Using lithography-based microfluidic technology, we produce monodisperse single-core microcapsules with UV-cured TPGDA (triprophylene glycol diacrylate) shells. We show that the geometrical and mechanical characteristics of the microcapsules can be predicted on a quantitative basis and tuned by varying the flow conditions. Shell thicknesses are varied by changing the flow rates of the inner or intermediate phases, according to mass conservation constraint. Off-centering of the core with respect to the shell is controlled by varying the shell phase viscosity. The mechanical properties of the capsules can be varied by changing the flow conditions and are quantitatively predicted by a numerical simulation. The simulation moreover provides a correct qualitative description of their rupture. As a whole, the work carried out in the present paper shows, on a quantitative basis, that microfluidic technology allows to finely control the geometrical and mechanical properties of microcapsules generated on chip. The level of control we reach here is not accessible, by far, to conventional technologies. Combined with parallelization, the present work opens routes toward the production of novel families of monodisperse microcapsules with tunable properties.
This work describes a design strategy to scale up microfluidics for producing monodispersed emulsions. Scale-up to 180 microfluidic devices with tight distribution of droplet size has been achieved (coefficient of variation CV ∼ 5%) by designing a system that is capable of operating easily without active control on single devices within the microfluidic platform. This has been achieved by using existing knowledge gained in the formation of monodispersed emulsions using a single device. We have identified three important factors affecting the scale-up of microfluidic systems that can benefit industrial scale-up processing. First, we used a network model simulation (Matlab) to evaluate two different branching layouts used to distribute liquids from a single manifold into the parallelized device network. We checked how fabrication tolerances could affect droplet formation, and as a result of this step, the ladder-type layout was preferred to the tree-type arrangement. The second important contribution of this work is the introduction of separate drainage manifolds for the two phases connecting all the input streams which have improved the performance and the operability of the system. Finally, we introduced a large opening after a short channel (150 μm) downstream of the junction where the droplet is formed. This opening acts like a reservoir to damp any pressure variation which could travel back to the inlet point and disturb the flow of neighboring devices.
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