1. Introduction
In recent years, significant efforts have been devoted to the development of droplet-based lab-on-a-chip devices of which advantages include being programmable and reconfigurable. Among various droplet flow based microsystems [
1,
2,
3,
4,
5], electrowetting on dielectric (EWOD) digital microfluidics has many advantages, such as rapid switching response, no joule heating, no need for moving parts like pumps and valves, and, most importantly, low power requirements [
6]. Basic droplet handling techniques—droplet dispensing, transporting, merging and splitting—can be done by sequentially activating and deactivating specific electrodes, which allows to address each droplet individually and to perform various unit processes, such as encapsulation [
7], mixing [
8], extraction [
9,
10] and separation [
9] in lab-on-a chip devices. All of these applications are limited to mostly parallel plate EWOD device. Recently, droplets have been manipulated by AC voltages in microchannels for various applications, including a music jukebox [
11,
12,
13], with more versatility.
Understanding of the dynamics of droplet motion in an EWOD device is crucial to design and build devices in various applications. To date, many researchers have experimentally and numerically investigated droplet dynamics in EWOD. The review article by Mugele and Baret [
6] discussed approaches to understand the electrowetting theory applicable for low voltages. They analyzed the origin of electrostatic forces that reduce the apparent contact angle and induce droplet motion. They also briefly discussed droplet dynamics.
In EWOD, a series of electrodes are activated in a timed manner and a discrete droplet is actuated along these sequentially “fired” electrodes. The nature of the net electrostatic force on the droplet is not constant while a constant voltage is applied, because the actuation force depends on the dynamic shape of the droplet, which keeps changing due to deformation during transition from the grounded electrode to the activated one [
6]. Therefore, in practical cases, the velocity field of a droplet varies with time during its transition. In order to fully understand EWOD actuation, we need to study a complex unsteady problem. In some lab-on-a-chip devices utilizing EWOD, droplet speed needs to be maximized to enhance performance [
14,
15]. For achieving maximum droplet speed, it is necessary to identify the parameters to favorably tune the basic forces of the system to indirectly control the speed. Some parameters, such as liquid surface energy [
16,
17], liquid viscosity [
17], contact angle hysteresis [
17], contact line friction [
16,
17], dimensions [
18,
19,
20] and shape of electrodes or droplet [
20,
21,
22], gap between electrodes [
18,
20] and the channel height [
19] have been investigated numerically [
18,
19,
20,
21,
22,
23] and experimentally [
22].
As already discussed, controlling droplet speed may become very crucial in many of the EWOD applications towards achieving optimum device performance. However, to the best of our knowledge, none of the studies presented specific guidelines to accurately characterize and measure droplet speed. For example, in References [
18,
19], the droplet velocity was measured in terms of the switching speed—the distance travelled by a droplet during one switching period. However, this measurement method bears serious errors unless the switching time is carefully controlled so that a droplet does not sit idly during a switching period. Therefore, a proper characterization of switching time is required to estimate droplet velocity accurately [
24]. It becomes very important since, unlike droplet motion in microchannels, where the pressure drop is kept regular, droplet motion in EWOD device is very discrete, periodic, and unsteady in nature because of the on and off repetition of voltage. Therefore, the primary goal of this study was to establish a practical characterization method of droplet speed. The majority of previous studies on droplet velocities in an EWOD device have been focused on numerical studies and parameters that might have intrinsic restrictions in practical applications. A much lower number of experimental studies have been reported regarding droplet speed in an EWOD device. Since electrode design is a very convenient parameter to implement in any kind of practical application, we studied droplet velocity in an EWOD device with new electrode designs. In addition, we studied the electrode operation sequence effect on droplet velocity.
2. Methods
According to the rigid body model considered by Chatterjee
et al. [
25], and Bahadur and Garimella [
21], both the droplet actuation force and the opposing forces during motion influence the droplet dynamics, which depend on the shape of the droplet base area (
i.e., contact area or footprint area). For example, the average actuation force for a droplet with a rectangular contact area will be greater than that of a droplet with a circular contact area. In the case of a dynamic droplet, the shape itself is affected by the deformation that the droplet undergoes, and eventually it affects droplet velocity [
16,
18]. We will later show, in this study, that droplet deformation can be controlled by designing and operating electrodes in a certain way. Beforehand, droplet deformation will be briefly explained.
2.1. Droplet Deformation
According to Berthier
et al. [
26], an electrowetting force always acts normally to the droplet meniscus in an outward direction, whereas a dewetting force acts in an inward direction, which is also normal to the meniscus. Electrowetting and dewetting force per unit length of the meniscus can be expressed as follows:
where γ is the liquid-gas interfacial tension, θ(
V) is the apparent contact angle corresponding to an applied voltage
V, and θ(0) is the apparent contact angle corresponding to a zero applied voltage.
Figure 1 illustrates a dynamic droplet at the instant when the droplet partially wets an actuated (
V > 0 applied) electrode and a grounded (
V = 0) electrode. As shown in
Figure 1, the electrowetting force on the leading meniscus tries to spread the droplet towards the electrode edges. At the same time, the dewetting force acting on the receding meniscus tries to pull the meniscus in an inward direction. Special attention should be paid to the interface between the actuated and grounded electrodes. On the grounded side of the interface, opposing dewetting forces squeeze part of the droplet inward (
i.e., yellow arrows in
Figure 1). On the other hand, on the actuated side of the interface, electrowetting forces let the meniscus spread outward (
i.e., green arrows in
Figure 1). As a result, a neck is formed at the interface and a head and a tail are formed in a dynamic droplet. If a very high voltage is applied, the velocity of wetting meniscus is very high and the droplet may split in two.
It is worth mentioning that the above explanation about deformation does not take into account several important factors, such as contact angle hysteresis, viscous, and shear effects. Our explanation of capillary line forces acting on the three phase contact line can only explain the deformation of the droplet footprint (base area of droplet on top and bottom surfaces), in terms of x-y curvature change. However, EWOD droplet motion is a three-dimensional phenomenon and to get the complete picture of deformation, it might be necessary to consider the z-directional curvature change, which might be affected by shear or contact angle hysteresis. However, since capillary number in the present study is less than one (Ca ~ 4 × 10−4 << 1), deformation is mainly governed by capillary forces, and viscous effects may be neglected. Therefore, a 2-D model can predict the droplet deformation well enough. Additionally, for our present purposes, we are more interested in exploiting the idea of manipulating the capillary forces to enhance droplet motion.
As we can see from
Figure 1, if most of the meniscus remains on the activated electrode, there will not be any neck formation and droplet meniscus will be pulled outward, thus trying to overlap the activated electrode surface. Therefore, the droplet will manage to have an almost rectangular shape, similar to the shape of the activated electrode beneath it. According to the study by Bahadur and Garimella [
21], this rectangular-shaped droplet can, theoretically, give the maximum droplet velocity.
While keeping the above discussion in mind, we can assume that electrode geometry can significantly affect droplet deformation. Therefore, in the current study, we tried to decrease the transition distance or the effective electrode width to reduce deformation. An array of slender electrodes was introduced for this purpose. In addition, different electrode operating schemes were tested to allow more of the droplet meniscus to have wetting forces, even in the beginning of the transition, to obtain a higher velocity. Note that, in conventional approaches with square electrodes, a droplet remains completely on a grounded surface, thus experiencing very small wetting forces at the beginning of the transition.
2.2. Electrode Design and Operation Sequence
In order to achieve a higher velocity for a given voltage, we proposed using an array of slender rectangular shaped electrodes. The dimension of each electrode is 2 mm × 0.4 mm (
Figure 2b–e). Please note that width,
W, is the dimension parallel to motion and length,
L, is the vertical dimension of the electrode with respect to direction of motion. For the purpose of comparison, we also fabricated square electrodes with the same length and width (2 mm × 2 mm) (
Figure 2a). Further, in the case of slender rectangular electrodes, the number of simultaneously activated electrodes was varied to create variation in the initial actuation force and also to expose the droplet interface to different amounts of electrowetting and dewetting forces at different locations in order to have different dynamic droplet shapes. Four different operation schemes were studied, as shown in
Figure 2b–e. The first scheme is named as “S
L2”. “S
L” refers to slender electrodes and the “2” indicates two electrodes being activated simultaneously. In this scheme, during each switching time, two strips of slender electrodes are activated. At the beginning of each switching time period, the droplet keeps in contact with one activated and four non-activated electrodes. Thus, the total length of the activated electrode is two electrodes width, or 0.8 mm, and total transition distance is one electrode width, or 0.4 mm, during each switching time period. Other sequences can be explained and named in the same manner, where the total numbers of activated electrodes are varied but the transition distance is kept constant. In these cases, transition distance refers to the distance travelled during one switching time period.
2.3. Fabrication of EWOD Devices
All EWOD devices were fabricated in Nanofab at The University of Texas at Arlington. Indium tin oxide (ITO) electrodes (~100 nm) were patterned by wet etching of ITO after photolithography on an ITO coated glass substrate. Dielectric layer (SU-8, 5 μm) and hydrophobic layer (Teflon, 300 nm) were spin-coated and oven baked. The details of the fabrication steps can be found in
Appendix A.
2.4. Test, Data Acquisition and Analysis
To test different designs of devices, a 400 nL water droplet of DI water was placed in a device. The gap between the top and bottom plates of the devices were kept at 100 μm for all devices. The droplet motion was recorded using a high-speed camera (Model: Miro M310, Vision Research; frame rate: 1000 fps; resolution: 512 × 480) and later analyzed using Phantom CineViewer software. Experimental videos are included in the
Supplementary Materials. Details of the velocity measurements are described in the next section.
2.5. Characterization: Defining Droplet Velocity and Minimum Switching Time
Since the aim of present study is to propose a new electrode geometry to obtain faster droplet motion, it is necessary to have a clear definition of velocity that can be suitably measured in practical settings for comparison purposes. One definition found in other references is “switching speed” [
18,
22]. A switching speed (
vs) is defined as the distance travelled during a switching period. One limitation of this definition is that
vs does not necessarily gives us the true speed during the transition because the droplet may actually complete its travel in a much shorter time than the imposed switching period and sit idly during the remaining time of the period until the next electrode is activated. This means that droplet’s true speed can be much faster than
vs. Therefore, it is important to control the switching time correctly. If our interest is to achieve the maximum speed for a given set of parameters including voltage, we need to set the minimum switching time (
tmin) to activate electrodes so that the electrode next in the travel path of the droplet would be activated as soon as the droplet has completely moved onto the current electrode. In this way, droplet motion will be continuous without any significant interruption and
vs will become close to the true speed of the moving droplet.
In this study, droplet velocity was measured experimentally. A point on the droplet was first identified in a high-speed (1000 fps) camera images by analyzing frames. After every 50 frames for slender electrodes and 100 frames for square electrodes, the location of that particular point was identified and distance of the same point from the previous frame to the current frame was measured. Then, the distance was divided by the time interval between these two frames to obtain the velocity of the particular point. For a practical measurement of the average velocity of a droplet, three points on the horizontal axis of the droplet’s motion were considered. The front-most point on the droplet meniscus was designated as the droplet “head” (
H), the back most point is the droplet “tail” (
T), and the centroid of the droplet is (
C) (
Figure 3). To avoid rigorous calculations, the average of head, tail and centroid velocities was considered as a rough estimation of the droplet velocity (
vdroplet) of its horizontal motion:
The time-averaged droplet velocity (
vavg) during the entire course of droplet travel will be:
where
t* is the time to reach the destination.
4. Discussion
To explain the reasons for getting a higher
vavg for slender electrodes than for square electrodes, the first assumption, made in
Section 2.1, can be recalled. We know that the actuation force in EWOD is a function of transition distance and the maximum actuation force that can be achieved by operating the electrodes in a certain way, as we did in case of the slender electrodes. EWOD actuation force will vary by droplet shape because of the different gradients in the overlapped area (dA(
x)/d
x), which is generally a function of transition distance, unless a droplet is in a square shape [
21]. Using MATLAB (MathWorks, Natick, MA, USA) and the theoretical formulations based on a rigid body model [
21], we calculated the actuation force for a circular droplet for all of the experimental cases. All deformations were neglected, and the droplet was considered to behave like a rigid body. The droplet volume was the same for each case, and the droplet diameter was considered to be slightly larger than the electrode length. For the total actuation force calculation, we used an area integral in MATLAB during a transition time of 35.67 ms, for which a droplet travels 2 mm in a square electrodes device. The force plots have been provided in
Appendix B (
Figure A1). In the same period of time, droplets for other sequences experience different travelling distances. For example, in S
L5, a droplet completes more than five transitions, equivalent to more than 2 mm (5 × 0.4 mm). Then, by assuming the time averaged actuation force, we could roughly compare the actuation forces of different sequences. This is tabulated in
Table 2.
As seen in
Table 2, all of the sequences of slender electrodes show a higher time averaged actuation force in the given time period than that of the square electrode case. When the droplet starts to move, it has a different overlapped area for the square, and also different schemes for the slender electrodes. Compared to the square electrode case, the initial actuation force for slender electrodes is much higher. In addition, since it transits only 0.4 mm (one electrode strip distance) during each transition, the overlapped area of the droplet with the activated electrode changes very little during this time, the actuation force also changes very little. If the droplet moves a 2 mm distance, it will have repetitive actuation force profiles corresponding to each switching time period, which happens several times, as opposed to the parabolic profile of square electrodes (
Figure A1). When we calculate the time averaged actuation force for both cases, in general, we will always get a higher actuation force, as well as higher average velocity, for slender electrodes, which we derived from the experiments. One limitation of this theoretical calculation is that
tmin for square electrodes from this modeling (=35.67 ms) is almost three times shorter than
tmin from the experiment (≈100 ms), which indicates an overestimated actuation force or underestimated opposing forces that we predicted using this model. This difference is due to the fact that the droplet deforms significantly during one switching time in the square electrode case, which is neglected in the rigid body model. On the other hand, it is confirmed that droplet deformation is negligible within the constant shape region of S
L schemes, although they are not necessary circular or exactly square-shaped. Therefore, if we can update the shape of the droplet in the rigid body model from the circular shape to the final shape of the droplet in the constant shape region of the slender electrodes, the rigid body model may result in closer predictions to the experimental results. Thus, we modified the rigid body model by taking approximate droplet shapes for the slender electrodes cases, as shown in
Figure 7, where we assumed the droplet base area to be composed of a combination of elliptical, rectangular, and half circular regions, as opposed to being completely circular.
With these updated droplet shapes, actuation force, average velocity (
vavg) and minimum switching time (
tmin) were calculated for the slender electrodes using the rigid body model. The estimated switching times were 9.94 ms, 10.257 ms, 11.33 ms and 9.98 ms, for S
L2, S
L3, S
L4, and S
L5, respectively. The estimations using the rigid body model are very close to our experimental results, as shown in
Table 3. We also confirmed the validity of the rigid body model by simulating velocity and pressure field using COMSOL Multiphysics software (COMSOL, Stockholm, Sweden) for square electrode case and S
L5 scheme of slender electrodes. As shown in
Appendix C, unlike in square electrode, the uniform and unidirectional velocity field in S
L5 scheme justifies the assumption the droplet to be a rigid body. Thus, we can safely use the rigid body model results to explain higher velocities for different schemes of slender electrodes.
Since the theoretical calculations give an almost similar
tmin, the velocity results should also be similar. As we can see in
Figure 8a, the average velocity profiles for all of the cases are different depending on the shape of the contact area of the droplet with electrode. The time averaged velocity,
vavg calculated from the velocity plots in
Figure 8a shows a very close match to the final velocities (
vf) observed in the experiments (
Table 3). During the transport of the droplet over a distance of 2 mm, the theoretical time averaged velocity for S
L5 and S
L2 is at a maximum, which is 41 mm/s compared to an average velocity of 40 mm/s for S
L3 and 36.5 mm/s for S
L4. In our experiments, we also get the maximum average velocities for sequences, S
L2 and S
L5 with the velocity averaging to about 40 mm/s in the constant deformation regions. For the other two sequences, the average is about 36 mm/s once the droplet travels beyond the constant shape region. Thus, after modifying the droplet shapes, the rigid body model can predict the results acceptably for the slender electrodes. The minute deviation from the experimental results is due to the difference between the approximated droplet shape from the actual droplet shape and also to the slight changes in shape during the motion in each switching period in the experiments that was neglected for simplicity in the theoretical calculation.
Next, the time averaged actuation force is calculated and shown in
Figure 8b, and is also tabulated in
Table 3. In general, the time averaged actuation force is higher for the sequence giving a higher velocity, except for S
L5, which gives less actuation force than S
L2 and S
L3 but has a higher velocity than the two. This may be due to the fact that there might be some errors in the theoretical calculation resulting from both instantaneous deformations, which we neglected, and also inaccuracy in shape estimation during modeling. One observation is that the actuation force profiles are similar to the velocity profiles in
Figure 8a. This means that if the droplet shape is constant or the deformation is much less, droplet velocity is mainly governed by the actuation force, which has been previously found in the literature [
16].