Droplet-based microfluidics

Droplet-based microfluidics manipulate discrete volumes of fluids in immiscible phases with low Reynolds number and laminar flow regimes. Interest in droplet-based microfluidics systems has been growing substantially in past decades. Microdroplets offer the feasibility of handling miniature volumes (μl to fl) of fluids conveniently, provide better mixing, encapsulation, sorting, sensing and are suitable for high throughput experiments. Two immiscible phases used for the droplet based systems are referred to as the continuous phase (medium in which droplets flow) and dispersed phase (the droplet phase). Droplet-based microfluidics manipulate discrete volumes of fluids in immiscible phases with low Reynolds number and laminar flow regimes. Interest in droplet-based microfluidics systems has been growing substantially in past decades. Microdroplets offer the feasibility of handling miniature volumes (μl to fl) of fluids conveniently, provide better mixing, encapsulation, sorting, sensing and are suitable for high throughput experiments. Two immiscible phases used for the droplet based systems are referred to as the continuous phase (medium in which droplets flow) and dispersed phase (the droplet phase). In order for droplet formation to occur, two immiscible phases, referred to as the continuous phase (medium in which droplets are generated) and dispersed phase (the droplet phase), must be used. The size of the generated droplets is mainly controlled by the flow rate ratio of the continuous phase and dispersed phase, interfacial tension between two phases, and the geometry of the channels used for droplet generation. Droplets can be formed both passively and actively. Active droplet formation (electric, magnetic, centrifugal) often uses similar devices to passive formation but requires an external energy input for droplet manipulation. Passive droplet formation tends to be more common than active as it produces similar results with simpler device designs. Generally, three types of microfluidic geometries are utilized for passive droplet generation: (i) Cross-Flowing, (ii) Flow Focusing, and (iii) Co-Flowing. Droplet based microfluidics often operate under low Reynold’s numbers to ensure laminar flow within the system. Droplet size is often quantified with coefficient of variation (CV) as a description of the standard deviation from the mean droplet size. Each of the listed methods provide a way to generate microfluidic droplets in a controllable and tunable manner with proper variable manipulation. Cross-flowing is a passive formation method that involves the continuous and aqueous phases running at an angle to each other. Most commonly, the channels are perpendicular in a T-shaped junction with the dispersed phase intersecting the continuous phase; other configurations such as a Y-junction are also possible. The dispersed phase extends into the continuous and is stretched until shear forces break off a droplet. In a T-junction, droplet size and formation rate are determined by the flow rate ratio and capillary number. The capillary number relates the viscosity of the continuous phase, the superficial velocity of the continuous phase, and the interfacial tension. Typically, the dispersed phase flow rate is slower than the continuous flow rate. T-junction formation can be further applied by adding additional channels, creating two T-junctions at one location. By adding channels, different dispersed phases can be added at the same point to create alternating droplets of different compositions. Droplet size, usually above 10 μm, is limited by the channel dimensions and often produces droplets with a CV of less than 2% with a rate of up to 7 kHz. Flow focusing is a usually passive formation method that involves the dispersed phase flowing to meet the continuous phase typically at an angle (nonparallel streams) then undergoing a constraint that creates a droplet. This constraint is generally a narrowing in the channel to create the droplet though symmetric shearing, followed by a channel of equal or greater width. As with cross-flowing, the continuous phase flow rate is typically higher than the dispersed phase flow rate. Decreasing the flow of the continuous phase can increase the size of the droplets. Flow focusing can also be an active method with the constraint point being adjustable using pneumatic side chambers controlled by compressed air. The movable chambers act to pinch the flow, deforming the stream and creating a droplet with a changeable driving frequency. Droplet size is usually around several hundred nanometers with a CV of less than 3% and a rate of up to several hundred Hz to tens of kHz. Co-flowing is a passive droplet formation method where the dispersed phase channel is enclosed inside a continuous phase channel. At the end of the dispersed phase channel, the fluid is stretched until it breaks from shear forces and forms droplets either by dripping or jetting. Dripping occurs when capillary forces dominate the system and droplets are created at the channel endpoint. Jetting occurs, by widening or stretching, when the continuous phase is moving slower, creating a stream from the dispersed phase channel opening. Under the widening regime, the dispersed phase is moving faster than the continuous phase causing a deceleration of the dispersed phase, widening the droplet and increasing the diameter. Under the stretching regime, viscous drag dominates causing the stream to narrow creating a smaller droplet. The effect of the continuous phase flow rate on the droplet size depends on whether the system is in a stretching or widening regime thus different equations must be used to predict droplet size. Droplet size is usually around several hundred nanometers with a CV of less than 5% and a rate of up to tens of kHz. The benefits of microfluidics can be scaled up to higher throughput using larger channels to allow more droplets to pass or by increasing droplet size. Droplet size can be tuned by adjusting the rate of flow of the continuous and disperse phases, but droplet size is limited by the need to maintain the concentration, inter-analyte distances, and stability of microdroplets. Thus, increased channel size becomes attractive due to the ability to create and transport a large number of droplets, though dispersion and stability of droplets become a concern. Finally, thorough mixing of droplets to expose the greatest possible number of reagents is necessary to ensure the maximum amount of starting materials react. This can be accomplished by using a windy channel to facilitate unsteady laminar flow within the droplets. Microscale reactions performed in droplet-based applications conserve reagents and reduce reaction time all at kilohertz rates. Reagent addition to droplet microreactors has been a focus of research due to the difficulty of achieving reproducible additions at kilohertz rates without droplet-to-droplet contamination. Reagents can be added at the time of droplet formation through a “co-flow” geometry. Reagent streams are pumped in separate channels and join at the interface with a channel containing the continuous phase, which shears and creates droplets containing both reagents. By changing the flow rates in reagent channels, reagent ratios within a droplet can be controlled. The fusion of droplets with different contents can also be exploited for reagent addition. Electro-coalescence merges pairs of droplets by applying an electric field to temporarily destabilize the droplet-droplet interface to achieve reproducible droplet fusion in surfactant-stabilized emulsions. Electro-coalescence requires droplets (which are normally separated by the continuous phase) to come into contact. By manipulating droplet size in separate streams, differential flow of droplet sizes can bring droplets into contact before merging.