High throughput production of single core double emulsions in a parallelized microfluidic device

Double emulsions are useful templates for microcapsules and complex particles, but no method yet exists for making double emulsions with both high uniformity and high throughput. We present a parallel numbering-up design for microfluidic double emulsion devices, which combines the excellent control of microfluidics with throughput suitable for mass production. We demonstrate the design with devices incorporating up to 15 dropmaker units in a two-dimensional or three-dimensional array, producing single-core double emulsion drops at rates over 1 kg day(-1) and with diameter variation less than 6%. This design provides a route to integrating hundreds of dropmakers or more in a single chip, facilitating industrial-scale production rates of many tons per year.     

Biocompatible and pH-Responsive Colloidal Surfactants with Tunable Shape for Controlled Interfacial Curvature

Molecular-surfactant-stabilized emulsions are susceptible to coalescence and Ostwald ripening. Amphiphilic particles, which have a much stronger anchoring strength at the interface, could effectively alleviate these problems to form stable Pickering emulsions. Herein, we describe a versatile method to fabricate biocompatible amphiphilic dimer particles through controlled coprecipitation and phase separation. The dimer particles consist of a hydrophobic PLA bulb and a hydrophilic shellac–PEG bulb, thus resembling nonionic molecular surfactants. The size and diameter ratio of the dimer particles are readily tunable, providing flexible control over the water/oil interfacial curvature and thus the type of emulsion. The particle-stabilized emulsions were stable for a long period of time and could be destabilized through a pH-triggered response. The biocompatible amphiphilic dimer particles with tunable morphology and functionality are thus ideal colloidal surfactants for various applications.     

Breakup of a Multiple Emulsion Drop in a Uniform Electric Field

The steady deformation and breakup of emulsion drops in a uniform electric field are considered experimentally. Due to the low volume fraction of inner drops, the emulsions can be effectively assumed as Newtonian fluids with spatial nonuniformity. The measurements of the electrical properties show that the oil-in-water (o/w) emulsion drop behaves like a conducting drop. On the other hand, the water-in-oil (w/o) emulsion drops can be regarded as inhomogeneous leaky dielectric drops. It is found that the viscosity ratio is not an important parameter within the small deformation limit and breakup mode of the o/w emulsion drops. In the case of w/o emulsion drops, however, the breakup mode depends on the viscosity ratio. Inherent nonuniformity of the emulsion drops makes drop more deformable and unstable. The tip-streaming is the dominant breakup mode of o/w emulsion drops when the nonuniformity of drop phase is appreciable. Copyright 1999 Academic Press.     

Biocompatible and pH‐Responsive Colloidal Surfactants with Tunable Shape for Controlled Interfacial Curvature

Molecular‐surfactant‐stabilized emulsions are susceptible to coalescence and Ostwald ripening. Amphiphilic particles, which have a much stronger anchoring strength at the interface, could effectively alleviate these problems to form stable Pickering emulsions. Herein, we describe a versatile method to fabricate biocompatible amphiphilic dimer particles through controlled coprecipitation and phase separation. The dimer particles consist of a hydrophobic PLA bulb and a hydrophilic shellac–PEG bulb, thus resembling nonionic molecular surfactants. The size and diameter ratio of the dimer particles are readily tunable, providing flexible control over the water/oil interfacial curvature and thus the type of emulsion. The particle‐stabilized emulsions were stable for a long period of time and could be destabilized through a pH‐triggered response. The biocompatible amphiphilic dimer particles with tunable morphology and functionality are thus ideal colloidal surfactants for various applications.     

Preparation of PEG-modified urethane acrylate emulsion and its emulsion polymerization

In order to improve stability and reduce droplet size, the PEG-modified urethane acrylates were synthesized by the reaction of polyethylene glycol (PEG) with residual isocyanate groups of urethane acrylate to incorporate hydrophilic groups into the molecular ends. The droplet sizes of the PEG-modified urethane acrylate emulsions were much smaller than those of unmodified urethane acrylate emulsions at the same surfactant composition, and the droplet sizes of these emulsions were significantly effected not by surfactant compositions and types, but by the reaction molar ratio of PEG, because the urethane acrylate containing polyoxyethylene groups as terminal groups aided the interfacial activity of surfactant molecules and acted as a polymeric surfactant. The actions of PEG-modified urethane acrylate were confirmed by the investigation of adsorption of urethane acrylate in a water/benzene interface.For polymerization of emulsions, the stability of emulsion in the process of emulsion polymerization was changed by the type of surfactant or initiator. In the case of emulsion polymerization with a water soluble initiator (K₂S₂O₈), the emulsions prepared using TWEEN 60 were broken in the process of polymerization. However, polymerization of these emulsions could be carried out using an oil soluble initiator (AIBN). The conversion of emulsion polymerization changed with the type of urethane acrylates, that is, the reaction molar ratio of PEG to 2-HEMA.     

Biocompatible surfactants for water-in-fluorocarbon emulsions

Drops of water-in-fluorocarbon emulsions have great potential for compartmentalizing both in vitro and in vivo biological systems; however, surfactants to stabilize such emulsions are scarce. Here we present a novel class of fluorosurfactants that we synthesize by coupling oligomeric perfluorinated polyethers (PFPE) with polyethyleneglycol (PEG). We demonstrate that these block copolymer surfactants stabilize water-in-fluorocarbon oil emulsions during all necessary steps of a drop-based experiment including drop formation, incubation, and reinjection into a second microfluidic device. Furthermore, we show that aqueous drops stabilized with these surfactants can be used for in vitro translation (IVT), as well as encapsulation and incubation of single cells. The compatability of this emulsion system with both biological systems and polydimethylsiloxane (PDMS) microfluidic devices makes these surfactants ideal for a broad range of high-throughput, drop-based applications.     

Morphology control of magnetic latex particles prepared from oil in water ferrofluid emulsion

The use of magnetic latex particles as solid support in biomedical applications is favourable when homogeneous and well-defined core–shell polymer particles are used. Accordingly, this paper concerns with the synthesis of magnetic poly(styrene–divinylbenzene) latex particles using emulsion polymerization of styrene (St) and divinylbenzene (DVB) monomers in the presence of preformed oil in water organic ferrofluid emulsion droplets as seed. The key parameters which affect on formation and morphology of the prepared magnetic latexes were investigated, including type of magnetic emulsion, St/DVB monomers ratio, DVB amount, type of initiator and surfactant nature. In this study, two different magnetic emulsions were used, low and high octane content magnetic emulsions. The magnetic emulsions were stabilized using different types of surfactants including AP, Triton X 405 and SDS. In addition, four different initiators, including AIBN, V50, ACPA and KPS were examined. The morphology of the prepared magnetic latexes was investigated using transmission electron microscopy. In addition, particle size and size distribution, magnetic content and magnetic properties of the prepared magnetic latexes were also examined, using various techniques, e.g. dynamic light scattering, thermal gravimetric analysis and vibrating sample magnetometer, respectively. The results showed that the morphology type (Janus like, moon like and/or core–shell) of the prepared magnetic latex particles could be controlled depending mainly on the used formulation. In fact, the use of styrene monomer leads to anisotropic morphology. Whereas, the progressive use of DVB in presence of KPS intiator leads to a well-defined magnetic core and polymer shell structure.

A dynamic light scattering study of the influence of the phospholipid concentration in a model perfluorocarbon emulsion

Perfluorohexyl iodide in water emulsions stabilised by phospholipids were prepared by microfluidisation. Photon correlation spectroscopy revealed that the particle size distributions of these emulsions were bimodal. Centrifugation experiments indicated that the larger mode was caused by the emulsion droplets, whereas the smaller mode was due to phospholipid vesicles formed from the excess amount of phospholipid emulsifier. Comparing the particle size distributions of perfluorocarbon emulsions containing different amounts of phospholipids, it could be concluded that emulsions with a phospholipid/fluorocarbon ratio of 2% at the most were emulsifier limited, whereas those with a ratio of at least 5% were energy input limited.     

Screening of the effect of surface energy of microchannels on microfluidic emulsification

We report the results of a systematic study of the effect of the surface energy of the walls of microchannels on emulsification in parallel flow-focusing microfluidic devices. We investigated the formation of water-in-oil (W/O) and oil-in-water (O/W) emulsions and found that the stability of microfluidic emulsification depends critically on the preferential wetting of the walls of the microfluidic device by the continuous phase. The condition for stable operation of the device is, however, different than that of complete wetting of the walls by the continuous phase at equilibrium. We found that W/O emulsions form when the advancing contact angle of water on the channel wall exceeds theta approximately 92 degrees. This result is unexpected because at equilibrium even for theta < 92 degrees the microchannels would be completely wet by the organic phase. The criterion for the formation of W/O emulsions (theta > 92 degrees) is thus more stringent than the equilibrium conditions. Conversely, we observed the stable formation of O/W emulsions for theta < 92 degrees, that is, when the nonequilibrium transition to complete wetting by oil takes place. These results underlie the importance of pinning and the kinetic wetting effects in microfluidic emulsification. The results suggest that the use of parallel devices can facilitate fast screening of physicochemical conditions for emulsification.     

Physicochemical properties of structured phosphatidylcholine in drug carrier lipid emulsions for drug delivery systems

Drug carrier emulsions were prepared with structured phosphatidylcholine (PC-LM) which has both a long hydrocarbon chain and a medium hydrocarbon chain, and the characteristics of PC-LM as an emulsifier were investigated by measuring the creaming ratio, the surface tension of the emulsion system, and the mean particle size and zeta potential of the oil droplets in emulsions. The emulsion prepared with PC-LM as an emulsifier kept the condition and the ratio of separation was lower than those with purified egg yolk lecithin (PEL). The mean particle size of the emulsion prepared with PC-LM was smaller than that with PEL when using only sonication, approximately 250 nm. When using a high-pressure homogenizer after sonication, the mean emulsion size with PC-LM was also smaller than with PEL, approximately 150 nm. The surface tension of the various emulsions and the zeta potential of the emulsion droplets were measured to investigate the stability of the systems. In emulsions with PC-LM or PEL, the surface tension as an index of stability increased as the pressure of the homogenizer increased. Moreover, the zeta potential of the emulsion droplets prepared with PC-LM also increased with an increase in pressure of the homogenizer. As a result, it was found that the drug carrier emulsion prepared with PC-LM had significant advantages in terms of stability and mean diameter. We considered it could be used for the preparations of nanoparticle dispersion systems in drug delivery systems.     

Shape-controlled production of biodegradable calcium alginate gel microparticles using a novel microfluidic device

In this paper we describe a novel method of manufacturing shape-controlled calcium alginate gel microparticles in a microfluidic device. Both manufacturing shape-controlled microparticles and synthesizing hydrogel microparticles could be performed simultaneously in the microfluidic device. The novel microfluidic device comprised of two individual flow-focusing channels and a synthesizing channel was successfully applied as a continuous microfluidic reactor to synthesize gel microparticles with size and shape control. By passive control based on the microchannel geometric confinement and liquid-phase flow rates, we succeeded in producing monodisperse sodium alginate microparticles with diverse shapes (such as plugs, disks, microspheres, rods, and threads) in the flow-focusing channels of the microfluidic device. The shape and size of the sodium alginate microparticles could be tuned by adjusting the flow rates of the various streams. Further stages of the chemical reaction could be initiated by mixing sodium alginate microparticles and calcium chloride (CaCl2) solution in the synthesizing channel. The shapes of the sodium alginate microparticles could be permanently preserved by the synthesis of calcium alginate gel microparticles. The preparation conditions of size- and shape-controlled calcium alginate microparticles and influence factors were studied.     

Water-dispersible non-aqueous emulsions stabilized by a poly(butadiene)-b-poly(2-vinylpyridine) block copolymer

Submicron non-aqueous emulsions, of interest for biomedical and cosmetic formulations, were developed for the system comprising poly(ethylene glycol) (PEG) 400 and Miglyol 812, an enzymatic degradable liquid glycerine ester. These emulsions, with PEG 400 as continuous phase and Miglyol 812 droplets, in the size range of 200 nm, were stabilized by a poly(butadiene)-b-poly(2-vinylpyridine) (PBut-b-P2VP) block copolymer with a composition close to 50/50 wt%. The droplet size, stability and the rheological characteristics were examined as a function of the copolymer concentration. An original aspect of these anhydrous emulsions, with a water miscible continuous phase, is their water dispersibility without additional surfactant. In fact, the initial anhydrous emulsion is sterically stabilized and after water addition at low pH, the protonated P2VP sequence of the copolymer provides the electro-steric stabilization. This oil-in-water emulsion is characterized by sub micron sized Miglyol 812 droplets in an aqueous phase of PEG 400 and water at pH 1.     

Preparation of starch and laponite co-stabilized alkenyl succinic anhydride emulsions for paper sizing

Stable alkenyl succinic anhydride (ASA) emulsions with approximately 25% of ASA were prepared by using native maize starch and laponite particles as stabilizers. The morphology, sizing performance, and storage stability of the as-prepared ASA emulsions were evaluated. It was surprisingly found that the introduction of laponite particles could significantly improve the emulsion stability, reduce the emulsion droplet size, and enhance the sizing performance, while the occurrence of native maize starch depresses the deterioration of the ASA emulsion in sizing performance with increasing emulsion storage time.     

On-chip generation of microbubbles as a practical technology for manufacturing contrast agents for ultrasonic imaging

This paper presents a new manufacturing method to generate monodisperse microbubble contrast agents with polydispersity index (sigma) values of <2% through microfluidic flow-focusing. Micron-sized lipid shell-based perfluorocarbon (PFC) gas microbubbles for use as ultrasound contrast agents were produced using this method. The poly(dimethylsiloxane) (PDMS)-based devices feature expanding nozzle geometry with a 7 microm orifice width, and are robust enough for consistent production of microbubbles with runtimes lasting several hours. With high-speed imaging, we characterized relationships between channel geometry, liquid flow rate Q, and gas pressure P in controlling bubble sizes. By a simple optimization of the channel geometry and Q and P, bubbles with a mean diameter of <5 microm can be obtained, ideal for various ultrasonic imaging applications. This method demonstrates the potential of microfluidics as an efficient means for custom-designing ultrasound contrast agents with precise size distributions, different gas compositions and new shell materials for stabilization, and for future targeted imaging and therapeutic applications.     

Study of emulsion polymerization stabilized by amphiphilic polymer nanoparticles

Submicron-sized polystyrene (PS) microspheres with a relatively narrow particle size distribution can be easily produced through emulsion polymerization induced by γ-ray at room temperature using a new type of amphiphilic cross-linked poly(stearyl methacrylate-co-acrylamide-co-acrylic acid) particles as stabilizer. The properties of these amphiphilic particles were described, including morphology, size, ζ potential, and contact angles. The effect of the pH value and the content of amphiphilic particles on the formation and stability of emulsions were also investigated. Meanwhile, the obtained PS microspheres were characterized by Fourier transform infrared spectroscopy, transmission electron microscopy, scanning electron microscopy and X-ray photoelectron spectroscopy. In addition, through observing the morphology and size of emulsion droplets at different times under an optical microscope, we found it is interesting that Pickering emulsions formed initially disappeared gradually, which is different from the common Pickering emulsions stabilized by inorganic particles. Thus, the mechanism was further discussed.     

A technique to estimate the apparent surface pressure of emulsion particles using apolipoproteins as probes

The apparent pressures in the surface monolayer of emulsion particles can be estimated by comparing the absorption of an apolipoprotein to planar lipid monolayers and to emulsions. Lipids are spread at an air-water interface in a Pockels/Langmuir surface balance and the adsorption of [¹⁴C]-labeled apolipoproteins placed in the subphase is studied as a function of surface pressure using the surface radioactivity method. An apoprotein surface concentration/initial lipid surface pressure curve (Γ/gp_i) is constructed. The maximum apolipoprotein surface concentration Γ_e of emulsions is derived from standard emulsion/apolipoprotein binding isotherms. The apparent emulsion surface pressure is then estimated by comparing Γ_e to the Γ/π_i curve. Apolipoprotein A-I has been used as an example of a probe to estimate the effective surface pressure in ~1000 Å diameter egg yolk phosphatidylcholine/cholesterol/triolein emulsion particles. When the cholesterol content of emulsions is low, the surface pressure of the emulsion is about 17 dyne cm⁻¹. At high cholesterol concentrations (0.49 cholesterol/phospholipid mole ratio) the surface pressure is increased to 25 dyne cm⁻¹. The addition of the maximum amounts of apoA-I to these particles raises the effective surface pressure of the emulsion to about 30 dyne cm⁻¹ and stabilizes the particles.     

Designer polymer-based microcapsules made using microfluidics

Filled microcapsules made from double emulsion templates in microfluidic devices are attractive delivery systems for a variety of applications. The microfluidic approach allows facile tailoring of the microcapsules through a large number of variables, which in turn makes these systems more challenging to predict. To elucidate these dependencies, we start from earlier theoretical predictions for the size of double emulsions and present quantitative design maps that correlate parameters such as fluid flow rates and device geometry with the size and shell thickness of monodisperse polymer-based capsules produced in microcapillary devices. The microcapsules are obtained through in situ photopolymerization of the middle oil phase of water-in-oil-in-water double emulsions. Using polymers with selected glass transition temperatures as the shell material, we show through single capsule compression testing that hollow capsules can be prepared with tunable mechanical properties ranging from elastomeric to brittle. A quantitative statistical analysis of the load at rupture of brittle capsules is also provided to evaluate the variability of the microfluidic route and assist the design of capsules in applications involving mechanically triggered release. Finally, we demonstrate that the permeability and microstructure of the capsule shell can also be tailored through the addition of cross-linkers and silica nanoparticles in the middle phase of the double emulsion templates.     

A new emulsion method to synthesize well-defined mesoporous particles

A new emulsion method for preparing ordered mesoporous materials with polymer PEG as the swelling agent has been explored in the present work. The synthesis conditions including the chain length and the PEG concentration, the duration of aging, the kind of emulsion, and the time when the swelling agents were added to the reaction system are discussed. The results show that with the advantage of the emulsion method, the nucleation and growth were controlled very well. The nicely spherical particles produced by the emulsion method were more uniform and less prone to agglomerate than those produced through the hydrothermal method. When different MW PEG were added as swelling agents, the pore size changed little: it was centered around 4 nm and had a narrow distribution. When different concentrations of PEG were applied, BET surface area, pore size, and pore volume changed. To summarize, in the formation of mesoporous materials, polymers such as PEG can not only control the pore size from 3 to 70 nm through variation of concentration, but also regulate the structures and improve the morphology of particles by the chain length of polymers. By adjusting the time of addition of the swelling agents, a poroshell mesoporous material was prepared. This method is particularly important for those applications that strictly require particle uniformity, such as chromatography separation.     

Monodisperse w/w/w Double Emulsion Induced by Phase Separation

We develop an approach to fabricate monodisperse water-in-water-in-water (w/w/w) double emulsion in microfluidic devices. A jet of aqueous solution containing two incompatible solutes, dextran and polyethylene glycol (PEG), is periodically perturbed into water-in-water (w/w) droplets. By extracting water out of the w/w droplet, the solute concentrations in the droplet phase increase; when the concentrations exceed the miscibility limit, the droplet phase separates into two immiscible phases. Consequently, PEG-rich droplets are formed within the single emulsion templates. These PEG-rich droplets subsequently coalesce with each other, resulting in transiently stable w/w/w double emulsions with a high degree of size uniformity. These double emulsions are free of organic solvents and thus are ideal for use as droplet-vessels in protein purification, as microreactors for biochemical reactions, and as templates for fabrication of biomaterials.     

Experimental study on dynamic interfacial tension with mixture of SDS-PEG as surfactants in a coflowing microfluidic device

In this work, a coflowing microfluidic device was used to determine the influence of different mixed sodium dodecyl sulfate (SDS)-poly(ethylene glycol) (PEG) compound systems on dynamic interfacial tension and, by extension, corresponding emulsion droplet sizes. The aqueous solutions were used as the continuous phase in the microfluidic device, while octane was used as the organic dispersed phase. Combined SDS-PEG systems lower the interfacial tension more than either component can alone up to the critical aggregation concentration (CAC) of SDS. Octane droplet sizes produced in the microfluidic device using combined SDS-PEG systems were smaller than those produced using SDS alone, and a reduction in dynamic interfacial tension as determined by drop size followed a pattern similar to that observed in the static case (PEG4000 > PEG600 > PEG400 > PEG200 > PEG8000) with the exception of PEG8000. Finally, a previously formulated model relating interfacial tension to droplet size was used to estimate the dynamic interfacial tensions in the microfluidic device.