A review on emulsification via microfluidic processes

Simple Method to Generate Droplets Spontaneously by a Superhydrophobic Double-Layer Split Nozzle

Given the problems of traditional droplet generation devices, such as the complex structure and processing technology, difficulty in droplet separation, and low transfer accuracy, we propose a low-adhesion superhydrophobic double-layer split nozzle (SDSN). It realizes spontaneous droplet generation by using an interfacial tension force inside the micro-hole to drive the droplet snap-off. It successfully achieves stable and highly consistent droplets on the micrometer-scale circular micro-hole. Droplets with a volume in the range of 0.65-1.75 ± 0.007 μL can be precisely achieved by adjusting the hole size of the SDSN from 100 to 500 μm. The SDSN is prepared by conventional mechanical drilling, chemical etching, and low surface energy modification. Compared with traditional droplet generation devices, no photolithography process is required, and the cost is lower. Moreover, the droplets can be obtained directly without any post-processing, avoiding the problem of separating droplets from another solution. The stability of SDSN is good, and the droplet volume is not affected by the fluctuation of external conditions. The rate of droplet generation can be freely adjusted by adjusting the speed of the electronic microinjection pump without affecting the droplet volume. It enables efficient droplet transfer without liquid residue, which improves the transfer accuracy and helps to save the use of expensive reagents. This simple but effective structure will be of great help to make breakthroughs in next-generation spontaneous droplet generation, liquid transport, and digital microfluidic devices.

Review of High-Frequency Ultrasounds Emulsification Methods and Oil/Water Interfacial Organization in Absence of any Kind of Stabilizer

Emulsions are multiphasic systems composed of at least two immiscible phases. Emulsion formulation can be made by numerous processes such as low-frequency ultrasounds, high-pressure homogenization, microfluidization, as well as membrane emulsification. These processes often need emulsifiers’ presence to help formulate emulsions and to stabilize them over time. However, certain emulsifiers, especially chemical stabilizers, are less and less desired in products because of their negative environment and health impacts. Thus, to avoid them, promising processes using high-frequency ultrasounds were developed to formulate and stabilize emulsifier-free emulsions. High-frequency ultrasounds are ultrasounds having frequency greater than 100 kHz. Until now, emulsifier-free emulsions’ stability is not fully understood. Some authors suppose that stability is obtained through hydroxide ions’ organization at the hydrophobic/water interfaces, which have been mainly demonstrated by macroscopic studies. Whereas other authors, using microscopic studies, or simulation studies, suppose that the hydrophobic/water interfaces would be rather stabilized thanks to hydronium ions. These theories are discussed in this review.

Recent advances in the microfluidic production of functional microcapsules by multiple-emulsion templating

Multiple-emulsion drops serve as versatile templates to design functional microcapsules due to their core-shell geometry and multiple compartments. Microfluidics has been used for the elaborate production of multiple-emulsion drops with a controlled composition, order, and dimensions, elevating the value of multiple-emulsion templates. Moreover, recent advances in the microfluidic control of the emulsification and parallelization of drop-making junctions significantly enhance the production throughput for practical use. Metastable multiple-emulsion drops are converted into stable microcapsules through the solidification of selected phases, among which solid shells are designed to function in a programmed manner. Functional microcapsules are used for the storage and release of active materials as drug carriers. Beyond their conventional uses, microcapsules can serve as microcompartments responsible for transmembrane communication, which is promising for their application in advanced microreactors, artificial cells, and microsensors. Given that post-processing provides additional control over the composition and construction of multiple-emulsion drops, they are excellent confining geometries to study the self-assembly of colloids and liquid crystals and produce miniaturized photonic devices. This review article presents the recent progress and current state of the art in the microfluidic production of multiple-emulsion drops, functionalization of solid shells, and applications of microcapsules.

Spray-Assisted Formation of Micrometer-Sized Emulsions

Emulsion drops with defined sizes are frequently used to conduct chemical reactions on picoliter scales or as templates to form microparticles. Despite tremendous progress that has been achieved in the production of emulsions, the high throughput formation of drops with well-defined diameters of a few micrometers remains challenging. Drops of this size, however, are in high demand, for example, for many pharmaceutical, food, and materials science applications. Here, we introduce a scalable method to produce water-in-oil emulsion drops possessing controlled diameters of just a few micrometers: We fabricate calibrated aerosol drops and transfer them into an oil bath to form stable emulsions at rates up to 480 μL min^-1 of the dispersed phase. We demonstrate that the emulsification is thermodynamically driven such that design principles to successfully form emulsions can easily be deduced. We employ these emulsion drops as templates to form well-defined micrometer-sized hydrogel spheres and capsules.

Contactless Method of Emulsion Formation Using Corona Discharge

Electroemulsification methods use electrohydrodynamic (EHD) forces to manipulate fluids and droplets for emulsion formation. Here, a top-down method is presented using a contactless corona discharge for simultaneous emulsion formation and its pumping/collection. The corona discharge forms using a sharp conductive electrode connected to a high-voltage source that ionizes water vapor droplets (formed by a humidifier) and creates an ionic wind (electroconvection), dragging them into an oil medium. The nonuniform electric field induced by the corona discharge also drives the motion of the oil medium via an EHD pumping effect utilizing a modulated bottom electrode geometry. By these two effects, this contactless method enables the immersion of the water droplets into the moving oil medium, continuously forming a water-in-oil (W/O) emulsion. The impact of corona discharge voltage, vertical and horizontal distances between the two electrodes, and depth of the silicone oil on sizes of the formed emulsions is studied. This is a low-cost and contactless process enabling the continuous formation of the W/O emulsions.

Spherical Cellulose Micro and Nanoparticles: A Review of Recent Developments and Applications

Cellulose, the most abundant natural polymer, is a versatile polysaccharide that is being exploited to manufacture innovative blends, composites, and hybrid materials in the form of membranes, films, coatings, hydrogels, and foams, as well as particles at the micro and nano scales. The application fields of cellulose micro and nanoparticles run the gamut from medicine, biology, and environment to electronics and energy. In fact, the number of studies dealing with sphere-shaped micro and nanoparticles based exclusively on cellulose (or its derivatives) or cellulose in combination with other molecules and macromolecules has been steadily increasing in the last five years. Hence, there is a clear need for an up-to-date narrative that gathers the latest advances on this research topic. So, the aim of this review is to portray some of the most recent and relevant developments on the use of cellulose to produce spherical micro- and nano-sized particles. An attempt was made to illustrate the present state of affairs in terms of the go-to strategies (e.g., emulsification processes, nanoprecipitation, microfluidics, and other assembly approaches) for the generation of sphere-shaped particles of cellulose and derivatives thereof. A concise description of the application fields of these cellulose-based spherical micro and nanoparticles is also presented.

Optimisation of a Microfluidic Method for the Delivery of a Small Peptide

Peptides hold promise as therapeutics, as they have high bioactivity and specificity, good aqueous solubility, and low toxicity. However, they typically suffer from short circulation half-lives in the body. To address this issue, here, we have developed a method for encapsulation of an innate-immune targeted hexapeptide into nanoparticles using safe non-toxic FDA-approved materials. Peptide-loaded nanoparticles were formulated using a two-stage microfluidic chip. Microfluidic-related factors (i.e., flow rate, organic solvent, theoretical drug loading, PLGA type, and concentration) that may potentially influence the nanoparticle properties were systematically investigated using dynamic light scattering and transmission electron microscopy. The pharmacokinetic (PK) profile and biodistribution of the optimised nanoparticles were assessed in mice. Peptide-loaded lipid shell-PLGA core nanoparticles with designated size (~400 nm) and a sustained in vitro release profile were further characterized in vivo. In the form of nanoparticles, the elimination half-life of the encapsulated peptide was extended significantly compared with the peptide alone and resulted in a much higher distribution into the lung. These novel nanoparticles with lipid shells have considerable potential for increasing the circulation half-life and improving the biodistribution of therapeutic peptides to improve their clinical utility, including peptides aimed at treating lung-related diseases.

Scaling up the throughput of microfluidic droplet-based materials synthesis: A review of recent progress and outlook

The last two decades have witnessed tremendous progress in the development of microfluidic chips that generate micrometer- and nanometer-scale materials. These chips allow precise control over composition, structure, and particle uniformity not achievable using conventional methods. These microfluidic-generated materials have demonstrated enormous potential for applications in medicine, agriculture, food processing, acoustic, and optical meta-materials, and more. However, because the basis of these chips' performance is their precise control of fluid flows at the micrometer scale, their operation is limited to the inherently low throughputs dictated by the physics of multiphasic flows in micro-channels. This limitation on throughput results in material production rates that are too low for most practical applications. In recent years, however, significant progress has been made to tackle this challenge by designing microchip architectures that incorporate multiple microfluidic devices onto single chips. These devices can be operated in parallel to increase throughput while retaining the benefits of microfluidic particle generation. In this review, we will highlight recent work in this area and share our perspective on the key unsolved challenges and opportunities in this field.

Effects of Fiber Stiffening to a Soft Actuator with PEDOT/PSS Electrode Films on Actuation Cycling Stability

In this work, we fabricated a fiber-stiffened soft actuator with PEDOT/PSS films as electrode. Embedding nylon fibers in the soft actuator successfully suppressed twisting deformations, resulting in a large and persistent actuation displacement. We evaluated the effects of the fiber spacing (1, 2, 3 and 4 mm) on the displacement and assessed the actuation displacement as a function of applied voltage (0.5, 1.0 and 1.5 V) and frequency (0.2 and 1 Hz) with an actuation time of 500 s. We demonstrated that the fiberstiffened actuator with 2 mm fiber spacing exhibited steady actuation cycles (4.2 mm average displacement) in comparison with those with different spacings (1, 3, and 4 mm) and that without the fiber.

Liquid-Liquid Flows with Non-Newtonian Dispersed Phase in a T-Junction Microchannel

Immiscible liquid–liquid flows in microchannels are used extensively in various chemical and biological lab-on-a-chip systems when it is very important to predict the expected flow pattern for a variety of fluids and channel geometries. Commonly, biological and other complex liquids express non-Newtonian properties in a dispersed phase. Features and behavior of such systems are not clear to date. In this paper, immiscible liquid–liquid flow in a T-shaped microchannel was studied by means of high-speed visualization, with an aim to reveal the shear-thinning effect on the flow patterns and slug-flow features. Three shear-thinning and three Newtonian fluids were used as dispersed phases, while Newtonian castor oil was a continuous phase. For the first time, the influence of the non-Newtonian dispersed phase on the transition from segmented to continuous flow is shown and quantitatively described. Flow-pattern maps were constructed using nondimensional complex We^0.4·Oh^0.6 depicting similarity in the continuous-to-segmented flow transition line. Using available experimental data, the proposed nondimensional complex is shown to be effectively applied for flow-pattern map construction when the continuous phase exhibits non-Newtonian properties as well. The models to evaluate an effective dynamic viscosity of a shear-thinning fluid are discussed. The most appropriate model of average-shear-rate estimation based on bulk velocity was chosen and applied to evaluate an effective dynamic viscosity of a shear-thinning fluid. For a slug flow, it was found that in the case of shear-thinning dispersed phase at low flow rates of both phases, a jetting regime of slug formation was established, leading to a dramatic increase in slug length.

Biphasic nucleophilic aromatic substitution using a microreactor under droplet formation conditions

Biphasic nucleophilic aromatic substitution of 4-fluoronitrobenzene proceeded efficiently using a packed bed reactor.

Microfluidics Used as a Tool to Understand and Optimize Membrane Filtration Processes

Membrane filtration processes are best known for their application in the water, oil, and gas sectors, but also in food production they play an eminent role. Filtration processes are known to suffer from a decrease in efficiency in time due to e.g., particle deposition, also known as fouling and pore blocking. Although these processes are not very well understood at a small scale, smart engineering approaches have been used to keep membrane processes running. Microfluidic devices have been increasingly applied to study membrane filtration processes and accommodate observation and understanding of the filtration process at different scales, from nanometer to millimeter and more. In combination with microscopes and high-speed imaging, microfluidic devices allow real time observation of filtration processes. In this review we will give a general introduction on microfluidic devices used to study membrane filtration behavior, followed by a discussion of how microfluidic devices can be used to understand current challenges. We will then discuss how increased knowledge on fundamental aspects of membrane filtration can help optimize existing processes, before wrapping up with an outlook on future prospects on the use of microfluidics within the field of membrane separation.