Enhanced mixing efficiency and reduced droplet size with novel droplet generators

Abstract Nowadays, droplet microfluidics has become widely utilized for high-throughput assays. Efficient mixing is crucial for initiating biochemical reactions in many applications. Rapid mixing during droplet formation eliminates the need for incorporating micromixers, which can complicate the chip design. Furthermore, immediate mixing of substances upon contact can significantly improve the consistency of chemical reactions and resulting products. This study introduces three innovative designs for droplet generators that achieve efficient mixing and produce small droplets. The T-cross and cross-T geometries combine cross and T junction mixing mechanisms, resulting in improved mixing efficiency. Numerical simulations were conducted to compare these novel geometries with traditional T and cross junctions in terms of mixing index, droplet diameter, and eccentricity. The cross-T geometry exhibited the highest mixing index and produced the smallest droplets. For the flow rate ratio of 0.5, this geometry offered a 10% increase in the mixing index and a decrease in the droplet diameter by 10% compared to the T junction. While the T junction has the best mixing efficiency among traditional droplet generators, it produces larger droplets, which can increase the risk of contamination due to contact with the microchannel walls. Therefore, the cross-T geometry is highly desirable in most applications due to its production of considerably smaller droplets. The asymmetric cross junction offered a 8% increase in mixing index and around 2% decrease in droplet diameter compared to the conventional cross junction in flow rate ratio of 0.5. All novel geometries demonstrated comparable mixing efficiency to the T junction. The cross junction exhibited the lowest mixing efficiency and produced larger droplets compared to the cross-T geometry (around 1%). Thus, the novel geometries, particularly the cross-T geometry, are a favorable choice for applications where both high mixing efficiency and small droplet sizes are important.