Ultrasonic vibrator driving apparatus and mesh nebulizer

Abstract

An ultrasonic vibrator driving apparatus performs driving by applying an alternating voltage as a drive voltage to an ultrasonic vibrator that includes a piezoelectric element and has a unique resonance frequency. The drive voltage is generated with a variable frequency in a frequency range including the resonance frequency of the ultrasonic vibrator. The frequency of the drive voltage is repeatedly swept with a predetermined sweep width and a predetermined sweep period so as to include the resonance frequency, based on a reference frequency set according to the resonance frequency of the ultrasonic vibrator. The sweep period and the sweep width are restricted by being associated so as to fall within a predetermined allowed range on a two-dimensional map divided by the sweep period and the sweep width.

Claims

1. An ultrasonic vibrator driving apparatus that operates by applying an alternating voltage as a drive voltage to an ultrasonic vibrator that includes a piezoelectric element and has a unique resonance frequency, the ultrasonic vibrator driving apparatus comprising: a drive voltage generator to generate the drive voltage with a variable frequency in a frequency range including the resonance frequency of the ultrasonic vibrator; and a sweep controller to repeatedly sweep the frequency of the drive voltage with a predetermined sweep width and a predetermined sweep period so as to include the resonance frequency, based on a reference frequency set according to the resonance frequency of the ultrasonic vibrator, and to associate and restrict the sweep period and the sweep width such that the sweep period and the sweep width fall within a predetermined allowed region on a two-dimensional map divided by the sweep period and the sweep width.

2. The ultrasonic vibrator driving apparatus according to claim 1, further comprising a reference frequency setter to search for and obtain the resonance frequency of the ultrasonic vibrator by sweeping the frequency of the drive voltage before a start of operation of the ultrasonic vibrator, and to set the reference frequency according to the obtained resonance frequency.

3. The ultrasonic vibrator driving apparatus according to claim 1, wherein the ultrasonic vibrator is a horn vibrator defined by an integral structure including the piezoelectric element and a horn to transmit vibration of the piezoelectric element.

4. A mesh nebulizer comprising: the ultrasonic vibrator driving apparatus according to claim 3; and a flat plate-shaped or sheet-shaped mesh portion facing a vibration surface of the horn vibrator; wherein a medicinal liquid supplied between the vibration surface and the mesh portion is nebulized and sprayed through the mesh portion.

5. The ultrasonic vibrator driving apparatus according to claim 1, wherein the vibration of the ultrasonic vibrator is used to nebulize and spray a medicinal liquid; and the allowed region on the two-dimensional map is set such that a spray amount of the medicinal liquid is about 90% or more of a spray amount achieved when the ultrasonic vibrator is vibrated at the resonance frequency.

6. The ultrasonic vibrator driving apparatus according to claim 1, wherein the sweep controller sets the sweep width to sweep toward a side of exceeding the reference frequency to be smaller than the sweep width to sweep toward a side of being less than the reference frequency, while keeping the sweep period constant.

7. The ultrasonic vibrator driving apparatus according to claim 6, wherein the sweep controller sets the sweep width to sweep toward the side of exceeding the reference frequency to about 0.10 kHz and the sweep width to sweep toward the side of being less than the reference frequency to about 0.25 kHz, while keeping the sweep period constant.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a diagram showing a block configuration of an ultrasonic vibrator driving apparatus of a preferred embodiment of the present invention.

(2) FIG. 2 is a diagram showing a configuration of a nebulization unit of a mesh nebulizer in which the ultrasonic vibrator driving apparatus is mounted.

(3) FIG. 3 is a diagram showing a flow of control for a controller included in the ultrasonic vibrator driving apparatus.

(4) FIG. 4 is a diagram for illustrating processing for setting a reference frequency in the ultrasonic vibrator driving apparatus.

(5) FIG. 5A is a time-frequency (t-f) line diagram illustrating a manner in which a frequency f of a driving voltage is swept over time. FIG. 5B corresponds to FIG. 5A, and is a time-voltage (t-V) line diagram schematically showing a manner in which the drive voltage changes over time. FIG. 5C is a time-frequency (t-f) line diagram illustrating another manner in which the frequency f of the drive voltage is swept over time.

(6) FIG. 6 is a diagram showing an allowed range A for sweep periods and sweep widths in a table serving as a two-dimensional map divided by the sweep periods and the sweep widths.

(7) FIG. 7 is a diagram schematically showing how change in temperature of a horn vibrator and its surroundings is feedback-controlled.

(8) FIG. 8 is a diagram showing changes in impedance (indicated by a solid line) and phase (indicated by a broken line) of the horn vibrator accompanying a change in the frequency of the drive voltage.

(9) FIG. 9 is a diagram showing a practical range of frequencies of the drive voltage for a certain horn vibrator (resonance frequency is denoted by “fr”).

(10) FIG. 10 is a diagram showing changes in spray amount per unit time when the frequency of the drive voltage is changed, for three horn vibrator samples whose resonance frequencies differ due to manufacturing variations.

(11) FIG. 11 is a diagram showing changes in the resonance frequency accompanying changes in the ambient temperature (temperature dependency) for four horn vibrator samples with different resonance frequencies.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(12) Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings.

(13) FIG. 2 shows a configuration of a nebulization unit of a mesh nebulizer (indicated overall by the reference numeral 1) in which an ultrasonic vibrator driving apparatus 1 of a preferred embodiment of the present invention is mounted. The mesh nebulizer 1 includes a main body 10 that includes an opening 18 in its upper portion, and a horn vibrator 40 defining and functioning as an ultrasonic vibrator built into the main body 10. A power source switch (not shown) is provided on the outer surface of the main body 10.

(14) The horn vibrator 40 is preferably defined by an integrated structure including a vibration surface 43 horizontally opposing the opening 18 arranged thereabove, a piezoelectric element 41 arranged at a position separated downward from the vibration surface 43, and a horn 42 that is located between the piezoelectric element 41 and the vibration surface 43 and amplifies and transmits the vibration of the piezoelectric element 41 to the vibration surface 43. The drive voltage for the horn vibrator 40 (more accurately, the piezoelectric element 41) is supplied by a later-described ultrasonic vibrator driving apparatus 60. The horn vibrator 40 has a unique resonance frequency fr, as illustrated in FIGS. 8 and 9.

(15) A replacement member 20 is arranged by being detachably mounted between the opening 18 and the vibration surface 43. The replacement member 20 includes a film 21 defining and functioning as a flat sheet that opposes the vibration surface 43, and an approximately circular ring-shaped bottom plate portion 22 that supports the circumferential edge of the film 21. The film 21 is attached through adhesion or welding to the upper surface of the bottom plate portion 22. An approximately central region of the film 21 is a mesh portion 21a. Many minute through holes (not shown) that penetrate through the film 21 are provided in the mesh portion 21a. The bottom plate portion 22 is in contact at one location with an edge portion 43e of the vibration surface 43 in this example, for positioning. The replacement member 20 is supported by the horn vibrator 40 and an element (not shown) of the main body 10, in a state of being slightly inclined with respect to the vibration surface 43. Note that the mesh portion 21a may be include a structure including many minute through holes in a flat plate instead of the film 21.

(16) During operation of the mesh nebulizer 1, the user slightly tilts the main body 10 with respect to the vertical direction. Accordingly, liquid (in this example, medicinal liquid) is supplied from a liquid supply portion 17 in the main body 10 onto the vibration surface 43 of the horn vibrator 40 as indicated by arrow F. In other words, the medicinal liquid is supplied between the vibration surface 43 and the mesh portion 21a. Then, when the user switches on the power source switch, the drive voltage is applied to the piezoelectric element 41 of the horn vibrator 40 and the vibration surface 43 is vibrated via the horn 42. Accordingly, the medicinal liquid is nebulized through the mesh portion 21a (more accurately, through the multiple through holes penetrating through the film 21) and is sprayed through the opening 18.

(17) FIG. 1 shows a block configuration of the ultrasonic vibrator driving apparatus 60 mounted in the mesh nebulizer 1.

(18) The ultrasonic vibrator driving apparatus 60 includes a drive voltage generator 62 that generates a drive voltage (alternating voltage) to be applied to the horn vibrator 40 (more accurately, the piezoelectric element 41), a current detector 65 that detects the current flowing in the horn vibrator 40, and a controller 61 that controls the above-described drive voltage generator 62. Reference numeral 69 indicates grounding (GND).

(19) The drive voltage generator 62 includes a variable frequency oscillator 63 and an amplifier 64. The variable frequency oscillator 63 includes a commercially-available function generator IC (integrated circuit), for example, and generates a square-wave alternating voltage that is to be the origin of the drive voltage, with a variable frequency within a frequency range including the resonance frequency fr of the horn vibrator 40. In this example, the variable frequency oscillator 63 includes a function according to which it is possible to vary the frequency by about 0.05 kHz at a time, within a range of at least about 175 kHz to about 185 kHz. Also, the ratio between the positive voltage period and the negative voltage period of the alternating voltage is variable, but in this example, it is 1 to 1 (e.g., about 50% duty). The amplifier 64 amplifies the alternating voltage generated by the variable frequency oscillator 63 and outputs a drive voltage having sufficient amplification for driving the horn vibrator 40.

(20) The current detector 65 includes a resistance element (not shown) for current detection, for example, and an operational amplifier (not shown) that amplifies the voltage that dropped in the resistance element, and outputs the current that is to flow in the horn vibrator 40. In this example, the current detector 65 is used only to set a later-described reference frequency fo before the start of driving of the horn vibrator 40 and is not used during driving.

(21) The controller 61 includes a CPU (Central Processing Unit), controls the operation of the drive voltage generator 62 by functioning as a sweep controller, and controls the overall operation of the mesh nebulizer 1.

(22) As described with reference to FIGS. 8 and 9, when the frequency f of the drive voltage is slightly lower than the resonance frequency fr of the horn vibrator 40, the horn vibrator 40 vibrates efficiently, whereas if the frequency f of the drive voltage slightly exceeds the resonance frequency fr of the horn vibrator 40, the horn vibrator 40 substantially stops vibrating. Also, as described with reference to FIG. 11, if the temperature of the horn vibrator 40 and its surroundings increases, the resonance frequency fr of the horn vibrator 40 decreases, whereas if the temperature of the horn vibrator 40 and its surroundings decreases, the resonance frequency fr of the horn vibrator 40 increases.

(23) In view of this, in this mesh nebulizer 1, the controller 61 performs the processing shown in FIG. 3 to stably drive the horn vibrator 40, regardless of the manufacturing variation and temperature dependency of the resonance frequency.

(24) Specifically, when the power source switch of the mesh nebulizer 1 is switched on, before the start of the nebulization operation (the operation of the horn vibrator 40), in step S11 of FIG. 3, the controller 61 functions as a reference frequency setter to perform the following processing to set the reference frequency.

(25) That is, as shown in FIG. 4, the controller 61 sequentially changes the frequency f of the drive voltage generated by the drive voltage generator 62 (more accurately, the variable frequency oscillator 63) by about 0.2 kHz at a time in a range of about 175 kHz to about 185 kHz in this example. Here, the range in which the frequency f=about 175 kHz to about 185 kHz is a range in which it is expected that the resonance frequency fr of the horn vibrator 40 mounted on the main body 10 is definitely included, considering the manufacturing variation and temperature dependency of the resonance frequency. In addition, the controller 61 receives the output of the current detector 65 and sequentially samples and inputs the current value (effective value) of the current flowing in the horn vibrator 40. Furthermore, the controller 61 divides the voltage value (effective value) Ve of the drive voltage by the current value Ie to obtain the minimum value Zmin of the impedance Z of the horn vibrator 40 in the range in which the frequency f of the drive voltage is about 175 kHz to about 185 kHz, for example. Also, the frequency f when the minimum value Zmin is obtained is recognized as being the resonance frequency fr of the horn vibrator 40. In this manner, the controller 61 searches for and obtains the resonance frequency fr. Also, in this example, the reference frequency fo is set according to the obtained resonance frequency fr, so as to match the resonance frequency fr. That is, it is set such that fo=fr.

(26) Accordingly, even if the resonance frequencies fr of the individual horn vibrators 40 differ due to the manufacturing variation and temperature dependency of the horn vibrator 40, the reference frequency fo is able to be set appropriately according to the resonance frequencies fr of the individual horn vibrators 40.

(27) Note that in this example, the reference frequency fo is set so as to match the obtained resonance frequency fr, but there is no limitation to this. The controller 61 may also set the reference frequency fo to be slightly lower, for example, about 0.2 kHz lower than the obtained resonance frequency fr.

(28) Next, in step S12 of FIG. 3, the controller 61 functions as the sweep controller to control the frequency f of the drive voltage as described in (1) and (2) below.

(29) (1) Essentially, as shown in FIG. 5A, the controller 61 repeatedly sweeps the frequency f of the drive voltage by predetermined sweep widths Δf1 and Δf2 and a predetermined sweep period ΔS so as to include the resonance frequency fr, based on the reference frequency fo set according to the resonance frequency fr of the horn vibrator 40. Here, Δf1=Δf2>0 is set. In this example, in one sweep period ΔS, the frequency f of the drive voltage increases from the reference frequency fo to (fo+Δf1) toward the side of exceeding the reference frequency fo as time t elapses, and thereafter, the frequency f of the drive voltage linearly decreases to (fo−Δf2) toward the side of being less than the reference frequency fo, via the reference frequency fo, and furthermore linearly increases and returns to the reference frequency fo. FIG. 5B corresponds to FIG. 5A, and schematically shows a manner in which the drive voltage V changes accompanying the elapse of time t.

(30) In this manner, the controller 61 repeatedly sweeps the frequency f of the drive voltage with the predetermined sweep widths Δf1 and Δf2 and the predetermined sweep period ΔS so as to include the resonance frequency fr, based on the reference frequency fo set according to the resonance frequency fr of the horn vibrator 40. For example, at the time of starting operation, when the frequency f of the drive voltage is slightly (e.g., about 0.2 kHz) lower than the resonance frequency fr of the horn vibrator 40, the horn vibrator 40 vibrates efficiently. Accordingly, the temperature T of the horn vibrator 40 and its surroundings increases as indicated by arrow P1 in FIG. 7. When the temperature T of the horn vibrator 40 and its surroundings increases, the resonance frequency fr of the horn vibrator 40 decreases as indicated by the arrow P2 in FIG. 7. Accordingly, compared to the state at the time of starting operation, the period in the sweep period ΔS in which the frequency f of the drive voltage exceeds the resonance frequency fr of the horn vibrator 40 becomes longer, and the period of the sweep period ΔS in which the horn vibrator 40 substantially does not vibrate becomes longer. Accordingly, the temperature T of the horn vibrator 40 and its surroundings decreases as indicated by the arrow P3 in FIG. 7. When the temperature T of the horn vibrator 40 and its surroundings decreases, the resonance frequency fr of the horn vibrator 40 increases as indicated by the arrow P4 in FIG. 7. Accordingly, compared to the immediately prior state, the period in the sweep period ΔS in which the frequency f of the drive voltage is less than the resonance frequency fr of the horn vibrator 40 becomes longer, and the period of the sweep period ΔS in which the horn vibrator 40 efficiently vibrates becomes longer. Accordingly, the temperature T of the horn vibrator 40 and its surroundings increases once again as indicated by arrow P1 in FIG. 7. In this manner, the temperature change of the horn vibrator 40 and its surroundings is substantially feedback-controlled and suppressed or prevented. As a result, the horn vibrator 40 is stably driven, regardless of the temperature dependency of the resonance frequency fr of the horn vibrator 40. Also, since the sweeping is performed based on the reference frequency fo set according to the resonance frequency fr of the horn vibrator 40, the horn vibrator 40 is driven stably, regardless of the manufacturing variation of the resonance frequency fr of the horn vibrator 40.

(31) Note that, as shown in FIG. 5C, the sweep width Δf1 of sweeping toward the side of exceeding the reference frequency fo may also be set to be smaller than the sweep width Δf2 of sweeping toward the side of being less than the reference frequency fo while the sweep width ΔS is kept constant. Accordingly, a period of the sweep period ΔS in which the horn vibrator 40 substantially does not vibrate is shorter than the period in which the horn vibrator 40 efficiently vibrates. Accordingly, reduction of the driving efficiency of the horn vibrator 40 is suppressed or prevented.

(32) (2) Furthermore, the controller 61 associates and restricts the above-described sweep period ΔS and the sweep widths Δf1 and Δf2 for the frequency f of the drive voltage.

(33) Specifically, FIG. 6 shows an allowed region (denoted by diagonal lines) A for the sweep frequency ΔS and the sweep widths Δf1 and Δf2 in a table serving as a two-dimensional map divided by the sweep period and the sweep width. The table head (top row) of the table shown in FIG. 6 shows the divisions for the sweep period ΔS. In this example, the sweep period ΔS is divided into four divisions, namely about 0.05 msec, about 0.1 msec, about 1 sec, and about 10 sec. The table side (left column) of the table shown in FIG. 6 shows the divisions for the sweep widths Δf1 and Δf2. In this example, the sweep widths Δf1 and Δf2 are divided into five divisions with the following approximate values, namely “fo±0.75 kHz”, which indicates that Δf1=Δf2=0.75 kHz, “fo±0.5 kHz”, which indicates that Δf1=Δf2=0.5 kHz, “fo±0.25 kHz”, which indicates that Δf1=Δf2=0.25 kHz, “fo±0.1 kHz”, which indicates that Δf1=Δf2=0.1 kHz, and “fo-0.25 kHz to fo+0.1 kHz”, which indicates that Δf1=0.1 kHz and Δf2=0.25 kHz. The ◯ marks in the body of the table shown in FIG. 6 indicate that the spray amount of the medicinal liquid is about 90% or more of the spray amount (in this example, about 0.5 ml/m) when the horn vibrator 40 is vibrated at the resonance frequency fr in the divisions denoted by that mark. On the other hand, the x marks indicate that the spray amount of the medicinal liquid is less than about 90% of the spray amount achieved when the horn vibrator 40 is vibrated at the resonance frequency fr in the divisions denoted by that mark. For example, in the case where the sweep period ΔS=about 0.05 msec, if the sweep width Δf1=Δf2=about 0.74 kHz, the ◯ mark is used, and if Δf1=Δf2=about 0.76 kHz, the x mark is used. On the other hand, in the case where the sweep width Δf1=Δf2=about 0.5 kHz, if the sweep period ΔS=about 0.09 msec, the ◯ mark is used, and if the sweep period ΔS=about 1.1 msec, the x mark is used. The boundary Ao between the allowed region A denoted by the ◯ marks and the non-allowed region B denoted by the x marks was first confirmed through an experiment conducted by the inventors of preferred embodiments of the present invention. Note that in the division “fo-0.25 kHz to fo+0.1 kHz”, indicating that the sweep width Δf1=about 0.1 kHz and Δf2=about 0.25 kHz, the upper limit of the sweep period ΔS is greater than about 10 sec, which is extremely long, and therefore the upper limit of the sweep period ΔS was not confirmed.

(34) In view of this, regarding the frequency f of the drive voltage, the controller 61 controls the sweep period ΔS and the sweep widths Δf1 and Δf2 such that they fall within the allowed range A of the table shown in FIG. 6. For example, the sweep period ΔS is set to about 10 sec, the sweep width Δf1 is set to about 0.1 kHz, and the sweep width Δf2 is set to about 0.25 kHz. Accordingly, reduction of the driving efficiency of the horn vibrator 40 can be reliably suppressed or prevented. In this example, the spray amount of the medicinal liquid is about 90% or more of the spray amount achieved when the horn vibrator 40 is vibrated at the resonance frequency fr.

(35) During the nebulization operation, the controller 61 does not return to step S11 in FIG. 3, but continues the control (step S12 in FIG. 3) of the frequency f of the drive voltage in (1) and (2) above. Accordingly, the nebulization operation is not interrupted in order to obtain the resonance frequency fr and the user is not made to wait. Thereafter, in step S13 of FIG. 3, when a certain period (e.g., about 10 minutes) has elapsed since the user switched on the power source switch, or when the user switches off the power source switch, the controller 61 ends the processing.

(36) In this manner, with the mesh nebulizer 1 including the ultrasonic vibrator driving apparatus 60, the horn vibrator 40 accompanying the manufacturing variation and the temperature dependency of the resonance frequency is able to be driven stably while suppressing or preventing reduction of the driving efficiency. As a result, the medicinal liquid is able to be effectively nebulized and sprayed.

(37) In the above example, as shown in FIG. 6, the “two-dimensional map” preferably is a two-dimensional table with four divisions for the sweep period and five divisions for the sweep width, for example, but there is no limitation to this. There may also be fewer divisions for the sweep period and for the sweep width. Conversely, it is also possible to use a two-dimensional graph in which the divisions for the sweep period ΔS and the sweep widths Δf1 and Δf2 are very small, and thus the boundary Ao between the allowed region A and the non-allowed region B is substantially smooth. This kind of “two-dimensional map” is preferably stored in a storage or memory (not shown) included in the controller 61.

(38) Also, in the above example, as shown in FIGS. 5A and 5C, the frequency f of the driving voltage was increased and reduced linearly accompanying the elapse of time t, but there is no limitation to this. The frequency f of the drive voltage may also be swept in a curved manner, so as to draw a sine wave accompanying the elapse of time, for example.

(39) Also, in the above example, the ultrasonic vibrator was the horn vibrator 40, but there is no limitation to this. Preferred embodiments of the present invention can also be applied to an ultrasonic vibrator that does not include a horn and includes a piezoelectric element.

(40) While preferred embodiments of the present invention have been described above, it is to be understood that variations and modifications will be apparent to those skilled in the art without departing from the scope and spirit of the present invention. The scope of the present invention, therefore, is to be determined solely by the following claims.