Confinement-induced evolution and breakup of viscoelastic filaments in microfluidic coflows

Abstract

Viscoelastic filament thinning is classically described by elastocapillary dynamics in extensional flows, yet in confined microchannels the combined effects of wall-induced shear, elasticity, and capillarity remain poorly understood. Here, we experimentally investigate the breakup of a shear-thinning viscoelastic liquid coflowing with an immiscible Newtonian fluid in a rectangular microchannel, focusing on the formation, stretching, instability, and breakup of the thin filament connecting the primary droplet to the upstream liquid. Four regimes: stable coflow, squeezing, dripping, and jetting are identified and mapped using the capillary numbers of the dispersed and continuous phases and an elastocapillary parameter. Although elasticity weakly affects the onset of primary droplet formation, it strongly alters later filament dynamics by delaying capillary breakup and stabilising long-lived filaments. Scaling analyses based on capillary, viscous, and elastic force balances predict the primary droplet size, critical filament thickness at instability onset, maximum filament length, and critical jet length. Particle tracking shows that confinement creates a non-uniform wall-induced shear field along the inclined filament, producing spatial variations in interfacial velocity and initiating the first bead-on-a-string instability at the location of maximum shear. A Rayleigh-Plateau analysis incorporating an effective viscosity derived from the Oldroyd-B model predicts the instability wavelength and growth rate to the correct order of magnitude. These results show that confined viscoelastic breakup is governed not solely by classical elastocapillary thinning, but by a coupled wall-shear-elasticity mechanism controlling filament stretching, instability, and secondary droplet formation, thereby providing a predictive framework for filament-mediated breakup in confined viscoelastic multiphase flows.