High-throughput generation of monodisperse double emulsions via controllable symmetric splitting in Y-shaped microchannels

• Splitting dynamics of double emulsions in Y-shaped microchannels are investigated. • The flow pattern transition laws of the splitting of double emulsions are clarified. • Flow pattern diagrams for predicting the boundary of pattern transitions are established. • Multi-level splitting microchannels are designed for symmetric breakup of double emulsions. • High-throughput generation of monodisperse double emulsions is controllably achieved. To achieve high-throughput generation of monodisperse double emulsions via controllable symmetric splitting, the splitting dynamics of double emulsions in Y-shaped microchannels are systematically investigated by the combination of experimental study and numerical simulation. Four distinct breakup flow patterns of double emulsions splitting are initially identified, namely non-breakup, once uneven breakup, twice uneven breakup and twice even breakup, and the underlying hydrodynamic mechanisms of each flow pattern are further elucidated through the flow field structures and pressure distributions. The results show that the upstream pressure created by the flow obstruction of continuous phase governs the stable and symmetric splitting of double emulsions in Y-shaped microchannels. Effects of the flowrates of continuous phase, the outer and inner diameters of double emulsions, the physical properties of all the inner, middle and outer fluids as well as the angle of Y-shaped microchannel on the flow pattern transition laws are systematically clarified, and the corresponding universal flow pattern diagrams for predicting the critical boundary for the transition of flow patterns are established. Based on controllable symmetric splitting of double emulsions, three-level splitting microfluidic networks are rationally designed to achieve high-throughput generation of monodisperse double emulsions as well as monodisperse microcapsules via template synthesis. The results in this study not only advance the deep understanding of the breakup dynamics of double emulsions in Y-shaped microchannels, but also offer valuable guidance for the rational design of microfluidic devices for mass production of monodisperse double emulsions, thus providing a significant contribution to the fields of micro-chemical engineering and droplet microfluidics.