Microsphere Droplet Generator With U-Shaped Channel Blockage Control
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Solution Overview
Problem
Existing multi-bead droplet generators face issues such as blockage of encoded microsphere flow channels, poor control over flow rates, and permeation of oil phase into the aqueous phase, leading to low effective droplet ratios and inefficient droplet generation.
Innovation Solution
The droplet generator employs a large-corner continuous U-shaped flow channel for encoded microspheres with controlled turning radii and a buffer tank for both encoded microsphere and oil phases to manage flow rates and prevent blockage, ensuring precise control over droplet formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional flow channel is used for encoded microspheres, then the structure is simple, but the channel is easily blocked by microfibers in the microsphere suspension at the turn
Solution Approach 1:
The patent employs a large-corner continuous U-shaped flow channel design where the turning radius is specifically controlled to be more than 6 times the width of the flow channel. This curved geometry prevents microfibers from accumulating at sharp corners, thereby reducing blockage while maintaining a relatively simple overall structure.
2Productivity
If the flow rate of encoded microspheres is increased to improve productivity, then the generation efficiency is improved, but the flow rate control becomes difficult and channel blockage increases
Solution Approach 1:
The patent introduces a buffer tank for encoded microspheres that pre-arranges the microspheres before they enter the flow channel. This preliminary organization stabilizes the flow rate and prevents random fluctuations that could lead to blockage, while still allowing for efficient droplet generation.
3Productivity
If the flow rate of oil phase is increased to improve productivity, then the droplet generation speed is improved, but the oil phase permeates into the aqueous phase
Solution Approach 1:
The patent employs a buffer tank for the oil phase that must be filled before the oil phase can enter the droplet generation flow channel. This preliminary filling action creates a stable pressure boundary that prevents oil phase from permeating into the aqueous phase, while still allowing for high-speed droplet generation.
4Reliability
If multiple buffer tanks are added to control flow rates, then the flow rate controllability is improved, but the device complexity increases
Solution Approach 1:
The patent strategically places buffer tanks only at critical locations where flow rate control is most needed - specifically for encoded microspheres and oil phase - rather than throughout the entire system. This localized approach provides effective flow control while minimizing overall device complexity.
Data Source
AI summary
The present invention provides a droplet generator. The droplet generator includes a large-corner continuous U-shaped flow channel on the encoded microsphere flow channel. Controlling the turning radius of the continuous U-shaped flow channel prevents the blockage resulted from accumulation of microfibers in the encoded microsphere suspension at the turn of the continuous U-shaped flow channel. A buffer tank is arranged at the encoded microsphere flow channel, which is used for the pre-arrangement of the encoded microspheres, to increase the controllability of the flow rate of the encoded microspheres. The buffer tank is provided in the oil-phase flow channel to prevent the oil phase from infiltrating into the aqueous phase due to excessive flow rate, and increase the controllability of the oil phase flow rate. The droplet generator has simple structure, low cost, high-throughput, and high-stability, and may be used to prepare single-cell single-encoded microsphere droplets.