Suppression of instabilities in multiphase flow by geometric confinement

Phase Change Materials Meet Microfluidic Encapsulation

Improving the utilization of thermal energy is crucial in the world nowadays due to the high levels of energy consumption. One way to achieve this is to use phase change materials (PCMs) as thermal energy storage media, which can be used to regulate temperature or provide heating/cooling in various applications. However, PCMs have limitations like low thermal conductivity, leakage, and corrosion. To overcome these challenges, PCMs are encapsulated into microencapsulated phase change materials (MEPCMs) capsules/fibers. This encapsulation prevents PCMs from leakage and corrosion issues, and the microcapsules/fibers act as conduits for heat transfer, enabling efficient exchange between the PCM and its surroundings. Microfluidics-based MEPCMs have attracted intensive attention over the past decade due to the exquisite control over flow conditions and size of microcapsules. This review paper aims to provide an overview of the state-of-art progress in microfluidics-based encapsulation of PCMs. The principle and method of preparing MEPCM capsules/fibers using microfluidic technology are elaborated, followed by the analysis of their thermal and microstructure characteristics. Meanwhile, the applications of MEPCM in the fields of building energy conservation, textiles, military aviation, solar energy utilization, and bioengineering are summarized. Finally, the perspectives on MEPCM capsules/fibers are discussed.

Double emulsions with ultrathin shell by microfluidic step-emulsification

Double emulsions with ultrathin shells are important in some biomedical applications, such as controlled drug release. However, the existing production techniques require two or more manipulation steps, or more complicated channel geometry, to form thin-shell double emulsions. This work presents a novel microfluidic tri-phasic step-emulsification device, with an easily fabricated double-layer PDMS channel, for production of oil-in-oil-in-water and water-in-water-in-oil double emulsions in a single step. The shell thickness is controlled by the flow rates and can reach 1.4% of the μm-size droplet diameter. Four distinct emulsification regimes are observed depending on the experimental conditions. A theoretical model for the tri-phasic step-emulsification is proposed to predict the boundaries separating the four regimes of emulsification in plane of two dimensionless capillary numbers, Ca. The theory yields two coupled nonlinear differential equations that can be solved numerically to find the approximate shape of the free interfaces in the shallow (Hele-Shaw) microfluidic channel. This approximation is then used as the initial guess for the more accurate finite element method solution, showing very good agreement with the experimental findings. This study demonstrates the feasibility of co-flow step-emulsification as a promising method to production of double (and multiple) emulsions and micro-capsules with ultrathin shells of controllable thickness.

Dripping, jetting and tip streaming

Dripping, jetting and tip streaming have been studied up to a certain point separately by both fluid mechanics and microfluidics communities, the former focusing on fundamental aspects while the latter on applications. Here, we intend to review this field from a global perspective by considering and linking the two sides of the problem. First, we present the theoretical model used to study interfacial flows arising in droplet-based microfluidics, paying attention to three elements commonly present in applications: viscoelasticity, electric fields and surfactants. We review both classical and current results of the stability of jets affected by these elements. Mechanisms leading to the breakup of jets to produce drops are reviewed as well, including some recent advances in this field. We also consider the relatively scarce theoretical studies on the emergence and stability of tip streaming in open systems. Second, we focus on axisymmetric microfluidic configurations which can operate on the dripping and jetting modes either in a direct (standard) way or via tip streaming. We present the dimensionless parameters characterizing these configurations, the scaling laws which allow predicting the size of the resulting droplets and bubbles, as well as those delimiting the parameter windows where tip streaming can be found. Special attention is paid to electrospray and flow focusing, two of the techniques more frequently used in continuous drop production microfluidics. We aim to connect experimental observations described in this section of topics with fundamental and general aspects described in the first part of the review. This work closes with some prospects at both fundamental and practical levels.

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.

Stability of a jet moving in a rectangular microchannel

We study numerically the basic flow and linear stability of a capillary jet confined in a rectangular microchannel. We consider both the case where the interface does not touch the solid surfaces and that in which the jet adheres to them with a contact angle slightly smaller than 180^{∘}. Given an arbitrary set of values of the governing parameters, the fully developed (parallel) two-dimensional basic flow is calculated and then the growth rate of the dominant perturbation mode is determined as a function of the wave number. The flow is linearly stable if that growth rate is negative for all the wave numbers considered. We show that when the coflowing stream viscosity is sufficiently small in terms of that of the jet, there is an interval of the flow rate ratio Q for which the jet adheres to the walls or not depending on whether the flow is established by decreasing or increasing the value of Q. When the distance between the interface and the channel wall is of the order of the jet radius, the jet is unconditionally unstable. However, for sufficiently small interface-to-wall distances, the viscous stress can dominate the capillary pressure and fully stabilize the flow. Our results suggest that the capillary modes are suppressed and the flow becomes stable when the jet adheres to the channel walls. The combination of the above results indicates that, under certain parametric conditions, stable or unstable jets can be formed depending on whether the experimenter sets the flow rate ratio by decreasing or increasing progressively the jet flow rate while keeping constant that of the outer stream. Our theoretical predictions for the stablity of a coflow in a rectangular channel are consistent with previous experimental results [Humphry et al., Phys. Rev. E 79, 056310 (2009)PLEEE81539-375510.1103/PhysRevE.79.056310].

Criteria for drop generation in multiphase microfluidic devices

A theory is presented for the transition between the coflowing and the drop-generation regimes observed in microfluidic channels with a rectangular cross section. This transition is characterized by a critical ratio of the dispersed- to continuous-phase volume flow rates. At flow-rate ratios higher than this critical value, drop generation is suppressed. The critical ratio corresponds to the fluid cross section where the dispersed-phase fluid is just tangent to the channel walls. The transition criterion is a function of the ratio of the fluid viscosities, the three-phase contact angle formed between the fluid phases and the channel walls, and the aspect ratio of the channel cross section; the transition is independent of interfacial tension. Hysteretic behavior of drop generation with respect to the flow-rate ratio is predicted for partially wetting dispersed-phase fluids. Experimental data are consistent with this theory.

Ultrathin Double-Shell Capsules for High Performance Photon Upconversion

Triplet-fusion-based photon upconversion capsules with ultrathin double shells are developed through a single dripping instability in a microfluidic flow-focusing device. An inner separation layer allows use of a brominated hydrocarbon oil-based fluidic core, demonstrating significantly enhanced upconversion quantum yield. Furthermore, a perfluorinated photocurable monomer serves as a transparent shell phase with remote motion control through magnetic nanoparticle incorporation.

Parallelization of microfluidic flow-focusing devices

Microfluidic flow-focusing devices offer excellent control over fluid flow, enabling formation of drops with a narrow size distribution. However, the throughput of microfluidic flow-focusing devices is limited and scale-up through operation of multiple drop makers in parallel often compromises the robustness of their operation. We demonstrate that parallelization is facilitated if the outer phase is injected from the direction opposite to that of the inner phase, because the fluid injection flow rate, where the drop formation transitions from the squeezing into the dripping regime, is shifted towards higher values.

Passive and active droplet generation with microfluidics: a review

Precise and effective control of droplet generation is critical for applications of droplet microfluidics ranging from materials synthesis to lab-on-a-chip systems. Methods for droplet generation can be either passive or active, where the former generates droplets without external actuation, and the latter makes use of additional energy input in promoting interfacial instabilities for droplet generation. A unified physical understanding of both passive and active droplet generation is beneficial for effectively developing new techniques meeting various demands arising from applications. Our review of passive approaches focuses on the characteristics and mechanisms of breakup modes of droplet generation occurring in microfluidic cross-flow, co-flow, flow-focusing, and step emulsification configurations. The review of active approaches covers the state-of-the-art techniques employing either external forces from electrical, magnetic and centrifugal fields or methods of modifying intrinsic properties of flows or fluids such as velocity, viscosity, interfacial tension, channel wettability, and fluid density, with a focus on their implementations and actuation mechanisms. Also included in this review is the contrast among different approaches of either passive or active nature.

Pore Scale Dynamics of Microemulsion Formation

Experiments in various porous media have shown that multiple parameters come into play when an oleic phase is displaced by an aqueous solution of surfactant. In general, the displacement efficiency is improved when the fluids become quasi-miscible. Understanding the phase behavior oil/water/surfactant systems is important because microemulsion has the ability to generate ultralow interfacial tension (<10(-2) mN m(-1)) that is required for miscibility to occur. Many studies focus on microemulsion formation and the resulting properties under equilibrium conditions. However, the majority of applications where microemulsion is present also involve flow, which has received relatively less attention. It is commonly assumed that the characteristics of an oil/water/surfactant system under flowing conditions are identical to the one under equilibrium conditions. Here, we show that this is not necessarily the case. We studied the equilibrium phase behavior of a model system consisting of n-decane and an aqueous solution of olefin sulfonate surfactant, which has practical applications for enhanced oil recovery. The salt content of the aqueous solution was varied to provide a range of different microemulsion compositions and oil-water interfacial tensions. We then performed microfluidic flow experiments to study the dynamic in situ formation of microemulsion by coinjecting bulk fluids of n-decane and surfactant solution into a T-junction capillary geometry. A solvatochromatic fluorescent dye was used to obtain spatially resolved compositional information. In this way, we visualized the microemulsion formation and the flow of it along with the excess phases. A complex interaction between the flow patterns and the microemulsion properties was observed. The formation of microemulsion influenced the flow regimes, and the flow regimes affected the characteristics of the microemulsion formation. In particular, at low flow rates, slug flow was observed, which had profound consequences on the pore scale mixing behavior and resulting microemulsion properties.

Coexistence of different droplet generating instabilities: new breakup regimes of a liquid filament

The coexistence of multiple droplet breakup instabilities in a Step-emulsification geometry is studied. A liquid filament, which is confined in one dimension by channel walls and surrounded by a co-flowing immiscible continuous phase, decays into droplets when subject to a sudden release of confinement. Depending on the filament aspect ratio and liquid flow rates, an unexpectedly rich variety of droplet breakup regimes is found. All of these breakup regimes are composed of two basic instabilities, i.e. a step- and a jet-instability, that coexist in various combinations on the same filament. Surprisingly, even an asymmetric breakup regime is found, producing droplet families of significantly different diameters, while the filament is subject to a fully symmetric flow field. We suggest key physical principles explaining the spontaneous symmetry breaking and the transitions between individual droplet breakup regimes. The particular ability to produce distinct droplet families from a single filament is demonstrated to allow for simultaneous concentration and encapsulation of particles into one droplet family while excess bulk liquid is released into another family of droplets.

Step-emulsification in a microfluidic device

We present a comprehensive study of the step-emulsification process for high-throughput production of colloidal monodisperse droplets. The 'microfluidic step emulsifier' combines a shallow microchannel operating with two co-flowing immiscible fluids and an abrupt (step-like) opening to a deep and wide reservoir. Based on Hele-Shaw hydrodynamics, we determine the quasi-static shape of the fluid interface prior to transition to oscillatory step-emulsification at low capillary numbers. The theoretically derived transition threshold yields an excellent agreement with experimental data. A closed-form expression for the size of the droplets generated in the step-emulsification regime and derived using geometric arguments also shows a very good agreement with the experiment.

Dripping and jetting in microfluidic multiphase flows applied to particle and fiber synthesis

Dripping and jetting regimes in microfluidic multiphase flows have been investigated extensively, and this review summarizes the main observations and physical understandings in this field to date for three common device geometries: coaxial, flow-focusing and T-junction. The format of the presentation allows for simple and direct comparison of the different conditions for drop and jet formation, as well as the relative ease and utility of forming either drops or jets among the three geometries. The emphasis is on the use of drops and jets as templates for microparticle and microfiber syntheses, and a description is given of the more common methods of solidification and strategies for achieving complex multicomponent microparticles and microfibers.

Influence of substrate confinement on the phase-correlation in the capillary breakup of arrays of patterned polymer stripes

We investigated the influence of substrate confinement on the capillary breakup of parallel nonaxisymmetric polymer stripes suspended on top of, or confined between, another immiscible polymer pattern. When the residual layer thickness of the pattern was reasonably large, the PS (or PMMA) stripes confined within PMMA (or PS) trenches broke up, either nucleated, out-of-phase, or without clear phase correlation depending on the geometry and viscosity ratio between the two polymers. In stark contrast, for the two extreme cases of viscosity ratios we studied, in-phase breakup of confined polymer stripes was always observed when the alternating PS/PMMA stripes were formed, that is, without residual layer, regardless of the specific geometry.

Emulsion droplet formation in coflowing liquid streams

We investigate emulsion droplet formation in coflowing liquid streams based on a computational fluid dynamics simulation using the volume-of-fluid method to track the interface motion with a focus on the dynamics of the dripping and jetting regimes. The simulations reproduce dripping, widening jetting and narrowing jetting simultaneously in a coflowing microchannel in agreement with the experimental observations in this work. The result indicates that the dripping regime, rather than the jetting regime, is a favorable way to producing monodisperse emulsions. We find that, in dripping and widening jetting regimes, the breakup of a drop is induced by higher pressure in the neck which squeezes liquid into the lower-pressure region in subsequent and primary droplets, while the breakup in the narrowing jetting regime is due to slow velocity at the back end of the trough with respect to the leading end of the trough. In addition, the capillary number of the outer fluid and the Weber number of the inner fluid not only determine the drop diameter and generation rate but also the regime of emulsification.

Control of the length of microfibers

Uniform polymeric microfibers of prescribed lengths were synthesized in microfluidic devices using two different approaches--valve actuation and pulses of ultraviolet (UV) light. The more versatile valve approach was employed to demonstrate control of the length of the microfiber as a function of the frequency of valve actuation.

Slow growth of the Rayleigh-Plateau instability in aqueous two phase systems

This paper studies the Rayleigh-Plateau instability for co-flowing immiscible aqueous polymer solutions in a microfluidic channel. Careful vibration-free experiments with controlled actuation of the flow allowed direct measurement of the growth rate of this instability. Experiments for the well-known aqueous two phase system (ATPS, or aqueous biphasic systems) of dextran and polyethylene glycol solutions exhibited a growth rate of 1 s(-1), which was more than an order of magnitude slower than an analogous experiment with two immiscible Newtonian fluids with viscosities and interfacial tension that closely matched the ATPS experiment. Viscoelastic effects and adhesion to the walls were ruled out as explanations for the observed behavior. The results are remarkable because all current theory suggests that such dilute polymer solutions should break up faster, not slower, than the analogous Newtonian case. Microfluidic uses of aqueous two phase systems include separation of labile biomolecules but have hitherto be limited because of the difficulty in making droplets. The results of this work teach how to design devices for biological microfluidic ATPS platforms.

Comparison of monodisperse droplet generation in flow-focusing devices with hydrophilic and hydrophobic surfaces

A thin flow-focusing microfluidic channel is evaluated for generating monodisperse liquid droplets. The microfluidic device is used in its native state, which is hydrophilic, or treated with OTS to make it hydrophobic. Having both hydrophilic and hydrophobic surfaces allows for creation of both oil-in-water and water-in-oil emulsions, facilitating a large parameter study of viscosity ratios (droplet fluid/continuous fluid) ranging from 0.05 to 96 and flow rate ratios (droplet fluid/continuous fluid) ranging from 0.01 to 2 in one geometry. The hydrophilic chip provides a partially-wetting surface (contact angle less than 90°) for the inner fluid. This surface, combined with the unusually thin channel height, promotes a flow regime where the inner fluid wets the top and bottom of the channel in the orifice and a stable jet is formed. Through confocal microscopy, this fluid stabilization is shown to be highly influenced by the contact angle of the liquids in the channel. Non-wetting jets undergo breakup and produce drops when the jet is comparable to or smaller than the channel thickness. In contrast, partially-wetting jets undergo breakup only when they are much smaller than the channel thickness. Drop sizes are found to scale with a modified capillary number based on the total flow rate regardless of wetting behavior.

Droplet formation in microfluidic T-junction generators operating in the transitional regime. II. Modeling

This is the second part of a two-part study on the generation of droplets at a microfluidic T-junction operating in the transition regime. In the preceding paper [Phys. Rev. E 85, 016322 (2012)], we presented our experimental observations of droplet formation and decomposed the process into three sequential stages defined as the lag, filling, and necking stages. Here we develop a model that describes the performance of microfluidic T-junction generators working in the squeezing to transition regimes where confinement of the droplet dominates the formation process. The model incorporates a detailed geometric description of the drop shape during the formation process combined with a force balance and necking criteria to define the droplet size, production rate, and spacing. The model inherently captures the influence of the intersection geometry, including the channel width ratio and height-to-width ratio, capillary number, and flow ratio, on the performance of the generator. The model is validated by comparing it to speed videos of the formation process for several T-junction geometries across a range of capillary numbers and viscosity ratios.

Droplet based microfluidics

Droplet based microfluidics is a rapidly growing interdisciplinary field of research combining soft matter physics, biochemistry and microsystems engineering. Its applications range from fast analytical systems or the synthesis of advanced materials to protein crystallization and biological assays for living cells. Precise control of droplet volumes and reliable manipulation of individual droplets such as coalescence, mixing of their contents, and sorting in combination with fast analysis tools allow us to perform chemical reactions inside the droplets under defined conditions. In this paper, we will review available drop generation and manipulation techniques. The main focus of this review is not to be comprehensive and explain all techniques in great detail but to identify and shed light on similarities and underlying physical principles. Since geometry and wetting properties of the microfluidic channels are crucial factors for droplet generation, we also briefly describe typical device fabrication methods in droplet based microfluidics. Examples of applications and reaction schemes which rely on the discussed manipulation techniques are also presented, such as the fabrication of special materials and biophysical experiments.

Air-bubble-triggered drop formation in microfluidics

In microfluidic devices, droplets are normally formed using T-junction or flow focus mechanisms. While both afford a high degree of control over drop formation, they are limited in maximum production rate by the jetting transition. Here, we introduce a new drop formation mechanism that is not limited by jetting, allowing much faster drop production.

Monodisperse hydrogel microspheres by forced droplet formation in aqueous two-phase systems

This paper presents a method to form micron-sized droplets in an aqueous two-phase system (ATPS) and to subsequently polymerize the droplets to produce hydrogel beads. Owing to the low interfacial tension in ATPS, droplets do not easily form spontaneously. We enforce the formation of drops by perturbing an otherwise stable jet that forms at the junction where the two aqueous streams meet. This is done by actuating a piezo-electric bending disc integrated in our device. The influence of forcing amplitude and frequency on jet breakup is described and related to the size of monodisperse droplets with a diameter in the range between 30 and 60 μm. Rapid on-chip polymerization of derivatized dextran inside the droplets created monodisperse hydrogel particles. This work shows how droplet-based microfluidics can be used in all-aqueous, surfactant-free, organic-solvent-free biocompatible two-phase environment.

Dynamics of microfluidic droplets

This critical review discusses the current understanding of the formation, transport, and merging of drops in microfluidics. We focus on the physical ingredients which determine the flow of drops in microchannels and recall classical results of fluid dynamics which help explain the observed behaviour. We begin by introducing the main physical ingredients that differentiate droplet microfluidics from single-phase microfluidics, namely the modifications to the flow and pressure fields that are introduced by the presence of interfacial tension. Then three practical aspects are studied in detail: (i) The formation of drops and the dominant interactions depending on the geometry in which they are formed. (ii) The transport of drops, namely the evaluation of drop velocity, the pressure-velocity relationships, and the flow field induced by the presence of the drop. (iii) The fusion of two drops, including different methods of bridging the liquid film between them which enables their merging.

A circular cross-section PDMS microfluidics system for replication of cardiovascular flow conditions

Since the inception of soft lithography, microfluidic devices for cardiovascular research have been fabricated easily and cost-effectively using the soft lithography method. The drawback of this method was the fabrication of microchannels with rectangular cross-sections, which did not replicate the circular cross-sections of blood vessels. This article presents a novel, straightforward approach for the fabrication of microchannels with circular cross-sections in poly(dimethylsiloxane) (PDMS), using soft lithography. The method exploits the polymerization of the liquid silicone oligomer around a gas stream when both of them are coaxially introduced in the microchannel with a rectangular cross-section. We demonstrate (i) the ability to control the diameter of circular cross-sections of microchannels from ca. 40-100 mum; (ii) the fabrication of microchannels with constrictions, and (iii) the capability to grow endothelial cells on the inner surface of the microchannels.

Continuous flow structuring of anisotropic biopolymer particles

We review concepts and provide examples for the controlled structuring of biopolymer particles in hydrodynamic flow fields. The structuring concepts are grouped by the physical mechanisms governing drop deformation and shaping: (i) capillary structuring, (ii) shear and elongational structuring and (iii) confined flow methods. Non-spherical drops can be permanently structured if a solidification process, such as gelation or glass formation in the bulk or at the interface, is superimposed to the flow field. The physical and engineering properties of these processes critically depend on an elaborate balance between capillary phenomena, rheology, gel or glass formation kinetics, and bulk heat, mass and momentum transfer in multiphase fluids. This overview is motivated by the potential of non-spherical suspension particles, in particular those formed from 'natural' and 'sustainable' biopolymers, as rheology modifiers in food materials, consumer products, cosmetics or pharmaceuticals.

Impact of inlet channel geometry on microfluidic drop formation

We study the impact of inlet channel geometry on microfluidic drop formation. We show that drop makers with T-junction style inlets form monodisperse emulsions at low and moderate capillary numbers and those with Flow-Focus style inlets do so at moderate and high capillary numbers. At low and moderate capillary number, drop formation is dominated by interfacial forces and mediated by the confinement of the microchannels; drop size as a function of flow-rate ratio follows a simple functional form based on a blocking-squeezing mechanism. We summarize the stability of the drop makers with different inlet channel geometry in the form of a phase diagram as a function of capillary number and flow-rate ratio.