Currently available device designs for creating multiple streams of droplets destined for microencapsulation use design parameters which incorporate parallelizable microfluidic dropmakers with multilayer geometry all in one singular enclosed microfluidic central housing. These traditional multi-channel devices rely on parts where the assembly of the microfluidic channel is completely integrated and thus hard to clean and troubleshoot when streams are not uniform. This also makes it so that when one stream is non optimized that the entire production unit must be shut down.
This invention focuses on the design of a fully interchangeable hub-droplet device apparatus for multiple droplet generation in parallel. The novel central hub combined with interchangeable chip configuration allows the use of different planar droplet generation devices that can be replaced and exchanged as needed. By separating the central housing hub which distributes incoming liquids into the droplet generation chips from the surrounding the hub the design allows for chip replacement, cleaning, and design to be separated from the central hub operation. The droplet generation devices can be created through different ways such as 3D printing, hot embossing, photolithography.
The overall apparatus contains a central hub unit that takes liquid coming from a connected fluid dispensing unit and distributes the liquid into radially arranged droplet generation chips located around the central hub. The droplet generation chips have microfluidic pathways that can create consistent liquid streams in each chip outlet. Droplets created from the system can then be treated (e.g., with UV or heat) to turn into hard/soft capsules and particles or used as-is. By changing fluid flow rates, rheological properties, and liquid pinching parameters, system can also be used to produce fibers with multiple sheath layers.
Image Caption: Photo(s) of a representative hub unit with and without chips
MECS will only be commercially viable if cost effective methods are developed to scale their production. The In-air Droplet Encapsulation Apparatus (IDEA) innovations are a first step in that direction. The nozzle technology
- Increases production scale by orders of magnitude
- Works seamlessly with existing lab MECS and IDEA technology
- Allows the use of different planar droplet generation devices that can be replaced and exchanged when needed
- The droplet generation devices/chips can be created using a variety of different ways (e.g., 3D printing, hot embossing, photolithography)
- Separates chip design and manufacturing method from the central hub design
Materials created from the IDEA apparatus utilizing this interchangeable multi nozzle apparatus can be used for but not limited to CO2 capture, pharmaceutical, food industry, and cosmetics.
Current stage of technology development: TRL ☐ 0-2 ☒ 3-5 ☐ 5-9
LLNL has filed for patent protection on this invention.