Micro Atomizer Liquid-Gas Contact Space for Stable Aerosol Generation
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Solution Overview
Problem
Existing methods for generating aerosols at ultra-low liquid flow rates, such as those required in inhalation toxicology research, are inconsistent and unreliable, particularly in producing stable aerosol concentrations with particle sizes suitable for deposition in human airways, and often require large equipment or materials not resistant to organic solvents and caustic solutions.
Innovation Solution
A micro atomizer with a precisely formed liquid-gas contact space, utilizing a thick-wall liquid channel and cap with a controlled aerosol outlet orifice, where pressurized carrier gas and liquid interact, allowing for reproducible aerosol generation with liquid flow rates in the microliter per minute range, using a syringe and syringe drive for continuous liquid supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a modified commercially available pneumatic atomizer is used to generate aerosol at low liquid flow rates, then aerosol particle size and concentration can be adjusted, but the device requires large equipment size and high air flow rates (20 liters per minute) that are inappropriate for small aerosol chambers
Solution Approach 1:
The device segments the atomization process into distinct functional components: a micro-bore capillary tube for liquid delivery, a separate gas flow channel, and a defined interaction zone. This segmentation allows each component to be optimized independently, enabling ultra-low liquid flow rates while maintaining compact overall device dimensions suitable for small aerosol chambers.
Solution Approach 2:
The invention implements local quality by creating a specific region of intense gas-liquid interaction within the capillary tube structure. The gas flow is concentrated at the liquid exit point, creating a localized atomization zone that achieves efficient aerosol generation at ultra-low flow rates without requiring large device volumes or high air flow rates.
2Quantity of substance
If a modified commercially available pneumatic atomizer is used to generate aerosol at ultra-low liquid flow rates, then liquid flow control is improved, but the device requires air flow rates on the order of 20 liters per minute which cannot be operated in small aerosol chambers
Solution Approach 1:
The invention fundamentally changes the operating parameters by using a micro-bore capillary structure that enables atomization at air flow rates suitable for small chambers (less than 5 liters per minute) while maintaining precise control over ultra-low liquid flow rates. The capillary dimensions and gas-liquid interaction geometry are optimized to achieve efficient atomization at these reduced parameters.
3Quantity of substance
If existing atomization methods are used to generate aerosols at ultra-low liquid flow rates, then aerosol generation is achieved, but the aerosol concentrations are inconsistent and unreliable
Solution Approach 1:
The liquid is delivered through a micro-bore capillary tube that pre-configures the liquid flow into a consistent, controlled stream before it enters the atomization zone. This preliminary structuring of the liquid flow, combined with the defined gas-liquid interaction geometry, ensures reproducible aerosol generation at ultra-low flow rates, eliminating the inconsistency and unreliability of existing methods.
4Shape
If existing atomization methods are used to generate aerosols with particle sizes suitable for human airway deposition, then aerosol generation is achieved, but the particle size control is inconsistent and unreliable
Solution Approach 1:
The device creates a highly localized atomization zone within the capillary tube structure where gas and liquid interact in a precisely defined geometry. This local concentration of interaction energy, combined with the micro-bore dimensions, provides consistent control over particle size formation, reliably producing aerosols with MMAD between 0.5 and 10 microns suitable for human airway deposition.
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
The micro atomizer achieves stable and reproducible aerosol concentrations with particle sizes between 0.5 and 10 μm MMAD, suitable for inhalation studies and other applications, maintaining consistency and precision over extended periods, even at low liquid flow rates like 50 μl/hr.
Implementation Method 1
a liquid-gas contact space is formed by the internal surface of the cap and the substantially flat end of the liquid channel. Pressurized carrier gas and the liquid to be aerosolized are allowed to come into contact within the liquid-gas contact space
Implementation Method 2
A micro atomizer with a precisely formed liquid-gas contact space, utilizing a thick-wall liquid channel and cap with a controlled aerosol outlet orifice, where pressurized carrier gas and liquid interact, allowing for reproducible aerosol generation
Data Source
AI summary
A micro atomizer to produce stable aerosol concentrations having an aerosol mass median aerodynamic diameter (MMAD) of less than 10 microns with liquid flow rates in the microliter per minute range is provided. The micro atomizer includes a liquid channel in the shape of a thick-wall tube and a cap having an aerosol outlet orifice whereby a liquid-gas contact space is formed by the internal surface of the cap and the substantially flat end of the liquid channel. Pressurized carrier gas and the liquid to be aerosolized are allowed to come into contact within a precisely formed liquid-gas contact space. The desired aerosol characteristics are accurately established, stable, and reproducible. In an exemplary embodiment, the micro atomizer is used with a syringe and syringe drive to provide a continuous liquid source for aerosol generation.