in two stages, raw materials on the low-flow-rate sides are of one type, there may be only one microreactor <NUM> of the present embodiment. For example, there is a difference between the flow rate ratios of two types among the three types, but the flow rate of the mixture of the raw materials having different flow rate ratios may be substantially the same as the flow rate of the remaining one type of raw material. In such a case, the microreactor configured to mix different flow rate ratios of the two microreactors <NUM> can be the microreactor <NUM> according to the present embodiment, and the microreactor in which the mixture and the remaining one type of raw material are mixed can be a general microreactor (not the microreactors of the present embodiment). At this time, the shape of flow path in the general microreactor may be a shape which form a multilayer flow, such as a Y-shape or a T-shape as long as the two types of raw materials are rapidly mixed.

Here, it is assumed that the raw materials having different flow rate ratios are firstly mixed, and then the raw material having substantially the same flow rate as the flow rate of the mixture are mixed, but the sequence may be reversed. That is, after the raw materials having substantially the same flow rates are mixed, the raw material having different flow rates from the mixture may be mixed. In this case, a general microreactor (not the microreactor of the present embodiment) is arranged in a former section, and the microreactor <NUM> according to the present embodiment is arranged at a subsequent section.

In a case where a plurality of (n) types (n is <NUM> or more) of raw materials are on the low-flow-rate side, with respect to the raw material on the high-flow-rate side, and n+<NUM> types of raw materials are mixed in n stages, the chemical product manufacturing system <NUM> in <FIG> may be expanded and configured such that n microreactors <NUM> according to the present embodiment are mounted. In a case where n+<NUM> types of raw materials are mixed in n stages, but m types (m is <NUM> or less) of raw materials are on the low-flow-rate side and m microreactors <NUM> of the present embodiment may be mounted, the remaining n-m microreactors are general microreactors (not the microreactor in the present embodiment) the shape of which may be a shape which form a multilayer flow, such as a Y shape or a T shape as long as the two types of materials are rapidly mixed. Further, a microreactor having flow paths for mixing three or more types of raw materials may be used as the general microreactor other than the microreactor <NUM>. The raw materials may be mixed uniformly, or may be non-uniform (in a so-called emulsified state) without being mixed.

By using the chemical product manufacturing system <NUM> shown in <FIG>, a chemical product manufacturing system <NUM> having the effect of the microreactor <NUM> can be realized. Further, by connecting a plurality of microreactors <NUM>, two or more types of raw materials which can be mixed in one microreactor <NUM> can be mixed and react with each other.

<FIG> is an external view showing a microreactor to which an adjustment microreactor is connected.

As described above, when the raw materials introduced into the microreactor <NUM> are mixed to react with each other, the reaction is performed on the downstream side of the microreactor <NUM> (after leaving the microreactor <NUM>) if the residence time in the residence flow path <NUM> is shorter than the reaction time. When the reaction time is long, it is necessary to lengthen the residence flow path <NUM> so as to ensure a sufficient residence time in the flow paths of the microreactor <NUM>. For this reason, the microreactor <NUM> becomes huge. In order to ensure the reaction time, an adjustment microreactor <NUM> as shown in <FIG> is prepared.

The adjustment microreactor <NUM> of <FIG> is configured by a residence flow path <NUM>, a mixture introduction port <NUM>, and a reactant discharge port <NUM>. The discharge port <NUM> of the microreactor <NUM> and the mixture introduction port <NUM> of the adjustment microreactor <NUM> are connected with each other by a tube <NUM>.

As shown in <FIG>, a mixture obtained in the microreactor <NUM> passes through the discharge port <NUM> and the tube <NUM>. Then the mixture is introduced into the residence flow path <NUM> of the adjustment microreactor <NUM> through the mixture introduction port <NUM>. In addition to the residence flow path <NUM> of the microreactor <NUM>, reactions of the mixture are also performed in the residence flow path <NUM> of the adjustment microreactor <NUM>. As a result, the obtained reactant is discharged from the reactant discharge port <NUM>.

Here, the reaction time of the mixture can be adjusted by operating the pumps <NUM> (see <FIG>) continuously and setting the time during which the mixture flows in the residence flow paths <NUM> and <NUM> as the reaction time. Meanwhile, the pumps <NUM> may be temporarily stopped after the mixture filled the residence flow paths <NUM>, <NUM> and the tubes <NUM>. Then, after a predetermined time when the pumps <NUM> are stopped, the pumps <NUM> may be operated again and the mixture may be recovered from the reactant discharge port <NUM>. A time obtained by adding the time during which the pumps <NUM> are stopped and the time during which the mixture flows in the residence flow paths <NUM>, <NUM> and the tubes <NUM> can also be set as the reaction time of the mixture.

The adjustment microreactor <NUM> is configured by two plates: an upper plate <NUM> and a lower plate <NUM>. The residence flow path <NUM> is formed on the upper plate <NUM>. The mixture introduction port <NUM> and the reactant discharge port <NUM> are formed on the lower plate <NUM>. The upper plate <NUM> and the lower plate <NUM> are integrated by welding by a method described later with reference to <FIG>. In this way, since the adjustment microreactor <NUM> is integrated, leakage from the residence flow path <NUM> and contamination from the outside can be prevented, so that compounds having high safety and high stability can be manufactured even in a case where highly corrosive substances and synthesis reactions requiring attention in handling are handled or in a case where cross-contamination may occur.

The residence flow path <NUM> may also be formed on the lower plate <NUM>.

In order to perform the reaction satisfactorily, it is desirable that the representative diameter of the flow path of the residence flow path <NUM> in the adjustment microreactor <NUM> is set to be <NUM> or less. In addition, in the adjustment microreactor <NUM>, the mixture flowing in the residence flow path <NUM> may be mixed uniformly, or may be non-uniform (in a so-called emulsified state) without being mixed.

A material of the adjustment microreactor <NUM>, similar to the microreactor <NUM>, can be appropriately changed according to the type of the mixture as long as the material has no negative influence on the mixing and subsequent reactions. For example, stainless steel, silicon, gold, glass, Hastelloy, silicone resin, PP (polypropylene), TPX (polymethylpentene), PE (polyethylene), fluorine-based resin, or the like can be used. Further, a glass lining, a material obtained by coating a surface of a metal with nickel or gold, a material obtained by oxidizing a surface of silicon, or the like, which has improved corrosion resistance, may be used as the material of the adjustment microreactor <NUM>.

A flow path internal volume of the residence flow path <NUM> in the adjustment microreactor <NUM> is set to be larger than the flow path internal volume of the residence flow path <NUM>, so that the residence time of the mixture is increased.

<FIG> is a side view for showing the microreactor manufacturing method according to the first embodiment.

A material of the microreactor <NUM> in <FIG> is polymethylpentene or polyethylene.

As described above, the microreactor <NUM> is configured by two plates: the upper plate <NUM> and the lower plate <NUM>. Each of the flow paths (the high-flow-rate side flow path <NUM>, the branch flow paths 102a, 102b, the low-flow-rate side flow path <NUM>, and the residence flow path <NUM>) is formed on the upper plate <NUM>, or may be formed on the lower plate <NUM>. It is desirable that the upper plate <NUM> is made of white TPX (polymethylpentene) or PE (polyethylene). It is desirable that the lower plate <NUM> is made of colored (for example black) TPX (polymethylpentene) or PE (polyethylene). In this way, the upper plate <NUM> and the lower plate <NUM> are made of resins such as TPX or PE, so that the microreactor <NUM> can be inexpensive and combustible. That is, the microreactor <NUM> can be manufactured for single use. The upper plate <NUM> and the lower plate <NUM> are overlapped such that the flow paths (the high-flow-rate side flow path <NUM>, the branch flow paths 102a, 102b, the low-flow-rate side flow path <NUM>, and the residence flow path <NUM>) are formed therein. By irradiating the entire surface of the upper plate <NUM> with a laser light <NUM> from above the upper plate <NUM> (on the side of the upper plate <NUM>), portions other than the flow paths are welded to form the microreactor <NUM>.

Here, it is desirable that the cross-sectional areas of the high-flow-rate side flow path <NUM>, the branch flow paths 102a, 102b, the low-flow-rate side flow path <NUM> and the residence flow path <NUM> are the same. In particular, since the flow path widths of each of the flow paths (the high-flow-rate side flow path <NUM>, the branch flow paths 102a, 102b, the low-flow-rate side flow path <NUM>, and the residence flow path <NUM>) are set to be the same, and the flow path depths of each of the flow paths are set to be the same, the possibility that the flow path is buried during welding can be reduced.

As described above, in the first embodiment, the microreactor <NUM> and the chemical product manufacturing system <NUM> which have high production efficiency and safety when two or more types of raw materials are mixed at a high flow rate ratio (high volume ratio) can be provided.

The microreactor <NUM> having the effects of the first embodiment can be easily manufactured by the manufacturing method shown in <FIG>.

The upper plate <NUM> and the lower plate <NUM> can be integrated by such a manufacturing method. Accordingly, leakage from each of the flow paths (the high-flow-rate side flow path <NUM>, the branch flow paths 102a, 102b, the low-flow-rate side flow path <NUM> and the residence flow path <NUM>) and contamination of foreign matters from the outside can be prevented, so that chemical products having high safety and high stability can be manufactured even in a case where highly corrosive substances and synthesis reactions requiring attention in handling are handled or in a case where cross-contamination may occur.

Hereinafter, a second embodiment will be described with reference to <FIG>.

<FIG> is an external view of a microreactor according to the second embodiment. In <FIG>, the same reference numerals are attached to configurations similar to those of <FIG>, and the descriptions thereof are omitted.

A microreactor 101a in <FIG> includes two orifices <NUM> (502a and 502b) and two abrupt expansion portions <NUM> (503a and 503b) based on the microreactor <NUM> in <FIG>.

As shown in <FIG>, a raw material on the high-flow-rate side is introduced into the high-flow-rate side flow path <NUM> from the high-flow-rate side introduction port <NUM>. In addition, a raw material on the low-flow-rate side is introduced into the low-flow-rate side flow path <NUM> from the low-flow-rate side introduction port <NUM>. The raw material on the high-flow-rate side is branched into two parts at the branch point 111a as the high-flow-rate side flow path <NUM> is branched into two branch flow paths 102a, 102b at the branch point 111a, then, similarly to the first embodiment, the two parts merge at the merging point 111b (refer to <FIG>) in a way of sandwiching the raw material on the low-flow-rate side, and a mixture is formed. After the mixture was introduced into the first orifice 502a, the mixture is finally introduced into a residence flow path <NUM> via the first abrupt expansion portion 503a, the second orifice 502b, and the second abrupt expansion portion 503b. As a result, the obtained mixture is discharged from the discharge port <NUM>.

The microreactor 101a is configured by the upper plate <NUM> and the lower plate <NUM>. The high-flow-rate side flow path <NUM>, branch flow paths 102a, 102b, the low-flow-rate side flow path <NUM>, the residence flow path <NUM>, the orifices <NUM> (502a and 502b), and the abrupt expansion portions <NUM> (503a and 503b) are formed on the upper plate <NUM>. In addition, the high-flow-rate side introduction port <NUM>, the low-flow-rate side introduction port <NUM> and the discharge port <NUM> are formed on the lower plate <NUM>.

<FIG> is a view showing a detailed structure of the orifice.

A configuration of the orifice 502a in <FIG> is shown in <FIG>, and a configuration of the orifice 502b is similar to that of the orifice 502a. In <FIG>, the same reference numerals are attached to configurations similarly to those of <FIG>, and the descriptions thereof are omitted.

As shown in <FIG>, a flow path of the orifice 502a is formed to be narrower than a flow path on an upstream side thereof. Further, the abrupt expansion portion 503a is disposed on a downstream side of the orifice 502a.

In order to perform mixing or a reaction satisfactorily, it is desirable to set the representative diameters of the high-flow-rate side flow paths <NUM> (the branch flow paths 102a and 102b), the low-flow-rate side flow path <NUM>, the residence flow path <NUM>, the orifices 502a and 502b, and the flow paths of the abrupt expansion portions 503a and 503b to be <NUM> or less. In particular, in order to rapidly mix the raw materials by molecular diffusion in the merging point 111b, the residence flow path <NUM> and the orifices 502a, 502b, the representative diameters of flow paths are desired to be within a range of tens of µm to <NUM>. In the microreactor 101a, since the raw materials are atomized in the abrupt expansion portion <NUM> rearward than the orifice <NUM>, it is desirable that two types of raw materials are formed into a non-uniform combination without being mixed, rather than being mixed uniformly. In the case of the non-uniform combination, the raw material with small amount on the low-flow-rate side is present in the raw material with large amount by the orifice <NUM> in a state of being atomized, which is a so-called emulsified state. As a result, the area of the raw material on the low-flow-rate side in contact with the raw material on the high-flow-rate side is increased, and a good reaction is promoted.

According to the microreactor 101a in accordance with the second embodiment, the reaction can be promoted by setting the raw materials having a low mixability in the emulsified state, in addition to effects similar to those of the microreactor <NUM> according to the first embodiment.

Hereinafter, a third embodiment will be described with reference to <FIG> and <FIG>.

<FIG> is an external view of a microreactor according to the third embodiment. In <FIG>, the same reference numerals are attached to configurations similar to those of <FIG>, and the descriptions thereof are omitted.

A microreactor 101b in <FIG> is configured by the high-flow-rate side flow path <NUM>, a branch flow path 102Z1, branch flow paths 102A1 to 102D1, flow paths A1 to D1, the low-flow-rate side flow path <NUM>, the residence flow path <NUM>, the high-flow-rate side introduction port <NUM>, the low-flow-rate side introduction port <NUM>, and the discharge port <NUM>.

As shown in <FIG>, in the microreactor 101b, a raw material on the high-flow-rate side is introduced into the high-flow-rate side flow path <NUM> from the high-flow-rate side introduction port <NUM>. In addition, a raw material on the low-flow-rate side is introduced into the low-flow-rate side flow path <NUM> from the low-flow-rate side introduction port <NUM>. Further, the high-flow-rate side flow path <NUM> is branched into four branch flow paths 102A1 to 102D1. Consequently, the raw material on the high-flow-rate side is branched into four parts, and the four parts merge stepwise with the raw material on the low-flow-rate side or mixtures at merging points <NUM> to <NUM> respectively, so that a final mixture is formed. Subsequently, the final mixture is introduced into the residence flow path <NUM>, and the obtained mixture is discharged from the discharge port <NUM>.

Here, as shown in <FIG>, the flow path from the high-flow-rate side introduction port <NUM> to a branch point <NUM> is defined as the high-flow-rate side flow path <NUM>. Further, the flow path from a bend point 700a to a merging point <NUM> is defined as the branch flow path 102A1. The flow path from a branch point 700b to a merging point <NUM> is defined as the branch flow path 102B1. The flow path from a branch point 700c to a merging point <NUM> is defined as the branch flow path 102C1. The flow path from a bend point 700d to a merging point <NUM> is defined as the branch flow path 102D1. The flow path from the bend point 700a to the bend point 700d is defined as the branch flow path 102Z1.

In addition, the flow path from the merging point <NUM> to the merging point <NUM> is defined as a flow path A1, and the flow path from the merging point <NUM> to the merging point <NUM> is defined as a flow path B1. The flow path from the merging point <NUM> to the merging point <NUM> is defined as a flow path C1, and the flow path from the merging point <NUM> to the discharge port <NUM> is defined as a flow path D1. The flow path D1 is the residence flow path <NUM>.

Further, the microreactor 101b is configured by two plates: the upper plate <NUM> and the lower plate <NUM>. The high-flow-rate side flow path <NUM>, the branch flow path 102Z1, the branch flow paths 102A1 to 102D1, the flow paths A1 to D1, the low-flow-rate side flow path <NUM>, and the residence flow path <NUM> are formed on the upper plate <NUM>. In addition, the high-flow-rate side introduction port <NUM>, the low-flow-rate side introduction port <NUM>, and the discharge port <NUM> are formed on the lower plate <NUM>. According to the manufacturing method shown in <FIG>, the upper plate <NUM> and the lower plate <NUM> are welded and integrated.

In the microreactor 101b, the flow paths having identical cross-sectional area merge at the merging points <NUM> to <NUM> of the branched raw materials on the high-flow-rate side respectively, and the cross-sectional area of the merged flow path does not change. Although the high-flow-rate side flow path <NUM> is branched into four branch paths 102A1 to 102D1 via the branch flow path 102Z1, the cross-sectional area of each of branch flow paths 102A1 to 102D1 is halved every time the flow paths merge respectively. Hereinafter, it will be described in detail. Although the case where the mixing volume ratio of the raw material on the high-flow-rate side and the raw material on the low-flow-rate side is <NUM>:<NUM> is shown as an example in the third embodiment, other mixing volume ratios may be used. It also applies to the fourth to the sixth embodiments.

Here, as shown in <FIG>, the section from the branch point <NUM> to the first merging point <NUM> is defined as a section <NUM>, and the section from the merging point <NUM> to the next merging point <NUM> is defined as a section <NUM>. Further, the section from the merging point <NUM> to the next merging point <NUM> is defined as a section <NUM>, and the section from the merging point <NUM> to the next merging point <NUM> is defined as a section <NUM>.

Further, when the cross-sectional area of the low-flow-rate side flow path <NUM> is set to be one, it is desirable that the cross-sectional area of the branch flow path 102D1 in the section <NUM> is eight. It is desirable that the cross-sectional area of the branch flow path 102D1 in the section <NUM> is four. Further, it is desirable that the cross-sectional area of the branch flow path 102D1 in the section <NUM> is two, and the cross-sectional area of the branch flow path 102D1 in the section <NUM> is one.

In addition, when the cross-sectional area of the low-flow-rate side flow path <NUM> is set to be one, it is desirable that the cross-sectional area of the branch flow path 102C1 in the section <NUM> is four. Further, it is desirable that the cross-sectional area of the branch flow path 102C1 in the section <NUM> is two, and the cross-sectional area of the branch flow path 102C1 in the section <NUM> is one.

Further, when the cross-sectional area of the low-flow-rate side flow path <NUM> is set to be one, it is desirable that the cross-sectional area of the branch flow path 102B1 in the section <NUM> is two, and the cross-sectional area of the branch flow path 102B1 in the section <NUM> is one.

When the cross-sectional area of the low-flow-rate side flow path <NUM> is set to be one, it is desirable that the cross-sectional area of the branch flow path 102A1 in the section <NUM> is one.

Accordingly, in the third embodiment, it is desirable that the cross-sectional area of each of the branch flow paths 102B1 to 102D1 is halved for each of the sections <NUM> to <NUM> respectively. However, it is not necessary to strictly set the cross-sectional area to be the above-mentioned value. The cross-sectional area of the flow path from the high-flow-rate side introduction port <NUM> to the branch point <NUM> (the high-flow-rate side flow path <NUM>) and the branch flow path 102Z1 may be any value.

As a result, the cross-sectional area of the flow path to be merged at each of the merging points <NUM> to <NUM> can be set to be same respectively. The raw materials with a similar flow rate ratio are easily mixed in the microreactor 101b, so that the cross-sectional area of the flow path to be merged at each of the merging points <NUM> to <NUM> is set to be same, and the cross-sectional area of each of the branch flow paths 102B1 to 102D1 is halved for each of the sections <NUM> to <NUM> respectively. Therefore, the pressure losses in the flow paths at the merging points <NUM> to <NUM> can be equalized.

Hereinafter, the description will be focused on the merging point <NUM>.

For example, when it is assumed that the flow rate of each of the branch flow paths 102A1 to 102D1 is proportional to the cross-sectional area thereof in the section <NUM> respectively, the flow path C1 has a cross-sectional area same as that of the low-flow-rate side flow path <NUM>, and the flow rate of the mixture flowing therethrough is eight which is the total flow rate of the low-flow-rate side flow path <NUM>, the branch flow path 102A1, the branch flow path 102B1 and the branch flow path 102C1 when the flow rate flowing through the low-flow-rate side flow path <NUM> is set to be one. Meanwhile, the flow rate flowing in the branch flow path 102D1 is eight, and the cross-sectional area of the branch flow path 102D1 in the section <NUM> has a cross-sectional area same as the low-flow-rate side flow path <NUM>. Therefore, since the branch flow path 102D1 and the flow path C1 in the section <NUM> have the same flow rate and same cross-sectional area, the pressure losses thereof are similar. It also applies to the other merging points <NUM> to <NUM>.

In addition, for example, the flow path B1 has a cross-sectional area same as that of the low-flow-rate side flow path <NUM>, and the flow rate of the flow path B1 is four which is the total flow rate of the low-flow-rate side flow path <NUM>, the branch flow path 102A1 and the branch flow path 102B1, when the section <NUM> is focused on. The flow rate of the branch flow path 102C1 in the section <NUM> is four, and the cross-sectional area of the branch flow path 102C1 is same as that of the low-flow-rate side flow path <NUM>. Therefore, in the section <NUM>, the pressure loss in the flow path B1 is same as that in the branch flow path 102C1. Further, the flow rate of the branch flow path 102D1 is eight, and the cross-sectional area thereof in the section <NUM> is twice that of the low-flow-rate side flow path <NUM>. Thus, in the section <NUM>, the pressure loss in the branch flow path 102D1 is same as that in the flow path B1 and the branch flow path 102C1. It also applies to the other sections <NUM>, <NUM> and <NUM>.

Accordingly, in the microreactor 101b, the pressure losses in each of the flow paths A1 to D1 and in each of the branch flow paths 102A1 to 102D1 can be same for each of the sections <NUM> to <NUM>. Accordingly, the raw material on the low-flow-rate side, the raw materials on the high-flow-rate side, and the mixtures can merge substantially simultaneously at the branch points <NUM> to <NUM> respectively.

Accordingly, a good mixing can be achieved.

In addition, the flow path internal volume of the high-flow-rate side flow path <NUM> becomes larger than that of the low-flow-rate side flow path <NUM> due to such branches of the high-flow-rate side flow path <NUM>. Accordingly, the microreactor 101b has effects similar to those of the microreactor <NUM> according to the first embodiment.

Next, details of the merging state of the two types of raw materials, as viewed from above the upper plate <NUM> (on the side of the upper plate <NUM>), will be described with reference to <FIG> and <FIG>. In order to make the merging state easily understood, in <FIG>, the raw material <NUM> on the high-flow-rate side and the raw material <NUM> on the low-flow-rate side are described as not being mixed with each other. Actually, the raw material <NUM> on the high-flow-rate side and the raw material <NUM> on the low-flow-rate side are in a mixed state.

As shown in <FIG>, the raw material <NUM> on the high-flow-rate side from the branch flow path 102A1 and the raw material <NUM> on the low-flow-rate side merge adjacently to each other in the flow path A1. As a result, as shown in <FIG>, the raw material <NUM> on the low-flow-rate side and the raw material <NUM> on the high-flow-rate side are in an adjacent state in the flow path A1.

Further, in the flow path B1, the raw material <NUM> on the high-flow-rate side from the branch flow path 102B1 merges with, from the right side of the drawing, the mixture from the flow path A1. As a result, as shown in <FIG>, the raw material <NUM> on the high-flow-rate side merges on, with respect to the state of the flow path A1, the right side of the drawing in the flow path B1.

Next, in the flow path C1, the raw material on the high-flow-rate side from the branch flow path 102C1 merges with, from the right side of the drawing, the mixture from the flow path B1. As a result, as shown in <FIG>, the raw material <NUM> on the high-flow-rate side merges on, with respect to the state of the flow path B1, the right side of the drawing in the flow path C1.

Further, in the flow path D1, the raw material on the high-flow-rate side from the branch flow path 102D1 merges with, from the right side of the drawing, the mixture from the flow path C1. As a result, as shown in <FIG>, the raw material <NUM> on the high-flow-rate side merges on, with respect to the state of the flow path C1, the right side of the drawing in the flow path D1.

As described above, in order to make the merging state easily understood, in <FIG>, the raw material <NUM> on the high-flow-rate side and the raw material <NUM> on the low-flow-rate side are described as not being mixed with each other. Actually, the raw material <NUM> on the high-flow-rate side and the raw material <NUM> on the low-flow-rate side are in a mixed state. If the raw material <NUM> on the high-flow-rate side and the raw material <NUM> on the low-flow-rate side are not mixed, it can be said that the raw material <NUM> on the high-flow-rate side merges with, from the right side of the drawing, the raw material <NUM> on the low-flow-rate side.

It is desirable that the ratio, which is between the total flow path internal volume of the high-flow-rate side flow path <NUM>, the branch flow paths 102A1 to 102D1 and flow paths A1 to D1, and the flow path internal volume of the low-flow-rate side flow path <NUM>, is similar to the flow rate ratio (volume ratio) between the two types of raw materials. Further, it is desirable that the total pressure losses in the high-flow-rate side flow path <NUM>, the branch flow paths 102A1 to 102D1 and the flow paths A1 to D1 are substantially equal to the pressure loss in the low-flow-rate side flow path <NUM>.

Accordingly, the high-flow-rate side flow path <NUM> is branched into four flow paths in the microreactor 101b, so that the total flow path internal volume of the raw material on the high-flow-rate side becomes larger than the flow path internal volume of the low-flow-rate side flow path <NUM>. For this reason, similarly to the first embodiment, the raw material on the high-flow-rate side can be prevented from flowing into the low-flow-rate side flow path <NUM> at the beginning of compound manufacture.

When an overall flow rate is high, the pressure loss may increase and the use of the microreactor may become difficult if the representative diameters of the flow paths are reduced in the microreactor <NUM> (refer to <FIG>) and the microreactor 101a (refer to <FIG>), and conversely the mixing efficiency may be worsened if the representative diameters of the flow paths are increased.

According to the microreactor 101b in accordance with the third embodiment, the raw materials <NUM> on the high-flow-rate side are merged stepwise, so that good mixing can be achieved even if the flow rate ratio between the raw material on the low-flow-rate side and the raw material on the high-flow-rate side is greatly different.

The desired mixture is obtained in the flow path D1 in the microreactor 101b, but the flow path D1 has a short length, so that it is desirable that only the mixing of the raw materials is performed in the microreactor 101b, the reaction is performed in the adjustment microreactor <NUM> (<FIG>) or the like that is connected to the discharge port <NUM> of the microreactor 101b.

In order to perform the mixing satisfactorily, it is desirable that the representative diameters of the flow paths, the high-flow-rate side flow path <NUM>, the branch flow paths 102A1 to 102D1, the flow paths A1 to D1, the low-flow-rate side flow path <NUM>, and the residence flow path <NUM> in the microreactor 101b are set to be <NUM> or less. In particular, in order to rapidly mix the raw materials by molecular diffusion in the merging points <NUM> to <NUM> and the residence flow path <NUM>, the representative diameters of flow paths are desired to be within a range of tens of µm to <NUM>. In addition, in the microreactor 101b, the two types of raw materials may be mixed uniformly, or may be non-uniform (may be the so-called emulsified state) without being mixed.

Although the high-flow-rate side flow path <NUM> is branched into four flow paths in the microreactor 101b, it may be branched into three, or five or more flow paths in accordance with the flow rate ratio (volume ratio) of the two types of raw materials. In general, as the flow rate ratio (volume ratio) of the two types of raw materials increases, it is desirable to increase the number of branches of the high-flow-rate side flow path <NUM>.

Hereinafter, a fourth embodiment will be described with reference to <FIG> and <FIG>.

<FIG> is an external view of a microreactor according to the fourth embodiment. In <FIG>, the same reference numerals are attached to configurations similar to those of <FIG>, and the descriptions thereof are omitted.

A microreactor 101c in <FIG> differs from the microreactor 101b in <FIG> in an arrangement of the branch flow paths of the high-flow-rate side flow path <NUM>.

The microreactor 101c in <FIG> is configured by the high-flow-rate side flow path <NUM>, a branch flow path 102Z2, branch flow paths 102A2 to 102D2, flow paths A2 to D2, the low-flow-rate side flow path <NUM>, the residence flow path <NUM>, the high-flow-rate side introduction port <NUM>, the low-flow-rate side introduction port <NUM>, and the discharge port <NUM>.

As shown in <FIG>, a raw material on the high-flow-rate side is introduced into the high-flow-rate side flow path <NUM> from the high-flow-rate side introduction port <NUM>. In addition, a raw material on the low-flow-rate side is introduced into the low-flow-rate side flow path <NUM> from the low-flow-rate side introduction port <NUM>. Here, the high-flow-rate side flow path <NUM> is branched into four branch flow paths 102A2 to 102D2. Consequently, the raw material on the high-flow-rate side is branched into four parts, and the raw materials on the high-flow-rate side merge stepwise with the raw material on the low-flow-rate side or mixtures, so that a final mixture is generated. Subsequently, the final mixture is finally introduced into the residence flow path <NUM>, and the obtained mixture is discharged from the discharge port <NUM>.

Here, as shown in <FIG>, the flow path from the high-flow-rate side introduction port <NUM> to a branch point <NUM> is defined as the high-flow-rate side flow path <NUM>. The flow path from a bend point 710a to a merging point <NUM> is defined as the branch flow path 102A2. The flow path from a branch point 710b to a merging point <NUM> is defined as the branch flow path 102B2. The flow path from a branch point 710c to a merging point <NUM> is defined as the branch flow path 102C2. Further, the flow path from a bend point 710d to a merging point <NUM> is defined as the branch flow path 102D2. The flow path from the bend point 710a to the bend point 710d is defined as the branch flow path 102Z2.

In addition, as shown in <FIG>, the flow path from the merging point <NUM> to the merging point <NUM> is defined as a flow path A2, and the flow path from the merging point <NUM> to the merging point <NUM> is defined as a flow path B2. The flow path from the merging point <NUM> to the merging point <NUM> is defined as a flow path C2, and the flow path from the merging point <NUM> to the discharge port <NUM> is defined as a flow path D2. The flow path D2 is the residence flow path <NUM>.

Further, the microreactor 101c is configured by two plates: the upper plate <NUM> and the lower plate <NUM>. The high-flow-rate side flow path <NUM>, the branch flow path 102Z2, the branch flow paths 102A2 to 102D2, the flow paths A2 to D2, the low-flow-rate side flow path <NUM>, and the residence flow path <NUM> are formed on the upper plate <NUM>. In addition, the high-flow-rate side introduction port <NUM>, the low-flow-rate side introduction port <NUM>, and the discharge port <NUM> are formed on the lower plate <NUM>. According to the manufacturing method shown in <FIG>, the upper plate <NUM> and the lower plate <NUM> are welded and integrated.

In the microreactor 101c, the flow paths having identical cross-sectional area merge at merging points <NUM> to <NUM> of the branched raw material on the high-flow-rate side respectively, and the cross-sectional area of the merged flow path does not change. Although the high-flow-rate side flow path <NUM> is branched into four branch paths 102A2 to 102D2 via the branch flow path 102Z2, the cross-sectional area of each of branch flow paths 102A2 to 102D2 is halved every time the flow paths merge respectively.

Hereinafter, it will be described in detail.

Further, when the cross-sectional area of the low-flow-rate side flow path <NUM> is set to be one, it is desirable that the cross-sectional area of the branch flow path 102A2 in the section <NUM> is eight. It is desirable that the cross-sectional area of the branch flow path 102A2 in the section <NUM> is four. Further, it is desirable that the cross-sectional area of the branch flow path 102A2 in the section <NUM> is two, and the cross-sectional area of the branch flow path 102A2 in the section <NUM> is one.

When the cross-sectional area of the low-flow-rate side flow path <NUM> is set to be one, it is desirable that the cross-sectional area of the branch flow path 102D2 in the section <NUM> is four. Further, it is desirable that the cross-sectional area of the branch flow path 102D2 in the section <NUM> is two, and the cross-sectional area of the branch flow path 102D2 in the section <NUM> is one.

Further, when the cross-sectional area of the low-flow-rate side flow path <NUM> is set to be one, it is desirable that the cross-sectional area of the branch flow path 102B2 in the section <NUM> is two, and the cross-sectional area of the branch flow path 102B2 in the section <NUM> is one.

When the cross-sectional area of the low-flow-rate side flow path <NUM> is set to be one, it is desirable that the cross-sectional area of the branch flow path 102C2 in the section <NUM> is one.

Accordingly, it is desirable that the cross-sectional areas of the branch flow paths 102A2, 102B2 and 102D2 are halved for the sections <NUM> to <NUM> respectively in the fourth embodiment. However, it is not necessary to strictly set the cross-sectional area to be the above-mentioned value. The cross-sectional areas of the flow path from the high-flow-rate side introduction port <NUM> to the branch point <NUM> (the high-flow-rate side flow path <NUM>) and the branch flow path 102Z2 may be any value.

As a result, the cross-sectional area of the flow path to be merged at each of the merging points <NUM> to <NUM> can be set to be same respectively. The raw materials with a similar flow rate ratio are easily mixed in the microreactor 101b, so that the cross-sectional area of the flow path to be merged at each of the merging points <NUM> to <NUM> is set to be same. Therefore, the pressure losses in the flow paths at the merging points <NUM> to <NUM> can be equalized. Since the reason why the pressure losses in the flow paths at the merging points <NUM> to <NUM> can be equalized has already been described in the third embodiment, the description here is omitted. Accordingly, good mixing can be achieved.

In addition, the flow path internal volume of the high-flow-rate side flow path <NUM> becomes larger than that of the low-flow-rate side flow path <NUM> due to such branches of the high-flow-rate side flow path <NUM>. Accordingly, the microreactor 101c can obtain effects similar to those of the microreactor <NUM> shown in <FIG>.

Next, details of the merging state of two types of raw materials, as viewed from above the upper plate <NUM> (on the side of the upper plate <NUM>), will be described with reference to <FIG> and <FIG>. In order to make the merging state easily understood, in <FIG>, the raw material <NUM> on the high-flow-rate side and the raw material <NUM> on the low-flow-rate side are described as not being mixed with each other. Actually, the raw material <NUM> on the high-flow-rate side and the raw material <NUM> on the low-flow-rate side are in a mixed state.

As shown in <FIG>, the raw material <NUM> on the high-flow-rate side from the branch flow path 102C2 and the raw material <NUM> on the low-flow-rate side merge adjacently to each other in the flow path A2. As a result, as shown in <FIG>, the raw material <NUM> on the low-flow-rate side and the raw material <NUM> on the high-flow-rate side are in an adjacent state in the flow path A2.

In addition, in the flow path B2, the raw material <NUM> on the high-flow-rate side from the branch flow path 102B2 merges with, from the left side of the drawing, the mixture from the flow path A2. As a result, as shown in <FIG>, the raw material <NUM> on the high-flow-rate side merges on, with respect to the state of the flow path A2, the left side of the drawing in the flow path B2.

Further, in the flow path C2, the raw material on the high-flow-rate side from the branch flow path 102D2 merges with, from the right side of the drawing, the mixture from the flow path B2. As a result, as shown in <FIG>, the raw material <NUM> on the high-flow-rate side merges on, with respect to the state of the flow path B2, the right side of the drawing in the flow path C2.

Further, in the flow path D2, the raw material on the high-flow-rate side from the branch flow path 102A2 merges with, from the left side of the drawing, the mixture from the flow path C2. As a result, as shown in <FIG>, the raw material <NUM> on the high-flow-rate side merges on, with respect to the state of the flow path C2, the left side of the drawing in the flow path D2 (the residence flow path <NUM>).

As described above, the raw material <NUM> on the high-flow-rate side and the raw material <NUM> on the low-flow-rate side are not separated (are mixed), but in <FIG>, the raw material <NUM> on the high-flow-rate side and the raw material <NUM> on the low-flow-rate side are described as not being mixed in order to make the merging state easily understood. If the raw material <NUM> on the high-flow-rate side and the raw material <NUM> on the low-flow-rate side are not mixed, it can be said that the raw material <NUM> on the high-flow-rate side alternately merges with, from the left-right direction of the drawing, the raw material <NUM> on the low-flow-rate side.

It is desirable that the ratio, between the total flow path internal volume of the high-flow-rate side flow path <NUM>, the branch flow paths 102A2 to 102D2 and flow paths A2 to D2, and the flow path internal volume of the low-flow-rate side flow path <NUM>, is similar to the flow rate ratio (volume ratio) between the two types of raw materials. Further, it is desirable that the total pressure losses in flow paths, the high-flow-rate side flow path <NUM>, the branch flow paths 102A2 to 102D2 and the flow paths A2 to D2 is substantially equal to the pressure loss in the low-flow-rate side flow path <NUM>.

When the overall flow rate of the raw material on the high-flow-rate side is high, the pressure loss may increase and the use of the microreactor may become difficult if the representative diameters of the flow paths are reduced in the microreactor <NUM> (refer to <FIG>) and the microreactor 101a (refer to <FIG>), and conversely the mixing efficiency may be worsened if the representative diameters of the flow paths are increased.

According to the microreactor 101c in accordance with the fourth embodiment, the raw materials <NUM> on the high-flow-rate side are merged stepwise, so that favorable mixing can be achieved even if the flow rate ratio between the raw material on the low-flow-rate side and the raw material on the high-flow-rate side is greatly different.

The desired mixture is obtained in the flow path D2 in the microreactor 101c, but the flow path D2 has a short length, so that it is desirable that only the mixing of the raw materials is performed in the microreactor 101c, the reaction is performed in the adjustment microreactor <NUM> (<FIG>) or the like that is connected to the discharge port <NUM> of the microreactor 101c.

In order to perform the mixing satisfactorily, it is desirable that the representative diameters of the flow paths, the high-flow-rate side flow path <NUM>, the branch flow paths 102A2 to 102D2, the flow paths A2 to D2, the low-flow-rate side flow path <NUM>, and the residence flow path <NUM> in the microreactor 101c are set to be <NUM> or less. In particular, in order to rapidly mix the raw materials by molecular diffusion in the merging points <NUM> to <NUM> and the residence flow path <NUM>, the representative diameters of the flow paths are desired to be within a range of tens of µm to <NUM>. In addition, in the microreactor 101c, the two types of raw materials may be mixed uniformly, or may be non-uniform (in the so-called emulsified state) without being mixed.

Accordingly, the high-flow-rate side flow path <NUM> is branched into four flow paths in the microreactor 101c, so that the total flow path internal volume of the raw materials on the high-flow-rate side becomes larger than the flow path internal volume of the low-flow-rate side flow path <NUM>. For this reason, similarly to the first embodiment, the raw material on the high-flow-rate side can be prevented from flowing into the low-flow-rate side flow path <NUM> at the beginning of compound manufacture.

In addition, the high-flow-rate side flow path <NUM> is branched into four flow paths, and stepwise merge from the left-right direction of the drawing with respect to the raw material on the low-flow-rate side, so that the interfacial area of the two types of raw materials is increased, compared with conventional microreactors (not the microreactor of the present embodiment), and the mixing efficiency can be improved even if the structure is not such fine.

Further, since the raw materials <NUM> on the high-flow-rate side alternately merge from the left-right direction of the drawing in the microreactor 101c as shown in <FIG>, the mixing efficiency can be improved compared with the microreactor 101b (refer to <FIG>).

Although the high-flow-rate side flow path <NUM> is branched into four flow paths in the microreactor 101c, it may be branched into three, or five or more flow paths in accordance with the flow rate ratio (volume ratio) of the two types of raw materials. In general, as the flow rate ratio (volume ratio) of the two types of raw materials increases, it is desirable to increase the number of branches of the high-flow-rate side flow path <NUM>.

Hereinafter, a fifth embodiment will be described with reference to <FIG>.

<FIG> is an external view of a microreactor according to the fifth embodiment. <FIG> is an exploded view of the microreactor according to the fifth embodiment. In <FIG> and <FIG>, the same reference numerals are attached to configurations similar to those of <FIG>, and the descriptions thereof are omitted.

As shown in <FIG>, in the microreactor 101d, a raw material on the high-flow-rate side is introduced into the high-flow-rate side flow path <NUM> from the high-flow-rate side introduction port <NUM>. In addition, a raw material on the low-flow-rate side is introduced into the low-flow-rate side flow path <NUM> from the low-flow-rate side introduction port <NUM>. Here, as the high-flow-rate side flow path <NUM> is branched into four branch flow paths 102A3 to 102D3, the raw material on the high-flow-rate side is branched into four parts. Further, the raw materials on the high-flow-rate side merge stepwise with the raw material on the low-flow-rate side or a mixture in flow paths A3 to D3 respectively, so that a final mixture is formed. The final mixture is introduced into the residence flow path <NUM>, and is discharged from the discharge port <NUM>.

In addition, the cross-sectional area of the high-flow-rate side flow path <NUM> is reduced every time the flow path is branched.

Here, the flow path from the high-flow-rate side introduction port <NUM> to a bend point <NUM> is defined as the high-flow-rate side flow path <NUM>. In addition, the flow path from a branch point <NUM> to a merging point <NUM> is defined as a branch flow path 102A3, and the flow path from a merging point <NUM> to a merging point <NUM> is defined as a branch flow path 102B3. The flow path from a branch point <NUM> to a merging point <NUM> is defined as a branch flow path 102C3, and the flow path from a bend point <NUM> to a merging point <NUM> is defined as a branch flow path 102D3.

Further, the flow path from a merging point <NUM> to a merging point <NUM> is defined as a flow path A3, and the flow path from a merging point <NUM> to a merging point <NUM> is defined as a flow path B3. Further, the flow path from a merging point <NUM> to a merging point <NUM> is defined as a flow path C3, and the flow path from a merging point <NUM> to the discharge port <NUM> is defined as a flow path D3. The flow path D3 is also the residence flow path <NUM>.

Further, as shown in <FIG> and <FIG>, the microreactor 101d is configured by two plates: an upper plate 108d and a lower plate 109d. The high-flow-rate side flow path <NUM>, the branch flow paths 102A3 and 102C3, and the flow paths A3 and C3 are formed on the upper plate 108d. In addition, the low-flow-rate side flow path <NUM>, the branch flow paths 102B3 and 102D3, and the flow paths B3 and D3 (the residence flow path <NUM>) are formed on the lower plate 109d. In addition, the high-flow-rate side introduction port <NUM>, the low-flow-rate side introduction port <NUM>, and the discharge port <NUM> are formed on the lower plate 109d.

Further, the upper plate 108d and the lower plate 109d are integrated by welding according to the manufacturing method shown in <FIG>.

In the microreactor 101d, the flow paths having identical cross-sectional area merge in the flow paths A3 to D3 respectively, and the cross-sectional area of the merged flow path does not change. It is desirable that the cross-sectional area of the high-flow-rate side flow path <NUM> is halved every time the flow path is branched. That is, when the cross-sectional area of the low-flow-rate side flow path <NUM> is set to be one, it is desirable that the cross-sectional area of the high-flow-rate side flow path <NUM> is eight before being branched to the branch flow path 102A3, four before being branched to the branch flow path 102B3, two before being branched to the branch flow path 102C3, and one before being branched to the branch flow path 102D3. It is desirable that the cross-sectional areas of the branch flow paths 102A3 to 102D3, and the flow paths A3 to D3 are same as that of the low-flow-rate side flow path <NUM>. As a result, the flow rate in the branch flow paths 102A3 to 102D3 can be identical to the flow rate in the low-flow-rate side flow path <NUM>, and the pressure losses in the branch flow paths 102A3 to 102D3 and the low-flow-rate side flow path <NUM> can be equalized.

In addition, the total flow path internal volume of the high-flow-rate side flow path <NUM>, the branch flow paths 102A3 to 102D3 and the flow paths A3 to D3 becomes larger than the flow path internal volume of the low-flow-rate side flow path <NUM> due to such branches of the high-flow-rate side flow path <NUM>. The cross-sectional area of the high-flow-rate side flow path <NUM> does not have to be strictly halved every time the flow path is branched.

It is desirable that the ratio, between the total flow path internal volume of the high-flow-rate side flow path <NUM>, the branch flow paths 102A3 to 102D3 and the flow paths A3 to D3, and the flow path internal volume of the low-flow-rate side flow path <NUM>, is similar to the flow rate ratio (volume ratio) between the two types of raw materials. Further, it is desirable that the pressure losses in the flow paths of the raw material on the high-flow-rate side (the high-flow-rate side flow path <NUM>, the branch flow paths 102A3 to 102D3 and the flow paths A3 to D3) are substantially equal to the pressure loss in the low-flow-rate side flow path <NUM>. It also applies to the sixth embodiment described below.

Next, a state where the two types of raw materials merge will be described with reference to <FIG> and <FIG>.

<FIG> is a schematic diagram of each flow path in the microreactor 101d. <FIG> is a diagram showing the mixing states in the flow paths A3 to D3, as viewed from the upstream side of the flow paths. In <FIG>, the flow path formed in the upper plate 108d is shown by a solid line, and the flow path formed in the lower plate 109d is shown by a broken line. In <FIG>, the same reference numerals are attached to configurations similar to those of <FIG>, and the descriptions thereof are omitted. In addition, <FIG> does not clearly show the cross-sectional area variation of the high-flow-rate side flow path <NUM>.

In addition, the raw material <NUM> on the high-flow-rate side and the raw material <NUM> on the low-flow-rate side are mixed actually, but in <FIG>, the raw material <NUM> on the high-flow-rate side and the raw material <NUM> on the low-flow-rate side are described as not being mixed in order to make the merging state easily understood, similarly to the above description.

As shown in <FIG>, in the flow path A3 formed in the upper plate 108d, the raw material <NUM> on the high-flow-rate side from the branch flow path 102A3 formed in the upper plate 108d merges with the raw material <NUM> on the low-flow-rate side from the low-flow-rate side flow path <NUM> formed in the lower plate 109d. For this reason, as shown in <FIG>, in the flow path A3, the raw material <NUM> on the high-flow-rate side which is on the upper side of the drawing and the raw material <NUM> on the low-flow-rate side which is on the lower side of the drawing, flow through the upper plate 108d in an adjacent state.

Subsequently, as shown in <FIG>, in the flow path B3 formed in the lower plate 109d, the raw material <NUM> on the high-flow-rate side and the branch flow path 102B3 formed in the lower plate 109d, merges with the mixture from the flow path A3 formed in the upper plate 108d. Accordingly, as shown in <FIG>, in the flow path B3, the raw material <NUM> on the high-flow-rate side flow through the lower plate 109d in an adjacent state, from the lower side of the drawing, to the mixture in the flow path A3 on the upper side.

Further, as shown in <FIG>, in the flow path C3 formed in the upper plate 108d, the material on the high-flow-rate side from the branch flow path 102C3 formed in the upper plate 108d merges with the mixture in the flow path B3 formed in the lower plate 109d. Accordingly, as shown in <FIG>, in the flow path C3, the raw material <NUM> on the high-flow-rate side flows through the upper plate 108d in an adjacent state, from the upper side of the drawing, to the mixture in the flow path B3 on the lower side.

Further, as shown in <FIG>, in the flow path D3 formed in the lower plate 109d, the raw material on the high-flow-rate side from the branch flow path 103D3 formed in the lower plate 109d merges with the mixture from the flow path C3 formed in the upper plate 108d. Accordingly, as shown in <FIG>, in the flow path D3 (the residence flow path <NUM>), the raw material <NUM> on the high-flow-rate side flows through, with respect to the state of the flow path C3 on the upper side, the lower plate 109d in an adjacent state from the lower side of the drawing.

As described above, the raw material <NUM> on the high-flow-rate side and the raw material <NUM> on the low-flow-rate side are mixed actually, but in <FIG>, the raw material <NUM> on the high-flow-rate side and the raw material <NUM> on the low-flow-rate side are described as not being mixed in order to make the merging state easily understood, similarly to the above description. If the raw material <NUM> on the high-flow-rate side and the raw material <NUM> on the low-flow-rate side are not mixed, it can be said that the raw materials <NUM> on the high-flow-rate side merge in a way of sandwiching the raw material <NUM> on the low-flow-rate side from the upper-lower direction of the drawing.

The microreactor 101d according to the fifth embodiment has a merge direction different from that of the microreactor 101b (<FIG>) and the microreactor 101c (<FIG>), but the microreactor 101d enables mixing more efficient than the microreactor 101b and the microreactor 101c since the raw materials <NUM> on the high-flow-rate side stepwise and alternately merge from the upper-lower direction of the drawing.

In order to obtain good mixing, it is desirable that the representative diameters of the flow paths A3 to C3, and D3 (the residence flow path <NUM>) in the microreactor 101d are set to be <NUM> or less. In particular, in order to rapidly mix the raw materials by molecular diffusion in the merging points <NUM> to <NUM>, and the residence flow path <NUM>, the representative diameters of flow paths are desired to be within a range of tens of µm to <NUM>. In addition, in the microreactor 101d, the two types of raw materials may be mixed uniformly, or may be non-uniform (in the so-called emulsified state) without being mixed.

Although the high-flow-rate side flow path <NUM> is branched into four flow paths in the microreactor 101d according to the fifth embodiment, it may be branched into three, or five or more flow paths in accordance with the flow rate ratio (volume ratio) of the two types of raw materials. In general, as the flow rate ratio (volume ratio) of the two types of raw materials increases, it is desirable to increase the number of branches of the high-flow-rate side flow path <NUM>.

Hereinafter, a sixth embodiment will be described with reference to <FIG>.

<FIG> is an external view of a microreactor according to the sixth embodiment. <FIG> is an exploded view of the microreactor according to the sixth embodiment. In <FIG> and <FIG>, the same reference numerals are attached to configurations similar to those of <FIG>, and the descriptions thereof are omitted.

A microreactor 101e in <FIG> differs from the microreactor 101d shown in <FIG> in the direction of the flow path rearward than merging points <NUM> to <NUM>.

As shown in <FIG>, the microreactor 101e is configured by the high-flow-rate side flow path <NUM>, the low-flow-rate side flow path <NUM>, the residence flow path <NUM>, the high-flow-rate side introduction port <NUM>, the low-flow-rate side introduction port <NUM>, and the discharge port <NUM>.

As shown in <FIG>, a raw material on the high-flow-rate side is introduced into the high-flow-rate side flow path <NUM> from the high-flow-rate side introduction port <NUM>. A raw material on the low-flow-rate side is introduced into the low-flow-rate side flow path <NUM> from the low-flow-rate side introduction port <NUM>. In addition, the high-flow-rate side flow path <NUM> is branched into four branch flow paths 102A4 to 102D4. Further, the raw materials on the high-flow-rate side merge stepwise with the raw material on the low-flow-rate side or a mixture in flow paths A4 to D4 respectively, so that a final mixture is formed. The final mixture is introduced into the residence flow path <NUM> and is discharged from the discharge port <NUM>.

Here, the flow path from the high-flow-rate side introduction port <NUM> to a bend point <NUM> is defined as the high-flow-rate side flow path <NUM>. In addition, the flow path from a branch point <NUM> to a merging point <NUM> is defined as a branch flow path 102A4, and the flow path from a merging point <NUM> to a merging point <NUM> is defined as a branch flow path 102B4. In addition, the flow path from a branch point <NUM> to a merging point <NUM> is defined as a branch flow path 102C4, and the flow path from the bend point <NUM> to a merging point <NUM> is defined as a branch flow path 102D4.

Further, the flow path from a merging point <NUM> to a merging point <NUM> is defined as a flow path A4, and the flow path from a merging point <NUM> to a merging point <NUM> is defined as a flow path B4. Further, the flow path from a merging point <NUM> to a merging point <NUM> is defined as a flow path C4, and the flow path from a merging point <NUM> to the discharge port <NUM> is defined as a flow path D4. The flow path D4 is also the residence flow path <NUM>.

Further, as shown in <FIG> and <FIG>, the microreactor 101e is configured by two plates: an upper plate 108e and a lower plate 109e. The high-flow-rate side flow path <NUM>, the branch flow paths 102A4 and 102C4, and the flow paths A4 and C4 are formed on the upper plate 108e. In addition, the low-flow-rate side flow path <NUM>, the branch flow paths 102B4 and 102D4, and the flow paths B4 and D4 (the residence flow path <NUM>) are formed on the lower plate 109e. The high-flow-rate side introduction port <NUM>, the low-flow-rate side introduction port <NUM>, and the discharge port <NUM> are formed on the lower plate 109e.

Further, the upper plate 108e and the lower plate 109e are welded and integrated according to the manufacturing method shown in <FIG>.

In the microreactor 101e, the flow paths having identical cross-sectional area merge in the flow paths A4 to D4 respectively, and the cross-sectional area of the merged flow path does not change. The cross-sectional area of the high-flow-rate side flow path <NUM> is halved every time the flow path is branched. That is, when the cross-sectional area of the low-flow-rate side flow path <NUM> is set to be one, it is desirable that the cross-sectional area of the high-flow-rate side flow path <NUM> is eight before being branched to the branch flow path 102A4, four before being branched to the branch flow path 102B4, two before being branched to the branch flow path 102C4, and one before being branch to the branch flow path 102D4. It is desirable that the cross-sectional areas of the branch flow paths 102A4 to 102D4, and the flow paths A4 to D4 are same as that of the low-flow-rate side flow path <NUM> respectively. As a result, the flow rates in the branch flow paths 102A4 to 102D4 can be same as the flow rate in the low-flow-rate side flow path <NUM> respectively, and the pressure losses in the branch flow paths 102A4 to 102D4 and the low-flow-rate side flow path <NUM> can be equalized.

In addition, the total flow path internal volume of the high-flow-rate side flow path <NUM>, the branch flow paths 102A4 to 102D4 and flow paths A4 to D4 becomes larger than the flow path internal volume of the low-flow-rate side flow path <NUM>, due to such branches of the high-flow-rate side flow path <NUM>. The cross-sectional area of the high-flow-rate side flow path <NUM> does not have to be strictly halved every time the flow path is branched.

It is desirable that the ratio, between the total flow path internal volume of the high-flow-rate side flow path <NUM>, the branch flow paths 102A4 to 102D4 and flow paths A4 to D4, and the flow path internal volume of the low-flow-rate side flow path <NUM>, is similar to the flow rate ratio (volume ratio) between the two types of raw materials. Further, it is desirable that the pressure losses in the flow paths of the raw material on the high-flow-rate side (the high-flow-rate side flow path <NUM>, the branch flow paths 102A4 to <NUM> and flow paths A4 to D4) are substantially equal to the pressure loss in the low-flow-rate side flow path <NUM>.

The flow paths A4 to D4 move in the extension line direction of the branch flow paths 102A4 to 102D4 respectively only by a predetermined distance after merging, and then move towards the direction of the discharge port <NUM>. The microreactor 101e makes the flow of the mixture after each merging smoother than that of the microreactor 101d shown in <FIG> by adopting such a configuration.

<FIG> is a schematic diagram of each flow path in the microreactor 101e. <FIG> is a diagram showing the mixing states in the flow paths A4 to D4 as viewed from the upstream side of the flow paths. In <FIG>, the flow path formed in the upper plate 108e is shown by a solid line, and the flow path formed in the lower plate 109e is shown by a broken line. In addition, in <FIG>, the same reference numerals are attached to configurations similar to those of <FIG>, and the descriptions thereof are omitted. <FIG> does not specify the cross-sectional area of each flow path.

As shown in <FIG>, in the flow path A4 formed in the upper plate 108e, the raw material <NUM> on the high-flow-rate side from the branch flow path 102A4 formed in the upper plate 108e is adjacent to and merges with the raw material <NUM> on the low-flow-rate side from the low-flow-rate side flow path <NUM> formed in the lower plate 109e. For this reason, as shown in <FIG>, in the flow path A4 formed in the upper plate 108e, the raw material <NUM> on the high-flow-rate side that is on the upper side of the drawing and the raw material <NUM> on the low-flow-rate side that is on the lower side of the drawing flow through the upper plate 108e in an adjacent state.

Subsequently, as shown in <FIG>, in the flow path B4 formed in the lower plate 109e, the raw material <NUM> on the high-flow-rate side from the branch flow path 102B4 formed in the lower plate 109e, merges with the mixture from the flow path A4 formed in the upper plate 108e.

Accordingly, as shown in <FIG>, in the flow path B4, the raw material <NUM> on the high-flow-rate side flows through the lower plate 109e in an adjacent state from the lower side of the drawing, with respect to the mixture in the flow path A4 on the upper side.

Next, as shown in <FIG>, in the flow path C4 formed in the upper plate 108e, the raw material on the high-flow-rate side from the branch flow path 102C4 formed in the upper plate 108e merges with the mixture in the flow path B4 formed in the lower plate 109e. Accordingly, as shown in <FIG>, in the flow path C4, the raw material <NUM> on the high-flow-rate side flows through the upper plate 108e in an adjacent state from the upper side of the drawing, with respect to the mixture in the flow path B4 on the lower side.

Then, as shown in <FIG>, in the flow path D4 formed in the lower plate 109e, the raw material on the high-flow-rate side from the branch flow path 102D4 formed in the lower plate 109e, merges with the mixture from the flow path C4 formed in the upper plate 108e. Accordingly, as shown in <FIG>, in the flow path D4 (the residence flow path <NUM>), the raw material <NUM> on the high-flow-rate side flows through, with respect to the state of the flow path C4 on the upper side, the lower plate 109e in an adjacent state from the lower side of the drawing.

In order to perform the mixing satisfactorily, it is desirable that the representative diameters of the flow paths A4 to C4, and D4 (the residence flow path <NUM>) in the microreactor 101e are set to be <NUM> or less. In particular, in order to rapidly mix the raw materials by molecular diffusion in the merging points <NUM> to <NUM>, and the residence flow path <NUM>, the representative diameters of flow paths are desired to be within a range of tens of µm to <NUM>. In addition, in the microreactor 101e, the two types of raw materials may be mixed uniformly, or may be non-uniform (in the so-called emulsified state) without being mixed.

Although the high-flow-rate side flow path <NUM> is branched into four flow paths in the microreactor 101e according to the sixth embodiment, it may be branched into three, or five or more flow paths in accordance with the flow rate ratio (volume ratio) of the two types of raw materials. In general, as the flow rate ratio (volume ratio) of the two types of raw materials increases, it is desirable to increase the number of branches of the high-flow-rate side flow path <NUM>.

As described above, according to the microreactor 101e according to the sixth embodiment, the flow paths A4 to D4 move in the extension line direction of the branch flow paths 102A4 to 102D4 respectively only by a predetermined distance after merging, and then move towards the discharge port <NUM>. The microreactor 101e makes the flow of the mixture after each merging smoother than that of the microreactor 101d shown in <FIG> by adopting such a configuration.

Although each flow path is formed in the upper plate <NUM> in the first to the fourth embodiments, it may be formed in the lower plate 109d.

In addition, in the fifth embodiment, the high-flow-rate side flow path <NUM>, the branch flow paths 102A3 and 102C3, and the flow paths A3 and C3 are formed in the upper plate 108d, and the low-flow-rate side flow path <NUM>, the branch flow paths 102B3 and 102D3, and the flow paths B3 and D3 (the residence flow path <NUM>) are formed in the lower plate 109d, but the above configurations may be reversed. It also applies to the sixth embodiment.

Further, although the microreactors 101A and 101B include the structure same as the microreactor <NUM> shown in <FIG>, the microreactor 101a shown in <FIG>, the microreactor 101b shown in <FIG>, the microreactor 101c shown in <FIG>, the microreactor 101d shown in <FIG> and the microreactor 101e shown in <FIG> may be used. In addition, a device to which the adjustment microreactor <NUM> shown in <FIG> is connected may be used as the microreactors 101A and 101B shown in <FIG>.

Although raw materials having two types of flow rates may be used in the present embodiment, three or more types of raw materials may be used. In this case, for example, the raw materials on the high-flow-rate side may sequentially merge in a way of sandwiching the raw material with the lowest flow rate. Further, in this case, the flow path internal volume of the flow path may be increased as the flow rate increases.

The microreactors <NUM> and 101a to 101e according to the first to the sixth embodiments are used in the manufacture of Antibody Drug Conjugate (ADC)-pharmaceutical product, and used in the on-demand pharmaceutical product manufacturing device.

This invention is not limited to the above-described embodiments and includes various modifications. For example, the above-described embodiments have been described in detail in order to facilitate the understanding of the invention, but the invention is not necessarily limited to have all of the described configurations. A part of the configuration of one embodiment can be replaced with the configuration of another embodiment, and the configuration of another embodiment can also be added to the configuration of a certain embodiment. With respect to a part of a configuration of each embodiment, another configuration can be added, removed, or replaced.

Claim 1:
A microreactor, comprising:
a plurality of flow paths for a plurality of raw materials with different flow rates to flow therethrough respectively,
wherein the flow paths are branched and merge such that a flow path for a high-flow-rate raw material (<NUM>) is branched into a plurality of paths and then merges to a flow path for a low-flow-rate raw material (<NUM>),
characterized in that,
a first flow path for the high-flow-rate raw material among the plurality of the branched flow paths for the-high-flow rate raw material (<NUM>) is merged with the flow path for the low-flow-rate raw material (<NUM>) at a first merging point,
wherein remaining flow paths for the high-flow-rate raw material (<NUM>) among the plurality of the branched flow paths for the high-flow-rate raw material (<NUM>) are merged stepwise with a flow path after the first merging point,
wherein the flow paths are formed such that the high-flow-rate raw material alternately merges with the low-flow-rate raw material from different directions,
wherein the microreactor (<NUM>) is configured by two plates,
the flow paths are formed on each of the plates, and
the flow paths are formed such that the high-flow-rate raw material alternately merges with the low-flow-rate raw material from directions of each of the two plates.