Fast mixing remains a major challenge in droplet-based microfluidics. The low Reynolds number operating regime typical of most microfluidic devices signify laminar and orderly flows that are devoid of any inertial characteristics. To increase mixing rates in droplet-based devices, a novel technique is presented that uses a high Reynolds number gaseous phase for droplet generation and transport and promotes mixing through binary droplet collisions at velocities near 1m/s. Control of multiple gas and liquid streams is provided by a newly constructed microfluidic test bed that affords the stringent flow stability required for generating liquid droplets in gaseous flows. The result is droplet production with size dispersion and generation frequencies not previously achievable. Limitations of existing mixing diagnostic methods have led to the development of a new measurement technique for measuring droplet collision mixing in confined microchannels. The technique employs single fluorophore laser-induced fluorescence, custom image processing, and meaningful statistical analysis for monitoring and quantifying mixing in high-speed droplet collisions. Mixing information is revealed through three governing statistics that that separate the roles of convective rearrangement and molecular diffusion during the mixing process. The end result is a viewing window into the rich dynamics of droplet collisions with spatial and temporal resolutions of 1μm and 25μs, respectively. Experimental results obtained across a decade vi of Reynolds and Peclet numbers reveal a direct link between droplet mixing time and the collision convective timescale. Increasing the collision velocity or reducing the collision length scale is the most direct method for increasing droplet mixing rates. These characteristics are complemented by detaching droplets under inertial conditions, where increasing the Reynolds number of the continuous gaseous phase generates and transports smaller droplets at faster rates. This work provides valuable insight into the emerging field of two-phase gas-liquid microfluidics and opens the door to fundamental research possibilities not offered by traditional oil-based architectures. / text

The development of a novel method of droplet levitation to be employed in lab-on-a-chip (LOC) applications relies upon the mechanism of thermocapillary convection (due to the temperature dependence of surface tension) to drive a layer of lubricating gas between droplet and substrate. The fact that most droplets of interest in LOC applications are aqueous in nature, coupled with the fact that success in effecting thermocapillary transport in aqueous solutions has been limited, has led to the development of a technique for the controlled encapsulation of water droplets within a shell of inert silicone oil. These droplets can then be transported, virtually frictionlessly, resulting in ease of transport due to the lack of friction as well as improvements in sample cross-contamination prevention for multiple-use chips. Previous reports suggest that levitation of spherical O(nL)-volume droplets requires squeezing to increase the apparent contact area over which the pressure in the lubricating layer can act allowing sufficient opposition to gravity. This research explores thermocapillary levitation and translation of O(nL)-volume single-phase oil droplets; generation, capture, levitation, and translation of O(nL)-volume oil-encapsulated water droplets to demonstrate the benefits and applicability to LOC operations.

Introduced in 1991, solid ink color printing technology is widely used in the office printing, prepress proofing, and wide format color printing markets. Ink droplets are first deposited on a rotating drum and then transferred to paper to reproduce images with high print quality. The objective of this thesis is to develop scientific knowledge of ink droplet deposition, which is needed for precise image buildup on the drum surface. The first problem studied in the thesis is droplet formation from the printhead with varied working voltages and jetting frequencies. Attention is paid to the formation of satellite droplets, the contraction of ligaments and the startup of high frequency jetting. The jetting conditions for obtaining consistent droplet generation with satellites are determined. A theoretical model is developed to predict the lifetime of ligaments. The second problem we studied is the deposition of single droplets on solid surfaces. The surface texture and final shape of deposited droplets are correlated with impact conditions, which include printhead temperature, substrate temperature, distance from printhead to substrate, and the type of substrate surface. An analytical model is developed to evaluate the interaction of oscillation and viscous damping in the droplet during impact. The third problem covered in the thesis is the deposition of multiple ink droplets on the drum surface. Interaction between droplets causes drawback effect, which degrades print quality. We define a parameter to quantify the drawback effect with varied deposition conditions. A simple model is provided to predict conditions for making continuous lines based on the results of two ink droplets deposition. To understand the hydrodynamics in causing drawback effect, a series of experiments using large liquid droplets are carried out. Focus is put on the evolution of spread length and dynamics of contact line. Correlations for maximum and minimum spread lengths are developed, which are used to reveal the cause of drawback effect in the deposition of ink droplets.

Introduced in 1991, solid ink color printing technology is widely used in the office printing, prepress proofing, and wide format color printing markets. Ink droplets are first deposited on a rotating drum and then transferred to paper to reproduce images with high print quality. The objective of this thesis is to develop scientific knowledge of ink droplet deposition, which is needed for precise image buildup on the drum surface. The first problem studied in the thesis is droplet formation from the printhead with varied working voltages and jetting frequencies. Attention is paid to the formation of satellite droplets, the contraction of ligaments and the startup of high frequency jetting. The jetting conditions for obtaining consistent droplet generation with satellites are determined. A theoretical model is developed to predict the lifetime of ligaments. The second problem we studied is the deposition of single droplets on solid surfaces. The surface texture and final shape of deposited droplets are correlated with impact conditions, which include printhead temperature, substrate temperature, distance from printhead to substrate, and the type of substrate surface. An analytical model is developed to evaluate the interaction of oscillation and viscous damping in the droplet during impact. The third problem covered in the thesis is the deposition of multiple ink droplets on the drum surface. Interaction between droplets causes drawback effect, which degrades print quality. We define a parameter to quantify the drawback effect with varied deposition conditions. A simple model is provided to predict conditions for making continuous lines based on the results of two ink droplets deposition. To understand the hydrodynamics in causing drawback effect, a series of experiments using large liquid droplets are carried out. Focus is put on the evolution of spread length and dynamics of contact line. Correlations for maximum and minimum spread lengths are developed, which are used to reveal the cause of drawback effect in the deposition of ink droplets.

Drop-on-demand (DOD) inkjet print-head has a major share of the market due to simplicity and feasibility of miniature system. The efficiency of droplet generation from DOD print-head is a result of several factors, include viscosity, surface tension, nozzle size, density, driving waveform (wave shape, frequency, and amplitude), etc. Key roles in the formation and behavior of liquid jets and drops combine three dimensionless groups: Reynolds number, Weber number and Ohnesorge number. These dimensionless groups provide some bounds to the “printability” of the liquid. Adequate understanding of these parameters is essential to improve the quality of droplets and provide guidelines for the process optimization. This thesis research describes the application of computational fluid dynamics (CFD) to simulate the creation and evolution process of droplet generation and transport of a highly viscous Newtonian fluid. The flow field is governed by unsteady Navier-Stokes equations. Volume of Fluid (VOF) model is used to solve this multi-phase (liquid-gas) problem.

Droplet microfluidics is a promising field since it overcomes many of the limitations of single phase microfluidic systems. The improved mixing time scale, the increase of number of samples and the isolation of droplets are some of its virtues. The core of droplet microfluidics is a two-phase flow condition that is subjected to scaling of the confining geometry. With the scaling the complexities of the flow phenomena arise. For that reason both the processes of droplet generation and transport are not fully understood for various flow and fluid conditions. The work in this thesis aims to experimentally examine droplet generation and transport in microchannels for flow and fluid conditions that are experimentally challenging to perform. Examination of droplet generation in a T-junction microchannel design was performed with a quantitative velocity field approach known as micro particle image velocimetry (μPIV). The studies on droplet generation focused on very fast generation regimes, namely transition and dripping that have not been studied for a T-junction design. This achievement was accomplished because of the development of a fast optical detection and triggering system that allowed for acquiring images of different identical droplets at the same position. μPIV results indicate that the quantitative velocity field patterns of different regimes share some similarities. The filling stage in the transition and dripping regimes had some resemblance in their velocity patterns. The velocity patterns for the start of droplet pinch-off were alike for the squeezing and transition regimes. Furthermore, the presence of a surfactant in the droplet phase above the critical micelle concentration (CMC) did not have an effect on the general velocity patterns as long as the capillary number Ca was matched with the no-surfactant condition. The studies of hydrodynamic properties of droplet transport were performed in hard materials to avoid cumulative error sources, such as material pressure compliance and swelling effects. The project had several parts: designing a microchannel network that allowed studying the hydrodynamic properties of small droplets, surface treatments of the channel material for stable droplet generation and examining the hydrodynamics of small liquid droplets with sizes that have not been reported in the literature. The studies examined effects of changing the interfacial tension, viscosity, and flow conditions on the transport of droplets. The experimental results from the hydrodynamic transport studies indicated that for the droplet sizes that were examined the pressure drop of droplets was affected by the capillary number Ca and length of the droplet Ld. Also, the presence of surfactants altered the hydrodynamic properties of droplets. At a high concentration of surfactants the droplets pressure drop was reduced significantly. Moreover, the type of surfactant affected the magnitude of the pressure drop. Experimental results indicate that if the concentration of surfactants was very low (below CMC) it did not have an effect on the droplet excess pressure. These findings are important to consider in designing droplet microfluidic systems with complex channel networks that involve droplet sorting, splitting, and merging for droplets that contain surfactants.

<p>Microdroplets find use in a variety of applications ranging from chemical synthesis to biological analysis. However, commercial use of microdroplets has been stymied in many applications, as current devices lack one or more of the critical features such as precise and dynamic control of the droplet size, high throughput and easy fabrication. This work involves design, fabrication and characterization of a microdroplet generating device that uses low cost fabrication, allows dynamic control of the droplet size and achieves parallelized droplet generation for high throughput.</p> <p>Dynamic droplet size control by DC electric field has been demonstrated with the device. By varying the potential from 300 V to 1000 V, the droplet size can change from 140 microns to around 40 microns . The transition of the droplet size just takes few seconds. Parallelized droplet generation has also been demonstrated. The standard deviation of the droplet size is lower than 4% for the three-capillary device and lower than 6% for the five-capillary device under different operating conditions. Highest throughput of 0.75 mL/hour is achieved on the five-capillary device. It has been show that this proposed device has a better performance than the existing PDMS based parallel droplet generating devices. A theoretical model of the droplet generating process has also been developed which is able to predict the droplet size at various potentials. The theoretical results are in good agreement with experimental ones.</p> / Master of Applied Science (MASc)

During this investigation, vibration induced droplet generation from a liquid layer was examined as a means for achieving high heat flux evaporative cooling. Experiments were performed in which droplets were generated from a liquid layer using a submerged vibrating piezoelectric driver. Parameters determined during this investigation of droplet generation were droplet mass flow rate, droplet size, driver frequency, driver voltage, and liquid layer thickness. The results showed that as the liquid layer thickness was increased, the frequencies and frequency ranges at which droplet generation occurred decreased. Droplet mass flow rates were varied by adjustment of the liquid layer thickness, driver frequency, and driver voltage. The dependence of the drivers displacement, velocity, and acceleration on frequency and voltage was determined, and the drivers frequency response was related to the occurrence of droplet generation. As a result, a frequency-dependent dimensionless parameter was proposed as a method for predicting droplet generation from the surface of the liquid layer. The dimensionless parameter is a combination of the Froude number and the dimensionless driver acceleration. The measurements have shown that droplet generation occurs when the parameter is between distinct upper and lower bounds. An analytical heat transfer model of a droplet cooling heat transfer cell was developed to simulate the performance of such a cell for thermal management applications. Using droplet flow rates determined as functions of driver voltage, driver frequency, liquid layer thickness, and interception distance, the heat transfer rate of a droplet cooling heat transfer cell was predicted for varied heat source temperatures and cell conditions. The heat transfer model was formulated in such a way as to accommodate a number of parameter variations that can be used for the design of a simple heat transfer cell. The model was used to determine the effect of droplet cooling on the heat transfer rate from a heated surface, but it can also be used to determine the influence of any of the other embodied parameters that may be of interest for thermal management applications.

This study is devoted to some of the most important issues for advancing inkjet printing for possible application in the coating industry with a focus on piezoelectric droplet on demand (DOD) inkjet technology. Current problems, as embodied in liquid filament breakup along with satellite droplet formation and reduction in droplet sizes, are discussed and then potential solutions identified. For satellite droplets, it is shown that liquid filament break-up behavior can be predicted by using a combination of two pi-numbers, including the Weber number, We and the Ohnesorge number, Oh, or the Reynolds number, Re, and the Weber number, We. All of these are dependent only on the ejected liquid properties and the velocity waveform at the print-head inlet. These new criteria are shown to have merit in comparison to currently used criteria for identifying filament physical features such as length and diameter that control the formation of subsequent droplets. In addition, this study performs scaling analyses for the design and operation of inkjet printing heads. Because droplet sizes from inkjet nozzles are typically on the order of nozzle dimensions, a numerical simulation is carried out to provide insight into how to reduce droplet sizes by employing a novel input waveform impressed on the print-head liquid inflow without changing the nozzle geometry. A regime map for characterizing the generation of small droplets based on We and a non-dimensional frequency, Ω is proposed and discussed. In an attempt to advance inkjet printing technology for coating purposes, a prototype was designed and then tested numerically. The numerical simulation successfully proved that the proposed prototype could be useful for coating purposes by repeatedly producing mono-dispersed droplets with controllable size and spacing. Finally, the influences of two independent piezoelectric characteristics - the maximum head displacement and corresponding frequency, was investigated to examine the quality of filament breakup quality and favorable piezoelectric displacements and frequencies were identified.

<p>Microdroplets have large and varied areas of application ranging from document printing to complex lab-on-chip devices. Lab-on-chip systems often require precise volume control as well as high throughput operations. Microdroplets fulfill these requirements and have become a staple in these devices. The work presented in this thesis involves the design and characterization of two individual devices capable of droplet generation utilizing flow focusing and electrogeneration methods.</p> <p>The first design involved the generation of gel microdroplets utilizing the flow focusing technique. This device proved to be robust and reliable producing large volumes of uniformly mixed droplets. Long term operation of this device was analyzed and determined to be a feasible route for the manufacture of large quantities of droplets. The device was operated for over 30 hours creating gel droplets ranging from 40-200 μm in diameter with acceptable polydispersities for use in drug release studies.</p> <p>The second device involved the design and characterization of a system for the electrogeneration of microdroplets. This novel device involved the injection of droplets via high voltage and high frequency signals into a cross-flow of oil. The droplet generation was characterized and different droplet generation modes were observed. With the careful selection of parameters ideal conditions were obtained to generate monodisperse droplets of sizes ranging from under 5 to over 100 μm in a highly repeatable manner.</p> <p>To conclude, two separate microfluidic droplet generation devices operating in distinct modes were designed and analyzed. These devices are robust, reliable, and flexible with some applications being tested.</p> / Master of Applied Science (MASc)