The Flow Focusing platform is especially advantageous for micro- and nanoparticle production. This versatile technique is amenable to designing the size, surface treatment and internal topology of the particles; mechanical stresses are minimal-an optimal feature for the manipulation of delicate substances. Multiplexing and high-rate production are readily implemented. Adaptive operational design can lead, in one single step, to finely tuned microcapsules encasing different products within a targeted morphology. This achievement is of great significance for most microcapsule applications in the biosciences (for example, drug delivery, cell encapsulation, and the production of bead arrays).

No abstract

An ultra-fine liquid atomization procedure combining the advantages of electrospray and flow focusing is presented. Both techniques are known to produce strikingly small and steady liquid micro-jets issuing from menisci held by capillary forces. Such menisci take the form of a cusp-like drop attached to the feeding tube (flow focusing: FF) or a Taylor cone (electrospray: ES). The issuing micro-jets are forced or ‘sucked’ from the parent meniscus either by pressure or electrohydrodynamic forces. Subsequent capillary breakup of the jet leads to fine sprays of remarkable quality. Here we describe the joint effect of pressurization and electrification in a flow focusing device, and the subsequent coupling of both ES and FF phenomena. For any given liquid and flow rate, the combined procedure gives rise to significantly smaller droplet sizes than observed in any of the source techniques. The co-flowing gas stream removes space charges; in addition, the perforated plate facing the feed tube provides an electric barrier, shielding the jet-meniscus or ‘production’ area from the spray or ‘product’ area. As a result, space charges and electrified droplets are removed from the production area, thus avoiding the ambient electric saturation which becomes a limiting factor in ES-spraying: a significantly enhanced spraying stability ensues, with a much wider operation range than FF or ES. Other unexpected outcomes from the combination are also shown. A theoretical model is developed to predict the emitted droplet size: a first integral of the momentum equation yielding a generalized Bernoulli equation, and an explicit approximation for the jet diameter and droplet size, accurate within a broad parametrical band.

The liquid cone-jet mode can be produced upon stimulation by a coflowing gas sheath. Most applications deal with the jet breakup, leading to either of two droplet generation regimes: Jetting and dripping. The cone-jet flow pattern is explored by direct axisymmetric volume of fluid (VOF) numerical simulation; its evolution is studied as the liquid flow rate is increased around the jetting-dripping transition. As observed in other focused flows such as electrospraying cones upon steady thread emission, the flow displays a strong recirculating pattern within the conical meniscus; it is shown to play a role on the stability of the system, being a precursor to the onset of dripping. Close to the minimum liquid flow rate for steady jetting, the recirculation cell penetrates into the feed tube. Both the jet diameter and the size of the cell are accurately estimated by a simple theoretical model. In addition, the transition from jetting to dripping is numerically analyzed in detail in some illustrative cases, and compared, to good agreement, with a set of experiments.

A discussion is presented on the role of limited conductivity and permittivity on the behavior of electrified jets. Under certain conditions, significant departures with respect to the perfect-conductor limit are to be expected. In addition, an exploration is undertaken concerning the validity of one-dimensional average models in the description of charged jets. To that end, a temporal linear modal stability analysis is carried out of poor-conductor viscous liquid jets flowing relatively to a steady radial electric field. Only axisymmetric perturbations, leading to highest quality aerosols, are considered. A grounded coaxial electrode is located at variable distance. Most available studies in the literature are restricted to the perfect-conductor limit, while the present contribution is an extension to moderate and low electrical conductivity and permittivity jets, in an effort to describe a situation increasingly prevalent in the sector of small-scale free-surface flows. The influence of the electrode distance b, a parameter ␣ defined as the ratio of the electric relaxation time scale to the capillary time scale, and the relative permittivity ␤ on the growth rate has been explored yielding results on the stability spectrum. In addition, arbitrary viscosity and electrification parameters are contemplated. In a wide variety of situations, the perfect-conductor limit provides a good approximation; however, the influence of ␣ and ␤ on the growth rate and most unstable wavelength cannot be neglected in the general case. An interfacial boundary layer in the axial velocity profile occurs in the low-viscosity limit, but this boundary layer tends to disappear when ␣ or ␤ are large enough. The use of a one-dimensional ͑1D͒ averaged model as an alternative to the 3D approach provides a helpful shortcut and a complementary insight on the nature of the jet's perturbative behavior. Lowest-order 1D approximations ͑average model͒, of widespread application in the literature of electrified jets, are shown to be inaccurate in low-viscosity imperfect-conductor jets.