Breaking one into three: surface-tension-driven droplet breakup in T-junctions

Droplet breakup is an important phenomenon in the field of microfluidics to generate daughter droplets. In this work, a novel breakup regime in the widely studied T-junction geometry is reported, where the pinch-off occurs laterally in the two outlet channels, leading to the formation of three daughter droplets, rather than at the center of the junction for conventional T-junctions which leads to two daughter droplets. It is demonstrated that this new mechanism is driven by surface tension, and a design rule for the T-junction geometry is proposed. A model for low values of the capillary number $Ca$ is developed to predict the formation and growth of an underlying carrier fluid pocket that accounts for this lateral breakup mechanism. At higher values of $Ca$, the conventional regime of central breakup becomes dominant again. The competition between the new and the conventional regime is explored. Altogether, this novel droplet formation method at T-junction provides the functionality of alternating droplet size and composition, which can be important for the design of new microfluidic tools.