Coupling atomization, emulsification, and polymerization steps for creating gel microspheres

We report a high throughput strategy to produce gel microspheres. This method is based on the controlled fragmentation of an aqueous jet in air that results in droplets of monomer solution, their entry and collection in an oil bath containing a catalyzer and surfactants, followed by polymerization of the emulsion droplets which thus turn into gel beads. Adjusting the impact area of the stream of droplets at the free surface with an electric field allows to minimize coalescence of droplets as well as mass transport between the droplets and the continuous phase which is correlated to the sedimentation flow features of the dilute emulsion.