Dislodgement of Hydrogen Bubbles in Microchannels with Embedded Pillars: An Analytical, Experimental, and Numerical Study

Abstract Microchannels with integrated pillars have enhanced the production capabilities and performance of various applications due to their high surface‐to‐volume ratio. However, emerging gas bubbles can become trapped, potentially limiting the functionality or efficiency of the device when scaled down to the low‐micrometer scale. Understanding the conditions required to dislodge these bubbles is thus critical for optimizing microfluidic devices with complex physical behaviors. Here an analytical model is presented that outlines the dislodgment conditions and driving forces for such gas–liquid flows. These terms are derived from the gas–liquid interface properties, geometry, and processing parameters. As the density of the pillar arrangement is scaled down, the resistance to bubble dislodgment typically increases. Nevertheless, the bubble is compelled to dislodge at lower pressure loads when critical volumes are reached. This newly discovered effect is particularly noticeable in densely packed arrays and can be explained by the interplay of increased surface tension, geometrical restrictions, and volume‐preserving forces. The analytical terms and effects are validated through novel experimental and numerical methods tailored for microchannels in the low‐micrometer scale, showing strong agreement.