Controlled generation of high-frequency liquid metal microdroplets

Liquid metal (LM) microdroplets with high conductivity and fluidity have drawn extensive attention in the field of electronics, biomedicine, and catalysis. The properties of LM droplets, e.g., melting points, electrical actuation, and stability, are affected by their sizes. Continuous generation of LM microdroplets with precisely controlled size will benefit their applications, which however, remains an outstanding challenge. In this study, we have designed a scalable high frequency droplet generator for the liquid metal (EGaIn) that works on the principle of manipulating the electrohydrodynamic behaviour of EGaIn. By applying electric potentials < − 0.75 V vs Ag/ AgCl, EGaIn droplets with uniform sizes can be rapidly and continuously generated. The electric potential effectively tunes the thickness of the oxide layer on the EGaIn surface which in turn modulates the surface tension of the EGaIn and induces the generation of consistent sized EGaIn droplets. The size of the EGaIn microdroplets can be varied between 40 and 200 µm, depending on the electric potential applied and the diameter of the exit orifice. Droplet generation using this method requires relatively low energies, i.e., 2.77 × 10-7 kWh, and is coupled with high frequency droplet generation ∼ 60 droplet/min. The scalability of this droplet generation methodology can be further increased via design of an array of exit orifice. With the presence of surfactants, these EGaIn droplets can remain well-dispersed without coalescing. This considerably widens their capability for further applications.