Emulsion Device Volume Variation for Satellite Drop Control
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Solution Overview
Problem
Existing methods for producing emulsions with large drop sizes and high flow speeds result in polydisperse emulsions due to the formation of satellite drops, which are not suitable for certain industrial applications, and require stable flows that are difficult to maintain.
Innovation Solution
A device comprising a movement generator, a first channel for the dispersed phase, and a variation system that adjusts the internal volume of the channel to coordinate fluid flow and volume changes, generating signals with extrema to control the injection and suction of the dispersed phase, reducing the likelihood of satellite drop formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If microfluidics or millifluidics techniques are used to produce monodisperse emulsions, then droplet size uniformity is improved, but satellite drops are formed when flow speed or droplet size increases
Solution Approach 1:
The patent applies periodic action by using oscillating flow rates for both the dispersed and continuous phases. The flow rates vary periodically with specific duty cycles (e.g., 0.3-0.7 for dispersed phase, 0.4-0.6 for continuous phase), creating synchronized periodic injection and withdrawal cycles that prevent tail formation and satellite drop generation while maintaining monodisperse droplet sizes even at high flow speeds and large droplet dimensions (0.5-5mm).
Solution Approach 2:
The patent implements dynamics by making the flow rates of both phases variable rather than constant. The dispersed phase flow rate and continuous phase flow rate are dynamically adjusted during operation, with each phase experiencing periodic acceleration and deceleration cycles. This dynamic control allows the system to maintain precise droplet size control (low polydispersity index) while operating at high flow speeds and producing large droplets without satellite drop formation.
2Productivity
If high flow speeds are used to increase productivity, then production efficiency is improved, but polydispersity increases due to satellite drop formation
Solution Approach 1:
The patent uses periodic action with specific duty cycles to enable high flow speeds without satellite drop formation. The dispersed phase operates with a duty cycle of 0.3-0.7 and the continuous phase with 0.4-0.6, creating synchronized periodic cycles that allow rapid injection and withdrawal. This periodic operation maintains low polydispersity index (≤0.1) while achieving high productivity through increased flow rates and faster droplet production cycles.
Solution Approach 2:
The patent implements continuity of useful action by maintaining continuous operation with periodic modulation of flow rates. The system operates continuously without interruption, with both phases flowing throughout the process but with periodically varying rates. This continuous operation with periodic control enables sustained high productivity while maintaining consistent droplet size uniformity and low polydispersity over extended production periods.
3Loss of substance
If large droplet sizes are produced to reduce surface area, then material loss is reduced, but satellite drops are more likely to form and stretch into the continuous phase
Solution Approach 1:
The patent applies periodic action with coordinated duty cycles to produce large droplets (0.5-5mm diameter) without stretching or satellite formation. The dispersed phase flow rate oscillates with duty cycle 0.3-0.7 while the continuous phase oscillates with duty cycle 0.4-0.6, creating synchronized periodic cycles. This periodic control allows large droplets to be formed and detached cleanly, reducing material loss while preventing the stretching and satellite drop problems that normally occur with large droplet sizes.
Solution Approach 2:
The patent uses dynamic flow rate adjustment to produce large droplets without satellite formation. Both the dispersed phase and continuous phase experience dynamic flow rate variations during the droplet formation cycle, with rates being modulated to optimize droplet detachment. This dynamic control enables the production of large droplets (reducing surface area and material loss) while maintaining clean detachment and preventing tail formation or satellite drop generation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device produces emulsions with a low degree of polydispersity, allowing for controlled drop size distribution and reduced satellite formation, even at large drop sizes and high flow speeds, making it suitable for continuous production.
Implementation Method 1
a variation system for varying the internal volume of the first channel as a function of time... an increase in the internal volume of the first channel... This increase causes a suction of a portion of the drop of first fluid
Data Source
Figure 1~2
Figure 3(A)~3(D)
Figure 4~6
AI summary
The invention relates to a device for creating an emulsion consisting of a dispersed phase in the form of drops in a continuous phase, the device comprising: - a motion generator (11) for setting in motion at least one first fluid (3) intended for forming the dispersed phase, - a first channel (21) inside which the first fluid (3) set in motion can flow, the first channel (21) extending to an outlet opening (23) through which the first fluid is injected into at least one second fluid (5) intended for forming the continuous phase, - a variation system (40) for varying the internal volume (Vi) of the first channel (21) over time.