High-Quality Preparation of Energy-Containing Microspheres with Cross-Scale Particle Size

Microfluidic granulation technology enables high-quality production of energy-containing microspheres, significantly enhancing both performance and safety. Although microfluidic methods allow control over microsphere particle size, the adjustment range remains limited; low yield and process discontinuity also restrict broader application in the synthesis of energy-containing materials. This paper presents a microfluidic granulation system for energy-containing materials utilizing pulsed pneumatic printing, co-flow, and flow-focusing techniques to achieve wide particle size adjustment, consistent particle formation, high granulation speed, and production efficiency. This system allows microsphere sizes between 110 and 2500 μm, with a coefficient of variation (CV) as low as 1.9%, a frequency exceeding 13,000 Hz, and a suspension consumption rate reaching 100 mL/h. Calcium alginate/potassium perchlorate microspheres, prepared with sodium alginate hydrogel as a binder, exhibit uniform structure, narrow size distribution, and efficient energy material loading. We anticipate further advancements in applying microfluidic technology to energy-containing microsphere production based on this system.