Formation of shaped drops in a fast continuous flow process

Drop shaping, i.e., flow-induced deformation and fixation by gel formation, was studied under dynamic conditions in a fast continuous process for a water-in-oil system. The system consisted of sunflower oil with different surfactant concentrations (0.1-2% Admul Wol) and a 1.5% kappa-carrageenan solution with different Na(+) and K(+) concentrations. The continuous phase flowed in a 10-mm-wide straight channel into which the dispersed phase was injected via a thin needle. A subsequent shaping channel with a width of 1 or 2 mm deformed the drops. Gel formation was induced by a temperature gradient between the continuous and dispersed phase. Drop sizes in the range 220-roughly 1000 microm were produced at the needle tip by varying the ratio between the oil and carrageenan flow rate. A diffusion zone before the narrow channel allowed the surfactant to adsorb at the interface. In the elongation flow at the entrance of the shaping geometry, drops underwent initial elongation. In the narrow channel, the drops developed a parabolic shape within a residence time of 0.03-0.15 s. Choosing the correct parameter combinations made it possible to fix the deformation by gel formation within this time period. Shaped drops were shown to be functional. At a concentration of 25% in an emulsion, they increased the viscosity by about 15-20% compared to spherical drops even though 45% of the shaped drops had an aspect ratio of less than 1.2.     

Drop deformation dynamics and gel kinetics in a co-flowing water-in-oil system

Drop deformation and superimposed gel kinetics were studied in a fast continuous-flow process for a water-in-oil system. Highly monodisperse drops were generated in a double capillary and then deformed passing through a narrowing rectangular channel geometry. Nongelling deformation experiments were used to establish the process and compare it with existing theories. Thereafter, temperature induced drop gelation was included to study its effect on deformation and gel kinetics on short timescales and at high temperature gradients. The disperse phase was a kappa-carrageenan solution with additional sodium and potassium ions for gelation experiments. Sunflower oil was used for the continuous phases. Nongelling experiments showed that shear forces are able to deform drops into ellipsoids. A comparison with the small deformation theory by Taylor was surprisingly good even when drop deformation and flow conditions were not in steady state. Superimposed gelation on the deformation process showed clearly the impact of the altered rheological properties of the dispersed and continuous phase. Deformation first increased on cooling the continuous phase until the onset of gel formation, where a pronounced decrease in deformation due to increasing droplet viscosity/viscoelasticity was observed. Drop deformation analyses were then used to detect differences in gelation kinetics at high cooling rate within process times as short as 1.8 s.     

Continuous flow structuring of anisotropic biopolymer particles

We review concepts and provide examples for the controlled structuring of biopolymer particles in hydrodynamic flow fields. The structuring concepts are grouped by the physical mechanisms governing drop deformation and shaping: (i) capillary structuring, (ii) shear and elongational structuring and (iii) confined flow methods. Non-spherical drops can be permanently structured if a solidification process, such as gelation or glass formation in the bulk or at the interface, is superimposed to the flow field. The physical and engineering properties of these processes critically depend on an elaborate balance between capillary phenomena, rheology, gel or glass formation kinetics, and bulk heat, mass and momentum transfer in multiphase fluids. This overview is motivated by the potential of non-spherical suspension particles, in particular those formed from ‘natural’ and ‘sustainable’ biopolymers, as rheology modifiers in food materials, consumer products, cosmetics or pharmaceuticals.     

Effect of sol-gel transition on shear-induced drop deformation in aqueous mixtures of gellan and kappa-carrageenan

In this work, we present an experimental methodology to investigate the dynamics under shear flow of a drop that is gelling as a consequence of a temperature quench. The experiments were carried out on the system water/gellan/kappa-carrageenan in the biphasic region of the phase diagram, the gellan-rich phase being used as the dispersed phase. Gelation was brought about by lowering the temperature during flow after steady state drop deformation had been reached. Simple shear flow was applied by using a parallel plate apparatus equipped with optical microscopy and image analysis, which made it possible to monitor drop shape evolution before, during, and after gelation. The onset of gelation trapped drop deformation, thus producing anisotropic particles. The fingerprint of gelation was the simultaneous tumbling of the drops, which rotated as rigid ellipsoids under the action of shear flow. Interfacial tension between the two equilibrium phases was determined at different times during the temperature quench by analyzing drop retraction upon cessation of flow. Up to gelation, no significant change was observed in the measured values.     

The drop size in membrane emulsification determined from the balance of capillary and hydrodynamic forces

Here, we investigate experimentally and theoretically the factors that determine the size of the emulsion droplets produced by membrane emulsification in "batch regime" (without applied crossflow). Hydrophilic glass membranes of pore diameters between 1 and 10 mum have been used to obtain oil-in-water emulsions. The working surfactant concentrations are high enough to prevent drop coalescence. Under such conditions, the size of the formed drops does not depend on the surfactant type and concentration, on the interfacial tension, or on the increase of viscosity of the inner (oil) phase. The drops are monodisperse when the working transmembrane pressure is slightly above the critical pressure for drop breakup. At higher pressures, the size distribution becomes bimodal: a superposition of a "normal" peak of monodisperse drops and an "anomalous" peak of polydisperse drops is observed. The theoretical model assumes that, at the moment of breakup, the hydrodynamic ejection force acting on the drop is equal to the critical capillary force that corresponds to the stability-instability transition in the drop shape. The derived equations are applied to predict the mean size of the obtained drops in regimes of constant flow rate and constant transmembrane pressure. Agreement between theory and experiment is established for the latter regime, which corresponds to our experimental conditions. The transition from unimodal to bimodal drop size distribution upon increase of the transmembrane pressure can be interpreted in terms of the transition from "dripping" to "jetting" mechanisms of drop detachment.     

Destabilization mechanisms in a triple emulsion with Janus drops

The destabilization mechanism was investigated of a triple Janus emulsion. The inner part of the emulsion consisted of Janus drops of a vegetable oil (VO) and a silicone oil (SO) in an aqueous (W) drop, (VO+SO)/W. This drop, in turn was dispersed in a VO drop forming a double emulsion (VO+SO)/W/VO. Finally, these complex drops generated a complex Janus (SO+VO)/W/VO/SO triple emulsion by being dispersed in a continuous SO phase. The observations were limited to the time dependence of the over-all creaming/sedimentation processes, to the separation of layers of the compounds and to optical microscopy of the drop configuration with time. In the destabilization process the rise of the complex drops, (SO+VO)/W/VO, caused crowding in the upper part of the emulsion, which in turn led to enhanced coalescence, inversion and separation of a dilute vegetable oil emulsion. As a consequence of the separation of VO in the process, the remaining drops contained a greater W fraction and greater density. This change, in turn, resulted in sedimentation of the complex drops to form several high internal ratio morphologies in an SO continuous emulsion in the lower part of the test tube, among them a W/VO/SO emulsion. Finally, an inversion took place into an SO/VO/W double emulsion forming a separate bottom layer.     

A novel gel deformation technique for fabrication of ellipsoidal and discoidal polymeric microparticles

A simple fabrication technique for anisotropic particles of ellipsoidal/discoidal shape has been developed, based on stretching/compressing of oil-in-water emulsion templates embedded into an elastic aqueous gel; a range of solid anisotropic microparticles have been fabricated by polymerising of the deformed oil drops in the elastic gel matrix and their shape and aspect ratios have been studied as a function of the gel deformation.     

Emulsification in turbulent flow 2. Breakage rate constants

Systematic experimental study of the effects of several factors on the breakage rate constant, k(BR), during emulsification in turbulent flow is performed. These factors are the drop size, interfacial tension, viscosity of the oil phase, and rate of energy dissipation in the flow. As starting oil-water premixes we use emulsions containing monodisperse oil drops, which have been generated by the method of membrane emulsification. By passing these premixes through a narrow-gap homogenizer, working in turbulent regime of emulsification, we study the evolution of the number concentration of the drops with given diameter, as a function of the emulsification time. The experimental data are analyzed by a kinetic scheme, which takes into account the generation of drops of a given size (as a result of breakage of larger drops) and their disappearance (as a result of their own breakage process). The experimental results for k(BR) are compared with theoretical expressions from the literature and their modifications. The results for all systems could be described reasonably well by an explicit expression, which is a product of: (a) the frequency of collisions between drops and turbulent eddies of similar size, and (b) the efficiency of drop breakage, which depends on the energy required for drop deformation. The drop deformation energy contains two contributions, originating from the drop surface extension and from the viscous dissipation inside the breaking drop. In the related subsequent paper, the size distribution of the daughter drops formed in the process of drop breakage is analyzed for the same experimental systems.     

Silica particle-stabilized emulsions of silicone oil and water: aspects of emulsification

A study of the emulsification of silicone oil and water in the presence of partially hydrophobic, monodisperse silica nanoparticles is described. Emulsification involves the fragmentation of bulk liquids and the resulting large drops and the coalescence of some of those drops. The influence of particle concentration, oil/water ratio, and emulsification time on the relative extents of fragmentation and coalescence during the formation of emulsions, prepared using either batch or continuous methods, has been investigated. For batch emulsions, the average drop diameter decreases with increasing particle concentration as the extent of limited coalescence is reduced. Increasing the oil volume fraction in the emulsion at fixed aqueous particle concentration results in an increase in the average drop diameter together with a dramatic lowering of the uniformity of the drop size distribution as coalescence becomes increasingly significant until catastrophic phase inversion occurs. For low oil volume fractions (phi(o)), fragmentation dominates during emulsification since the mean drop size decreases with emulsification time. For higher phi(o) close to conditions of phase inversion, coalescence becomes more prevalent and the drop size increases with time with stable multiple emulsions forming as a result.     

Effects of magnetite nanoparticles on the thermorheological properties of carrageenan hydrogels

The influence of magnetite (Fe(3)O(4)) nanoparticles on the rheological properties of kappa-, iota- and lambda-carrageenan gels has been investigated. Small amplitude oscillatory shear measurements were performed to study the effect of the presence of Fe(3)O(4) nanoparticles with particle sizes of ca. 10 nm on the gel properties, as a function of carrageenan type, carrageenan concentration and magnetite load. The formation of Fe(3)O(4) nanoparticles on the presence of biopolymer was observed to promote the gelation process and lead to stronger gels as indicated by an increase in the gel viscoelastic moduli and of the gelation temperature. This effect was more marked for kappa-carrageenan than for iota- and lambda-carrageenan and has been proposed to depend not only on Fe(3)O(4) concentration but also on the concentration of potassium ions. A mechanism based on the combined effect of Fe(3)O(4) nanoparticles and potassium ions was suggested, involving the adsorption of potassium ions on the negatively charged surface of the Fe(3)O(4) nanoparticles, thus leading to an increase of the potassium ion concentration within the "carrageenan cages" containing the magnetite. This would, therefore, promote more extensive biopolymer helical aggregation, thus resulting in the formation of a stronger kappa-carrageenan gel in the presence of Fe(3)O(4), as observed. Since iota- and lambda-carrageenan gels are known to be less sensitive to potassium ions concentration, the effect of precipitating Fe(3)O(4) within these biopolymers is reduced.     

Microfluidic approach for rapid multicomponent interfacial tensiometry

We report a microfluidic instrument to rapidly measure the interfacial tension of multi-component immiscible liquids. The measurement principle rests upon the deformation and retraction dynamics of drops under extensional flow and was implemented for the first time in microfluidics (S. D. Hudson et al., Appl. Phys. Lett., 2005, 87, 081905 (ref. )). Here we describe in detail the instrument design and physics and extend this principle to investigate multicomponent mixtures, specifically two-component drops of adjustable composition. This approach provides fast real-time sigma measurements (on the order of 1 s), the possibility of rapidly adjusting drop composition and utilizes small sample volumes (approximately 10 microL). The tensiometer operation is illustrated with water drops and binary drops (water/ethylene glycol mixtures) in silicone oils. The technique should be particularly valuable for high-throughput characterization of complex fluids.     

Modeling drop shape on contaminated surfaces or surfaces with physical structures

Surface contaminants are commonly found on films. They get transferred to the surface from incompletely cured silicone liners on the films or owing to migration of additives to the surface from within the film. During the process of ink jet printing (a noncontact printing process), surface contamination affects the shape of the drops (causing the formation of fingers and crescents) and hence image quality. This study uses modeling methods to examine how such surface contamination affects the drops shapes. Subsequently, it models the effect of surface structures (pits) on the drop shape. This study explores how image quality can be controlled in the presence of surface contamination and surface structures.     

One-step inversion process to a Janus emulsion with two mutually insoluble oils

High internal phase ratio (HIPR) aqueous Janus emulsions of two immiscible oils, silicone oil (SO) and a vegetable oil (VO), were prepared using a vibration mixer. The simple HIPR Janus emulsions, (VO + SO)/W, were found at weight fractions of the aqueous phase in excess of 0.3, while at a corresponding fraction of 0.1, a triple emulsion was obtained with the Janus emulsion forming a drop inside the vegetable oil to give a double Janus emulsion, (VO + SO)/W/VO, which in turn formed drops in the silicone oil resulting in a triple Janus emulsion (VO + SO)/W/VO/SO. Increasing the aqueous-phase fraction from 0.1 to 0.3 consequently meant an inversion, of which one intermediate stage was observed: a more complex configuration, e.g., one in which large SO drops with highly distorted VO drops attached were dispersed in a regular aqueous emulsion with spherical Janus (VO + SO) drops. A preliminary investigation was made into the destabilization process of the triple emulsions.     

Giant reduction in dynamic modulus of kappa-carrageenan magnetic gels

Effects of magnetization on the complex modulus of kappa-carrageenan magnetic gels have been investigated. The magnetic gel was made of a natural polymer, kappa-carrageenan, and a ferrimagnetic particle, barium ferrite. The complex modulus was measured before and after magnetization of the gel by dynamic viscoelastic measurements with a compressional strain. The gels showed a giant reduction in the storage modulus of approximately 10(7) Pa and also in the loss modulus of approximately 10(6) Pa due to magnetization. The reduction increased with increasing volume fraction of ferrite, and it was nearly independent of the frequency. It was also found that the change in the modulus was nearly independent of the magnetization direction and irradiation time of the magnetic fields to the gel. The magnetic gels demonstrating the giant reduction in the dynamic modulus showed a large nonlinear viscoelastic response. It was observed that the magnetic gel was deformed slightly due to magnetization. The observed giant complex modulus reduction could be attributed to the nonlinear viscoelasticity and deformation caused by magnetization. Magnetism, nonlinear viscoelasticity, and effects of magnetization on the morphological and shape changes were discussed.     

Salt-induced protein phase transitions in drying drops

Protein phase transitions in drying sessile drops of protein-salt-water colloidal systems were studied by means of optical and atom-force microscopy. The following sequence of events was observed during drop drying: attachment of a drop to a glass support; redistribution of colloidal phase due to hydrodynamic centrifugal stream; protein ring formation around the edge; formation of protein spatial structures inside a protein ring that pass into gel in the middle of the drop; salt crystallization in the shrinking gel. It was assumed that rapid drying of a protein ring over the circle of high colloidal volume fraction and low strength of interparticle attraction leads to formation of colloidal glass, whereas gel forms only in the middle of the drop at very low protein volume fraction and strong attraction between the particles. Before gelation, colloidal particles form fractal clusters. In dried drops of salt-free protein solutions, no visual protein structures were observed. Structural evolution of protein in sessile drying drops of protein-salt aqueous colloidal solutions is discussed on the basis of experimental data.     

Shear force induced monodisperse droplet formation in a microfluidic device by controlling wetting properties

Perpendicular flow is used to induce oil droplet breakup by using a capillary as water phase flow channel. It is a new route to produce monodisperse emulsions. The wetting properties of the fluids on the walls are exceedingly important parameters. Depending on the oil and water flow rates, different spatial distributions of the two phases as laminar, plugs, cobbles and drops, are obtained. The effects of two-phase flow rates on plugs and drop size are studied, and the different droplet formation mechanisms of plug flow and drop flow are discussed. Two quantitative equations utilized to predict the droplet size are developed.     

Effects of Applied Electric Fields on Drop—Interface and Drop—Drop Coalescence*

In this work, coalescence of a single organic or aqueous drop with its homophase at a horizontal liquid interface was investigated under applied electric fields. The coalescence time was found to decrease for aqueous drops as the applied voltage was increased, regardless of the polarity of the voltage. For organic drops, the coalescence time increased with increasing applied voltage of positive polarity and decreased with increasing applied voltage of negative polarity. Under an electric field, the coalescence time of aqueous drops decreases due to polarization of both the drop and the flat interface. The dependency of organic drop-interface coalescence on the polarity of the electric field may be a result of the negatively charged organic surface in the aqueous phase. Due to the formation of a double layer, organic drops are subjected to an electrostatic force under an electric field, which, depending on the field polarity, can be attractive or repulsive. Pair-drop coalescence of aqueous drops in the organic phase was also studied. Aqueous drop-drop coalescence is facilitated by polarization and drop deformation under applied electric fields. Without applied electric fields, drop deformation increases the drainage time of the liquid film between two approaching drops. Therefore, a decrease in the interfacial tension, which causes drop deformation, accelerates drop-drop coalescence under an electric field and inhibits drop coalescence in the absence of an electric field.     

Amphiphilic crescent-moon-shaped microparticles formed by selective adsorption of colloids

We use a microfluidic device to prepare monodisperse amphiphilic particles in the shape of a crescent-moon and use these particles to stabilize oil droplets in water. The microfluidic device is comprised of a tapered capillary in a theta (θ) shape that injects two oil phases into water in a single receiving capillary. One oil is a fluorocarbon, while the second is a photocurable monomer, which partially wets the first oil drop; silica colloids in the monomer migrate and adsorb to the interface with water but do not protrude into the oil interface. Upon UV-induced polymerization, solid particles with the shape of a crescent moon are formed; removal of fluorocarbon oil yields amphiphilic particles due to the selective adsorption of silica colloids. The resultant amphiphilic microparticles can be used to stabilize oil drops in a mixture of water and ethanol; if they are packed to sufficient surface density on the interface of the oil drop, they become immobilized, preventing direct contact between neighboring drops, thereby providing the stability.     

Destabilization of a dual emulsion to form a Janus emulsion

A vegetable oil (VO) was added to an emulsion of silicone oil in water (SO/W) with mixing limited to once turning the test tube upside down. Initially, the VO was dispersed into virtually centimeter-sized drops and the emulsion contained effectively no Janus drops, while after 1 h of agitation at a low level to prevent creaming, drops of 50–100-μm size of the two oils were observed: in addition to an insignificant number of Janus drops. The topology of the latter showed them to emanate from flocculated individual drops of the two oils, but with no discernible effect by the interfacial tension equilibrium on the drop topology. Continued gentle mixing gave increasing fraction of Janus drops of increased size with a topology gradually approaching the one expected from the interfacial equilibrium at the contact line. The spontaneous formation of Janus drops indicated a reduction of the interfacial free energy in the process and the interfacial energy difference between separate and Janus drops was calculated for an appropriate range of interfacial tensions and for all oil fractions. The calculations enabled a distinction of the decrease due to interfacial area changes from the reduction of interfacial tensions per se, with the latter only a minor fraction. Figure

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Experimental investigation of bubble and drop formation at submerged orifices

The aim of this study was to investigate bubble/drop formation at a single submerged orifice in stagnant Newtonian fluids and to gain qualitative understanding of the formation mechanism. The effects of various governing parameters were studied. Formation behavior of bubbles and drops in Newtonian aqueous solutions were investigated experimentally under different operating conditions with various orifices. The results show that the volume of the detached dispersed phase (bubble or drop) increases with the viscosity of the continuous phase (or dispersion medium), surface tension, orifice diameter, and dispersed phase flow rate. A PIV system was employed to measure the velocity flow field quantitatively during the bubble/drop formation, giving interesting information useful for the elucidation of the fundamental formation process at the orifice. It was revealed that the orifice shape strongly influences the size of the bubble formed. Furthermore, based on a simple mass balance, a general correlation successfully predicting both bubble and drop sizes has been proposed.