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Volume 109
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Synergistically enhanced high-efficiency mixing in multi-stage micro-mixers with hybrid design
Jun Dong a *, Jiangkun Liu a, Huimin Lv b, Yonggang Zhu b, Chengyue Wang a *
a Department of Mechanics and Engineering Science, School of Physics, Nanjing University of Science and Technology, Nanjing, 210094, China
b Center for Microflows and Nanoflows, School of Mechanical Engineering and Automation, Harbin Institute of Technology, Shenzhen, 518055, China
10.1016/j.partic.2025.12.006
Volume 109, February 2026, Pages 26-44
Received 4 November 2025, Revised 29 November 2025, Accepted 10 December 2025, Available online 13 December 2025, Version of Record 18 December 2025.
E-mail: dongjun@njust.edu.cn; wangchengyue@njust.edu.cn
Highlights

• Two novel hybrid micromixers designed: multi-channel and super-efficient types.

• Hybrid mixers integrate tree-shape distributor, SAR, and Focus mixer units.

• Hybrid micromixers produce ultra-high mixing efficiency (>97 %) across Re 0.5–120.

• SAR mixers achieve >90 % efficiency via Baker's transformation and secondary flow.

• Tree-shape distributor uniformly splits flow, and Focus mixer thins liquid lamellae.


Abstract

This study designs and analyzes two high-performance hybrid micromixers: a multi-channel type Mixer 1 and a super-efficient type Mixer 2. Mixer 1 integrates a tree-shape distributor with Split-and-Recombine (SAR) mixers, while Mixer 2 incorporates an additional tree-shape Focus mixer after the SAR mixers. Mixing performance was analyzed across a Reynolds number (Re) range of 0.5–120. The distributor, designed via entropy generation minimization, uniformly splits flow into eight outlets while preserving the inlet concentration distribution. The SAR unit significantly enhances transverse mass transport through Baker's transformation and secondary flows. Using over four SAR units yields >90 % efficiency across the entire Re range. The Focus mixer reduces fluid-layer thickness through bifurcation-merging processes and induces secondary flow; with four branching generations, its efficiency surpasses 90 % at Re > 10 and 99 % at Re > 35. In hybrid configurations with six SAR units, Mixer 1 exhibits a mixing efficiency dip to 95 % for Re = 6 across all outlets, exceeding 99 % for Re < 3 and Re > 8. Mixer 2 also shows a dip at Re = 6, but its minimum efficiency remains >97 %, validating its ultra-high-efficiency design.

Graphical abstract
Keywords
Jun Dong a *, Jiangkun Liu a, Huimin Lv b, Yonggang Zhu b, Chengyue Wang a *
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