Experimental study of liquid–liquid dispersion patterns in T-inlet microchannels with different junction angles

Liquid-liquid two-phase flow in T-inlet microchannels with different junction angles (θ = 30°, 60°, 90°, 120° and 150°) was investigated experimentally. Four flow regimes of the dispersed phase were identified, i.e., parallel flow, jetting, dripping and squeezing, and the distribution of flow regimes for the dispersed phase corresponding to variations in the junction angle was plotted. The consequences of varying junction angle and flow conditions in the squeezing regime on the generated droplet size were analyzed. The results indicate that low capillary number and large flow rate ratio are conducive to the formation of large-size droplets. For constant flow conditions, junction angle θ = 90° is detrimental to the formation of squeezing microdroplets. The increase in microchannel junction angle causes the droplet size to decrease until θ > 90°, where the droplet size increases with the junction angle. On the basis of experimental results, the scaling law correlation equations containing the junction angle for predicting the droplet length and droplet volume are proposed, respectively. The predicted values match well with the experimental data. The results of this work contribute to the enhancement of the monodispersity of microdroplets and the precise control over a wide range of the generated droplet size by adjusting the junction angle.