Generation of uniform drops via through-hole arrays micromachined in stainless-steel plates

This study investigated the generation of oil drops using new symmetric and asymmetric through-hole-array devices made of stainless steel. The through-hole-array devices were built by piling up six stainless-steel plates, each having circular micro-holes with a diameter of 300 or 500 mu m or micro-slots with a shorter line of 300 or 500 mu m. Drops were generated by injecting a dispersed phase (refined soybean oil) via the through-hole array into a compartment filled with a continuous phase (Milli-Q water solution containing one of two emulsifiers). The drop detachment from symmetric and asymmetric through holes was observed in real time and analyzed. Uniform oil drops with average diameters of 1.0-4.1 mm and coefficients of variation of typically less than 6% were generated using symmetric and asymmetric through-hole-array devices. The resultant drop diameters for asymmetric through-hole arrays were significantly smaller than those for symmetric through-hole arrays. This paper also discusses experimental results regarding the effects of the microstructure, the dimensions of the through holes, and the type of emulsifier on drop generation and the resultant drop diameter.