We report tip-multi-breaking (TMB) mode of droplet breakup in capillary microfluidic devices. This new mode appears in a region embraced by Cai = 0 and lg(Cai) = − 8.371(Ca0) −7.36 with Ca0 varying from 0.35 to 0.63 on the Cai – Ca0 phase diagram, Cai and Ca0 being the capillary numbers of inner and outer fluids, respectively. The mode is featured with a periodic, constant-speed thinning of the inner liquid tip and periodic formation of a sequence of droplets. The droplet number n in a sequence is determined by and increases with outer phase capillary number, and varies from two to over ten. The distribution of both pinch-off time and size of the droplets in a sequence is a geometric progression of common ratio that depends exclusively on and increases monotonically with the droplet number from its minimum value of 0.5 at n = 2 to its maximum value of 1 as n tends to infinity. These features can help identify the unique geometric morphology of droplet clusters and make them promising candidates for encryption and anti-fake identification.

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The evolution of double-emulsion droplets is of great importance for the application of microdroplets and microparticles. We study the driving force of the dewetting process, the equilibrium configuration and the dewetting time of double-emulsion droplets. Through energy analysis, we find that the equilibrium configuration of a partial engulfed droplet depends on a dimensionless interfacial tension determined by the three relevant interfacial tensions, and the engulfing part of the inner phase becomes larger as the volume of the outer phase increases. By introducing a dewetting boundary, the dewetting time can be calculated by balancing the driving force, caused by interfacial tensions, and the viscous force. Without considering the momentum change of the continuous phase, the dewetting time is an increasing function against the viscosity of the outer phase and the volume ratio between the outer phase and inner phase.

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We investigate the influences of expansion-contraction microchannels on droplet breakup in capillary microfluidic devices. With variations in channel dimension, local shear stresses at the injection nozzle and focusing orifice vary, significantly impacting flow behavior including droplet breakup locations and breakup modes. We observe transition of droplet breakup location from focusing orifice to injection nozzle, and three distinct types of recently-reported tip-multi-breaking modes. By balancing local shear stresses and interfacial tension effects, we determine the critical condition for breakup location transition, and characterize the tip-multi-breaking mode quantitatively. In addition, we identify the mechanism responsible for the periodic oscillation of inner fluid tip in tip-multi-breaking mode. Our results offer fundamental understanding of two-phase flow behaviors in expansion-contraction microstructures, and would benefit droplet generation, manipulation and design of microfluidic devices.

The controlled generation of microparticles with non-spherical features is of increasing importance. Such particles are useful for fundamental studies in areas such as self-assembly, as well as biomedical applications from drug carriers to photonic devices. We propose a simple model that captures the dominating factors controlling the size and morphology of non-spherical particles from phase separated droplets. The validity of our model is verified by comparing the generated non-spherical microparticles by droplet microfluidics. This simple relationship between the dominating factors and the final morphologies enables the production of non-spherical particles with well-defined shapes and tightly-controlled dimensions for a variety of applications from drug delivery vehicles to structural materials.

A photothermal nanoconfinement reactor (PNCR) system is proposed and demonstrated by using hollow carbon nanospheres (HCNs) to enhance the performance of the chemical reaction. Under light irradiation, the local temperature of the HCN inner void space was much higher than the bulk solution temperature because the confined space concentrates heat and inhibits heat loss. Using the temperature‐sensitive model reaction, peroxydisulfate (PDS) activation to oxidize micropollutant, it is shown that the degradation rate of sulfamethoxazole in the PNCR system is 7.1 times of that without nanoconfinement. It is further discovered that the high‐quality local heat inside the nanoconfined space shifted the model reaction from an otherwise non‐radical pathway to a radical‐based pathway. This work provides an interesting strategy to produce a locally high temperature, which has a wide range of applications to energy and environmental fields.