Biopolymer microgels produced in microfluidic devices via the formation of a water-in-oil emulsion are usually collected at the outlet of the device and thoroughly washed from the oil phase in an additional, lengthy processing step. This paper reports a microfluidic-based method which allows for continuous on-chip manufacture of aqueous-based biopolymer microparticles in an oily continuous phase and thereafter the transfer of these particles from the oily carrier phase to a second aqueous continuous phase. This was achieved by surface patterning the PDMS channel walls using UV polymerization of poly(acrylic acid) (PAA) in order to obtain a hybrid device with distinct hydrophilic and hydrophobic sections. The surface patterning was stable for at least 4 months. This selective surface patterning of the channel was shown to initiate and assist the transfer of the biopolymer particles from the oil phase into the aqueous phase. The flow conditions required for a stable biphasic flow in the transfer section of the device were evaluated based on the theoretical shear stress at the interface of the two fluids. Experimental outcomes were found to be in good agreement with the prediction. After the particles cross the liquid–liquid interface and are transferred into the aqueous phase, they are collected and characterized. The resulting suspension was found to be stable for several weeks and no aggregation was observed.
