Micro-droplet formation in non-Newtonian fluid in a microchannel

Micro-droplet formation from an aperture with a diameter of micrometers is numerically investigated under the cross-flow conditions of an experimental microchannel emulsification process. The process involves dispersing an oil phase into continuous phase fluid through a microchannel wall made of apertured substrate. Cross-flow in the microchannel is of non-Newtonian nature, which is included in the simulations. Micro-droplets of diameter 0.76–30 μm are obtained from the simulations for the apertures of diameter 0.1–10.0 μm. The simulation results show that rheology of the bulk liquid flow greatly affects the formation and size of droplets and that dispersed micro-droplets are formed by two different breakup mechanisms: in dripping regime and in jetting regime characterized by capillary number Ca. Relations between droplet size, aperture opening size, interfacial tension, bulk flow rheology, and disperse phase flow rate are discussed based on the simulation and the experimental results. Data and models from literature on membrane emulsification and T-junction droplet formation processes are discussed and compared with the present results. Detailed force balance models are discussed. Scaling factor for predicting droplet size is suggested.     

Liquid–liquid micro-dispersion in a double-pore T-shaped microfluidic device

For further understanding the dispersion process in the T-shaped microfluidic device, a double-pore T-shaped microchannel was designed and tested with octane/water system to form monodispersed plugs and droplets in this work. The liquid–liquid two-phase flow patterns were investigated and it was found that only short plugs, relative length L/w < 1.4, were produced. Additionally, the droplets flow was realized at phase ratios (F _C /F _D) just higher than 0.5, which is much smaller than that in the single-pore T-shaped microchannels. A repulsed effect between the initial droplets was observed in the droplet formation process and the periodic fluctuation flow of the dispersed phase was discussed by analyzing the resistances. Besides, the effect of the two-phase flow rates on the plug length and the droplet diameter was investigated. Considering the mutual effect of the initial droplets and the equilibrium between the shearing force with the interfacial tension, phase ratio and Ca number were introduced into the semi-empirical models to present the plug and droplet sizes at different operating conditions.     

Capillary filling with the effect of pneumatic pressure of trapped air

This article presents an investigation into the effects of pneumatic pressure of trapped air on the dynamics of capillary filling. Controlled experiments were carried out in horizontal closed-end capillaries with diameters of 200–700 μm. Glycerol–DI water mixture solutions having viscosities ranging from 8 to 80 mPa s were used as the filling liquids. The pneumatic air backpressure is built up as a result of the air compressed at the closed end of the capillary. A model is presented based on the conventional theory of capillary filling (i.e., Washburn’s equation) with consideration of the effect of air backpressure force on the advancing meniscus. The molecular kinetics theory of Blake and De Coninck’s model (Adv Colloid Interface Sci 96:21–36, 2002) is also incorporated in the model to account for the dependence of dynamic contact angle on wetting velocity. The model predictions agree reasonably well with the experimental data. It is observed that due to the presence of air backpressure, the smaller the capillary diameter, the longer the length that the liquid fills the capillary, regardless of the liquid viscosity. It is also shown that the increased pneumatic air backpressure reduces the equilibrium contact angle (θ ⁰). A relation is then proposed among liquid penetration, capillary length and radius, and contact angle. In addition, a dimensionless analysis is performed on experimental data, and the power law dependence of dimensionless meniscus position on dimensionless time is obtained.     

Pressure drop of gas–liquid Taylor flow in round micro-capillaries for low to intermediate Reynolds numbers

In this paper, a model is presented that describes the pressure drop of gas–liquid Taylor flow in round capillaries with a channel diameter typically less than 1 mm. The analysis of Bretherton (J Fluid Mech 10:166–188, 1961) for the pressure drop over a single gas bubble for vanishing liquid film thickness is extended to include a non-negligible liquid film thickness using the analysis of Aussillous and Quéré (Phys Fluids 12(10):2367–2371, 2000). This result is combined with the Hagen–Poiseuille equation for liquid flow using a mass balance-based Taylor flow model previously developed by the authors (Warnier et al. in Chem Eng J 135S:S153–S158, 2007). The model presented in this paper includes the effect of the liquid slug length on the pressure drop similar to the model of Kreutzer et al. (AIChE J 51(9):2428–2440, 2005). Additionally, the gas bubble velocity is taken into account, thereby increasing the accuracy of the pressure drop predictions compared to those of the model of Kreutzer et al. Experimental data were obtained for nitrogen–water Taylor flow in a round glass channel with an inner diameter of 250 μm. The capillary number Ca _gl varied between 2.3 × 10⁻³ and 8.8 × 10⁻³ and the Reynolds number Re _gl varied between 41 and 159. The presented model describes the experimental results with an accuracy of ±4% of the measured values.     

Correlations of droplet formation in T-junction microfluidic devices: from squeezing to dripping

In this work, we have systematically analyzed the scaling law of droplet formation by cross-flow shear method in T-junction microfluidic devices. The droplet formation mechanisms can be distinguished by the capillary number for the continuous phase (Ca_c), which are the squeezing regime (Ca_c < 0.002), dripping regime (0.01 < Ca_c < 0.3), and the transient regime (0.002 < Ca_c< 0.01). Three corresponding correlations have been suggested in the different range of Ca_c. In the dripping regime, we developed a modified capillary number for the continuous phase (Ca_c′) by considering the influence of growing droplet size on the continuous phase flow rate. And the modified model could predict droplet diameter more accurately. In the squeezing regime, the final plug length was contributed by the growth and ‘squeeze’ stages based on the observation of dynamic break-up process. In the transient regime, we firstly suggested a mathematical model by considering the influences of the above two mechanisms. The correlations should be very useful for the application of controlling droplet size in T-junction microfluidic devices.     

Critical conditions and breakup of non-squashed microconfined droplets: effects of fluid viscoelasticity

Droplet breakup in systems with either a viscoelastic matrix or a viscoelastic droplet is studied microscopically in bulk and confined shear flow, using a parallel plate counter rotating shear flow cell. The ratio of droplet diameter to gap spacing is systematically varied between 0.1 and 0.85. In bulk shear flow, the effects of matrix and droplet viscoelasticity on the critical capillary number for breakup are very moderate under the studied conditions. However, in confined conditions a profoundly different behaviour is observed: the critical capillary numbers of a viscoelastic droplet are similar to those of a Newtonian droplet, whereas matrix viscoelasticity causes breakup at a much lower capillary number. The critical capillary numbers are compared with the predictions of a phenomenological model by Minale et al. (Langmuir 26:126–132, 2010); the model results are in qualitative disagreement with the experimental data. It is also found that the critical dimensionless droplet length, the critical capillary number, and the dimensionless droplet length at breakup show a similar dependency on confinement ratio. As a result, confined droplets in a viscoelastic matrix have a smaller dimensionless length at breakup than droplets in a Newtonian matrix, which affects the breakup mode. Whereas confined droplets in a Newtonian matrix can break up into multiple parts, only two daughter droplets are obtained after breakup in a viscoelastic matrix, up to very large confinement ratios.     

Effects of actuating waveform,ink property,and nozzle size on piezoelectrically driven inkjet droplets

Computational fluid dynamics and micro-flow visualization (μ-FV) have been complementarily performed to study the evolution of a single droplet ejected from a bend-mode piezoelectric inkjet printhead. The numerical simulation is characterized by the coupled piezoelectric-structural-fluid solution procedure and verified by the μ-FV results. The in-house numerical code is subsequently applied to investigate the influences of electric voltage φ _pp, pulse shape, ink property, and nozzle diameter D _n on the droplet volume, velocity, and configurations. φ _pp studied ranges from 14 to 26 V and pulse shape is explored by varying the key time intervals with fixed voltage slopes. The influence of ink property is examined by investigating the dynamic viscosity μ and surface tension σ separately. Investigation on the effects of nozzle diameter is also conducted by decreasing D _n from 26 to 11 at 3 μm interval. The computed results are found in good agreement with the experimental ones. New findings are to discover the critical ranges of electric waveform parameters, μ, and σ outside which the phenomena of satellite droplets and puddle formation at the nozzle opening are absent. In addition, the imbedded physical rationales for these critical ranges are provided. The results are also new in terms of the identifications of the critical σ and D _n for the reference of improving the droplet quality.     

Electroosmotic flows in an electric double layer overlapped channel with rectangle-waved surface roughness

To further understand the wall-roughness effect, the present study has performed numerical simulations, by employing the Poisson–Nernst–Planck model, on the two-dimensional electroosmotic flow in a plane channel with dielectric walls of rectangle-waved surface roughness where the two electric double layers (EDLs) are overlapped. Results show that the steady electroosmotic flow and ionic-species transport depend significantly on the shape of the surface roughness such as the amplitude and periodic length of wall wave, but their characteristics are basically different from those in the case where the EDLs are not overlapped at all (Kang and Suh in Microfluid Nanofluid, doi:, 2008). It is found that the fluid flows over the waved wall (or wall roughness) with involving a separation or recirculation of flow in the cavity, which resembles much the traditional pressure-driven flow. In addition, the flow characteristics are determined chiefly by the level of the electric-charge density in the bulk region above the waved wall. As a result, with increasing wall-wave amplitude (0.01 ≤ h/H ≤ 0.2), the flow rate increases due to the enhanced amount of electric charges released from the enlarged wet surface at low amplitudes and then decreases due to the reduced flow-passage area at high amplitudes above a certain critical value. With increasing periodic length (0.2 ≤ L/H ≤ 1.2), on the other hand, the flow rate decreases in a hyperbolic fashion due to the reduced amount of electric charges.     

Scalable attoliter monodisperse droplet formation using multiphase nano-microfluidics

We demonstrate a robust method to produce monodisperse femtoliter to attoliter droplets by using a nano-microfluidic device. Two immiscible liquids are forced through a nanochannel where a steady nanoscopic liquid filament forms, thinning close to the nanochannel exit to a microchannel due to the capillary focusing. When the nanoscopic filament enters the microchannel, monodisperse droplets are formed by capillary instability. In a certain range of physical parameters and geometrical configurations, the droplet size is only determined by the nanochannel height and independent of liquid flow rates and ratios, surfactants, and continuous phase viscosity. By using nanochannels with a height of 100–900 nm, 0.4–3.5 μm diameter droplets (volume down to 30 aL) have been produced. The generated droplets are stable for at least weeks.     

A scaling model for electrowetting-on-dielectric microfluidic actuators

A hydrodynamic scaling model of droplet actuation in an electrowetting-on-dielectric (EWD) actuator is presented that takes into account the effects of contact angle hysteresis, drag from the filler fluid, drag from the solid walls, and change in the actuation force while a droplet traverses a neighboring electrode. Based on this model, the threshold voltage, V _T, for droplet actuation is estimated as a function of the filler medium of a scaled device. It is shown that scaling models of droplet splitting and liquid dispensing all show a similar scaling dependence on [t/ε_r(d/L)]^1/2, where t is insulator thickness and d/L is the aspect ratio of the device. It is also determined that reliable operation of a EWD actuator is possible as long as the device is operated within the limits of the Lippmann–Young equation. The upper limit on applied voltage, V _sat, corresponds to contact-angle saturation. The minimum 3-electrode splitting voltages as a function of aspect ratio d/L < 1 for an oil medium are less than V _sat. However, for an air medium the minimum voltage for 3-electrode droplet splitting exceeds V _sat for d/L ≥ 0.4. EWD actuators were fabricated to operate with droplets down to 35pl. Reasonable scaling results were achieved.

Static and dynamic behaviour of gas bubbles in T-shaped non-clogging micro-channels

Preventing micro-channels from clogging is a major issue in most micro and nanofluidic systems (Gravesen et al., J Micromech Microeng 3(4):168–182, 1993; Jensen et al., In: Proc. of MicroTAS 2002, Nara, Japan, pp 733–735, 2002; Wong et al., J Fluid Mech 292:71–94, 1995). The T-shaped channel first reported by Kohnle et al. (In: IEEE MEMS, the 15th international IEEE micro electro mechanical conference (ed), Las Vegas, pp 77–80, 2002) prevents micro-channels from clogging by the aid of the equilibrium bubble position in such a geometry. This work is concerned with the static and dynamic behaviour of bubbles in such T-shaped micro-channels. The aspect ratio of a rectangle enclosing the T-shaped channel and the contact angle of the walls are the main parameters influencing the static and dynamic bubble behaviour. It is investigated in this article how these parameters relate to the equilibrium bubble shape and how optimum bubble velocities can be achieved inside the channel. An analytical model depending on the contact angle and the channel geometry is presented that allows to determine the bubble configuration inside the channel by minimizing the bubble’s surface energy. A second model is derived to predict the velocity of gas bubbles driven by buoyancy in vertical T-shaped channels. The model is applied to design T-shaped channels with a maximum mobility of gas bubbles. Experiments with MEMS fabricated devices and CFD simulations are used to verify the models. Furthermore design rules for an optimum non-clogging channel geometry which provides the highest gas bubble mobility are given.     

Droplet dynamics passing through obstructions in confined microchannel flow

Motivated by the previous studies (Lee et al., Lab Chip 10:1160–1166, 2010; Link et al., Phys Rev Lett 92:054503-1–054503-4, 2004), the droplet dynamics passing through obstructions in confined microchannel was explored both numerically and experimentally. The effects of obstruction shape (cylinder and square), droplet size, and capillary number (Ca) on droplet dynamics were investigated. For the size control, due to an obstruction-induced droplet breakup, the cylinder obstruction was found to be advantageous over square type for practical purposes. The thread breakup was attributed to both normal and shear components of velocity gradients near the obstruction, in particular, near the corners of the square. As a result, the square obstruction was considered to generate more non-trivial satellite droplets. The droplet size showed little influence on the droplet dynamics. Considering the wetting process on the cylinder surface, we explored the droplet dynamics passing through two successive cylinder obstructions, where more complicated dynamics was observed depending on Ca (capillary number ~ viscous force / interface tension), cylinder interval, and droplet size. Here, we propose two requirements for independent wetting on each cylinder: (i) low Ca droplet should be manipulated, and (ii) cylinder interval should be larger than channel width. That is, low Ca droplet could intrude the region between two cylinders if the cylinder interval was far enough, while the droplet could not intrude due to geometric hindrance for close obstructions. In the numerical viewpoint, the proposed requirements were also valid for multi-cylinder obstructions up to 6. In addition, we propose a novel design of array structure of cylinders for a selective wetting, which might be useful to fabricate Janus particles. We hereby prove by both simulation and experiments that the wetting on the obstruction is controllable by changing Ca and cylinder design in the multilayer deposition process.     

Viscous heating in nanoscale shear driven liquid flows

Three-dimensional Molecular Dynamics (MD) simulations of heat and momentum transport in liquid Argon filled shear-driven nano-channels are performed using 6–12 Lennard–Jones potential interactions. Work done by the viscous stresses heats the fluid, which is dissipated through the channel walls, maintained at isothermal conditions through a recently developed interactive thermal wall model. Shear driven nano-flows for weak wetting surfaces (ε _wf /ε ≤ 0.6) are investigated. Spatial variations in the fluid density, kinematic viscosity, shear- and energy dissipation rates are presented. Temperature profiles in the nano-channel are obtained as a function of the surface wettability, shear rate and the intermolecular stiffness of wall molecules. The energy dissipation rate is almost a constant for ε _wf /ε ≤ 0.6, which results in parabolic temperature profiles in the domain with temperature jumps due to the well known Kapitza resistance at the liquid/solid interfaces. Using the energy dissipation rates predicted by MD simulations and the continuum energy equation subjected to the temperature jump boundary conditions developed in [Kim et al. Journal of Chemical Physics, 129, 174701, 2008b], we obtain analytical solutions for the temperature profiles, which agree well with the MD results.     

Effect of dispersed phase viscosity on maximum droplet generation frequency in microchannel emulsification using asymmetric straight-through channels

Uniformly sized droplets of soybean oil, MCT (medium-chain fatty acid triglyceride) oil and n-tetradecane with a Sauter mean diameter of d _3,2 = 26–35 μm and a distribution span of 0.21–0.25 have been produced at high throughputs using a 24 × 24 mm silicon microchannel plate consisting of 23,348 asymmetric channels fabricated by photolithography and deep reactive ion etching. Each channel consisted of a 10-μm diameter straight-through micro-hole with a length of 70 μm and a 50 × 10 μm micro-slot with a depth of 30 μm at the outlet of each channel. The maximum dispersed phase flux for monodisperse emulsion generation increased with decreasing dispersed phase viscosity and ranged from over 120 L m⁻² h⁻¹ for soybean oil to 2,700 L m⁻² h⁻¹ for n-tetradecane. The droplet generation frequency showed significant channel to channel variations and increased with decreasing viscosity of the dispersed phase. For n-tetradecane, the maximum mean droplet generation frequency was 250 Hz per single active channel, corresponding to the overall throughput in the device of 3.2 million droplets per second. The proportion of active channels at high throughputs approached 100% for soybean oil and MCT oil, and 50% for n-tetradecane. The agreement between the experimental and CFD (Computational Fluid Dynamics) results was excellent for soybean oil and the poorest for n-tetradecane.     

The spreading of a viscous microdrop on a solid surface

The spreading of a liquid microdrop across a solid surface is examined using the interface formation model. This model allows for variable surface tension at constant temperature and a flow induced Maragoni effect, by incorporating irreversible thermodynamics into the continuum model. The model is solved for small Capillary number and small Reynolds number. This problem has been considered before for much larger drops in Shikhmurzaev (Phys Fluids 9:266, 1997a), which examined the spreading of a drop for ε = τ U _CL/R ≪ 1, where U _CL is the speed of the moving contact line across the solid surface, τ is the surface tension relaxation time of the viscous liquid, and R is a typical length scale for the size of the drop. This paper extends that work by examining ε = O(1), which will be shown to be the appropriate scaling for very small liquid drops, on the scale of micrometres or less.     

Propagation of adhesives in joints during capillary adhesive bonding of microcomponents

 Capillary adhesive bonding is used successfully to integrate microsystems. To ensure high reliability and quality of the interconnection technique, it is imperative that the propagation of adhesives in the joints be controlled. Two adhesives frequently used in capillary adhesive bonding were examined: a one-component, UV-curing methacrylate adhesive (Dymax 191-M), and a two-component epoxy resin bonding adhesive curing at room temperature (Epo-tek 302-3M). The propagation of these adhesives in joints with different gap heights of 2–20 μm between two PMMA surfaces and between one PMMA and one PI surface was measured and compared with the theoretical adhesive propagation in accordance with the Hagen–Poiseuille equation for a gap flow, with the capillary pressure taken into account. Once the dynamic viscosity, the wetting angle and the surface tension of the adhesive have been determined as a function of the measuring time, the measured propagation of the Epo-tek 302-3M and Dymax 191-M adhesives can be described in good agreement with the theory for all the gap heights under study. Received: 30 March 1999 / Accepted: 12 April 1999     

Generating gas/liquid/liquid three-phase microdispersed systems in double T-junctions microfluidic device

This article describes the generation of microdispersed bubbles and droplets in a double T-junctions microfluidic device to form immiscible gas/liquid/liquid three-phase flowing systems. Segmented gas plugs are controllably prepared in water at the first T-junction to form gas/liquid two-phase fluid with the perpendicular flow cutting method. Then using this two-phase fluid as the cross-shearing fluid for the oil phase at the second T-junction, the gas/liquid/liquid three-phase flowing systems are prepared. Interestingly, it is found that the break-up of the oil droplets is mainly dominated by the cutting effect of the gas/liquid interface or the pressure drop across the emerging droplet, but independent with the viscous shearing effect of the continuous phase, even at the capillary number (Ca = u _wμ_w/γ_ow) higher than 0.01. The size laws and the distributions of the bubbles and droplets are investigated carefully, and a mathematical model has been developed to relating the operating conditions with the dispersed sizes.     

Simulations of unsteady cavitating turbulent flow in a Francis turbine using the RANS method and the improved mixture model of two-phase flows

This paper reports the simulation results for the unsteady cavitating turbulent flow in a Francis turbine using the mixture model for cavity–liquid two-phase flows. The RNG k–ε turbulence model is employed in the Reynolds averaged Navier–Stokes equations in this study. In the mixture model, an improved expression for the mass transfer is employed which is based on evaporation and condensation mechanisms with considering the effects of the non-dissolved gas, the turbulence, the tension of interface at cavity and the effect of phase change rate and so on. The computing domain includes the guide vanes, the runner, and the draft tube, which is discretized with a full three-dimensional mesh system of unstructured tetrahedral shapes. The finite volume method is used to solve the governing equations of the mixture model and a full coupled method is combined into the algorithm to accelerate the solution. The computing results with the mixture model have been compared with those by the single-phase flow model as well as the experimental data. The simulation results show that the cavitating flow computation based on the improved mixture model agrees much better with experimental data than that by the single-phase flow calculation, in terms of the amplitude and dominated frequency of the pressure fluctuation. It is also observed from the present simulations that the amplitude of the pressure fluctuation at small flow rate is larger than that at large flow rate, which accords with the experimental data.     

Local abstraction–refinement for the <Emphasis Type="Italic">μ</Emphasis>-calculus

A key technique for the verification of programs is counterexample-guided abstraction–refinement (CEGAR). Grumberg et al. (LNCS, vol 3385, pp. 233–249. Springer, Berlin, 2005; Inf Comput 205(8):1130–1148, 2007) developed a CEGAR-based algorithm for the modal μ-calculus. There, every abstract state is split in a refinement step. In this paper, the work of Grumberg et al. is generalized by presenting a new CEGAR-based algorithm for the μ-calculus. It is based on a more expressive abstract model and applies refinement only locally (at a single abstract state), i.e., the lazy abstraction technique for safety properties is adapted to the μ-calculus. Furthermore, it separates refinement determination from the (3-valued based) model checking. Three different heuristics for refinement determination are presented and illustrated.     

Effects of planar inlet plenums on the hydrodynamically developing flows in rectangular microchannels of complementary aspect ratios

The effects of planar inlet plenum geometry on the developing flow fields in two rectangular microchannels of reciprocal aspect ratios (H/W ∼2.75 and ∼0.40) were investigated for Re _D =  1–100 using micro particle image velocimetry (μPIV). These two microchannels were made by a precision sawing and silicon microfabrication techniques. Both the velocity profiles and centerline velocity developments were clearly resolved and extracted along the axial distance from μPIV results. The entrance lengths were found from the centerline velocities using a decaying exponential fitting function where the centerline velocity reaches 99% of the fully developed centerline velocity. The proposed fitting function showed excellent agreement with the experimental results. The planar plenum was shown to cause an upstream predevelopment resulting in the significant reductions in the entrance lengths. Two entrance length correlations were proposed in the forms of Atkinson et al.’s (AIChE J 15:548–553, 1969) and Chen’s (J Fluids Eng 95:153–158, 1973) correlations. The proposed entrance length correlations showed that acquired constant portion and slope of the entrance lengths showed 23–27 and 70–81% reductions for H/W =  2.75 while the entrance length correlation for H/W =  0.40 showed 69–73% increase and 41–63% decrease in the constant portion and slope, respectively.