Investigation of microfluidic co-flow effects on step emulsification: Wall contact angle and critical dimensions

Abstract

We propose a co-flowing step emulsification strategy for the on-line control of micro-droplet generation. The effects of four parameters including wall contact angle, plateau length, channel distance and diameter are investigated numerically and experimentally in this study. The results indicate that the wall contact angle, whose applicable range can be expanded to 90°–180° by co-flow, is critical to droplet formation. The effect of the plateau length on droplet generation is reduced by the co-flow, and the droplet diameter is almost independent of the plateau length, which ranges from 0.7 to 1.5 mm. In addition, the droplet diameter increases significantly with increasing channel distance and diameter. Combining these results with those of our previous study, we derived an explicit equation for droplet diameter prediction. The predicted droplet diameter based on this equation has good agreement with the simulation and experimental results. Furthermore, we proposed a coefficient α as a function of physical and dimensional parameters to predict the regimes and modes in the co-flowing step emulsification process. The conclusion of this study not only provides an important reference for the design and improvement of step emulsification chips, but also offers a new idea and a scientific basis for tuneable monodisperse micro-droplet production.