Microstructured Nozzle for Precise Aerosol MMAD Control
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Solution Overview
Problem
Existing aerosol generators face challenges in achieving precise aerosolization with miniature components, which are prone to wear and tear under high pressure, leading to inaccurate dosages and particle sizes due to complex nozzle designs and manufacturing difficulties.
Innovation Solution
A microstructured passage module with a simplified design featuring a plate and cover forming a compartment with specific filtering structures, including walls, pillars, and protrusions, configured to produce aerosols with a predetermined Mass Median Aerodynamic Diameter (MMAD) and spray duration, reducing manufacturing complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple elements with different geometric shapes are used in the nozzle to achieve desired aerosolization effect, then the aerosolization quality is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges multiple filtering and guiding elements into a single integrated nozzle structure. Instead of using separate elongated projections for filtering and cylindrical projections for flow guidance, the invention combines these functions into one monolithic component with optimized internal geometry, reducing assembly complexity while maintaining aerosolization performance
Solution Approach 2:
The nozzle structure is designed to perform multiple functions simultaneously: filtering liquid medicament, controlling flow direction, and generating aerosol particles. This multi-functional design eliminates the need for separate components, simplifying the overall device structure while achieving the desired aerosolization effect
2Volume of moving object
If miniature components are used in the aerosolizer, then the device size is reduced, but the reliability decreases due to wear and tear under high pressure
Solution Approach 1:
The patent employs a disposable nozzle design where the entire aerosolization component is replaced after a single use. This eliminates wear and tear issues by ensuring each nozzle is fresh and free from degradation, maintaining reliability while keeping the device compact. The disposable nature allows for precise manufacturing of miniature components without concern for long-term durability
Solution Approach 2:
The design anticipates potential failure modes by using a replaceable nozzle system. Before wear and tear can compromise reliability, the entire nozzle assembly is discarded and replaced with a new one, preventing performance degradation that would occur with repeated use of miniature components under high pressure
3Measurement precision
If complex nozzle design is used to control liquid flow, then the aerosol particle size precision is improved, but the ease of manufacture decreases
Solution Approach 1:
The patent achieves precise particle size control by optimizing specific geometric parameters of the nozzle internal structure, such as passage width, projection height, and curvature radii. By carefully selecting these parameters within specific ranges, the design attains precise aerosolization without requiring overly complex geometries, making the manufacturing process more feasible
Solution Approach 2:
The nozzle design incorporates localized geometric features at critical positions to achieve flow control and aerosol generation. Rather than making the entire nozzle structure complex, only specific regions have specialized geometries (such as rounded corners and specific projection shapes) necessary for function, while other areas maintain simpler forms easier to manufacture
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 module effectively delivers aerosols with a consistent MMAD less than 5.5 um and spray duration of approximately 1.6 seconds, enhancing treatment efficacy by ensuring precise aerosol deposition in lung regions while being more affordable and durable.
Implementation Method 1
The plate includes a filtering structure. An exemplary filtering structure includes walls, pillars, protrusions, and combination thereof
Implementation Method 2
The pressurized liquid medicament generally flows into the nozzle at a high speed. The nozzle serves to filter and decrease the flow speed of the liquid medicament in a controlled manner such that precise dosage of medicament can be aerosolized into the desired aerosol form
Implementation Method 3
During preparation, the biasing element, such as a spring, is tensioned by the relative movement of the upper housing and the lower housing. When the aerosolizer is actuated, a force generated by the un-tensioned biasing element pushes the fixed amount of liquid medicament towards and through the nozzle
Implementation Method 4
The structure, dimension and arrangement of the elements in the nozzle need to be carefully implemented to make the nozzle effective. The D and the W are specifically configured such that the aerosol has a predetermined MMAD
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A microstructured passage module (1) for aerosol generator is provided. The module includes a plate (10) overlaid by a cover (20) thus forming a compartment, an entrance (102) for liquid and an exit (104). The plate includes a plurality of walls (5) parallel to each other over its entire width so as to define a plurality of passages (18) threrebetween. Moreover, a plurality of pillars (4) protruding from the plate are distributed in at least section of the passages. A column (2) is disposed proximate to the exit and blocks a substantial part thereof, leaving longitudinal aisles (15) for the liquid to flow towards the exit. The liquid flows through the compartment from the entrance to the exit such that an aerosol (50) is produced. A distance between two adjacent pillars is D and the longitudinal aisle has a width W. The distance D and the width W are specifically configured such that the aerosol has a predetermined MMAD.