High-speed, clinical-scale microfluidic generation of stable phase-change droplets for gas embolotherapy

In this study we report on a microfluidic device and droplet formation regime capable of generating clinical-scale quantities of droplet emulsions suitable in size and functionality for in vivo therapeutics. By increasing the capillary number-based on the flow rate of the continuous outer phase-in our flow-focusing device, we examine three modes of droplet breakup: geometry-controlled, dripping, and jetting. Operation of our device in the dripping regime results in the generation of highly monodisperse liquid perfluoropentane droplets in the appropriate 3-6 μm range at rates exceeding 10(5) droplets per second. Based on experimental results relating droplet diameter and the ratio of the continuous and dispersed phase flow rates, we derive a power series equation, valid in the dripping regime, to predict droplet size, D(d) approximately equal 27(Q(C)/Q(D))(-5/12). The volatile droplets in this study are stable for weeks at room temperature yet undergo rapid liquid-to-gas phase transition, and volume expansion, above a uniform thermal activation threshold. The opportunity exists to potentiate locoregional cancer therapies such as thermal ablation and percutaneous ethanol injection using thermal or acoustic vaporization of these monodisperse phase-change droplets to intentionally occlude the vessels of a cancer.     

Surface properties of surfactant-free oil droplets dispersed in water studied by confocal fluorescence microscopy

The fluorescence spectrum of dye molecules, 4-(dicyanomethylene)-2-methyl-6-(p-dimethylaminostyryl)-4H-pyron (DCM), dissolved in surfactant-free n-decane droplets (average diameters of approximately 300 and approximately 2000 nm) dispersed in water was measured by a confocal microscope. The fluorescence spectra for 300- and 2000-nm droplets are found to exhibit a peak at 640 and 625 nm, respectively, and the peak red shifts with a decrease in the droplet diameter (solvatochromic shift of DCM molecules). It is concluded that (1) DCM molecules are located in a polar surface region of n-decane droplets and (2) the polarity increases with decreasing the droplet diameter.     

A predictive approach of the influence of the operating parameters on the size of polymer particles synthesized in a simplified microfluidic system

Monodisperse and size-controlled spherical polymer particles were synthesized by in situ photopolymerization of O/W monomer emulsions. Monomer droplets were produced without surfactant or pretreatment at a needle tip in a simplified axisymmetric microfluidic device. The effect of the viscosity of the continuous phase on the particle size was studied. The system operated in the dripping mode, at a low Reynolds number. A dimensionless master curve describes the particle diameter as a function of the needle inner diameter as well as velocity and viscosity ratios of continuous and dispersed phases. An empirical law predicts the particle size. The normalized particle diameter depends upon the ratio of the capillary numbers of continuous and dispersed phases with an exponent equal to -0.22.     

High-performance flow-focusing geometry for spontaneous generation of monodispersed droplets

A high-performance flow-focusing geometry for spontaneous generation of monodispersed droplets is demonstrated. In this geometry, a two-phase flow is forced through a circular orifice integrated inside a silicon-based microchannel. The orifice with its cusp-like edge exerts a ring of maximized stress around the flow and ensures controlled breakup of droplets for a wide range of flow rates, forming highly periodic and reproducible dispersions. The droplet generation can be remarkably rapid, exceeding 10(4) s(-1) for water-in-oil droplets and reaching 10(3) s(-1) for oil-in-water droplets, being largely controlled by flow rate of the continuous phase. The droplet diameter and generation frequency are compared against a quasi-equilibrium model based on the critical Capillary number. The droplets are obtained despite the low Capillary number, below the critical value identified by the ratio of viscosities between the two phases and simple shear-flow.     

Preparation of monodisperse crosslinked polymelamine microcapsules by phase separation method

Monodisperse polymelamine microcapsules were prepared by phase separation method. Control of microcapsule diameter was investigated using the uniform-sized oil-in-water emulsion droplets as the capsule core. The monodisperse emulsion droplets were prepared using the Shirasu porous glass (SPG) membrane emulsification technique. The effects of the diameter of the oil droplet and concentration of sodium dodecyl sulfate (SDS), which is a typical emulsifier in SPG membrane emulsification, on microencapsulation were investigated. The microcapsules were aggregated when oil droplets with small size were microencapsulated at high SDS concentration. To reduce the SDS concentration, the creamed emulsion was used. The monodisperse polymelamine microcapsules were successfully prepared by using the creamed emulsion. The microcapsule diameter was almost similar to the diameter of the encapsulated oil droplet. The coefficient of variation values was about 10% for all microcapsules prepared in this study. Control of microcapsule diameter was achieved in the range of 5–60 μm.     

A microfluidic method to study demulsification kinetics

We present the results of experiments studying droplet coalescence in a dense layer of emulsion droplets using microfluidic circuits. The microfluidic structure allows direct observation of collisions and coalescence events between oil droplets dispersed in water. The coalescence rate of a flowing hexadecane-in-water emulsion was measured as a function of the droplet velocity and droplet concentration from image sequences measured with a high-speed camera. A trajectory analysis of colliding droplet pairs allows evaluation of the film drainage profile and coalescence time t(c.) The coalescence times obtained for thousands of droplet pairs enable us to calculate coalescence time distributions for each set of experimental parameters, which are the mean droplet approach velocity (v(0)), the mean dispersed phase fraction (φ) and the mean hydraulic diameter of a droplet pair (d(p)). The expected value E(t(c)) of the coalescence time distributions scales as E(t(c)) is proportional to (v(0))(-0.105±0.043)(d(p))(0.562±0.287), but is independent of φ. We discuss the potential of the procedure for the prediction of emulsion stability in industrial applications.     

Breakup of double emulsion droplets in a tapered nozzle

When double emulsion droplets flow through a tapered nozzle, the droplets may break up and cause the core to be released. We model the system on the basis of the capillary instability and show that a droplet will not break up when the tilt angle of the nozzle is larger than 9°. For smaller tilt angles, whether the droplet breaks up also depends on the diameter ratio of the core of the droplet to the orifice of the nozzle. We verified this mechanism by experiments. The ideas are useful for the design of nozzles not only to break droplets for controlled release but also to prevent the droplet from rupturing in applications requiring the reinjection of an emulsion.     

Highly productive droplet formation by anisotropic elongation of a thread flow in a microchannel

We developed a microfluidic device to form monodisperse droplets with high productivity by anisotropic elongation of a thread flow, defined as a threadlike flow of a dispersed liquid phase in a flow of an immiscible, continuous liquid phase. The thread flow was anisotropically elongated in the depth direction in a straight microchannel with a step, where the microchannel depth changed. Consequently, the elongated thread flow was given capillary instability (Rayleigh-Plateau instability) and was continuously transformed into monodisperse droplets at the downstream area of the step in the microchannel. We examined the effects of the flow rates of the dispersed phase and the continuous phase on the droplet formation behavior, including the droplet diameter and droplet formation frequency. The droplet diameter increased as the fraction of the dispersed-phase flow rate relative to the total flow rate increased and was independent of the total flow rate. The droplet formation frequency proportionally increased with the total flow rate at a constant dispersed-phase flow rate fraction. These results are explained in terms of a mechanism similar to that of droplet formation from a cylindrical liquid thread flow by Rayleigh-Plateau instability. The microfluidic device described was capable of forming monodisperse droplets with a 160-microm average diameter and 3-microm standard deviation at a droplet formation frequency of 350 droplets per second from a single thread flow. The highest total flow rate achieved was 6 mL/h using the present device composed of a straight microchannel with a step. We also demonstrated parallel droplet formation by anisotropic elongation of multiple thread flows; the process was applied to form W/O and O/W droplets. The highly productive droplet formation process presented in this study is expected to be useful for future industrial applications.     

Manufacture of large uniform droplets using rotating membrane emulsification

A new rotating membrane emulsification system using a stainless steel membrane with 100 microm laser drilled pores was used to produce oil/water emulsions consisting of 2 wt% Tween 20 as emulsifier, paraffin wax as dispersed oil phase and 0.01-0.25 wt% Carbomer (Carbopol ETD 2050) as stabilizer. The membrane tube, 1 cm in diameter, was rotated inside a stationary glass cylinder, diameter of 3 cm, at a constant speed in the range 50-1500 rpm. The oil phase was introduced inside the membrane tube and permeated through the porous wall moving radially into the continuous phase in the form of individual droplets. Increasing the membrane rotational speed increased the wall shear stress which resulted in a smaller average droplet diameter being produced. For a constant rotational speed, the average droplet diameter increased as the stabilizer content in the continuous phase was lowered. The optimal conditions for producing uniform emulsion droplets were a Carbomer content of 0.1-0.25 wt% and a membrane rotational speed of 350 rpm, under which the average droplet diameter was 105-107 microm and very narrow coefficients of variation of 4.8-4.9%. A model describing the operation is presented and it is concluded that the methodology holds potential as a manufacturing protocol for both coarse and fine droplets and capsules.     

Generation of Water-In-Oil-In-Water (W/O/W) Double Emulsions by Microfluidics

Novel compartment microparticles prepared with double emulsion droplets as templates provide a protected internal space for material encapsulation. The effect of three-phase flow rate on the micro-droplet generation of double emulsion mechanism is available for reference to produce precise size and highly monodisperse particles. The influence of three-phase flow rate on the formation mode and size of the emulsion droplets is investigated by combination of experiment and numerical simulation. The size of compound droplets decreases and frequency increases with the increasing outer fluid flow rate. The monodispersity of the double emulsion reduces due to transition from dripping to narrowing jetting regime. Outer droplet size increases with the increasing flow rate of the middle fluid, whereas inner droplet size is the opposite. The frequency increases and then stabilizes, which leads to a widening regime. When Q₂/Q₁ > 6, the multi-core type double emulsion droplets are produced. Droplet coalescence occurs when surfactants is not involved. As Q₁ increases, there is an increasing tendency for inner drop size. The outer drop size is proportional to the sum of the inner and middle flow rate, and that is irrelevant to Q₁/Q₂. For drop size, the ratio of core-shell and internal structure is precisely controlled by adjusting three-phase flow rate respectively.     

Preparation of monodisperse SiO2 nanoparticles by membrane emulsification using ideally ordered anodic porous alumina

Monodisperse SiO2 particles of nanometer dimensions were fabricated by membrane emulsification using ideally ordered anodic porous alumina. For the preparation of monodisperse emulsion droplets, the dispersed phase was pressed through a porous alumina membrane into the continuous phase. After solidification treatment of the emulsion droplets, prepared spherical SiO2 nanoparticles with uniform sizes were obtained. From scanning electron microscope observation of the obtained particles, it was confirmed that the size distribution of SiO2 nanoparticles is relatively narrow.     

Preparation of uniformly sized alginate microspheres using the novel combined methods of microchannel emulsification and external gelation

The purpose of this study was to prepare alginate (ALG) microspheres with narrow size distribution using a combination of microchannel (MC) emulsification technique and external gelation method. ALG solution was dispersed as water-in-oil (W/O) emulsion droplets in iso-octane containing 5 wt% Span 85 as the immiscible continuous phase via MC emulsification technique using hydrophobic MC array. The MC array used in this experiment is a grooved-type MC consisting of 1070 channels fabricated on a 25 mm × 28 mm silicon microchip. The monodisperse W/O emulsion droplets generated from the MCs were in the mean particle diameter (d_av) range of 18–22 μm and coefficient of variation (CV) of 5–26% at the ALG concentrations of 0.5–3.0 wt% and flow rates of 0.05–0.4 mL/h. The d_av of the emulsion droplets hardly changed below a dispersed phase threshold flow rate of 0.2 mL/h but gradually became smaller when the dispersed phase concentration was increased. The resulting emulsion droplets were then congealed to form rigid ALG gel particles by reacting them with calcium chloride (CaCl₂) solution. Gelation of the ALG droplets by calcium ion (Ca²⁺) resulted in shrinkage of its d_av, forming uniformly sized ALG microspheres with an average diameter of 6.2 μm and a CV of below 10% at the ALG concentration of 3 wt%.     

A micro-reactor for preparing uniform molecularly imprinted polymer beads

In this study, uniform spherical molecularly imprinted polymer beads were prepared via controlled suspension polymerization in a spiral-shaped microchannel using mineral oil and perfluorocarbon liquid as continuous phases. Monodisperse droplets containing the monomers, template, initiator, and porogenic solvent were introduced into the microchannel, and particles of uniform size were produced by subsequent UV polymerization, quickly and without wasting polymer materials. The droplet/particle size was varied by changing the flow conditions in the microfluidic device. The diameter of the resulting products typically had a coefficient of variation (CV) below 2%. The specific binding sites that were created during the imprinting process were analysed via radioligand binding analysis. The molecularly imprinted microspheres produced in the liquid perfluorocarbon continuous phase had a higher binding capacity compared with the particles produced in the mineral oil continuous phase, though it should be noted that the aim of this study was not to optimize or maximize imprinting performance, but rather to demonstrate broad applicability and compatibility with known MIP production methods. The successful imprinting against a model compound using two very different continuous phases (one requiring a surfactant to stabilize the droplets the other not) demonstrates the generality of this current simple approach.     

Influence of process parameters on the size distribution of PLA microcapsules prepared by combining membrane emulsification technique and double emulsion-solvent evaporation method

Relatively uniform-sized biodegradable poly(lactide) (PLA) microcapsules with various sizes were successfully prepared by combining a glass membrane emulsification technique and water-in-oil-in-water (w₁/o/w₂) double emulsion-solvent evaporation method. A water phase was used as the internal water phase, a mixture solvent of dichloromethane (DCM) and toluene dissolving PLA and Arlacel 83 was used as the oil phase (o). These two solutions were emulsified by a homogenizer to form a w₁/o primary emulsion. The primary emulsion was permeated through the uniform pores of a glass membrane into the external water phase by the pressure of nitrogen gas to form the uniform w₁/o/w₂ double emulsion droplets. Then, the solid polymer microcapsules were obtained by simply evaporating solvent. The influence of process parameters on the size distribution of PLA microcapsules was investigated, with an emphasis on the effect of oil-soluble emulsifier. A unique phenomenon was found that a large part of emulsifier could adsorb on the interface of internal water phase and oil phase, which suppressed its adsorption on the surface of glass membrane, and led to the successful preparation of uniform-sized double emulsion. Finally, by optimizing the process parameters, PLA microcapsules with various sizes having coefficient of variation (CV) value under 14.0% were obtained. Recombinant human insulin (rhI), as a model protein, was encapsulated into the microcapsules with difference sizes, and its encapsulation efficiency and cumulative release were investigated. The result suggested that the release behavior could be simply adjusted just by changing precisely the diameters of microcapsule, benefited from the membrane emulsification technique.     

Droplet migration in emulsion systems measured using MR methods

The migration of emulsion droplets under shear flow remains a largely unexplored area of study, despite the existence of an extensive literature on the analogous problem of solid particle migration. A novel methodology is presented to track the shear-induced migration of emulsion droplets based on magnetic resonance imaging (MRI). The work is in three parts: first, single droplets of one Newtonian fluid are suspended in a second Newtonian fluid (water in silicone oil (PDMS)) and are tracked as they migrate within a Couette cell; second, the migration of emulsion droplets in Poiseuille flow is considered; third, water-in-silicone oil emulsions are sheared in a Couette cell. The effect of (a) rotational speed of the Couette, (b) the continuous phase viscosity, and (c) the droplet phase concentration are considered. The equilibrium extent of migration and rate of migration increase with rotational speed for two different emulsion systems and increased continuous phase viscosity, leads to a greater equilibrium extent of migration. The relationship between the droplet phase concentration and migration is however complex. These results for semi-concentrated emulsion systems and wide-gap Couette cells are not well described by existing models of emulsion droplet migration.     

Preparation of insulin-loaded PLA/PLGA microcapsules by a novel membrane emulsification method and its release in vitro

Uniform-sized biodegradable PLA/PLGA microcapsules loading recombinant human insulin (rhI) were successfully prepared by combining a Shirasu Porous Glass (SPG) membrane emulsification technique and a double emulsion-evaporation method. An aqueous phase containing rhI was used as the inner water phase (w1), and PLA/PLGA and Arlacel 83 were dissolved in a mixture solvent of dichloromethane (DCM) and toluene, which was used as the oil phase (o). These two solutions were emulsified by a homogenizer to form a w1/o primary emulsion. The primary emulsion was permeated through the uniform pores of a SPG membrane into an outer water phase by the pressure of nitrogen gas to form the uniform w1/o/w2 droplets. The solid polymer microcapsules were obtained by simply evaporating solvent from droplets. Various factors of the preparation process influencing the drug encapsulation efficiency and the drug cumulative release were investigated systemically. The results indicated that the drug encapsulation efficiency and the cumulative release were affected by the PLA/PLGA ratio, NaCl concentration in outer water phase, the inner water phase volume, rhI-loading amount, pH-value in outer water phase and the size of microcapsules. By optimizing the preparation process, the drug encapsulation efficiency was high up to 91.82%. The unique advantage of preparing drug-loaded microcapsules by membrane emulsification technique is that the size of microcapsules can be controlled accurately, and thus the drug cumulative release profile can be adjusted just by changing the size of microcapsules. Moreover, much higher encapsulation efficiency can be obtained when compared with the conventional mechanical stirring method.     

Investigating the effects of precursor concentration and gelling parameters on droplet-based generation of Ca-Alginate microgels: identifying new stable modes of droplet formation

Droplet-based microfluidics is an attractive approach for producing microgels due to its high potential to control the size and shape of the particles and precisely entrap the substances within the hydrogel matrix. However, the microfluidic generation of monodisperse microgels with desired structures is still challenging. Indeed, the rheological and interfacial properties of the immiscible fluids, as well as the adopted gelling strategy, play important roles in microfluidic methods. Herein, sodium alginate droplets with different concentrations are generated via a microfluidic device with a flow-focusing unit. Besides, a combined in situ and ex situ strategy is optimized to crosslink sodium alginate droplets in the presence of calcium ions. The effects of alginate concentration and junction width in the flow focusing unit are investigated on droplet size and droplet formation regimes. It is observed that by increasing the alginate concentration, the dripping regime of droplet formation may be transformed to one of the binary dripping or quasijetting regimes. In the binary dripping regime, two successive different-sized droplets are generated in each period of droplet formation, which leads to low monodispersity in the collected droplets. However, the droplets produced in the quasijetting regime are interestingly monodisperse and also smaller than those of the dripping and binary dripping regimes. The breakup dynamics of the alginate thread is also analyzed with a computational fluid dynamics (CFD) code. This analysis discloses that the viscous stresses, as well as the viscous dissipation, have important roles in controlling the stable modes of droplet formation.     

Droplet formation in a microchannel network

A method is given for generating droplets in a microchannel network. With oil as the continuous phase and water as the dispersed phase, pico/nanoliter-sized water droplets can be generated in a continuous phase flow at a -junction. The channel for the dispersed phase is 100 microm wide and 100 microm deep, whereas the channel for the continuous phase is 500 microm wide and 100 microm deep. For given experimental parameters, regular-sized droplets are reproducibly formed at a uniform speed. The diameter of these droplets is controllable in the range from 100-380 microm as the flow velocity of the continuous phase is varied from 0.01 m s(-1) to 0.15 m s(-1).     

Controlled buckling and crumpling of nanoparticle-coated droplets

We introduce a new experimental approach to study the structural transitions of large numbers of nanoparticle-coated droplets as their volume is reduced. We use an emulsion system where the dispersed phase is slightly soluble in the continuous phase. By adding a fixed amount of unsaturated continuous phase, the volume of the droplets can be controllably reduced, causing them to buckle or crumple, thereby becoming nonspherical. The resultant morphologies depend both on the extent of volume reduction and the average droplet size. The buckling and crumpling behavior implies that the droplet surfaces are solid.     

Novel method for obtaining homogeneous giant vesicles from a monodisperse water-in-oil emulsion prepared with a microfluidic device

A novel technique called the "lipid-coated ice droplet hydration method" is presented for the preparation of giant vesicles with a controlled size between 4 and 20 microm and entrapment yields for water-soluble molecules of up to about 30%. The method consists of three main steps. In the first step, a monodisperse water-in-oil emulsion with a predetermined average droplet diameter between 4 and 20 microm is prepared by microchannel emulsification, using sorbitan monooleate (Span 80) and stearylamine as emulsifiers and hexane as oil. In the second step, the water droplets of the emulsion are frozen and separated from the supernatant hexane solution by precipitation, followed by a removal of the supernatant and followed by the replacement of Span 80 by using a hexane solution containing egg yolk phosphatidylcholine, cholesterol, and stearylamine (5:5:1, molar ratio). This procedure is performed at -10 degrees C to keep the water droplets of the emulsion in a frozen state and thereby to avoid extensive water droplet coalescence. In the third step, hexane is evaporated at -4 to -7 degrees C and an external water phase is added to the remaining mixture of lipids and water droplets to form giant vesicles that have an average size in the range of that of the initial emulsion droplets (4-20 microm). The entrapment yield and the lamellarity of the vesicles obtained depend on the lipid/water droplet ratio and on the composition of the external water phase. At high lipid/water droplet ratio, the giant vesicles have a thicker membrane (indicating multilamellarity) and a higher entrapment yield than in the case of a low lipid/water droplet ratio. The highest entrapment yield ( approximately 35%) is obtained if the added external water phase contains preformed unilamellar egg phosphatidylcholine vesicles with an average diameter of 50 nm. The addition of these small vesicles minimizes the water droplet coalescence during the third step of the vesicle preparation, thereby decreasing the extent of release of water-soluble molecules originally present in the water droplets. The GVs prepared can be extruded through polycarbonate membranes to yield large unilamellar vesicles with about 100 nm diameter. This size reduction, however, leads to a decrease in the entrapment yield to about 12% due to solute leakage from the vesicles during the extrusion process.