Laser-Drilled Vibratable Membranes for Faster Aerosol Nebulization
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Solution Overview
Problem
Existing aerosol generators struggle to efficiently emit large volumes of fluid, particularly liquid, in a short period of time, especially when dealing with high viscosity or high surface tension fluids, leading to prolonged nebulization times and reduced user acceptance.
Innovation Solution
The aerosol generator features through holes in the vibratable membrane with a defined nozzle portion ratio, where the length of the nozzle portion is proportional to the total output rate, and the ratio of the total hole length to nozzle portion length is optimized to enhance the total output rate and reduce geometric standard deviation of droplet size distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the nozzle portion length is increased, then the geometric standard deviation of droplet size distribution decreases (narrower distribution), but the total output rate decreases
Solution Approach 1:
The patent optimizes the nozzle portion length parameter to a specific range (5-20 μm) to achieve the desired balance between droplet size uniformity (GSD) and total output rate. By precisely controlling this dimensional parameter, the invention resolves the contradiction between producing uniform droplets and maintaining high fluid emission rate.
2Productivity
If the nozzle portion length is decreased, then the total output rate increases, but the geometric standard deviation of droplet size distribution increases (wider distribution)
Solution Approach 1:
The patent establishes a lower bound for the nozzle portion length (5 μm) to prevent the GSD from becoming too large. This parameter optimization ensures that the droplet size distribution remains sufficiently narrow while allowing the output rate to increase, thus resolving the contradiction between productivity and precision.
3Quantity of substance
If a larger volume of liquid is emitted to deliver high concentrations of compound, then the total amount of compound delivered increases, but the nebulization time increases
Solution Approach 1:
The optimized nozzle portion length (5-20 μm) increases the total output rate of the aerosol generator. This allows the system to emit larger volumes of liquid containing the compound more quickly, thereby delivering the required amount of compound in a shorter nebulization time, resolving the contradiction between quantity delivered and time required.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration allows for faster nebulization of fluids, reducing application time by approximately 36% without significantly affecting droplet size characteristics, enhancing user comfort and effectiveness, particularly for medical compounds.
Implementation Method 1
The membrane may be vibrated by means of a piezoelectric actuator or any other suitable means.
Data Source
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AI summary
An aerosol generator for generating an aerosol from a fluid, comprising: a vibratable membrane (22) having a first side (24) for being in contact with the fluid and an opposite second side (25), the membrane having a plurality of through holes (26) penetrating the membrane in an extension direction (E) from the first side to the second side, whereby the fluid passes the through holes from the first side to the second side when the membrane is vibrated for generating the aerosol at the second side, each through hole (26) having along its extension direction (E) a smallest diameter (DS), a larger diameter (DL) that is larger than the smallest diameter and defined by that diameter that is closest to triple, preferably twice said smallest diameter, each through hole having a nozzle portion (32) defined by that continuous portion of the through hole in the extension direction comprising the smallest diameter of the through hole and bordered by the larger diameter of the through hole, wherein the ratio of the total length of each through hole (26) in the extension direction to the length of a respective one of said nozzle portions (32) in the extension direction is at least 4, preferably at least 4.5 and most preferred equal to or larger than 5, and wherein the through holes (26) are laser drilled through holes.