Separation of highly viscous fluid threads in branching microchannels

We experimentally study the transport properties of threads made of high-viscosity fluids flowing in a sheath of miscible, low-viscosity fluids in bifurcating microchannels. A viscous filament is generated using a square hydrodynamic focusing section by injecting a ‘thick’ fluid into the central channel and a ‘thin’ fluid from the side channels. This method allows us to produce miscible fluid threads of various sizes and lateral positions in a straight channel and enables the systematic study of the downstream thread’s response to flow partitioning in branching microfluidic networks at low Reynolds numbers. A phase diagram detailing the various flow patterns observed at the first bifurcation, including thread folding, transport, and fouling, is presented along with transition lines. We also examine the role of viscous buckling instabilities on thread behavior and the formation of complex viscous mixtures and stratifications at the small scale. This work shows the possibility to finely control thread trajectory and stability as well as manipulate the structural arrangement of high-viscosity multiphase flows in complex microfluidic systems.