Inhaler Spray Nozzle Recess Structure for Uniform Jet Formation

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Solution Overview

Problem

Existing nebulizing nozzles face issues such as non-uniform channel lengths, channel exit deformation, and contamination due to high pressures, leading to suboptimal jet formation and droplet distribution, which are exacerbated by imprecise sawing and assembly processes.

Innovation Solution

A nozzle design with intersecting ejection channels and a recess at the front end, where channel exits are positioned within a recess with a depth greater than the channels, ensuring precise alignment and protection from damage or contamination, allowing for consistent jet formation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If wafer sawing is used to separate individual nozzles from the substrate, then productivity is improved through batch fabrication, but manufacturing precision deteriorates due to alignment errors affecting channel length uniformity

Engineering Contradiction:

Improvebatch fabrication efficiencyVSAvoidchannel length uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The recess is formed in the substrate before the wafer sawing process. This preliminary action creates a protective cavity that will house the channel exits, ensuring their positions are predetermined and protected against sawing-induced misalignment. The recess depth is specifically designed to extend beyond the channel exits, providing a buffer zone that compensates for potential alignment errors during subsequent separation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The recess acts as a cushioning structure that absorbs the impact of alignment errors during wafer sawing. By positioning the channel exits within this pre-formed recess rather than at the substrate surface, the design creates a tolerance buffer that protects against length variations caused by sawing angle deviations or positioning errors.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Productivity

If wafer sawing is used to separate nozzles, then productivity increases, but channel exit deformation occurs leading to non-uniform jet formation

Engineering Contradiction:

Improvebatch fabrication efficiencyVSAvoidjet formation quality

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The recess is formed in advance before wafer sawing, creating a protective cavity that houses the channel exits. This preliminary structuring ensures that the exits are positioned within a predefined geometric constraint that prevents deformation during the separation process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The recess provides a cushioning effect by absorbing mechanical stresses and alignment errors during sawing. The channel exits, being embedded within the recess rather than exposed at the surface, are protected from chip break-out and fringing that would otherwise deform the jet formation quality.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Ease of manufacture

If channel exits are positioned at the front end of the nozzle, then ease of manufacture is improved, but contamination risk increases during assembly and use

Engineering Contradiction:

Improvenozzle fabrication simplicityVSAvoidchannel exit contamination

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The channel exits are nested within the recess cavity rather than being exposed at the nozzle front surface. This nesting arrangement allows the exits to remain positioned at the front end for ease of manufacturing while simultaneously being protected within the recess structure that prevents dust and fingerprints from clogging the exits.

Inventive Principle:

Principle #7Nested doll (Nesting)

4Ease of operation

If channel exits are exposed at the front end, then ease of operation is improved, but damage risk increases during assembly and use

Engineering Contradiction:

Improvenozzle assembly simplicityVSAvoidchannel exit integrity

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The channel exits are nested within the recess, which provides a protective cavity that shields them from mechanical damage during assembly and use. The recess structure allows the exits to remain accessible for operation while being physically protected from impacts and contamination.

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentEP3768361B1Method for the fabrication of a spray nozzle for an inhalation device

Publication Date: 2025.11.26 INVOX BELGIUM NV

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AI summary

The invention relates to the field of inhalation devices for liquids. In particular, the invention relates to a nebulizing nozzle to be used in such an inhalation device, as well as a method for fabrication of such a nozzle. A nozzle for an inhalation device for nebulizing a liquid into a respirable aerosol has a nozzle body (1) which has a front end (1B) and which comprises at least two ejection channels (2, 2'), each channel (2, 2') having an channel exit (2A, 2A'), wherein the ejection channels (2, 2') are arranged such as to eject liquid along respective ejection trajectories which intersect with one another at a collision point. The nozzle is characterized in that at least one recess (3) is provided at the front end (1B) in which the channel exits (2A, 2A') are positioned. Disclosed is also a method for the fabrication of a nozzle body as defined above, use of such a nozzle in an inhalation device for nebulizing a liquid, and an inhalation device for nebulizing a liquid into a respirable aerosol, comprising such a nozzle.