AEROSOL GENERATOR WITH ELECTRICAL POWER CONDUCTING PINS

Abstract

An aerosol generator has a vibratable plate with apertures therein and an annular piezo which causes movement of the vibratable plate. An annular support member supports the piezo and the vibratable plate. A first electrical power conducting pin engages directly with a first, top, surface of the piezo. A second electrical power conducting pin indirectly conducts electrical power to a second surface of the piezo, by contacting an extension tab of the support member, also on its top side. There is a film of cured epoxy adhesive on the tab, providing excellent gripping force between the pin and the support. The aerosol generator avoids need for soldered joints for electrical contact, and the pins are conveniently mounted parallel to each on the same lateral and top side of the piezo and support member. The pins may have multi-point tips for particularly effective electrical contact.

Claims

1. An aerosol generator comprising: a first housing having a liquid reservoir; a second housing engaged with the first housing; a subassembly being received between the first housing and the second housing, the subassembly including: a vibratable member having apertures therein; a piezo element; and an annular member defining a central through hole, the vibratable member, and piezo element, and the annular member being located between the first housing and the second housing; a first electrical power conducting pin being received by the first housing and having an end electrically coupled with a first surface of the piezo element; and a second electrical power conducting pin being received by the first housing and contacting the annular member, the second electrical power conducting pin having an end electrically coupled with a second surface of the piezo element, the second surface being opposite the first surface.

2. The aerosol generator of claim 1, wherein the first electrical power conducting pin is positioned radially within the second electrical power conducting pin.

3. The aerosol generator of claim 2, wherein the first electrical power conducting pin is substantially parallel to the second electrical power conducting pin.

4. The aerosol generator of claim 3, wherein the first and second electrical power conducting pins are offset laterally on one side of the aerosol generator.

5. The aerosol generator of claim 1, wherein at least one of the first and second electrical power conducting pins is electrically coupled with a tab.

6. The aerosol generator of claim 1, wherein the liquid reservoir extends at an angle away from the first and second electrical power conducting pins.

7. The aerosol generator of claim 1, further including: a first seal element positioned upstream of the vibratable member; and a second seal element positioned downstream of the vibratable member.

8. The aerosol generator of claim 7, wherein the second housing includes a recess for receiving the second seal element.

9. The aerosol generator of claim 1, wherein the vibratable member is dome-shaped.

10. An aerosol generator comprising: a vibratable member having apertures therein; a piezo element electrically coupled with a source of electrical energy via a pair of contact pins so as to vibrate the vibratable member; an annular member defining a central through hole, wherein at least one contact pin of the pair of contact pins extending from a first surface of the annular member; a first seal element positioned upstream of the vibratable member; and a second seal element positioned downstream of the vibratable member, wherein at least one contact pin of the pair of contact pins is positioned radially between an outer diameter of the first seal element and an outer diameter of the second seal element.

11. The aerosol generator of claim 10, wherein at least one contact pin of the pair of contact pins is positioned radially outside of the outer diameter of the second seal element.

12. The aerosol generator of claim 10, wherein at least one contact pin of the pair of contact pins is positioned radially within the outer diameter of the second seal element.

13. The aerosol generator of claim 10, wherein a diameter of a radially inner surface of the first seal element is smaller than a diameter of a radially inner surface of the second seal element.

14. The aerosol generator of claim 10, further including a support housing receiving the second seal element and located on a downstream side of the annular member.

15. The aerosol generator of claim 14, wherein the support housing includes a recess for receiving the second seal element.

16. The aerosol generator of claim 10, wherein the pair of contact pins are offset laterally on one side of the aerosol generator.

17. The aerosol generator of claim 16, further including a liquid reservoir extending at an angle away from the pair of contact pins.

18. The aerosol generator of claim 10, wherein a first contact pin of the pair of contact pins is electrically coupled with a first surface of the piezo element, and wherein a second contact pin of the pair of contact pins is electrically coupled with a second surface of the piezo element, the second surface being opposite the first surface.

19. The aerosol generator of claim 18, wherein the first contact pin is positioned radially within the second contact pin.

20. An aerosol generator comprising: a first housing having a liquid reservoir; a second housing engaged with the first housing; a subassembly being received between the first housing and the second housing, the subassembly including: a dome-shaped vibratable member having apertures therein; a piezo element; an annular member defining a central through hole, the vibratable member, the piezo element, and the annular member being located between the first housing and the second housing; a first seal element positioned upstream of the dome-shaped vibratable member; and a second seal element positioned downstream of the dome-shaped vibratable member; a first electrical power conducting pin being received by the first housing and having an end electrically coupled with an upstream surface of the piezo element; and a second electrical power conducting pin being received by the first housing and contacting an upstream surface of the annular member, the second electrical power conducting pin having an end electrically coupled with a downstream surface of the piezo element, wherein the first electrical power conducting pin is positioned radially within the second electrical power conducting pin, and wherein at least one electrical power conducting pin of the first and second electrical power conducting pins is positioned radially between an outer diameter of the first seal element and an outer diameter of the second seal element.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0053] The invention will be more clearly understood from the following description of an embodiment thereof, given by way of example only, with reference to the accompanying drawings, in which:

[0054] FIGS. 1A and 1B are diagrammatic cross sectional views of a prior art aerosol generator, and

[0055] FIG. 2 is a perspective view of the connection of the aerosol generator of FIGS. 1A and 1B to conductive electrical pins;

[0056] FIG. 3 is an exploded perspective view of an aerosol generator according to the invention;

[0057] FIG. 4 is a cross sectional view of an aerosol generator according to the invention, including an enlarged view illustrating the core in more detail;

[0058] FIG. 5 is a perspective view showing how pins make solderless contact to drive the piezo, and

[0059] FIG. 6 shows conductive adhesive application on a support washer;

[0060] FIG. 7 is a perspective view of a spring pin;

[0061] FIG. 8 is a cross sectional view of the pin of FIG. 7; and

[0062] FIG. 9 is a perspective view of an alternative spring pin according to the invention.

[0063] FIGS. 10a-10e illustrate an alternative spring pin according to the invention.

DETAILED DESCRIPTION

[0064] Referring to FIGS. 3 to 6 of the drawings there is illustrated an aerosol generator 100 according to the invention. The aerosol generator comprises a vibratable member such as a vibratable aperture plate 1, a vibration generator 2, and a support washer 3. The vibration generator 2 in this case comprises an annular piezoelectric element (“piezo”) 2 having a first or upper surface and a second or lower surface. The piezo 2 is supported by the washer 3. The aperture plate 1 is supported by the support washer 3. A braze ring 4 is also provided.

[0065] In use, liquid to be aerosolised is received at a first upper surface of the aperture plate 1 and the piezo 2 is activated. Aerosolised liquid is generated at the second or lower surface of the aperture plate 1 by ejecting droplets of liquid upon activation of the piezo 2. The apertures in the aperture plate 1 are sized to aerosolise the liquid such that the majority of the droplets have a size of less than 6 micrometers.

[0066] The vibratable member could be non-planar, and may be dome-shaped in geometry.

[0067] Electrical power is supplied to the piezo 2 in this case by a first conducting pin 10 and a second conducting pin 11. The first conducting pin 10 is in direct contact with the upper surface of the piezo 2. The second conducting pin 11 is in electrical contact with the upper surface of the support washer 3 via conductive adhesive 20 on a tab 103 of the support washer 3. The washer 3 and the conductive adhesive 20 are in turn is in electrical contact with the lower surface of the piezo 2. This arrangement is best illustrated in FIGS. 4 to 6.

[0068] The support washer 3 in turn engages against a lower O-ring 25 which is housed in a groove 26 of a support housing 27. The support washer 3 also engages against an upper O-ring 28 in the upper part 29 of the main housing. The washer 3 is sandwiched between the upper O ring 28 and the lower O ring 25. This subassembly is in turn sandwiched between the upper housing 29 and the lower retainer clip 27. The arrangement of the lower retaining clip 27 provided uniform support around the support member 3, counter-balanced by the support forces applied via the O-ring 28 and the pins 10 and 11. This helps to achieve consistent operation of the aerosol generator 100, with reduced risk of fatigue in the seal between the plate 1 and the support washer 2, and a predictable plate vibration response to the applied electrical drive.

[0069] To accommodate automation low-cost manufacture and consequently greater manufacturing capacities to supply higher volume market demands, both spring pins 10, 11 are the same and are placed in the same direction of orientation.

[0070] By attaching the piezo 2 to the support washer 3 using an electrically conductive means, the second spring pin 11 provides electrical communication to the underside of the piezo 2 through the top surface of the washer 3. The first spring pin 10 provides electrical conduction through the top surface of the piezo 2.

[0071] In the invention electrical spring pins 10, 11 are used to connect directly between the female end of a detachable cable and the electrical surfaces of the piezoelectric generator 2. No soldering is required and the use of such pins facilitates assembly by automatic means.

[0072] To facilitate greater capacities, and to supply higher volume market demands the electrically conductive liquid adhesive 20 is used to attach the underside of the piezo 2 to the washer 3. This is applied by automatic means. The viscosity, rheology, application rate, bead thickness, pressure of support washer/piezo contact are optimised to facilitate application of the conductive liquid adhesive by automatic means, both in the annular pattern and as a pad on the tab 103. Such adhesives may be cured at normal temperature or may require exposure to higher predetermined temperatures for a preset period of time to form a strong bonding attachment. The optimum bonding attachment is achieved when the adhesive is cured to provide optimum strength condition. Epoxies are particularly suited for this application and more particularly those with tensile moduli in the range of 300 to 10,000 MPa and more typically in the range of 2,000-7,000 MPa. Such materials have resistances in the order of 1 milliohm/cm2, but could be higher up to 100 milliohm/cm2. Optimum mechanical properties are achieved when such adhesives are cured in the ranges of 3 minutes at 175 degrees centigrade to 240 minutes at 100 degrees centigrade. Typical hardness are in the range of 70-85 Shore D (ASTM D2240).

[0073] The piezo 2 may alternatively be attached to the washer 3 by means of soldering by automatic means to provide an electrically conductive path between the top of the washer and the bottom of the piezo 2.

[0074] Typically the piezo 2, when electrically excited, vibrates at approximately, 134 KHz. This presents several problems.

[0075] Using the spring pins 10 and 11, the interfacial electrical connection between the spring contact surface and the surface of the support washer 3 and the piezo 2, will be in pressure contact rather than mechanically connected together as with soldered joints. To ensure good electrical contact with spring pressure pins while the assembly vibrates at 134 KHz, to aerosolise medication in a corrosive ventilation circuit environment, the interfacial connection between the spring pin contact area and the surface of the washer and piezo are critical. Nebulisers incorporating the aerosol generator of the invention must be able to perform in a wide range of modes of use. Such nebulizers are often used intermittently over a 28 day period or can be used continuously for up to 7 days.

[0076] A number of undesirable mechanisms can occur such as oxidisation, corrosion mechanism, galvanic corrosion, mechanical vibrations, fretting wear to cause loss of electrical contact at the interface.

[0077] Referring particularly to FIG. 8, each pin 10, 11 comprises a plunger 30, a spring 31 and a barrel 32.

[0078] The spring contact force exerted by the spring pin is approximately between 1.3 and 3 Newtons which helps to reduce fretting wear as there is less pin bounce on the surface.

[0079] Choosing pin materials of a low electrical resistivity such as Beryllium Copper alloy (BeCu), Nickel (Ni), or Copper Zinc alloy (CuZn) and stainless steel (SS 303) contributes to increased electrical conductivity. Barrel materials such as copper, brass and bronze alloys exhibit good electrical conductivity as well as good corrosion resistance and mechanical strength and are suitable for this application.

[0080] Metallic coatings to prevent oxidisation of the interfacial surfaces such as Gold (Ag) over Nickel (Ni), also contribute to increased electrical conductivity. Coatings of 1-3 microns of gold over 3 microns of Nickel undercoat are particularly suitable. Spring parent materials can consist of Music Wire (ASTM A 228) and 304 Stainless Steel. Metallic coatings such as 0.05 microns of Gold over a 0.05 micron Nickel undercoat are especially suitable ‘Constriction’ of the electrical current at the electrical interface increases the contact electrical resistance and can cause an undesirable rise in temperature. The total effective area of electrical contact needs to be made as large as possible to help create and maintain acceptable quality of electrical connection.

[0081] A conventional semi-hemispherical pin head has the disadvantage of not being able to expose new effective contacting surfaces.

[0082] A vibrating multipoint contact pin head 50 as illustrated in FIG. 9 has the considerable advantage of being able to mechanically expose new areas for good electrical connection thus breaking down any oxidisation layers which can cause an insulation barrier. The multipoint contact pin increases the potential electrical contact surface area. The increased number of contact points, (which can vary in some embodiments from 7-14) act as a fail safe, if one contact becomes compromised the other contacts will form the required electrical contact. Additionally, the addition of the multi-points rather than a semi-hemispherical or flat contacting spring pin surface increases the specific force at these interfacial points, reducing the potential for undesirable fretting wear, and causing the multi-points to engage new micro surfaces. FIGS. 10a-10e show another multi-point head 60 having seven points 61, with a V angle between of 55°, giving a point angle of 62.5°.

[0083] It has been found that a combination of the multi-point conducting pin and the film of cured adhesive provide particularly good reliability of contact. The points or tips penetrate the film to a greater extent than they would the underlying material of the (steel) support member 3. This allows an optimum combination, in which the steel of the support member provides excellent rigidity for supporting the apertured membrane 1 and the piezo 2, while at the same time the film part of the support member allows excellent electrical contact despite the harsh environment, in which the nebulizer may be operating for a prolonged period.

[0084] Furthermore, the retainer and sealing arrangement also contribute to the above features to help ensure reliable operation. The retainer 27 and O-ring 25 provide comprehensive and uniform support directly below the piezo 2, while the smaller-diameter O-ring 28 transmits support forces from above closer to the circumference of the membrane 1 where it is supported by the support member 3.

[0085] As the aperture plate 1 is attached to the support washer 3 by a thermal means such as by brazing, the elevated temperatures to effect a good joint bond can have an undesirable effect on any plating applied to the washer 3, which is typically Stainless Steel or Hastelloy. It is not possible to apply plating afterwards as it is difficult to mask off the aperture plate to prevent the ingress of conductive plating materials such as silver, gold, nickel or such like into the apertures.

[0086] One way of overcoming this is to apply a conductive adhesive similar to the adhesive 20 that bonds the piezo 2 to the support washer 3. This can be applied by automatic means as part of the process of application to attach the piezo 2. It is not required on top of the piezo 2 to maintain conductivity with the spring pin 10 as such elements are typically silver coated.

[0087] A particular current and voltage is required to drive the nebulizer 100 at the desired frequency to generate the optimum aerosol range [2.5-6.5 μm particle size and flow rates between 0.1 and 2 ml/min] Voltages are typically 12V and the nebulizer is driven at 128 kHz. The multi-pointed spring pin 50 makes excellent electrical contact with the piezo 2 and the washer 3, achieving a uniform performance in which an aerosol plume has the desired characteristics of particle size and flow rate.

[0088] Because the piezo is annular it ensures uniform radial vibration, which allows the core to work at its optimum mode of vibration. This symmetrical arrangement allows the aperture plate to move perpendicular to the piezo in a uniform and consistent manner, with a uniform forces applied around its circumference. Importantly, the pins do not interfere with the mode of vibration. Their springs act as dampeners which ensure that these electrical connectors do not impact on the core's natural frequency. They add additional mass through a normal reaction to the core's movement, this normal reaction being absorbed via the pogo pin spring.

[0089] Also, it will be appreciated that the arrangement of the invention only requires two holding posts.

[0090] Because the pin 11 has conductive glue between itself and the main body of the support washer 3, fretting and resulting intermittency issues are avoided, and there is improved electrical connection. The use of a conductive glue reduces the potential of increased contact resistance which is a known indicator to electrical contact fatigue. Also, the use of multiple contact points 50 increases the potential electrical contact area.

[0091] The maintenance of electrical conductivity throughout the service life of the nebulizer is accomplished by the following features [0092] Pin contacting forces greater than L3N@2.1 mm deflection [0093] Materials selected with low electrical resistivity [0094] Less oxidising materials plated on to spring pin contacting surfaces [0095] Spring pin head geometry selected so as to provide multipoint connecting points to the mating surface [0096] Spring head geometry selected so as to expose new surfaces to better electrical connection.

[0097] Also, it will be appreciated that the invention is used in the manufacture of aerosol generators which require electrical connection which have demanding requirements and which are required to be manufactured in high volumes without the use of laborious hand soldering.

[0098] The invention is not limited to the embodiments hereinbefore described, with reference to the accompanying drawings, which may be varied in construction and detail. For example, there may be a film of a material such as that of the film 20 on the piezo, for contact with the first conducting pin.