Microfluidic crystals: dynamic interplay between rearrangement waves and flow

Stochastic Jetting and Dripping in Confined Soft Granular Flows

We report new dynamical modes in confined soft granular flows, such as stochastic jetting and dripping, with no counterpart in continuum viscous fluids. The new modes emerge as a result of the propagation of the chaotic behavior of individual grains-here, monodisperse emulsion droplets-to the level of the entire system as the emulsion is focused into a narrow orifice by an external viscous flow. We observe avalanching dynamics and the formation of remarkably stable jets-single-file granular chains-which occasionally break, resulting in a non-Gaussian distribution of cluster sizes. We find that the sequences of droplet rearrangements that lead to the formation of such chains resemble unfolding of cancer cell clusters in narrow capillaries, overall demonstrating that microfluidic emulsion systems could serve to model various aspects of soft granular flows, including also tissue dynamics at the mesoscale.

From dynamic self-organization to avalanching instabilities in soft-granular threads

We study the dynamics of threads of monodisperse droplets, including droplet chains and multi-chains, in which the droplets are interconnected by capillary bridges of another immiscible liquid phase. This system represents wet soft-granular matter - a class of granular materials in which the grains are soft and wetted by thin fluid films-with other examples including wet granular hydrogels or foams. In contrast to wet granular matter with rigid grains (e.g., wet sand), studied previously, the deformability of the grains raises the number of available metastable states and facilitates rearrangements which allow for reorganization and self-assembly of the system under external drive, e.g., applied via viscous forces. We use a co-flow configuration to generate a variety of unique low-dimensional regular granular patterns, intermediate between 1D and 2D, ranging from linear chains and chains with periodically occurring folds to multi-chains and segmented structures including chains of finite length. In particular, we observe that the partially folded chains self-organize via limit cycle of displacements and rearrangements occurring at a frequency self-adapted to the rate of build-up of compressive strain in the chain induced by the viscous forces. Upon weakening of the capillary arrest of the droplets, we observe spontaneous fluidization of the quasi-solid structures and avalanches of rearrangements. We identify two types of fluidization-induced instabilities and rationalize them in terms of a competition between advection and propagation. While we use aqueous droplets as the grains we demonstrate that the reported mechanisms of adaptive self-assembly apply to other types of soft granular systems including foams and microgels. We discuss possible application of the reported quasi-1D compartmentalized structures in tissue engineering, bioprinting and materials science.

Nonlinear Phenomena in Microfluidics

This review focuses on experimental work on nonlinear phenomena in microfluidics, which for the most part are phenomena for which the velocity of a fluid flowing through a microfluidic channel does not scale proportionately with the pressure drop. Examples include oscillations, flow-switching behaviors, and bifurcations. These phenomena are qualitatively distinct from laminar, diffusion-limited flows that are often associated with microfluidics. We explore the nonlinear behaviors of bubbles or droplets when they travel alone or in trains through a microfluidic network or when they assemble into either one- or two-dimensional crystals. We consider the nonlinearities that can be induced by the geometry of channels, such as their curvature or the bas-relief patterning of their base. By casting posts, barriers, or membranes─situated inside channels─from stimuli-responsive or flexible materials, the shape, size, or configuration of these elements can be altered by flowing fluids, which may enable autonomous flow control. We also highlight some of the nonlinearities that arise from operating devices at intermediate Reynolds numbers or from using non-Newtonian fluids or liquid metals. We include a brief discussion of relevant practical applications, including flow gating, mixing, and particle separations.

Computing foaming flows across scales: From breaking waves to microfluidics

Crashing ocean waves, cappuccino froths, and microfluidic bubble crystals are examples of foamy flows. Foamy flows are critical in numerous natural and industrial processes and remain notoriously difficult to compute as they involve coupled, multiscale physical processes. Computations need to resolve the interactions of the bubbles separated by stable thin liquid films. We present the multilayer volume-of-fluid method (Multi-VOF) that advances the state of the art in simulation capabilities of foamy flows. The method introduces a scheme to handle multiple bubbles that do not coalesce. Multi-VOF is verified and validated with experimental results and complemented with open-source software. We demonstrate capturing of crystalline structures of bubbles in realistic microfluidics devices and foamy flows involving tens of thousands of bubbles in a waterfall. The present technique extends the classical volume-of-fluid methodology and allows for large-scale predictive simulations of flows with multiple interfaces.

Dynamics of polydisperse multiple emulsions in microfluidic channels

Multiple emulsions are a class of soft fluid in which small drops are immersed within a larger one and stabilized over long periods of time by a surfactant. We recently showed that, if a monodisperse multiple emulsion is subject to a pressure-driven flow, a wide variety of nonequilibrium steady states emerges at late times, whose dynamics relies on a complex interplay between hydrodynamic interactions and multibody collisions among internal drops. In this work, we use lattice Boltzmann simulations to study the dynamics of polydisperse double emulsions driven by a Poiseuille flow within a microfluidic channel. Our results show that their behavior is critically affected by multiple factors, such as initial position, polydispersity index, and area fraction occupied within the emulsion. While at low area fraction inner drops may exhibit either a periodic rotational motion (at low polydispersity) or arrange into nonmotile configurations (at high polydispersity) located far from each other, at larger values of area fraction they remain in tight contact and move unidirectionally. This decisively conditions their close-range dynamics, quantitatively assessed through a time-efficiency-like factor. Simulations also unveil the key role played by the capsule, whose shape changes can favor the formation of a selected number of nonequilibrium states in which both motile and nonmotile configurations are found.

Translocation Dynamics of High-Internal Phase Double Emulsions in Narrow Channels

We numerically study the translocation dynamics of double emulsion drops with multiple close-packed inner droplets within constrictions. Such liquid architectures, which we refer to as HIPdEs (high-internal phase double emulsions), consist of a ternary fluid, in which monodisperse droplets are encapsulated within a larger drop in turn immersed in a bulk fluid. Extensive two-dimensional lattice Boltzmann simulations show that if the area fraction of the internal drops is close to the packing fraction limit of hard spheres and the height of the channel is much smaller than the typical size of the emulsion, the crossing yields permanent shape deformations persistent over long periods of time. Morphological changes and rheological response are quantitatively assessed in terms of the structure of the velocity field, circularity of the emulsion, and rate of energy dissipated by viscous forces. Our results may be used to improve the design of soft mesoscale porous materials, which employ HIPdEs as templates for tissue engineering applications.

Microfluidic formation of crystal-like structures

Crystal-like structures find application in several fields ranging from biomedical engineering to material science. For instance, droplet crystals are critical for high throughput assays and material synthesis, while particle crystals are important for particles and cell encapsulation, Drop-seq technologies, and single-cell analysis. Formation of crystal-like structures relies entirely on the possibility of manipulating with great accuracy the micrometer-size objects forming the crystal. In this context, microfluidic devices offer versatile tools for the precise manipulation of droplets and particles, thus enabling fabrication of crystal-like structures that form due to hydrodynamic interactions among droplets or particles. In this review, we aim at providing an holistic representation of crystal-like structure formation mediated by hydrodynamic interactions in microfluidic devices. We also discuss the physical origin of these hydrodynamic interactions and their relation to parameters such as device geometry, fluid properties, and flow conditions.

Mesoscale modelling of droplets' self-assembly in microfluidic channels

A recently proposed mesoscale approach for the simulation of multicomponent flows with near-contact interactions is employed to investigate the early stage formation and clustering statistics of soft flowing crystals in microfluidic channels. Specifically, we first demonstrate the ability of the aforementioned mesoscale model to accurately reproduce main mechanisms leading to the formation of two basic droplet patterns (triangular and hexagonal), in close agreement with experimental evidence. Next, we quantitatively evaluate the device-scale clustering efficiency of the crystal formation process by introducing a new orientational order parameter, based on the Delaunay triangulation and Voronoi diagrams analysis of the droplet patterns. The mesoscale computational approach employed in this work proves to be an efficient tool to shed new light on the complex dynamics of dense emulsions, from short-scale thin-film hydrodynamics, all the way up to global structure formation and statistics of the resulting droplets ensembles.

The vortex-driven dynamics of droplets within droplets

Understanding the fluid-structure interaction is crucial for an optimal design and manufacturing of soft mesoscale materials. Multi-core emulsions are a class of soft fluids assembled from cluster configurations of deformable oil-water double droplets (cores), often employed as building-blocks for the realisation of devices of interest in bio-technology, such as drug-delivery, tissue engineering and regenerative medicine. Here, we study the physics of multi-core emulsions flowing in microfluidic channels and report numerical evidence of a surprisingly rich variety of driven non-equilibrium states (NES), whose formation is caused by a dipolar fluid vortex triggered by the sheared structure of the flow carrier within the microchannel. The observed dynamic regimes range from long-lived NES at low core-area fraction, characterised by a planetary-like motion of the internal drops, to short-lived ones at high core-area fraction, in which a pre-chaotic motion results from multi-body collisions of inner drops, as combined with self-consistent hydrodynamic interactions. The onset of pre-chaotic behavior is marked by transitions of the cores from one vortex to another, a process that we interpret as manifestations of the system to maximize its entropy by filling voids, as they arise dynamically within the capsule.

Lattice Boltzmann simulations capture the multiscale physics of soft flowing crystals

The study of the underlying physics of soft flowing materials depends heavily on numerical simulations, due to the complex structure of the governing equations reflecting the competition of concurrent mechanisms acting at widely disparate scales in space and time. A full-scale computational modelling remains a formidable challenge since it amounts to simultaneously handling six or more spatial decades in space and twice as many in time. Coarse-grained methods often provide a viable strategy to significantly mitigate this issue, through the implementation of mesoscale supramolecular forces designed to capture the essential physics at a fraction of the computational cost of a full-detail description. Here, we review some recent advances in the design of a lattice Boltzmann mesoscale approach for soft flowing materials, inclusive of near-contact interactions (NCIs) between dynamic interfaces, as they occur in high packing-fraction soft flowing crystals. The method proves capable of capturing several aspects of the rheology of soft flowing crystals, namely, (i) a 3/2 power-law dependence of the dispersed phase flow rate on the applied pressure gradient, (ii) the structural transition between an ex-two and ex-one (bamboo) configurations with the associated drop of the flow rate, (iii) the onset of interfacial waves once NCI is sufficiently intense. This article is part of the theme issue 'Fluid dynamics, soft matter and complex systems: recent results and new methods'.

Microvorticity fluctuations affect the structure of thin fluid films

The dynamic interaction of complex fluid interfaces is highly sensitive to near-contact interactions occurring at the scale of ten of nanometers. Such interactions are difficult to analyze because they couple self-consistently to the dynamic morphology of the evolving interface, as well as to the hydrodynamics of the interstitial fluid film. In this work, we show that, above a given magnitude threshold, near-contact interactions trigger nontrivial microvorticity patterns, which in turn affect the effective near-contact interactions, giving rise to persistent fluctuating ripples at the fluid interface. In such a regime, near-contact interactions may significantly affect the macroscopic arrangement of emulsion configurations, such as those arising in soft-flowing microfluidic crystals.

Self-assembly of droplets in three-dimensional microchannels

Self-assembly of droplets guided by microfluidic channels have potential applications ranging from high throughput assays to materials synthesis, but such demonstrations have been limited primarily to two-dimensional (2D) assembly of droplets in planar microfluidic devices. We demonstrated the use of three-dimensional (3D) microchannels to self-assemble droplets into ordered 2D and 3D arrays by designing microchannels with axial gradients in height and controlling the volume fraction of the droplets in the channel. In contrast to previous demonstrations, ordered 2D arrays of droplets were assembled at low volume fractions of the dispersed phase. Interestingly, we found that the self-assembly of droplets in microchannels was highly path dependent. The assembly of droplets was governed by transitions in the cross-sectional shapes of the microchannel, not the final geometry of the chamber for the assembly of droplet, which is a hitherto rarely explored phenomenon. The assembled droplets were used as templates for the fabrication of millimeter scale, anisotropic hydrogel fibers with ordered pore sizes (∼250 μm). These demonstrations suggested that 3D microchannels would be a viable platform for the manipulation of droplets, and applicable for the continuous synthesis of complex materials with 3D morphologies.

Activity-induced instability of phonons in 1D microfluidic crystals

One-dimensional crystals of passively-driven particles in microfluidic channels exhibit collective vibrational modes reminiscent of acoustic 'phonons'. These phonons are induced by the long-range hydrodynamic interactions among the particles and are neutrally stable at the linear level. Here, we analyze the effect of particle activity - self-propulsion - on the emergence and stability of these phonons. We show that the direction of wave propagation in active crystals is sensitive to the intensity of the background flow. We also show that activity couples, at the linear level, transverse waves to the particles' rotational motion, inducing a new mode of instability that persists in the limit of large background flow, or, equivalently, vanishingly small activity. We then report a new phenomenon of phonons switching back and forth between two adjacent crystals in both passively-driven and active systems, similar in nature to the wave switching observed in quantum mechanics, optical communication, and density stratified fluids. These findings could have implications for the design of commercial microfluidic systems and the self-assembly of passive and active micro-particles into one-dimensional structures.

Porous Polymeric Films from Microbubbles Generated Using a T-Junction Microfluidic Device

In this work, a simple microfluidic junction with a T geometry and coarse (200 μm diameter) capillaries was used to generate monodisperse microbubbles with an alginate polymer shell. Subsequently, these bubbles were used to prepare porous alginate films with good control over the pore structure. The lack of pore size, shape, and surface control in scalable forming of polymeric films is a major application-limiting drawback at present. Controlling the thinning process of the shell of the bubbles to tune the surface of the resulting structures was also explored. Films were prepared with nanopatterned surfaces by controlling the thinning of the bubble shell, with the aid of surfactants, to induce efficient bursting (fragmentation) of bubbles to generate nanodroplets, which become embedded within the film surface. This novel feature greatly expands and enhances the use of hydrophilic polymers in a wide range of biomedical applications, particularly in drug delivery and tissue engineering, such as studying cellular responses to different morphological surfaces.

The science of foaming

The generation of liquid foams is at the heart of numerous natural, technical or scientific processes. Even though the subject of foam generation has a long-standing history, many recent progresses have been made in an attempt to elucidate the fundamental processes at play. We review the subject by providing an overview of the relevant key mechanisms of bubble generation within a coherent hydrodynamic context; and we discuss different foaming techniques which exploit these mechanisms.

Bubbles and foams in microfluidics

Microfluidics offers great tools to produce highly-controlled dispersions of gas into liquid, from isolated bubbles to organized microfoams. Potential technological applications are manifold, from novel materials to scaffolds for tissue engineering or enhanced oil recovery. More fundamentally, microfluidics makes it possible to investigate the physics of complex systems such as foams at scales where the capillary forces become dominant, in model experiments involving few well-controlled parameters. In this context, this review does not have the ambition to detail in a comprehensive manner all the techniques and applications involving bubbles and foams in microfluidics. Rather, it focuses on particular consequences of working at the microscale, under confinement, and hopes to provide insight into the physics of such systems. The first part of this work focuses on bubbles, and more precisely on (i) bubble generation, where the confinement can suppress capillary instabilities while inertial effects may play a role, and (ii) bubble dynamics, paying special attention to the lubrication film between bubble and wall and the influence of confinement. The second part addresses the formation and dynamics of microfoams, emphasizing structural differences from macroscopic foams and the influence of the confinement.

Influence of the elastic deformation of a foam on its mobility in channels of linearly varying width

We study foam flow in an elementary model porous medium consisting of a convergent and a divergent channel positioned side by side and possessing a fixed joint porosity. Configurations of converging or diverging channels are ubiquitous at the pore scale in porous media, as all channels linking pores possess a converging and diverging part. The resulting flow kinematics imposes asymmetric bubble deformations in the two channels, which modulate foam-wall friction and strongly impact the flux distribution. We measure, as well as quantitatively predict, the ratio of the fluxes in the two channels as a function of the channel widths by modeling pressure drops of both viscous and capillary origins. This study reveals the crucial importance of boundary-induced bubble deformation on the mobility of a flowing foam, resulting in particular in flow irreversibility.

Packings of monodisperse emulsions in flat microfluidic channels

In the lateral confinement of a flat microfluidic channel, monodisperse emulsion droplets spontaneously self-organize in a variety of topologically different packings. The explicit construction of mechanically equilibrated arrangements of effectively two-dimensional congruent droplet shapes reveals the existence of multiple mechanical equilibria depending on channel width W, droplet area A{d}, and volume fraction φ of the dispersed phase. The corresponding boundaries of local or global stability are summarized in a packing diagram for congruent droplet shapes in terms of the dimensionless channel width w=W/sqrt[A_{d}] and φ. In agreement with experimental results, an increasingly strong hysteresis of the transition between single-row and two-row packings is observed during changes of w above a threshold volume fraction of φ≃0.813.

Observation of hydrophobic-like behavior in geometrically patterned hydrophilic microchannels

We present our observation of meta-hydrophobicity, where geometrically patterned surfaces make hydrophilic microchannels exhibit hydrophobic-like behaviors. We analyze the wetting-induced energy decrease that results from the surface geometries and experimentally demonstrate how those geometries can modulate the dynamics of capillary-driven wetting and evaporation-driven drying of microfluidic systems. Our results also show that the modulated wetting dynamics can be employed to generate regulated patterns of microbubbles.

Laboratory observations of self-excited dust acoustic shocks

Repeated, self-excited dust acoustic shock waves (DASWs) have been observed in a dc glow discharge dusty plasma using high-speed video imaging. Two major observations are reported: (1) The self-steepening of a nonlinear dust acoustic wave (DAW) into a saw-tooth wave with sharp gradient in dust density, very similar to those found in numerical solutions of the fully nonlinear fluid equations for a nondispersive DAW [B. Eliasson and P. K. Shukla, Phys. Rev. E 69, 067401 (2004)], and (2) the collision and confluence of two DASWs.