Satellite droplet formation and its inertial separation in integrated microchannels

The breakup of filament is often accompanied by the formation of satellite droplet, which affects the uniformity of droplets, and inertial microfluidic technology is usually used to separate droplets of different sizes. In this study, different filament breakup modes are observed, and the variation of satellite droplet size with operating conditions are analyzed. Based on the experimental results, predictive model for the satellite droplet size is proposed. To better control the separation of particles with different sizes, the focusing and separation process of main and satellite droplets in microdevices are investigated by numerical simulation. It is found that increasing the fluid flow rate, the width of microchannel and rear cavity, and reducing the satellite droplet size are all beneficial for the separation of droplets of different sizes. At last, models for predicting the focusing positions of main and satellite droplets in rear cavity are established, and an integrated microfluidic device is proposed.