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Parallelization of Microfluidic Droplet Junctions for Ultraviscous Fluids.

Hyeon Ho Kim1, YongDeok Cho1, Dongjae Baek1

  • 1KU-KIST Graduate School of Converging Science and Technology, Korea University, Seoul, 02841, Republic of Korea.

Small (Weinheim an Der Bergstrasse, Germany)
|October 30, 2022
PubMed
Summary

This study presents a novel microfluidic device for uniform micro-emulsification of ultraviscous fluids. The design achieves high throughput, overcoming limitations of previous technologies for low-viscosity fluids.

Keywords:
Polydimethylsiloxane (PDMS)T-junctiondroplet microfluidicsmicrolens arrayspressure drop

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Area of Science:

  • Microfluidics
  • Materials Science
  • Chemical Engineering

Background:

  • Parallelization of microfluidic droplet junctions has improved production throughput for uniform microemulsions/particles.
  • Previous advancements were limited to low-viscosity fluids (10⁻²–10⁻³ Pa s).

Purpose of the Study:

  • To design and fabricate a microfluidic device for uniform micro-emulsification of ultraviscous fluids (3.5 Pa s).
  • To achieve high production throughput for ultraviscous microemulsions/particles.

Main Methods:

  • Fabrication of a microfluidic device with multiple T-junctions for the dispersed oil phase and a single post-crossflow channel for the continuous water phase.
  • Utilizing a series circuit design for the continuous water phase with accumulated resistances.
  • Incorporating independent corrugations in the dispersed oil phase channel to ensure consistent water-to-oil flow rate ratios across junctions.
  • Employing a 2D interconnection design amenable to single-step soft lithography.

Main Results:

  • Achieved uniform micro-emulsification of an ultraviscous fluid (3.5 Pa s).
  • Reached a production throughput of approximately 330,000 droplets per hour.
  • Demonstrated consistent water-to-oil flow rate ratios across all T-junctions.
  • Enabled device fabrication via simple, single-step soft lithography due to the 2D design.

Conclusions:

  • The developed microfluidic device successfully enables high-throughput, uniform micro-emulsification of ultraviscous fluids.
  • The 2D, easy-to-craft architecture simplifies fabrication compared to complex 3D designs.
  • This advancement facilitates broader adoption of high-throughput droplet microfluidics for both experts and new users.