To date, there has been little research attention paid to jetting deformation and pinching-off of microfluidic flows induced by the surface acoustic wave (SAW) mechanism. Further, such studies were almost limited to one sessile drop actuation without any confinement mechanisms. Such a scenario is likely attributable to the mechanism’s relatively poor controllability, the difficulty of maintaining the fluid loading position and issues related to stability and repeatability. In this paper, a novel SAW-microfluidic jetting system with a vertical capillary tube was designed, accompanied by a large number of experiments investigating the single droplet jetting mechanism with different device dimensions, resonance frequencies and radio frequency (RF) power capabilities. The study began with the whole jetting deformation and droplet pinching off through the use of a microscope with a high-speed camera, after which the results were discussed to explain the droplet jetting mechanism in a vertical capillary tube. After that, the study continued with experimental and theoretical examinations for high-quality single droplet jetting conditions. Jetting characterization parameters, including threshold RF power, resonance frequency, liquid volume, pinching off droplet dimensions, were thoroughly analyzed. Lastly, the Weber number range, a significant parameter in SAW-microfluidic jetting, was verified, and the pinching off microdroplet dimension was analyzed and compared via experiments. The significance of this study lies in the realization of microfluidic drop-on-demand based on SAW technology.

The rapid development of microfluidics has significantly highlighted the role of surface acoustic waves (SAWs) in microfluidic actuation. SAW influences droplet manipulation, inducing interface instability and processes such as droplet splitting, jetting, and atomization, which have been key research focal points. Previous studies have identified a close correlation between these instability mechanisms and three critical parameters: the Marangoni number (Ma), associated with piezoelectric substrate thermal effects; the slip coefficient (β0), related to piezoelectric substrate slip; and the acoustic capillary number (C). Given the intimate link between the aspect ratio (H/L, where H is the characteristic height, and L is the characteristic width of droplets) and atomization size, this study comprehensively investigates the combined effects of these factors on the droplet aspect ratio H/L. Specifically, increases in the acoustic capillary number C and slip coefficient β0 promote reductions in droplet height (H) and outward expansion (L), while the Marangoni number Ma counteracts this expansion, maintaining larger H/L values. This inhibitory effect is particularly pronounced when C and β0 are small but diminishes as their values increase. Additionally, higher values of C and β0 accelerate the convergence of the H/L ratio, whereas Ma decreases the rate of this convergence. Through the coordinated interplay of Ma, β0, and C, multidimensional and fine-tuned adjustments of the droplet aspect ratio H/L over a wide range can be achieved.

Highly efficient surface acoustic wave (SAW) transducers offer significant advantages for microfluidic atomization. Aiming at highly efficient atomization, we innovatively accomplish dual-surface simultaneous atomization by strategically positioning the liquid supply outside the IDT aperture edge. Initially, we optimize Lamb wave transducers and specifically investigate their performance based on the ratio of substrate thickness to acoustic wavelength. When this ratio $h/\lambda$ is approximately 1.25, the electromechanical coupling coefficient of A₀-mode Lamb waves can reach around 5.5% for 128° Y-X LiNbO₃. We then study the mechanism of droplet atomization with the liquid supply positioned outside the IDT aperture edge. Experimental results demonstrate that optimized Lamb wave transducers exhibit clear dual-surface simultaneous atomization. These transducers provide equivalent amplitude acoustic wave vibrations on both surfaces, causing the liquid thin film to accumulate at the edges of the dual-surface and form a continuous mist.

A traditional SAW (surface acoustic wave) atomizer directly supplies liquid to the surface of the atomized chip through a paper strip located in the path of the acoustic beam, resulting in irregular distribution of the liquid film, which generates an aerosol with an uneven particle size distribution and poor directional controllability, and a high heating phenomenon that can easily break the chip in the atomization process. This paper presents a novel atomization method: a paper strip located at the edge of the atomizer (PSLEA), which forms a micron-sized narrow liquid film at the junction of the atomization chip edge and the paper strip under the effect of acoustic wetting. By using this method, physical separation of the atomized aerosol and jetting droplets can be achieved at the initial stage of atomizer startup, and an ideal aerosol plume with no jetting of large droplets, a uniform particle size distribution, a vertical and stable atomization direction, and good convergence of the aerosol beam can be quickly formed. Furthermore, the effects of the input power, and different paper strips and liquid supply methods on the atomization performance, as well as the heating generation capacity of the liquid in the atomization zone during the atomization process were explored through a large number of experiments, which highlighted the advantages of PSLEA atomization. The experiments demonstrated that the maximum atomization rate under the PSLEA atomization mode reached 2.6 mL/min initially, and the maximum thermal stress was 45% lower compared with that in the traditional mode. Additionally, a portable handheld atomizer with stable atomization performance and a median aerosol particle size of 3.95 μm was designed based on the proposed PSLEA atomization method, showing the great potential of SAW atomizers in treating respiratory diseases.