Understanding the microfluidic generation of double emulsion droplets with alginate shell

The monodisperse double emulsions obtained by microfluidic method can serve as ideal templates for preparing core-shell alginate microcapsules, which have attracted much attention in biological applications, such as drug delivery systems and cell encapsulation, tissue engineering. However, the formation behavior and dynamic analysis of double emulsion with an alginate shell is still unclear due to the complex rheological behavior of alginate solutions. Herein, we employ a dual-coaxial microfluidic device to generate the high-quality double emulsion droplets with alginate shell, focusing on the effects of the fluid properties of alginate solution in the middle phase (viscosity, μ_m) and the fluid flow rate on the droplet formation mechanism. As the viscosity of the middle fluid (μ_m) increased, the size of compound droplets (D₂) increased and the size of inner droplets (D₁) decreased, and the break-up regimes occurred a dripping-to-jetting transition when μ_m = 160 mPa s. The number of encapsulated inner droplets can be predicted and precisely controlled by regulating the generation frequency of inner (f₁) and outer droplets (f₂). The breakup dynamics of the alginate thread are also analyzed by using the volume-of-fluid/continuum-surface-force (VOF/CSF) method. The results show that the pressure and velocity in the neck of pinch-off is lower in the jetting than that in the dripping regime. This study will provide useful guidance for the rational design and controllable preparation of core-shell alginate microcapsules.