Spatio-Temporal Electrowetting and Reaction Monitoring in Microfluidic Gas Diffusion Electrode Elucidates Mass Transport Limitations.

The use of gas diffusion electrodes (GDEs) enables efficient electrochemical CO2 reduction and may be a viable technology in CO2 utilization after carbon capture. Understanding the spatio-temporal phenomena at the triple-phase boundary formed inside GDEs remains a challenge; yet it is critical to design and optimize industrial electrodes for gas-fed electrolyzers. Thus far, transport and reaction phenomena are not yet fully understood at the microscale, among other factors, due to a lack of experimental analysis methods for porous electrodes under operating conditions. In this work, a realistic microfluidic GDE surrogate is presented. Combined with fluorescence lifetime imaging microscopy (FLIM), the methodology allows monitoring of wetting and local pH, representing the dynamic (in)stability of the triple phase boundary in operando. Upon charging the electrode, immediate wetting leads to an initial flooding of the catalyst layer, followed by spatially oscillating pH changes. The micromodel presented gives an experimental insight into transport phenomena within porous electrodes, which is so far difficult to achieve. The methodology and proof of the spatio-temporal pH and wetting oscillations open new opportunities to further comprehend the relationship between gas diffusion electrode properties and electrical currents originating at a given surface potential.

Porous Anisometric PNIPAM Microgels: Tailored Porous Structure and Thermal Response.

The porous structure of microgels significantly influences their properties and, thus, their suitability for various applications, in particular as building blocks for tissue scaffolds. Porosity is one of the crucial features for microgel-cell interactions and significantly increases the cells' accumulation and proliferation. Consequently, tailoring the porosity of microgels in an effortless way is important but still challenging, especially for nonspherical microgels. This work presents a straightforward procedure to fabricate complex-shaped poly(N-isopropyl acrylamide) (PNIPAM) microgels with tuned porous structures using the so-called cononsolvency effect during microgel polymerization. Therefore, the classical solvent in the reaction solution is exchanged from water to water-methanol mixtures in a stop-flow lithography process. For cylindrical microgels with a higher methanol content during fabrication, a greater degree of collapsing is observed, and their aspect ratio increases. Furthermore, the collapsing and swelling velocities change with the methanol content, indicating a modified porous structure, which is confirmed by electron microscopy micrographs. Furthermore, swelling patterns of the microgel variants occur during cooling, revealing their thermal response as a highly heterogeneous process. These results show a novel procedure to fabricate PNIPAM microgels of any elongated 2D shape with tailored porous structure and thermoresponsiveness by introducing the cononsolvency effect during stop-flow lithography polymerization.

Dynamics of the Boundary Layer in Pulsed CO2 Electrolysis.

Electrochemical reduction of CO2 poses a vast potential to contribute to a defossilized industry. Despite tremendous developments within the field, mass transport limitations, carbonate salt formation, and electrode degradation mechanisms still hamper the process performance. One promising approach to tweak CO2 electrolysis beyond today's limitations is pulsed electrolysis with potential cycling between an operating and a regeneration mode. Here, we rigorously model the boundary layer at a silver electrode in pulsed operation to get profound insights into the dynamic reorganization of the electrode microenvironment. In our simulation, pulsed electrolysis leads to a significant improvement of up to six times higher CO current density and 20 times higher cathodic energy efficiency when pulsing between -1.85 and -1.05 V vs SHE compared to constant potential operation. We found that elevated reactant availability in pulsed electrolysis originates from alternating replenishment of CO2 by diffusion and not from pH-induced carbonate and bicarbonate conversion. Moreover, pulsed electrolysis substantially promotes carbonate removal from the electrode by up to 83 % compared to constant potential operation, thus reducing the risk of salt formation. Therefore, this model lays the groundwork for an accurate simulation of the dynamic boundary layer modulation, which can provide insights into manifold electrochemical conversions.

A novel membrane stirrer system enables foam-free biosurfactant production.

Bioreactors are the operative backbone, for example, for the production of biopharmaceuticals, biomaterials in tissue engineering, and sustainable substitutes for chemicals. Still, the Achilles' heel of bioreactors nowadays is the aeration which is based on intense stirring and gas sparging, yielding inherent drawbacks such as shear stress, foaming, and sterility concerns. We present the synergistic combination of simulations and experiments toward a membrane stirrer for the efficient bubble-free aeration of bioreactors. A digital twin of the bioreactor with an integrated membrane-module stirrer (MemStir) was developed with computational fluid dynamics (CFD) studies addressing the determination of fluid mixing, shear rates, and local oxygen concentration. Usability of the MemStir is shown in a foam-free recombinant production process of biosurfactants (rhamnolipids) from glucose with different strains of Pseudomonas putida KT2440 in a 3-L vessel and benchmarked against a regular aerated process. The MemStir delivered a maximal oxygen transfer rate (OTRmax ) of 175 mmol L-1 h-1 in completely foam-free cultivations. With a high space-time yield (STY) of 118 mgRL L-1 h-1 during a fed-batch fermentation, the effectiveness of the novel MemStir is demonstrated. Simulations show the generic value of the MemStir beyond biosurfactant production, for example, for animal cell cultivation.

Fabrication, Flow Assembly, and Permeation of Microscopic Any-Shape Particles.

Today, millimeter-sized nonspherical any-shape particles serve as flexible, functional scaffold material in chemical and biochemical reactors tailoring their hydrodynamic properties and active surface-to-volume ratio based on the particle's shape. Decreasing the particle size to smaller than 100 µm would be desired as it increases the surface-to-volume ratio and promotes a particle assembly based on surface interactions, allowing the creation of tailored self-assembling 3D scaffolds. This study demonstrates a continuous high-throughput fabrication of microscopic 3D particles with complex shape and sub-micron resolution using continuous two-photon vertical flow lithography. Evolving from there, in-channel particle fabrication into a confined microfluidic chamber with a resting fluid enables the precise fabrication of a defined number of particles. 3D assemblies with various particle shapes are fabricated and analyzed regarding their permeability and morphology, representing convective accessibility of the assembly's porosity. Differently shaped particles highlight the importance of contact area regarding particle-particle interactions and the respective hydraulic resistance of an assembly. Finally, cell culture experiments show manifold cell-particle interactions promising applicability as bio-hybrid tissue. This study pushes the research boundaries of adaptive, responsive, and permeable 3D scaffolds and granular media by demonstrating a high throughput fabrication solution and a precise hydrodynamic analysis method for micro-particle assemblies.

Micromodel of a Gas Diffusion Electrode Tracks In-Operando Pore-Scale Wetting Phenomena.

Utilizing carbon dioxide (CO2 ) as a resource for carbon monoxide (CO) production using renewable energy requires electrochemical reactors with gas diffusion electrodes that maintain a stable and highly reactive gas/liquid/solid interface. Very little is known about the reasons why gas diffusion electrodes suffer from unstable long-term operation. Often, this is associated with flooding of the gas diffusion electrode (GDE) within a few hours of operation. A better understanding of parameters influencing the phase behavior at the electrolyte/electrode/gas interface is necessary to increase the durability of GDEs. In this work, a microfluidic structure with multi-scale porosity featuring heterogeneous surface wettability to realistically represent the behavior of conventional GDEs is presented. A gas/liquid/solid phase boundary was established within a conductive, highly porous structure comprising a silver catalyst and Nafion binder. Inoperando visualization of wetting phenomena was performed using confocal laser scanning microscopy (CLSM). Non-reversible wetting, wetting of hierarchically porous structures and electrowetting were observed and analyzed. Fluorescence lifetime imaging microscopy (FLIM) enabled the observation of reactions on the model electrode surface. The presented methodology enables the systematic evaluation of spatio-temporally evolving wetting phenomena as well as species characterization for novel catalyst materials under realistic GDE configurations and process parameters.

Three-dimensional membranes for artificial lungs: Comparison of flow-induced hemolysis.

BACKGROUND: Membranes based on triply periodic minimal surfaces (TPMS) have proven a superior gas transfer compared to the contemporary hollow fiber membrane (HFM) design in artificial lungs. The improved oxygen transfer is attributed to disrupting the laminar boundary layer adjacent to the membrane surface known as main limiting factor to mass transport. However, it requires experimental proof that this improvement is not at the expense of greater damage to the blood. Hence, the aim of this work is a valid statement regarding the structure-dependent hemolytic behavior of TPMS structures compared to the current HFM design. METHODS: Hemolysis tests were performed on structure samples of three different kind of TPMS-based designs (Schwarz-P, Schwarz-D and Schoen's Gyroid) in direct comparison to a hollow fiber structure as reference. RESULTS: The results of this study suggest that the difference in hemolysis between TPMS membranes compared to HFMs is small although slightly increased for the TPMS membranes. There is no significant difference between the TPMS structures and the hollow fiber design. Nevertheless, the ratio between the achieved additional oxygen transfer and the additional hemolysis favors the TPMS-based membrane shapes. CONCLUSION: TPMS-shaped membranes offer a safe way to improve gas transfer in artificial lungs.

Platelet count reduction during in vitro membrane oxygenation affects platelet activation, neutrophil extracellular trap formation and clot stability, but does not prevent clotting.

INTRODUCTION: Due to improved technology and increased application the mortality during extracorporeal membrane oxygenation (ECMO) is constantly declining. Nevertheless, complications including haemorrhage or thrombus formation remain frequent. Local mitigation of coagulation within an ECMO system to prevent thrombus formation on ECMO components and optimizing systemic anticoagulation is an approach to reduce clotting and bleeding complications at once. Foreign surfaces of ECMO systems, activate platelets (PLTs), which besides their major role in coagulation, can trigger the formation of neutrophil extracellular traps (NETs) contributing to robust thrombus formation. The impact of a reduced PLT count on PLT activation and NET formation is of paramount importance and worth investigating. METHODS: In this study platelet poor (PLT-) and native (PLT+) heparinized human blood was circulated in two identical in vitro test circuits for ECMO devices for 6 hours. PLT reduction was achieved by a centrifugation protocol prior to the experiments. To achieve native coagulation characteristics within the test circuits, the initial heparin dose was antagonized by continuous protamine administration. RESULTS: The PLT- group showed significantly lower platelet activation, basal NET formation and limited clot stability measured via thromboelastometry. Fluorescent and scanning electron microscope imaging showed differences in clot composition. Both groups showed equal clot formation within the circuit. CONCLUSIONS: This study demonstrated that the reduction of PLTs within an ECMO system is associated with limited PLT activation and NET formation, which reduces clot stability but is not sufficient to inhibit clot formation per se.

A scalable bubble-free membrane aerator for biosurfactant production.

The bioeconomy is a paramount pillar in the mitigation of greenhouse gas emissions and climate change. Still, the industrialization of bioprocesses is limited by economical and technical obstacles. The synthesis of biosurfactants as advanced substitutes for crude-oil-based surfactants is often restrained by excessive foaming. We present the synergistic combination of simulations and experiments towards a reactor design of a submerged membrane module for the efficient bubble-free aeration of bioreactors. A digital twin of the combined bioreactor and membrane aeration module was created and the membrane arrangement was optimized in computational fluid dynamics studies with respect to fluid mixing. The optimized design was prototyped and tested in whole-cell biocatalysis to produce rhamnolipid biosurfactants from sugars. Without any foam formation, the new design enables a considerable higher space-time yield compared to previous studies with membrane modules. The design approach of this study is of generic nature beyond rhamnolipid production.

Towards synergistic oscillations in enzymatically active hydrogel spheres.

Stimuli-responsive polymers are capable of reacting to an external trigger. We report self-regulated, enzymatically active, and pH-responsive hydrogels that show dynamic behavior without an external trigger. This is enabled by a feedback loop between the enzymatic conversion of glucose into gluconic acid and the pH-induced volume phase transition that leads to a modulation in glucose permeability. The synthesized hydrogel spheres combine all required properties for sustained oscillation including enzymatic activity, switchable reactivity, hysteresis in volume phase transition and feedback between the reaction and permeation. A simple model of the system identified possible operating points where sustained oscillations are possible. Experiments at these operating points revealed that the system is able to perform a self-regulated oscillation cycle under a constant nutrient supply. A sensitivity analysis showed that the system is especially sensitive around the point of oscillation, so that precise control of the process parameters is essential to achieve sustained oscillations.

About a Membrane with Microfluidic Porous-Wall Channels of Cylindrical Shape for Droplet Formation.

A low-energy emulsification process is hollow-fiber emulsification. In this process, the lumen diameter of the membrane mostly determines the droplet size. To gain smaller droplets, approaches for downsizing the inner diameter of membranes have to be carried out. In this work, we describe a new method for the fabrication of parallel microfluidic porous-wall channels of a homogeneous cylindrical shape with lumen diameters down to 7 µm. Parallel and symmetric porous-wall channels are induced into polyvinylidene fluoride membranes during the casting process. The technique comprises liquid-induced phase separation and phase-separation micromolding using thin glass and carbon fibers as molds and an in-house designed tool to position the fibers. The channel positioning and alignment are verified within this work. We show and investigate the droplet formation in these porous-wall channels via hollow-fiber emulsification. The formed droplets are very small in diameter and size distribution. The droplet formation at varying flow rates and channel diameters is examined in detail. Moreover, an area of sufficient operating conditions is given using Weber and capillary numbers. As a numbering-up approach, we show the simultaneous formation of spherical droplets in two parallel channels. With the proposed membrane fabrication using micromolding, we push the downscaling approach of hollow-fiber emulsification to lower micron ranges of the channel diameter. With these small channels, droplets with a diameter down to 25 µm were produced, which are more attractive for most applications.

Catalytically Active Hollow Fiber Membranes with Enzyme-Embedded Metal-Organic Framework Coating.

Metal-organic frameworks (MOFs) are suitable enzyme immobilization matrices. Reported here is the in situ biomineralization of glucose oxidase (GOD) into MOF crystals (ZIF-8) by interfacial crystallization. This method is effective for the selective coating of porous polyethersulfone microfiltration hollow fibers on the shell side in a straightforward one-step process. MOF layers with a thickness of 8 µm were synthesized, and fluorescence microscopy and a colorimetric protein assay revealed the successful inclusion of GOD into the ZIF-8 layer with an enzyme concentration of 29±3 µg cm-2 . Enzymatic activity tests revealed that 50 % of the enzyme activity is preserved. Continuous enzymatic reactions, by the permeation of ß-d-glucose through the GOD@ZIF-8 membranes, showed a 50 % increased activity compared to batch experiments, emphasizing the importance of the convective transport of educts and products to and from the enzymatic active centers.

Two-Photon Vertical-Flow Lithography for Microtube Synthesis.

Two-photon vertical-flow lithography is demonstrated for synthesis of complex-shaped polymeric microtubes with a high aspect ratio (>100:1). This unique microfluidic approach provides rigorous control over the morphology and surface topology to generate thin-walled (<1 µm) microtubes with a tunable diameter (1-400 µm) and pore size (1-20 µm). The interplay between fluid-flow control and two-photon lithography presents a generic high-resolution method that will substantially contribute toward the future development of biocompatible scaffolds, stents, needles, nerve guides, membranes, and beyond.

Cell Encapsulation in Soft, Anisometric Poly(ethylene) Glycol Microgels Using a Novel Radical-Free Microfluidic System.

Complex 3D artificial tissue constructs are extensively investigated for tissue regeneration. Frequently, materials and cells are delivered separately without benefitting from the synergistic effect of combined administration. Cell delivery inside a material construct provides the cells with a supportive environment by presenting biochemical, mechanical, and structural signals to direct cell behavior. Conversely, the cell/material interaction is poorly understood at the micron scale and new systems are required to investigate the effect of micron-scale features on cell functionality. Consequently, cells are encapsulated in microgels to avoid diffusion limitations of nutrients and waste and facilitate analysis techniques of single or collective cells. However, up to now, the production of soft cell-loaded microgels by microfluidics is limited to spherical microgels. Here, a novel method is presented to produce monodisperse, anisometric poly(ethylene) glycol microgels to study cells inside an anisometric architecture. These microgels can potentially direct cell growth and can be injected as rod-shaped mini-tissues that further assemble into organized macroscopic and macroporous structures post-injection. Their aspect ratios are adjusted with flow parameters, while mechanical and biochemical properties are altered by modifying the precursors. Encapsulated primary fibroblasts are viable and spread and migrate across the 3D microgel structure.

Effect of the 3D Swelling of Microgels on Their 2D Phase Behavior at the Liquid-Liquid Interface.

We investigate soft, temperature-sensitive microgels at fluid interfaces. Though having an isotropic, spherical shape in bulk solution, the microgels become anisotropic upon adsorption. The structure of microgels at interfaces is described by a core-corona morphology. Here, we investigate how changing temperature across the microgel volume phase transition temperature, which leads to swelling/deswelling of the microgels in the aqueous phase, affects the phase behavior within the monolayer. We combine compression isotherms, atomic force microscopy imaging, multiwavelength ellipsometry, and computer simulations. At low compression, the interaction between adsorbed microgels is dominated by their highly stretched corona and the phase behavior of the microgel monolayers is the same. The polymer segments within the interface lose their temperature-sensitivity because of the strong adsorption to the interface. At high compression, however, the portions of the microgels that are located in the aqueous side of the interface become relevant and prevail in the microgel interactions. These portions are able to collapse and, consequently, the isostructural phase transition is altered. Thus, the temperature-dependent swelling perpendicular to the interface ("3D") affects the compressibility parallel to the interface ("2D"). Our results highlight the distinctly different behavior of soft, stimuli-sensitive microgels as compared to rigid nanoparticles.

Aqueous-Phase Temperature Swing Adsorption for Pesticide Removal.

Recently, activated carbon adsorption for water treatment regained substantial attention due to the emerging task to remove trace organic compounds such as pesticides. In many applications, especially in decentralized water treatment, one major drawback of adsorbents is their limited recyclability due to inadequate logistics or uneconomical reactivation. In this lab-scale study, we present the temperature swing adsorption in the aqueous phase that allows the in situ regeneration of fixed-bed adsorbers, and prove its technical feasibility. Complying with circular water economy principles, we eliminated the pivotal need for regular replacement and consumables by employing only clean water instead of dedicated regeneration solutions. Adsorption of the herbicide amitrole in aqueous solution on granular activated carbon was exothermic (Δ H = -14.4 ± 3.2 kJ mol-1 for T = 20-94 °C) and followed the Freundlich model. The proposed method consisting of a short counterflow flush with liquid water at 125 °C effectively regenerated the adsorbent. Hence, we obtained a cyclic steady state operation with breakthrough after 122 ± 14 bed volumes (at cout/ cin = 0.2), cycle-average rejection of 90 ± 1%, and water recovery of up to 78 ± 4%. No thermal aging of adsorbent was observed over the investigated 17 cycles.

Parallel online determination of ethylene release rate by Shaken Parsley cell cultures using a modified RAMOS device.

BACKGROUND: Ethylene is an important plant hormone that controls many physiological processes in plants. Conventional methods for detecting ethylene include gas chromatographs or optical mid-infrared sensors, which are expensive and, in the case of gas chromatographs, are hardly suitable for automated parallelized online measurement. Electrochemical ethylene sensors are cheap but often suffer from poor resolution, baseline drifting, and target gas oxidation. Thus, measuring ethylene at extremely low levels is challenging. RESULTS: This report demonstrates the integration of electrochemical ethylene sensors into a respiration activity monitoring system (RAMOS) that measures, in addition to the oxygen transfer rate, the ethylene transfer rate in eight parallel shake flasks. A calibration method is presented that is not prone to baseline drifting and considers target gas oxidation at the sensor. In this way, changes in ethylene transfer rate as low as 4 nmol/L/h can be resolved. In confirmatory experiments, the overall accuracy of the method was similar to that of gas chromatography-mass spectrometry (GC/MS) measurements. The RAMOS-based ethylene determination method was exemplified with parsley suspension-cultured cells that were primed for enhanced defense by pretreatment with salicylic acid, methyl jasmonate or 4-chlorosalicylic acid and challenged with the microbial pattern Pep13. Ethylene release into the headspace of the shake flask was observed upon treatment with salicylic acid and methyl jasmonate was further enhanced, in case of salicylic acid and 4-chlorosalicylic acid, upon Pep13 challenge. CONCLUSION: A conventional RAMOS device was modified for simultaneous measurement of the ethylene transfer rate in eight parallel shake flasks at nmol/L/h resolution. For the first time electrochemical sensors are used to provide a medium-throughput method for monitoring ethylene release by plants. Currently, this can only be achieved by costly laser-based detection systems and automated gas chromatographs. The new method is particularly suitable for plant cell suspension cultures. However, the method may also be applicable to intact plants, detached leaves or other plant tissues. In addition, the general principle of the technology is likely extendable to other volatiles or gases as well, such as nitric oxide or hydrogen peroxide.

Basement Membrane Mimics of Biofunctionalized Nanofibers for a Bipolar-Cultured Human Primary Alveolar-Capillary Barrier Model.

In vitro reconstruction of an alveolar barrier for modeling normal lung functions and pathological events serve as reproducible, high-throughput pharmaceutical platforms for drug discovery, diagnosis, and regenerative medicine. Despite much effort, the reconstruction of organ-level alveolar barrier functions has failed due to the lack of structural similarity to the natural basement membrane, functionalization with specific ligands for alveolar cell function, the use of primary cells and biodegradability. Here we report a bipolar cultured alveolar-capillary barrier model of human primary cells supported by a basement membrane mimics of fully synthetic bifunctional nanofibers. One-step electrospinning process using a bioresorbable polyester and multifunctional star-shaped polyethylene glycols (sPEG) enables the fabrication of an ultrathin nanofiber mesh with interconnected pores. The nanofiber mesh possessed mechanical stability against cyclic expansion as seen in the lung in vivo. The sPEGs as an additive provide biofunctionality to fibers through the conjugation of peptide to the nanofibers and hydrophilization to prevent unspecific protein adsorption. Biofunctionalized nanofiber meshes facilitated bipolar cultivation of endothelial and epithelial cells with fundamental alveolar functionality and showed higher permeability for molecules compared to microporous films. This nanofiber mesh for a bipolar cultured barrier have the potential to promote growth of an organ-level barrier model for modeling pathological conditions and evaluating drug efficacy, environmental pollutants, and nanotoxicology.

Coupling between Buoyancy Forces and Electroconvective Instability near Ion-Selective Surfaces.

Recent investigations have revealed that ion transport from aqueous electrolytes to ion-selective surfaces is subject to electroconvective instability that stems from coupling of hydrodynamics with electrostatic forces. These systems inherently involve fluid density variation set by salinity gradients. However, the coupling between the buoyancy effects and electroconvective instability has not yet been investigated although a wide range of electrochemical systems are naturally prone to these interplaying effects. In this study we thoroughly examine the interplay of gravitational convection and chaotic electroconvection. Our results reveal that buoyant forces can significantly influence the transport rates, otherwise set by electroconvection, when the Rayleigh number Ra of the system exceeds a value Ra∼1000. We show that buoyancy forces can significantly alter the flow patterns in these systems. When the buoyancy acts in the stabilizing direction, it limits the extent of penetration of electroconvection, but without eliminating it. When the buoyancy destabilizes the flow, it alters the electroconvective patterns by introducing upward and downward fingers of respectively light and heavy fluids.

Microfiltration of deformable microgels.

Understanding the separation, concentration and purification processes of soft nanoparticles is essential for numerous applications in water filtration, bioprocessing and blood separation. Here we report unique translocation and rejection features of sub-micron sized microgels during frontal filtration using membranes having micron-sized porosity. Simultaneously measuring the increase in hydraulic resistance and electrical impedance change allows us to clearly distinguish two deposition phases: (a) microgel accumulation within the depth of the membrane porosity and (b) subsequent formation of a thin gel layer on the membrane surface. Such distinction is impossible using only classical hydraulic resistance analysis. The methodology only requires the ratio of microgel to solution conductivity as an input parameter.