Atomizer and method of atomizing a liquid

Abstract

An atomizer for use with a liquid, the atomizer comprising: a mesh coupled to a frame; an actuator having a proximal end. The proximal end being spaced apart from the mesh along an actuator axis; and a chamber formed between the mesh and the actuator to receive the liquid, the actuator in an operational state being configured to exhibit a vibrational displacement of the proximal end without physical contact with the mesh.

Description

“Atomizer and method of atomizing a liquid.”PRIORITY AND TECHNICAL FIELD

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63542059, filed on Oct. 2, 2023, which is incorporated by reference in entirety. This application relates to an atomizer, an atomizer module, and a method of atomizing a liquid.BACKGROUND

[0002] Some substances, including medication, are preferably provided in a viscous liquid instead of in water. Unfortunately, atomizing a viscous liquid remains a challenge for the conventional atomizers which are typically functional only for atomizing non-viscous liquids with the viscosity of water or close to water.SUMMARY

[0003] In one aspect, the present application discloses an atomizer for use with a liquid. The atomizer includes: a mesh coupled to a frame and an actuator having a proximal end. The proximal end is spaced apart from the mesh along an actuator axis. The atomizer also includes a chamber formed between the mesh and the actuator to receive the liquid. The actuator in an operational state is configured to exhibit a vibrational displacement of the proximal end without physical contact with the mesh.

[0004] In another aspect, the present application discloses a method of atomizing a liquid using the atomizer above. The method includes providing a vibrational displacement of themesh relative to the frame solely by energizing the liquid in a chamber by the vibrational displacement of the actuator.BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Various embodiments of the present disclosure are described below with reference to the appended drawings:|0006| FIG. 1 is a perspective view of an atomizer according to an embodiment of the present disclosure;

[0007] FIG. 2 is a perspective sectional view of the atomizer of FIG. 1 ;

[0008] FIG. 3 is an exploded side view of the atomizer of FIG. 1;

[0009] FIG. 4 is an exploded perspective view of an atomizer module of FIG. 3 ;

[0010] FIG. 5 is a perspective view of the atomizer module of FIG. 4;

[0011] FIG. 6 is a top view of a mesh;

[0012] FIG. 7 is a partial sectional side view of the atomizer;

[0013] FIG. 8A is a partial sectional side view of the atomizer in an operating mode;

[0014] FIG. 8B and FIG. 8B are partial views of the atomizer in different orientations;

[0015] FIG. 9 is a schematic diagram of the mesh in one time instant of the operating mode;

[0016] FIG. 10 is a schematic diagram of a circuit of the atomizer according to one embodiment;

[0017] FIG. 11 is a schematic diagram of the circuit according to an alternative embodiment;

[0018] FIG. 12 is a perspective view of an atomizer according to another embodiment of the present disclosure;

[0019] FIG. 13 is a perspective sectional view of the atomizer of FIG. 12;

[0020] FIG. 14 is an exploded side view of the atomizer of FIG. 12;

[0021] FIG. 15 is an exploded perspective view of an atomizer module according to an embodiment;

[0022] FIG. 16A is a sectional view and a detailed view of the atomizer module of FIG. 15;

[0023] FIG. 16B is a detailed view A of FIG. 16A;

[0024] FIG. 17 is a perspective sectional view of the atomizer module of FIG 15;

[0025] FIG. 18A and 18B are sectional views of the atomizer module in operation with different liquid level in the reservoir; and100261 FIG. 19 is a flowchart of a method of atomizing a liquid according to an embodiment.DETAILED DESCRIPTION

[0027] The following detailed description is made with reference to the accompanying drawings, showing details and embodiments of the present disclosure for the purposes of illustration. Features that are described in the context of an embodiment may correspondingly be applicable to the same or similar features in the other embodiments, even if not explicitly described in these other embodiments. Additions and / or combinations and / or alternatives as described for a feature in the context of an embodiment may correspondingly be applicable to the same or similar feature in the other embodiments.

[0028] In the context of various embodiments, the articles “a”, “an” and “the” as used with regard to a feature or element include a reference to one or more of the features or elements.

[0029] In the context of various embodiments, the term “about” or “approximately” as applied to a numeric value encompasses the exact value and a reasonable variance as generally understood in the relevant technical field, e.g., within 10% of the specified value.

[0030] As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0031] FIG. 1 illustrates an atomizer 50 according to some embodiments of the present disclosure. The atomizer 50 is useful in many applications, including but not limited to the delivery of medicine into the lungs. The atomizer 50 may be ergonomically configured to be portable and handholdable by a user. Preferably, the atomizer 50 has overall dimensions suitable to be held at the nose and operated by the same hand.

[0032] The terms "liquid product" and "atomized product" are to be understood in the context of the present disclosure. For the sake of brevity, the term "liquid product" refers to the pre- atomization product or to the liquid before it is atomized into liquid particles. The term "atomized product" refers to the post-atomization product or to the liquid found in the form of liquid particles.

[0033] As used herein, the terms “atomize”, “nebulize”, “vaporize”, and the like may be used interchangeably to refer to the formation of liquid particles (or droplets) in which the liquid particles are suspended in air or a gaseous medium. One skilled in the art would appreciate that the term “atomize” refers to a process of breaking bonds in a liquid to obtain the liquid constituent atoms in a gaseous phase, i.e., to obtain liquid particles. This is distinct and different from vaporization or evaporation which are phase transitions of a matter from a liquid state to a gaseous state.

[0034] For the sake of brevity, the term “liquid” as used herein refers generally to matter in a liquid state. A liquid may include, for example, a substantially pure substance in a liquid state, a mixture of substances, an aqueous solution, etc. In some examples, the liquid to be atomized may be an aqueous liquid such as a solution of a pharmaceutical substance in water. In some examples, the liquid may be a non-aqueous liquid such as propylene glycol, vegetarian glycerin, or a mixture thereof. In the course of an atomizing process, there may be a certain amount of gas present in / with the liquid. It will be understood that the term “liquid” as used herein may include a substance that is substantially in the liquid state with some gaseous matter included therein / therewith.

[0035] FIG. 2 is a schematic cross-sectional view of the atomizer 50 of FIG. 1. In some embodiments, various components of the atomizer 50 may be disposed in a housing 200. The housing 200 may include a base housing 210 and a cap 220 detachably coupled to the base housing 210. The cap 220 may define a mouthpiece or a spout 260. In some examples, the spout 260 can serve to direct liquid particles (atomized product) to a user’s mouth. In alternative examples, the cap 220 may be coupled to a mask such that the mask may be filled with the atomized product. In some embodiments, the base housing 210 may act as a handle for the atomizer 50.

[0036] Also referring to FIG. 3, the atomizer 50 includes a controller 230 operably connected to the atomizer module 100. Optionally, the atomizer 50 includes a switch 240. The switch 240 may be coupled to the controller 230 and configured to enable the user to control the atomizer 50, e.g., to start / stop a stream of atomized product by switching the atomizer 50 on / off, or to vary an atomizer setting, etc. A battery 250 may be provided to power the atomizer 50, e.g., the controller 230, circuitry, and various components of the atomizer 50. The battery 250 may be chargeable through a charger interface via the controller 230. Alternatively, the atomizer 50 may be electrically connected to an external power source by way of a cable connection, such as a wire connected to a power bank.

[0037] The controller 230 and the battery 250 may be disposed in the base housing 210, advantageously providing an integrated and compact product. The atomizer 50 further includes other components disposed interior of the housing 200 or, in some examples, interior of the base housing 210. For convenient reference and not to be limiting, these other components may be collectively referred to as an atomizer module 100 in the present disclosure, but it will be understood that these other components need not be provided as a pre-assembled modular unit. For example, the various components referred to as being part of the atomizer module 100 may be provided in the form of one or more sub-assemblies, or the components may be severally and / or separately provided for assembly with the housing 200. In various embodiments, one or more parts of the atomizer module 100 may be integrally fabricated with either the cap 220 or the base housing 210. In various embodiments, one or more parts of the atomizer module 100 may be disposable and / or interchangeable with one or more corresponding replacement parts by the user.

[0038] Parts of the atomizer 50 (e.g., parts of the atomizer module 100) are shown in greater detail in an exploded view in FIG. 4 and in assembly in FIG. 5. The atomizer 50 may include a frame 110 having an external wall 115. Referring also to FIG 5, the atomizer 50 may include amesh cap 122 that can be coupled to the frame 110 to collectively define a reservoir 116 and a chamber 112. The frame 110 may define a chamber 112 with an actuator 130 disposed at / near a base end of the chamber 112 and with a mesh disposed at / near a top end of the chamber 112. Therefore, the chamber 1 12 may be formed between the mesh 120 and the actuator 1 0. The mesh cap 122 preferably includes defines an opening 129 at which the mesh 120 may be disposed.

[0039] Referring also to FIG. 6 and FIG. 7, the mesh 120 may be coupled to the frame 110 via the mesh cap 122. In various embodiments, the mesh 120 may be a metallic sheet including opposing surfaces 120a / 120b which defines a mesh thickness (t) therebetween. The mesh 120 may include multiple openings or micro-apertures 123 formed thereon, each opening / microaperture 123 forming a miniature channel between the opposing surfaces 120a / 120b. The micro-apertures 123 of the mesh 120 may define an operating zone 121. The operating zone 121 may be described generally as an area which may come into contact with the liquid 60 during operation of the atomizer 50. Preferably, the plurality of micro-apertures 123 are distributed over substantially all or most of the operating zone 121. In some examples, the mesh 120 may have a mesh thickness of 0.02 millimeters to 0.03 millimeters. Preferably, the mesh 120 has a diameter or a lateral dimension that is significantly greater than the mesh thickness (t) such that the mesh has an overall profile similar to a disk or a wafer. Depending on the application, in some examples, the micro-apertures 123 of the mesh 120 may be sized within a range of 0.05 millimeters to 0.08 millimeters. Preferably, the micro- apertures 123 of the mesh 120 are substantially uniformly distributed across the mesh surfaces 120a / 120b as illustrated in FIG. 6. Alternatively, the micro-apertures 123 of the mesh 120 may be non-uniformly distributed across the mesh surfaces 120a / 120b. Alternatively, the micro-apertures 123 may be symmetrically distributed over the mesh 120.

[0040] In some embodiments, the mesh cap 122 may be an elastic cap or is made of a material that is elastically deformable. For example, the mesh cap 122 may be made from an elastic material including but not limited to latex, silicone, rubber, a polymer material, etc. Referring to FIG. 7, the mesh cap 122 is preferably coupled to the mesh 120 to allow for a limited displacement of the mesh 120 relative to the frame 110 along the mesh axis 82. In some examples, the elastic cap may be deformable to allow a movement of the mesh 120 along the mesh axis 82 relative to the frame 110. The mesh axis 82 may be defined as an axis extending through a thickness of the mesh 120.

[0041] As an alternative or in addition to the deformable mesh cap 122, a pair of mating rings 124 / 126 may be provided on opposing surfaces 120a / 120b of the mesh 120. Preferably, the mating rings 124 / 126 are made of metal. The mating rings 124 / 126 may clamp the mesh cap 122 therebetween. In some examples, outer edges of the mating rings 124 / 126 may be coupled to the perimenter of the opening 129, and inner edges of the mating rings 124 / 126 may be coupled to the mesh 120. That is, the mesh 120 may be coupled to the mesh cap 122 via the mating rings 124 / 126. In the example as shown in FIG. 7, the mesh 120 may be sandwiched by the pair of mating rings 124 / 126 leaving the operating zone 121 covering at least part of the opening 129. That is, preferably substantially all or most of the operating zone 121 is open to the chamber 112 on one side and to the open to the mouthpiece 260 on another side.

[0042] Preferably, the mating rings 124 / 126 form a slot 125 to loosely receive the mesh 120. The slot 125 (preferably circular or corresponding to the shape / profile of the mesh 120) may be sized to allow a movement of the mesh 120 relative to the mesh cap 122 along the mesh axis 82 (FIG. 7). That is, the coupling of the mesh 120 with the mesh cap 122 allows the mesh 120 to be moveable / displaceable relative to the mesh cap 122 and / or the frame 110. In some examples, the slot 125 may include a slot width (s) (measured parallel to the mesh axis 82), in which the slot width (s) is larger than the mesh thickness (t), thus allowing the mesh 120 tofreely move relative to the mating rings 124 / 126 and / or the mesh cap 122, without disengaging from the slot 125 or the mating rings 124 / 126, i.e., the mesh 120 is free to displace within the limits of the slot 125.

[0043] Tn some embodiments, the mesh cap 122 may he formed such that the mesh 120 is tilted relative to the actuator 130 or relative to the actuator axis 84. For the sake of brevity, reference to the mesh 120 being tilted relative to the actuator 130 includes reference to the mesh 120 being at an angular displacement (tilted or angled) relative to a proximal surface 130a of the actuator 130, where the proximal surface 130a is an end or a surface of the actuator physically disposed nearest to the mesh 120 and in which this end or this surface 130a is configured to vibrate when the actuator 130 is in an operational state. In some embodiments, the mesh cap 122 includes a tilted surface 127 (FIG. 4) that is angularly displaced relative to the actuator 130 or the actuator axis 84. The opening 129 is preferably defined at the tilted surface 127. The mating rings 124 / 126 may be correspondingly tilted relative to the actuator 130 or the actuator axis 84. In a non-operating state of the atomizer 50, the mesh 120 may be disposed in an orientation that is non-parallel to the actuator 130. In other words, the mesh axis 82 of the mesh 120 may form an oblique angle (0) with the actuator axis 84 of the actuator 130. As examples, the oblique angle (0) may be varied depending on application, and may preferably be in a range of 30 to 60 degrees.

[0044] In some embodiments, the frame 110 may further include a chamber wall 114 spaced apart from a part of the external wall 115a to define a reservoir 116, such that the chamber 112 is separated from the reservoir 116 by the chamber wall 114. The reservoir 116 is sized to store the liquid 60. The reservoir 116 may act as an intermediate storage tank or conduit to receive a refill of liquid 60.

[0045] Referring also to FIG. 7 and to FIGS. 8A-8C, in some embodiments, the height (h2) of the chamber wall 114 is sized to enable a flow of the liquid 60 from the reservoir 116 acrossthe chamber wall 114 to the chamber 112 (e.g., via a feed flow path 62). That is, the reservoir 116 and the chamber 112 are in fluidic communication via the feed flow path 62. In some embodiments, the external wall 115 has a height (hl) taller than a height (h2) of the chamber wall 114, providing the feed flow path 62 leading from the reservoir 1 16, across the chamber wall 114, to the chamber 112. In some embodiments, the chamber 1 12 is sized with a chamber volume (v2) that is smaller than a reservoir volume (vl) of reservoir 116. Preferably, the chamber 112 is configured (e.g., sized and shaped) such that the when a portion of the liquid 60 in the reservoir 116 is tipped into the chamber 112, a chamber- facing surface 130a (i.e., the proximal surface in this example) of the actuator 130 is submerged or in physical contact with the smaller amount of liquid in the chamber 112. In some examples, when the reservoir 116 is filled to its maximum capacity, the liquid in the reservoir may have a depth (dl) that is greater than a depth (d2) of the liquid in the chamber 112, the liquid in the chamber 112 being an overflow from the reservoir 116.

[0046] In some embodiments, in assembly, the mesh cap 122 is spaced apart from the chamber wall 114 to form a part of a channel defining the feed flow path 62. Preferably, the reservoir 116 is separated or spaced apart from the actuator 130 or the proximal surface 130a. Preferably, the reservoir 116 is separated or spaced apart from the mesh 120. Preferably, the liquid 60 in the reservoir 116 forms a body of liquid that is separate from the body of liquid in the chamber 112.

[0047] Further, an actuator 130 is coupled to the frame 110 via a module base 132. The actuator 130 may be caused to vibrate along an actuator axis 84. The actuator 130 (i.e., a proximal surface 130a of the actuator 130) may be spaced apart from the mesh 120 by the chamber 112. In other words, the actuator 130 is not in direct contact with the mesh 120. As used herein, the actuator 130 may also include a horn or a vibration amplifier coupled to an actuator 130.

[0048] In some embodiments, the chamber 112 may be defined collectively by a part of the frame 110, the mesh cap 122, and the actuator 130.

[0049] The atomizer module 100 may include a vibration unit 135 (FIG. 3). In various embodiments, the actuator 130 may be excited or activated into vibrational motion, which imparts a vibrational motion to the liquid in the chamber 1 12. The liquid in the reservoir 116 is not excited into vibration by the actuator 130 as the reservoir 116 is separate or distinct from the chamber 112, with the reservoir 116 and the chamber 112 in fluidic communication via a relatively narrower fluid flow path 62.

[0050] As used herein, the term “actuator” refers generally to a device that can be operated to provide a vibrational motion to the liquid in the chamber, and is not limited to the embodiments or examples as disclosed herein. In some preferred embodiments, the actuator 130 may be a piezoelectric element / ceramic, in particular, in a form of an actuator. In some preferred examples, the actuator 130 is an actuator. The actuator 130 may be in signal communication with the controller 230 via a wired connection 92. The actuator 130 may include opposingly surfaces 130a / 130b defining a thickness of the actuator 130. Preferably, the actuator 130 may be caused to vibrate along an actuator axis 84 which is parallel to the thickness of the actuator 130. As a preferred example, the actuator or the actuator 130 has a resonance frequency in the range of 1.6 MHz to 1.8 MHz.

[0051] In some embodiments, the module base 132 may include an upper base 132a and a lower base 132b. The actuator 130 may be disposed (e.g., clamped) between the upper base 132a and the lower base 132b. Preferably, a first sealing member 131 may be coupled between the frame 110 and the upper base 132a, the first sealing member 131 providing a first fluid sealed coupling therebetween. A second sealing member 133 may be coupled between the lower base 132b and the actuator 130 to provide a second fluid sealed coupling. This advantageously prevents any liquid 60 from leaking out from the chamber 112.

[0052] In some embodiments, a heating module may be provided for heating the liquid 60 in the chamber 112. In some embodiments, the heating module may be in signal communication with the controller 230. As a preferred embodiment, the heating module may include an induction member 140, such as a metallic plate, disposed interior of the chamber 112; and an induction coil 142 disposed exterior of the chamber 112. In some examples, the induction coil 142 is in signal communication with the controller 230 via a wired connection 94. The induction coil 142 may be housed interior of the lower base 132b. The induction member 140 may be coupled spaced apart from the actuator 130 such that it does not affect the vibration of the piezoelectric disk 130 and / or any vibration generated in the liquid 60. By way of the controller 230 driving the induction coil 142, heat can be induced or generated in the induction member 140 (e.g., by eddy current formation), and heats up or increases a temperature of the fluid 60 in the chamber 112. Advantageously, the induction member 140 is disposed interior of the chamber 112 and the induction coil 142 is disposed exterior of the chamber 112, to provide a form of “wireless heating”. This further ensures the integrity of the seals formed in the atomizer module 100. In some embodiments, the induction member 140 is spaced apart from the induction coil 142 along the actuator axis 84. Preferably, the induction member 140 and the induction coil 142 are disposed on opposing sides 130a / 130b of the actuator 130. As the actuator 130 is an insulator, the location of the induction member 140 and the induction coil 142 on opposing sides 130a / 130b of the actuator 130 does not negatively impact the performance of the induction heating, with the benefit of maximizing the interior space of the atomizer module for an overall more compact atomizer product.

[0053] Further, the induction coil 142 may provide induction heating to one or both of the mating rings 124 / 126, thus heating up the mesh 120, the liquid 60 in the viscinity of the mating rings 124 / 126, and the mesh cap 122. Further, it may be appreciated that the heating of the mating rings 124 / 216 may be controllable or even be stopped by way of controlling themagnetic field induced by the induction coil 142. Therefore, in some instances, the temperature of the mating rings 124 / 126 and the mesh cap 122 may be controlled by the controller 230 based on a maximum operating temperature of the mesh cap 122, i.e., not to cause the mesh cap 122 to be excessively elastic or to fail due to phase change. In other instances, by varying a temperature of the mesh cap 122, an elastic property (such as Young’s modulus) of the mesh cap 122 may be varied and controlled, thus allowing a variation in movement of the mesh 120 relative to the frame 110.

[0054] FIGS. 8A to 8C and FIG. 9 illustrate the atomizer module 50 in an operational state, according to an embodiment of the present disclosure. The controller 230 may be configured to control the atomizer module 100 and to drive the atomizer module 100 by way of providing one or more driving voltage / current. In some embodiments, the controller 230 drives the actuator 130, such as a piezoelectric element, in the atomizer module 100. Preferably, the controller 230 is configured to drive the actuator 130 to resonance such that a maximum vibration is generated. During operation, the controller 230 drives the actuator 130 to vibrate 74 thus providing a vibrational motion to the liquid 60 in the chamber 112. Preferably, the controller 230 drives the actuator 130 to resonance such that the vibrational motion is maximized, and efficiency is optimized. Responsive to the vibrational motion of the liquid 60, the liquid 60 moves towards the mesh 120. Upon the liquid 60 contacts or passes through the mesh 120, the mesh 120 moves 72 relative to the frame 110 along the mesh axis 82. One surprising technical effect of moving the mesh 120 via the liquid 60 is that the movement of the mesh 120 driven by the liquid 60 enables fine liquid particles 64 to be formed or atomized, and this is advantageously applicable for viscous liquid, such as glycol. When the liquid 60 passes through the mesh 120, the liquid 60 is atomized into liquid particles 64. The atomizer 50 relies on first moving / vibrating the liquid 60 to move / vibrate the mesh 120, and subsequently relyingon the movement / vibration of the mesh 120 to atomize the liquid 60. This is a departure from the conventional method of atomizing a liquid.

[0055] In some embodiments, as illustrated in FIG. 9, the vibrational motion of the liquid 60 is characterized by a harmonic wave 61 formed by the liquid 60 in the chamber 1 12. The harmonic wave 61 may include a single harmonic wave or multiple superimposed harmonic waves, formed by the liquid 60. In some embodiments, the harmonic wave 61 may predominantly include a first harmonic 61a, with subsequent harmonics 61b superimposed. It may be appreciated that the shape of the harmonic wave 61 illustrated by FIG. 9 is merely one of various examples, and the actual form / shape of the harmonic wave 61 may be limited by the chamber 112 shape, for example, defined by a geometrical shape of the mesh 120 and mesh cap 122. In some examples, the harmonic wave 61 may be a standing wave. By way of the formation of the harmonic wave 61, the liquid 60 is moved towards the mesh 120 such that the liquid 60 is atomized upon passing through the mesh 120 to form liquid particles 64.

[0056] Referring to FIG. 8A, in some embodiments, the chamber 1 12 and the chamber wall 114 defines an operating liquid level 66 when the atomizer 50 is not in operation. At the operating liquid level 66, the mesh 120 may not be in full contact with the liquid 60. In other words, the mesh surface 120b of the mesh 120 is not in full contact with the liquid and a part of the mesh surface 120b is exposed to air in the chamber 112. Therefore, by generating a harmonic wave 61 in the liquid 60, the liquid 60 moves towards the mesh 120 above the operating liquid level 66, passing through the mesh 120 to be atomized forming liquid particles 64. In some embodiments, the operating liquid level 66 may be a maximum liquid level in the chamber 112, wherein excess liquid flows back into the reservoir 116. The liquid 60 in the chamber 112 may continue to be atomized upon the liquid 60 level falling below the operating liquid level 66. This advantageously alleviates the need for typical atomizer device where aminimum liquid volume or liquid level are often required in ensuring a full contact with the mesh for atomization.

[0057] In some embodiments, the liquid particles 64 that condense upon passing through the mesh 120. Therefore, as the mesh 120 forms an oblique angle (0) with the actuator axis 84, in other words, the mesh 120 is tilted relative to the actuator 130, the condensed liquid particles 64 may flow 66 along the mesh 120 and away from the mesh 120. Advantageously, this prevents the liquid particles 64 or condensed liquid from restricting the movement of the mesh 120 or clogging the mesh 120, thus improving the atomization process and extending the operational time of the mesh 120 prior to replacement.

[0058] FIGS. 10 and 11 illustrate exemplary schematic electric circuits 270 of the atomizer 50. In some embodiments as shown in FIG. 10, the actuator 120 and the induction coil 142 may be connected in series with the controller 230 such that the liquid 60 is heated concurrently with the actuator 120 providing a vibrational motion to the liquid 60. Alternatively, as shown in FIG. 11, the actuator 120 and the induction coil 142 may be connected in parallel with the controller 230 such that the liquid 60 may be heated independently of the actuator 120 providing a vibrational motion to the liquid 60.

[0059] FIG. 12 shows another embodiment of an atomizer 55 of the present disclosure. FIG. 12 is a perspective view of the atomizer 55 and FIG. 13 is a schematic cross-sectional view of the atomizer 55 of FIG. 12. In some embodiments, various components of the atomizer 55 may be disposed in a housing 400. The housing 400 may include a base housing 410 and a cap 420 detachably coupled to the base housing 410. Referring to FIG. 13, the atomizer 55 may include an atomizer module 300. The atomizer 55 includes a controller 430 operably connected to various other components of the atomizer 55. The controller 430 may be in signal communication with the atomizer module 300. Optionally, the atomizer 55 includes a switch 440 coupled to the controller 430 and configured to enable the user to control the atomizer 50,e.g., to start / stop a stream of atomized product by switching the atomizer 55 on / off, or to vary an atomizer setting, etc. A battery 450 may be provided to power the atomizer 55, e.g., the controller 430, circuitry, and various components of the atomizer 50. The controller 430 and the battery 450 may be disposed in the base housing 410, advantageously providing an integrated and compact product.|0060| The atomizer 55 further includes other components disposed interior of the housing 400 or, in some examples, interior of the base housing 410. For convenient reference and not to be limiting, these other components may be collectively referred to as an atomizer module 300 in the present disclosure, but it will be understood that these other components need not be provided as a pre-assembled modular unit. For example, the various components referred to as being part of the atomizer module 300 may be provided in the form of one or more subassemblies, or the components may be severally and / or separately provided for assembly with the housing 400.

[0061] Parts of the atomizer 55 (e.g., parts of the atomizer module 300) are shown in greater detail in an exploded view in FIGS. 14 and 15. The cap 420 may include an outer wall 424 and an inner wall 426, forming therebetween an annular space. In some embodiments, an opening 422 on the cap 420 may be formed a fluidic communication between an exterior of the atomizer 55 and the annular space. A plug 462 may be detachably coupled with the opening 422 to selectively allow or stop the fluidic communication between the annular space and the exterior. In some embodiments, the outer wall 424 forms a coupling with the atomizer module 300. The inner wall 426 may define a central aperture 428. The cap 420 may be coupled to a mouthpiece or a spout 460 such that the mouthpiece is in sealing fluidic communication with the central aperture 428.

[0062] In some embodiments, the atomizer module 300 may include a frame 310; a vibration unit 335 couped to the frame 310; a feed member 340 coupled between the vibration unit 335and the frame 310; and a mesh 320 disposed on the feed member 340. The mesh 320 may be in contact with the feed member 340 and disposed between the frame 310 and the feed member 340.

[0063] Tn some embodiments, the frame 310 may be generally planar defining a central aperture 312 or a central opening. The central aperture 312 may define an aperture axis 80. The frame 310 may be coupled to the cap 420 to collectively define a reservoir 306 therebetween. In some examples, the frame 310 encloses the annular space of the cap 420 thereby forming the reservoir 306. The central aperture 312 may be in fluidic communication with the central aperture 428 of the cap 420. The central aperture 312 of the frame 310 may line up with the central aperture 428 of the cap 420 along the aperture axis 80. The frame 310 may include at least one or multiple through openings 316 in fluidic communication with the reservoir 306. In some embodiments, the openings 316 are disposed around the central aperture 312. In some embodiments, the openings 316 are formed circularly symmetrical about the aperture axis 80. Therefore, the openings 316 may be circularly distributed about the aperture axis 80 uniformly.

[0064] Referring to FIGS. 16 and 17, the mesh 120 may be displaceable along a mesh axis 82. In some embodiments, the mesh axis 82 is parallel to the aperture axis 80. In some embodiments, the mesh axis 82 is coaxial with the aperture axis 80. The mesh 120 may be coupled between the frame 310 and the feed member 340. The mesh 320 may be a metallic sheet including opposing surfaces which defines a mesh thickness (t) therebetween. The mesh 320 may include multiple openings or micro- apertures formed thereon. In some examples, the mesh 320 may have a mesh thickness (t) of 0.02 millimeters to 0.03 millimeters. Preferably, the mesh 320 has a diameter or a lateral dimension that is significantly greater than the mesh thickness (t) such that the mesh has an overall profile similar to a disk or a wafer. Depending on the application, in some examples, the micro- apertures of the mesh 320 may be sized within a range of 0.05 millimeters to 0.08 millimeters.

[0065] Referring again to FIGS. 14 to 15, a vibration unit 335 of the atomizer module 300 according to an embodiment is shown. The vibration unit 335 may include a top member 332 coupled to a base member 334; and an inner member 333 coupled between the top member 332 and the base member 334. In some examples, the top member 332 is coupled to the base member 334 via corresponding screw threads. Similarly, the base member 334 is coupled to the inner member 333 via corresponding screw threads. The top member 332 may be configured to couple with the frame 310 during assembly. Similarly, the base member 334 may be configured to couple with the base housing 410 during assembly. The vibration unit 335 may include an actuator 330 coupled between the inner member 333 and the base member 334. In some examples, the actuator 330 may be held by a sealing ring 336 or O-ring disposed between the actuator 330 and the base member 334. The sealing ring 336 may couple to or hold on to a periphery edge of the actuator 330 such that during operation, a central portion of the actuator 330 vibrates or displaces more that the periphery edge. In some embodiments, the controller 430 may be in signal communication with the actuator 330 to drive the actuator 330.

[0066] Referring to FIGS. 16A-16B and Fig. 17, the actuator 330, the top member 332, and the inner member 333 may collectively define a chamber 302 or a receiving space for receiving a liquid. In some embodiments, the chamber 302 may be formed between the mesh 320 and the actuator 330 to receive the liquid. The top member 332 may define an opening 332a, such that the chamber 302 is in fluidic communication with the opening 332a. Through the opening 332a of the top member 332 and the openings 316 formed on frame 310, the chamber 302 may be in fluidic communication 304 with the reservoir 306. Therefore, liquid in the reservoir 306 may be provided to the chamber 302 via fluidic communication path 304.

[0067] In some embodiments, a feed member 340 may be disposed in the chamber 302. in contact with the actuator 330. As shown in FIG. 15, the feed member 340 may include a centrally disposed contact region 342 circumscribed by a peripheral support region 344. Thefeed member 340 may be formed like a bowl or a valley with the peripheral support region 344 disposed elevated from the contact region 342. Therefore, the opening 332a of the top member 332 may receive at least a part of the feed member 340, for example, the contact region 342. The feed member 340 may act as a wick or an absorbent member to receive liquid from the reservoir 306. In some embodiments, the feed member 340 may soaked up the liquid or be saturated by the liquid, such that the feed member 340 can hold no more than a predetermined volume of liquid in the chamber 302 at any one time instant. Further, with the feed member 340 acting as a wick, the support region 344 of the feed member 340 may receive liquid 304 from the reservoir 306 passing through the openings 316. Thereafter, liquid in the support region 344 may move or displace by way of capillary action across the feed member 340 to provide a continuous supply of liquid for atomization. This allows the contact region 342 to also hold or be saturated with liquid. In some embodiments, the liquid is substantially uniformly distributed across the feed member 340 during use. In some embodiments, at least a part of or a whole of the feed member 340 is made of an absorbent material. In some embodiments, at least the contact region 342 of the feed member 340 is made of the absorbent material.[0068 J In various embodiments, the actuator 330 may include a proximal end 330a and an opposing distal end 330b. For example, the contact region 342 of the feed member 340 may be in physical contact with the proximal end 330a of the actuator 330. In an operational state, the actuator 330 may exhibit a vibrational displacement of the proximal end 330a. In some examples, the feed member 340 is in contact with the proximal end 330a of the actuator 330. In some examples, the proximal end 330a is not in physical contact with the mesh 320. The actuator 330 may be excited or activated and impart a vibrational motion to the feed member 340 in the chamber 302. When the actuator 330 provides a vibrational displacement of the proximal end 330a along an actuator axis 84, at least a part of the feed member 340 is displaced along the actuator axis 84. This may cause the feed member 340 to vibrate or displace, anddrive the mesh 320 to displace along the mesh axis 82. In some embodiments, as shown in FIG. 16A, the support region 344 of the feed member 340 may be coupled to or clamped by the frame 310 and the top member 332. In some examples, only the contact region 342 of the feed member 340 is displaced by the actuator 330.

[0069] Responsive to a substantially concurrent displacement of the feed member 340 and the mesh 320, the liquid held in the feed member 340 may form liquid particles 64. In some examples, the vibrational motion or vibrational energy from the actuator 330 applied to or concentrated to a limited amount of liquid in the chamber 302 held by the feed member 340 enables a preferred atomization performance and efficiency of the atomizer 55.

[0070] It is observed that provision of the feed member 340 provides a surprising technical effect to the process of atomization, e.g., the presence of the feed member 340 in the present atomizer 50 improves the atomization outcome over the case without the feed member 340. In some examples, as the feed member 340 undergoes vibration or displacement due to the actuator 300, heating occurs in the feed member 340, which advantageously increases the atomization performance. In some examples, provision of the feed member 340 and elevated temperature of the feed member 340 corresponds to an ability of the atomizer 50 to produce liquid particles 64 for a more viscous liquid and / or produce a larger volume of liquid particles 64 in a shorter time. In various examples, the material (absorbent material) of the feed member 340 is selected such that the feed member 340 does not combust or decompose as a result of the heating that may occur. For example, the material of the feed member 340 I absorbent material may be a woven material made from cotton, fiber glass fiber or ceramic based fiber. For example, the feed member 340 may be formed from a cotton-based fabric, fiber glass-based fabric or ceramic -based fabric. In some embodiments, the material of the feed member 340 / absorbent material may be a non-woven material made from fibers using one or a combination of a thermal-based process, a mechanical-based process or a chemical-based process. Someexamples of the processes include but are not limited to thermal bonding, hydroentangling, needle-punching, chemical bonding, etc. In some examples, the non-woven material may be made from cotton fiber, fiber glass fiber or ceramic based fiber. In some embodiments, the absorbent material of the feed member 340 has a lower stiffness than the mesh 320 and the proximal end 330a of the actuator 300, and the feed member 340 is deformable by the vibrational motion of the actuator 300.

[0071] In some embodiments, a flange 314 circumscribing the central aperture 312 about the aperture axis 80 may project from the frame 310. The mesh 320 may be received in a slot 315 or a recess defined by the flange 314. The slot 315 may be receive the mesh 320 such that the mesh 320 is disposed at the central aperture 312 and in fluidic communication with the central aperture 312. The mesh 320 may be displaceable along the mesh axis 82 within the slot 315. In some embodiments, the slot 315 may include a slot depth (DS) larger than the mesh thickness (t) of the mesh 320. In some examples, the slot 315 may limit a displacement of the mesh 320 along the mesh direction 82. In some examples, the depth (DS) of slot 315 may be in proportion to a limit to the displacement of the mesh 320 along the mesh axis 82. For example, the depth of the slot 315 may be at least equal to or larger than a maximum displacement of the mesh 320. The displacement of the mesh 320 may be defined as a direction lateral to the mesh axis 82 and limited by the slot 315.

[0072] Referring to FIGS. 18a and 18B, in operation, the controller 430 in signal communication with the actuator 330 may be configured to drive the actuator 330 to vibrate 74 and provide a vibrational motion to the feed member 340 (and liquid held by the feed member 340) in the chamber 302. Preferably, the controller 430 drives the actuator 330 to resonance such that the vibrational motion is maximized, and efficiency is optimized. In some examples, the resonance frequency is in a range from 1.6 MHz to 1.8 MHz. Responsive to the vibrational motion of the feed member 340, the liquid held by the feed member 340 contacts or passesthrough the mesh 320. The movement of the mesh 320 driven by the feed member 340, enables fine liquid particles 64 to be formed or atomized, and this is advantageously applicable for viscous liquid, such as glycol.

[0073] Advantageously, as illustrated in FIGS. 18A and 18B, the provision of the feed member 340 allows the atomizer 55 to be used in a plurality of different orientations. This alleviates the need for the atomizer 55 to be used in only one fixed orientation or a few specific orientations. For example, the present atomizer 55 does not limit its use in a fixed orientation that to ensure a flow of liquid by gravity. In some examples, the multiple openings 316 symmetrically disposed about the mesh axis 82 enables liquid from the reservoir 306 to be fed to the feed member 340 in any rotational orientation of the atomizer 55. Even if liquid level in the reservoir is very low, the atomizer 55 may be held in any orientation and still be operational. For example, in FIG. 18 A, liquid in the reservoir 306 may pass through opening 316a and 316b to be fed to the feed member 340. When the liquid in the reservoir 306 is reduced upon atomization as shown in FIG. 18B, the liquid in the reservoir 306 may continue to pass through opening 316b to be fed to the feed member 340.

[0074] According to another aspect of the disclosure, a method 500 of atomizing a liquid is disclosed. FIG. 19 illustrates the method 500 of atomizing a liquid according to a preferred embodiment. The method 500 may include in step 510, vibrating an actuator along an actuator axis to provide a vibrational motion to the liquid in a chamber of a frame; and in step 520, moving a mesh relative to the frame with the vibrational motion, wherein the mesh is spaced apart from the actuator by the chamber along the actuator axis. In some embodiments, the method 500 may further include in step 530, heating the liquid in the chamber. Preferably, the method 500 may also include in step 540, forming a harmonic wave in the liquid. In some embodiments, the method 500 may include in step 550, holding the liquid in the chamber with

[0075] Alternatively described, various embodiments of the present disclosure include an atomizer 50 / 55 for use with a liquid. The atomizer includes a mesh 120 / 320 coupled to a frame 110 / 310 and an actuator 130 / 330 having a proximal end. The proximal end is spaced apart from the mesh 120 / 320 along an actuator axis 84. The atomizer includes a chamber 1 12 / 302 formed between the mesh 120 / 320 and the actuator 130 / 330 to receive the liquid. The actuator in an operational state may be configured to exhibit a vibrational displacement of the proximal end without physical contact with the mesh 120 / 320.

[0076] In some embodiments, the atomizer may include a feed member 340 disposed in the chamber 302. The feed member 340 may be in physical contact with the proximal end of the actuator 330. The vibrational displacement of the proximal end may displace at least a part of the feed member 340 along the actuator axis 84. At least a part of the feed member 340 may be made of an absorbent material. The absorbent material may have a lower stiffness than the mesh. The absorbent material may include a woven material. The absorbent material may include a non-woven material.

[0077] The atomizer may include a liquid reservoir 306 in fluidic communication with the feed member 340 for feeding the liquid to the chamber 302. The frame may include a slot 315 to receive the mesh 320. The mesh 320 may be moveable relative to the slot 315 along at least a mesh axis 82. The feed member 340 may include a contact region 342 circumscribed by a peripheral support region 344. The contact region 342 may be in physical contact with the proximal end of the actuator 330.

[0078] In some embodiments, the chamber is defined by the frame 110. The atomizer includes a mesh 120 disposed at a first end of the chamber. The atomizer includes an actuator 130 having a proximal end 130a disposed at a second end of the chamber. The proximal end is spaced apart from the mesh along an actuator axis 84. The actuator in an operational state isconfigured to exhibit a vibrational displacement of the proximal end without physical contact with the mesh.

[0079] The atomizer may be configured to enable the vibrational displacement of the proximal end relative to the actuator axis. The mesh is displaceable relative to frame along at least a mesh axis 82. The mesh axis and the actuator axis are at an oblique angle relative to one another. The vibrational displacement of the proximal end may enable a vibrational motion of the liquid. The mesh may be displaceable relative to the frame by the vibrational motion of the liquid. The vibrational motion may be characterized by a harmonic wave formed by the liquid.

[0080] The liquid may be disposed in the chamber and in contact with the proximal end. The vibrational displacement of the proximal end may enable an amount of the liquid to pass through the mesh. The liquid may be atomized upon passing through the mesh.

[0081] The atomizer may further include a mesh cap 122 coupled between the frame and the mesh. The mesh cap may be deformable to allow a movement of the mesh relative to the frame.

[0082] The atomizer may include a pair of mating rings 124 / 126 disposed on opposing surfaces of the mesh. The pair of mating rings may define a slot 125 to receive the mesh. The mesh is preferably moveable relative to the slot along at least the mesh axis.

[0083] The atomizer may further include an induction member 140 disposed interior of the chamber and an induction coil 142 disposed exterior of the chamber. Driving the induction coil preferably induces heat in the induction member to increase a temperature of a fluid in the chamber. The induction member and the induction coil may be disposed on opposing sides of the actuator. The induction member may be spaced apart from the induction coil along the actuator axis. The atomizer may further include a pair of mating rings disposed on opposing surfaces of the mesh, wherein the pair of mating rings define a slot for receiving the mesh, wherein driving the induction coil induces heat in at least one of the mating rings, for heating up the mesh.

[0084] The atomizer may further include a reservoir 116. The chamber is preferably shallower than the reservoir. The atomizer may include a chamber wall 114 separating the reservoir from the chamber. The reservoir and the chamber may be in fluidic communication solely via a feed flow path 62 extending across the chamber wall. The liquid in the chamber may be replenishable with the liquid from the reservoir via the feed flow path. The chamber may define an operating liquid level 66. At the operating liquid level, an operating zone 121 of the mesh is preferably not in contact with the liquid.

[0085] The mesh may include a plurality of micro- apertures 123. The liquid is atomized upon passing through the micro- apertures.

[0086] The actuator is preferably a piezoelectric disk, with the actuator axis substantially parallel to a thickness of the piezoelectric disk.

[0087] The atomizer may further include a controller 230 in signal communication with the actuator. The controller is preferably configured to drive the actuator at a resonance frequency, in which the resonance frequency is in a range from 1.6 MHz to 1 .8 MHz.

[0088] Various embodiments of the present disclosure preferably includes a method 500 of atomizing a liquid using the atomizer as disclosed herein. The method includes providing a vibrational displacement of the mesh relative to the frame solely by energizing the liquid in a chamber by the vibrational displacement of the actuator. The method may further include heating the liquid in the chamber.

[0089] As described in the foregoing, various embodiments of the present atomizer 50 can be useful in addressing the challenges of atomizing viscous liquids. In some cases, the liquid to be atomized may be a liquid with a viscosity value higher than that of water. Advantageously, it has been experimentally verified that the present atomizer is capable of atomizing viscous liquids to provide a relatively consistent stream of liquid particles. The present atomizer is particularly useful in cases where the average liquid particle size (or droplet diameter) is preferably about 5 microns (0.005 millimeters) or preferably not greater than 5 microns.

Claims

CLAIMS1. An atomizer for use with a liquid, the atomizer comprising: a mesh coupled to a frame; an actuator having a proximal end, the proximal end being spaced apart from the mesh along an actuator axis; and a chamber formed between the mesh and the actuator to receive the liquid, wherein the actuator in an operational state is configured to exhibit a vibrational displacement of the proximal end without physical contact with the mesh.

2. The atomizer as recited in claim 1 , further comprising a feed member disposed in the chamber, wherein the feed member is in physical contact with the proximal end of the actuator.

3. The atomizer as recited in claim 2, wherein the vibrational displacement of the proximal end displaces at least a part of the feed member along the actuator axis.

4. The atomizer as recited in claim 2, wherein at least a part of the feed member is made of an absorbent material, and wherein the absorbent material has a lower stiffness than the mesh.

5. The atomizer as recited in claim 5, wherein the absorbent material includes a woven material.

6. The atomizer as recited in claim 2, further comprising a liquid reservoir in fluidic communication with the feed member for feeding the liquid to the chamber.

7. The atomizer as recited in claim 1 , wherein the frame further comprises a slot to receive the mesh, and wherein the mesh is moveable relative to the slot along at least a mesh axis.

8. The atomizer as recited in claim 2, wherein the feed member comprises a contact region circumscribed by a peripheral support region, and wherein the contact region is in physical contact with the proximal end of the actuator.

9. The atomizer as recited in claim 1, wherein the actuator is configured to enable the vibrational displacement of the proximal end relative to the actuator axis, and wherein the mesh is displaceable relative to frame along at least a mesh axis, the mesh axis and the actuator axis being at an oblique angle relative to one another.

10. The atomizer as recited in claim 1, wherein the vibrational displacement of the proximal end enables a vibrational motion of the liquid, and wherein the mesh is displaceable relative to the frame by the vibrational motion of the liquid.

11. The atomizer as recited in claim 10, wherein the vibrational motion is characterized by a harmonic wave formed by the liquid.

12. The atomizer as recited in claim 1, further comprising an elastic cap coupled between the frame and the mesh, wherein the elastic cap is deformable to allow a movement of the mesh relative to the frame.

13. The atomizer as recited in claim 1, further comprising a pair of mating rings disposed on opposing surfaces of the mesh, wherein the pair of mating rings define a slot to receive the mesh, and wherein the mesh is moveable relative to the slot along at least the mesh axis.

14. The atomizer as recited in claim 1, further comprising an induction member disposed interior of the chamber; and an induction coil disposed exterior of the chamber, wherein driving the induction coil induces heat in the induction member, to increase a temperature of a fluid in the chamber.

15. The atomizer as recited in claim 14, wherein the induction member and the induction coil are disposed on opposing sides of the actuator.

16. The atomizer as recited in claim 1, wherein the chamber defines an operating liquid level, wherein at the operating liquid level, an operating zone of the mesh is not in contact with the liquid.

17. The atomizer as recited in claim 1, further comprising a controller in signal communication with the actuator, the controller being configured to drive the actuator at a resonance frequency, wherein the resonance frequency is in a range from 1.6 MHz to 1.8 MHz.

18. A method of atomizing a liquid using the atomizer of claim 1, the method comprising: providing a vibrational displacement of the mesh relative to the frame solely by energizing the liquid in a chamber by the vibrational displacement of the actuator.

19. The method as recited in claim 18, further comprising heating the liquid in the chamber.

20. The method as recited in claim 18, further comprising holding the liquid in the chamber with a feed member.

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