Breakup of a fluid thread in a confined geometry: droplet-plug transition, perturbation sensitivity, and kinetic stabilization with confinement

Microfluidics at Fiber Tip for Nanoliter Delivery and Sampling

Delivery and sampling nanoliter volumes of liquid can benefit new invasive surgical procedures. However, the dead volume and difficulty in generating constant pressure flow limits the use of small tubes such as capillaries. This work demonstrates sub-millimeter microfluidic chips assembled directly on the tip of a bundle of two hydrophobic coated 100 µm capillaries to deliver nanoliter droplets in liquid environments. Droplets are created in a specially designed nanopipette and propelled by gas through the capillary to the microfluidic chip where a passive valve mechanism separates liquid from gas, allowing their delivery. By adjusting the driving pressure and microfluidic geometry, both partial and full delivery of 10 nanoliter droplets with 0.4 nanoliter maximum error, as well as sampling from the environment are demonstrated. This system will enable drug delivery and sampling with minimally invasive probes, facilitating continuous liquid biopsy for disease monitoring and in vivo drug screening.

On secondary atomization and blockage of surrogate cough droplets in single- and multilayer face masks

Face masks prevent transmission of infectious respiratory diseases by blocking large droplets and aerosols during exhalation or inhalation. While three-layer masks are generally advised, many commonly available or makeshift masks contain single or double layers. Using carefully designed experiments involving high-speed imaging along with physics-based analysis, we show that high-momentum, large-sized (>250 micrometer) surrogate cough droplets can penetrate single- or double-layer mask material to a significant extent. The penetrated droplets can atomize into numerous much smaller (<100 micrometer) droplets, which could remain airborne for a significant time. The possibility of secondary atomization of high-momentum cough droplets by hydrodynamic focusing and extrusion through the microscale pores in the fibrous network of the single/double-layer mask material needs to be considered in determining mask efficacy. Three-layer masks can effectively block these droplets and thus could be ubiquitously used as a key tool against COVID-19 or similar respiratory diseases.

AC electric field controlled non-Newtonian filament thinning and droplet formation on the microscale

Monodispersity and fast generation are innate advantages of microfluidic droplets. Other than the normally adopted simple Newtonian fluids such as a water/oil emulsion system, fluids with complex rheology, namely, non-Newtonian fluids, which are being widely adopted in industries and bioengineering, have gained increasing research interest on the microscale. However, challenges occur in controlling the dynamic behavior due to their complex properties. In this sense, the AC electric field with merits of fast response and easiness in fulfilling "Lab on a chip" has attracted our attention. We design and fabricate flow-focusing microchannels with non-contact types of electrodes for the investigation. We firstly compare the formation of a non-Newtonian droplet with that of a Newtonian one under an AC electric field and discover that viscoelasticity contributes to the discrepancies significantly. Then we explore the effect of AC electric fields on the filament thinning and droplet formation dynamics of one non-Newtonian fluid which has a similar rheological behavior to bio samples, such as DNA or blood samples. We investigate the dynamics of the thinning process of the non-Newtonian filament under the influence of an AC electric field and implement a systematic exploration of the non-Newtonian droplet generation influenced by parameters such as the flow conditions (flow rate Q, capillary number Ca), fluid property (Weissenberg number Wi), applied voltage (U) and frequency (f) of the AC electric field. We present the dependencies of the flow condition and electric field on the non-Newtonian droplet formation dynamics, and conclude with an operating diagram, taking into consideration all the above-mentioned parameters. Results show that the electric field plays a critical role in controlling the thinning process of the filament and the size of the generated droplet. Furthermore, for the first time, we quantitatively measure the flow field of the non-Newtonian droplet formation under the influence of an AC electric field, assisted by a high-speed micro particle imaging velocimetry (μPIV) system. The flow field distributions obtained using the correlation algorithm show that the electric field generated Maxwell stress deforms the interface, changes the flow recirculation pattern, stimulates the instability and hence reduces the size of the non-Newtonian droplet. Finally, we analyze the impact of Maxwell stress by means of the electric capillary number Ca_E. Our findings reveal the rich physics of non-Newtonian fluids and widen the applications of electric field in non-Newtonian environments, which could be critical for bioengineering.

Confined Pattern-Directed Assembly of Polymer-Grafted Nanoparticles in a Phase Separating Blend with a Homopolymer Matrix

The controlled organization of nanoparticle (NP) constituents into superstructures of well-defined shape, composition and connectivity represents a continuing challenge in the development of novel hybrid materials for many technological applications. We show that the phase separation of polymer-tethered nanoparticles immersed in a chemically different polymer matrix provides an effective and scalable method for fabricating defined submicron-sized amorphous NP domains in melt polymer thin films. We investigate this phenomenon with a view towards understanding and controlling the phase separation process through directed nanoparticle assembly. In particular, we consider isothermally annealed thin films of polystyrene-grafted gold nanoparticles (AuPS) dispersed in a poly(methyl methacrylate) (PMMA) matrix. Classic binary polymer blend phase separation related morphology transitions, from discrete AuPS domains to bicontinuous to inverse domain structure with increasing nanoparticle composition is observed, yet the kinetics of the AuPS/PMMA polymer blends system exhibit unique features compared to the parent PS/PMMA homopolymer blend. We further illustrate how to pattern-align the phase-separated AuPS nanoparticle domain shape, size and location through the imposition of a simple and novel external symmetry-breaking perturbation via soft-lithography. Specifically, submicron-sized topographically patterned elastomer confinement is introduced to direct the nanoparticles into kinetically controlled long-range ordered domains, having a dense yet well-dispersed distribution of non-crystallizing nanoparticles. The simplicity, versatility and roll-to-roll adaptability of this novel method for controlled nanoparticle assembly should make it useful in creating desirable patterned nanoparticle domains for a variety of functional materials and applications.

Collective Rayleigh-Plateau Instability: A Mimic of Droplet Breakup in High Internal Phase Emulsion

Using a microfluidic multi-inlet coflow system, we show the Rayleigh-Plateau instability of adjacent, closely spaced fluid threads to be collective. Although droplet size distributions and breakup frequencies are unaffected by cooperativity when fluid threads are identical, breakup frequencies and wavelengths between mismatched fluid threads become locked due to this collective instability. Locking narrows the size distribution of drops that are produced from dissimilar threads, and thus the polydispersity of the emulsion. These observations motivate a hypothesized two-step mechanism for high internal phase emulsification, wherein coarse emulsion drops are elongated into close-packed fluid threads, which break into smaller droplets via a collective Rayleigh Plateau instability. Our results suggest that these elongated fluid threads break cooperatively, whereupon wavelength-locking reduces the ultimate droplet polydispersity of high-internal phase emulsions, consistent with experimental observations.

Capillary rupture of suspended polymer concentric rings

We present the first experimental study on the simultaneous capillary instability amongst viscous concentric rings suspended atop an immiscible medium. The rings ruptured upon annealing, with three types of phase correlation between neighboring rings. In the case of weak substrate confinement, the rings ruptured independently when they were sparsely distanced, but via an out-of-phase mode when packed closer. If the substrate confinement was strong, the rings would rupture via an in-phase mode, resulting in radially aligned droplets. The concentric ring geometry caused a competition between the phase correlation of neighboring rings and the kinetically favorable wavelength, yielding an intriguing, recursive surface pattern. This frustrated pattern formation behavior was accounted for by a scaling analysis.

Analytical relations for long-droplet breakup in asymmetric T junctions

We develop accurate analytical relations for the droplet volume ratio, droplet length during breakup process, and pressure drop of asymmetric T junctions with a valve in each of the branches for producing unequal-sized droplets. An important advantage of this system is that after manufacturing the system, the size of the generated droplets can be changed simply by adjusting the valves. The results indicate that if the valve ratio is smaller than 0.65, the system enters a nonbreakup regime. Also the pressure drop does not depend on the time and decreases by increasing the valve ratio, namely, opening the degree of valve 1 to valve 2. In addition, the results reveal that by decreasing (increasing) the valve ratio, the droplet length of branch 1 decreases (increases) and the droplet length of branch 2 increases (decreases) linearly while the whole length of the droplet remains unchanged.

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.

Parallel assembly of particles and wires on substrates by dictating instability evolution in liquid metal films

Liquid metal wires supported on substrates destabilize into droplets. The destabilization exhibits many characteristics of the Rayleigh-Plateau model of fluid jet breakup in vacuum. In either case, breakup is driven by unstable, varicose surface oscillations with wavelengths greater than the critical one (λ(c)). Here, by controlling the nanosecond liquid lifetime as well as stability of a rivulet as a function of its length by lithography, we demonstrate the ability to dictate the parallel assembly of wires and particles with precise placement.

A sliding plate microgap rheometer for the simultaneous measurement of shear stress and first normal stress difference

A new generation of the "flexure-based microgap rheometer" (the N-FMR) has been developed which is also capable of measuring, in addition to the shear stress, the first normal stress difference of micrometer thin fluid films. This microgap rheometer with a translation system based on compound spring flexures measures the rheological properties of microliter samples of complex fluids confined in a plane couette configuration with gap distances of h = 1-400 μm up to shear rates of γ = 3000 s(-1). Feed back loop controlled precise positioning of the shearing surfaces with response times <1 ms enables to control the parallelism within 1.5 μrad and to maintain the gap distance within 20 nm. This precise gap control minimizes squeeze flow effects and allows therefore to measure the first normal stress difference N(1) of the thin film down to a micrometer gap distance, with a lower limit of N(1)/γ = 9.375×10(-11) η/h(2) that depends on the shear viscosity η and the squared inverse gap. Structural development of complex fluids in the confinement can be visualized by using a beam splitter on the shearing surface and a long working distance microscope. In summary, this new instrument allows to investigate the confinement dependent rheological and morphological evolution of micrometer thin films.

Pearling of lipid vesicles induced by nanoparticles

We show that cationic nanoparticles encapsulated within vesicles of phosphocholine lipid can induce pearling. The dynamic process occurs as two stages: formation of tubular protrusions followed by pearling instability. The breakup into individual vesicles can be controlled by nanoparticle concentration.

Formation of miscible fluid microstructures by hydrodynamic focusing in plane geometries

We experimentally investigate the flow structures formed when two miscible fluids that have large viscosity contrasts are injected and hydrodynamically focused in plane microchannels. Parallel viscous flows composed of a central stream surrounded by symmetric sheath streams are examined as a function of the flow rates, fluid viscosities, and rates of molecular diffusion. We study miscible interfacial morphologies and show a route for manipulating viscous flow-segregation processes in plane microsystems. The diffusion layer at the boundary of an ensheathed fluid grows as function of the distance downstream and depends on the Péclet number. In particular, we observe diffusion-enhanced viscous ensheathing processes. In the presence of a constriction, we investigate the formation of a lubricated viscous thread in the converging flow and also the buckling morphologies of the thread in the diverging flow. This study, relevant to multifluid flow between a "thick" material and a "thin" solvent, demonstrates the possibility to further control steady and oscillatory miscible fluid microstructures.

Microdroplets: a sea of applications?

The exploitation of microdroplets produced within microfluidic environments has recently emerged as a new and exciting technological platform for applications within the chemical and biological sciences. Interest in microfluidic systems has been stimulated by a range of fundamental features that accompany system miniaturization. Such features include the ability to process and handle small volumes of fluid, improved analytical performance when compared to macroscale analogues, reduced instrumental footprints, low unit cost, facile integration of functional components and the exploitation of atypical fluid dynamics to control molecules in both time and space. Moreover, microfluidic systems that generate and utilize a stream of sub-nanolitre droplets dispersed within an immiscible continuous phase have the added advantage of allowing ultra-high throughput experimentation and being able to mimic conditions similar to that of a single cell (in terms of volume, pH, and salt concentration) thereby compartmentalizing biological and chemical reactions. This review provides an overview of methods for generating, controlling and manipulating droplets. Furthermore, we discuss key fields of use in which such systems may make a significant impact, with particular emphasis on novel applications in the biological and physical sciences.

Stable jets of viscoelastic fluids and self-assembled cylindrical capsules by hydrodynamic focusing

We demonstrate formation of long-lived cylindrical jets of a viscoelastic fluid using hydrodynamic focusing. A solution of polyacrylamide in water is driven coaxially with immiscible oil and subjected to strong extensional flow. At high flow rates, the aqueous phase forms jets that are 4-90 microm in diameter and several centimeters long. The liquid surfaces of these jets are then used as templates for assembly of microspheres into novel rigid and hollow cylinders.

Arrested segregative phase separation in capillary tubes

Phase separation in a capillary tube with one of the phases fully wetting the capillary wall is arrested when the typical size of the phase domains reaches the value of the diameter of the tube. The arrested state consists of an alternating sequence of concave-capped and convex-capped cylindrical domains, called "plugs," "bridges," or "lenses," of wetting and nonwetting phase, respectively. A description of this arrested plug state for an aqueous mixture of two polymer solutions is the subject of this work. A phase separating system consisting of two incompatible polymers dissolved in water was studied. The phase volume ratio was close to unity. The initial state from which plugs evolve is characterized by droplets of wetting phase in a continuous nonwetting phase. Experiments show the formation of plugs by a pathway that differs from the theoretically well-described instabilities in the thickness of a fluid thread inside a confined fluid cylinder. Plugs appear to form after the wetting layer (the confined fluid cylinder) has become unstable after merging of droplet with the wetting layer. The relative density of the phases could be set by the addition of salt, enabling density matching. As a consequence, the capillary length can in principle be made infinitely large and the Bond number (which represents the force of gravity relative to the capillary force) zero, without considerably changing the interfacial tension. Using the possibility of density matching, the relations among capillary length and capillary diameter on the one hand, and the presence of plugs and their average size on the other were studied. It was found that stable plugs are present when the capillary radius does not exceed a certain value, which is probably smaller than the capillary length. However, the average plug size is independent of capillary length. At constant capillary length, average plug size was found to scale with the capillary diameter to a power 1.3, significantly higher than the expected value of 1. Plug sizes had a polydispersity between 1.1 and 1.2 for all capillary radii for which this number could be reliably determined, suggesting a universal plug size distribution. Within plug sequences, size correlations were found between plugs with one to three plugs in between. This suggests the presence of an additional length scale.

Anisotropic rupture of polymer strips driven by Rayleigh instability

We demonstrate that the separated polymer strips of micro- and sub-micro-length-scales rupture anisotropically along the strip direction, resulting in the formation of distinctly observable, regularly spaced polymer drops. The wavelength of the polymer drops and the surface tension dependence of the rupture behavior are found to be well represented by a relationship derived on the basis of Rayleigh instability. The period is proportional to the square root of the cross-sectional area of the strip and the proportionality constant depends on the contact angle. The rupture of polymer strips into polymer blocks instead of drops, which result when annealed with physically confining walls in place, is found to be well described by the same relationship.

Structure development in confined polymer blends: steady-state shear flow and relaxation

In this work, the structure development in immiscible polymer blends in confined geometries is systematically investigated. Poly(dimethylsiloxane)/poly(isobutylene) blends with a droplet-matrix structure are subjected to simple shear flows. The confined environment is created by using a Linkam shearing cell in which the gap is systematically decreased to investigate the transition from "bulk" behavior toward "confined" behavior. Small-angle light scattering experiments in a confinement, which have not yet been reported in the literature, and also microscopy are used to observe the morphology development during steady-state shearing and relaxation. These experiments indicate that the size and relaxation of single droplets in a confined environment are still governed by the relations that describe the structure development in bulk situations. Yet, depending on the applied shear rates and blend concentrations, the droplets organize in superstructures such as pearl necklaces or extended superstrings in a single layer between the plates. These structures are stable under flow. To observe a single layer, a critical ratio of droplet size to gap spacing is required, but this ratio is clearly below the one already reported in the literature.