RU2781445C2 - Sprayer assembly with oscillating chamber - Google Patents

Abstract

FIELD: spraying devices.

SUBSTANCE: invention relates to a sprayer assembly. The sprayer assembly contains an oscillating chamber containing a cavity containing liquid to be sprayed, an inlet for liquid for provision of supply of liquid to be sprayed to the cavity, an elastically deformed element, and a mesh element containing a set of nozzles. An actuator is made with the possibility of transfer of oscillations to the elastically deformed element. At the same time, the oscillating chamber and liquid contained in the cavity of the oscillating chamber form an oscillating system. Due to transfer of oscillations to the elastically deformed element by means of the actuator, pressure inside the cavity is changed. The actuator is made with the possibility of transfer of oscillations to the elastically deformed element at a resonance frequency of the oscillating system for pushing liquid contained in the cavity from the cavity through nozzles of the mesh element.

EFFECT: facilitation of generation of aerosol with a small drop size, while reducing power necessary for assembly operation.

25 cl, 7 dwg

Description

The present invention relates to an atomizer assembly. The present invention also relates to an aerosol generating system comprising an atomizer assembly, an aerosol generating apparatus for an aerosol generating system comprising an atomizer assembly, and a method for generating an aerosol with an atomizer assembly.

Portable electrical aerosol generating systems are known which consist of a power supply containing a battery and an electronic control circuit, and a cartridge containing an aerosol generating liquid substrate source held in a storage unit, and an electrical nebulizer assembly. In some examples, the nebulizer assembly may include an electrical heating element for generating an aerosol by heating and vaporizing a liquid substrate that generates an aerosol.

Some devices include an atomizer assembly comprising a mesh element defining one or more nozzles, wherein the device is configured to deliver an aerosol-forming liquid substrate to one side of the mesh element. The mesh member can vibrate when supplying the aerosol-forming liquid substrate to generate the aerosol by forcing droplets of the aerosol-forming liquid substrate through the nozzles. Such a design can be called an active mesh element.

Alternative embodiments may include an actuator configured to vibrate the mesh member when the aerosol-forming liquid substrate is supplied to force droplets of the aerosol-forming liquid substrate through the nozzles. This design can be called a passive mesh element.

An atomizer assembly containing a mesh element will exhibit the minimum droplet size that can be produced by the atomizer assembly for a particular liquid aerosol-forming substrate. A small droplet size is generally desirable in order to maximize delivery to the lungs of the aerosolized liquid substrate forming an aerosol. To maximize delivery to the lungs, droplet sizes of no more than 2.5 micrometers in diameter may be desirable. It is believed that at a droplet size of 2.5 micrometers in diameter or less, at least 80 percent of the droplets reach the lung alveoli upon inhalation.

One means of reducing the droplet size produced by the screen element is to reduce the size of the cross section of the nozzles. However, smaller cross-sectional nozzles require more pressure to force the aerosol-forming liquid substrate through the nozzles. Therefore, in known systems containing a mesh element, further reduction in the size of the cross section of the nozzles is usually not allowed when the required increase in fluid pressure is unacceptably large. Another means of reducing the droplet size produced by the screen element is to reduce the length of the nozzles. However, shorter nozzle lengths require a thinner screen element, which reduces the stiffness of the screen element and reduces the maximum pressure that the screen element can withstand. Other means are needed to reduce the droplet size produced by the mesh.

It would be desirable to provide an atomizer assembly that facilitates the generation of an aerosol having a small droplet size. For example, it would be desirable to provide an atomizer assembly that facilitates the generation of an aerosol having a droplet size of no more than 2.5 micrometers in diameter. It would be desirable to provide an atomizer assembly that reduces or minimizes the power required to operate the assembly.

According to a first aspect of the present invention, an atomizer assembly is provided. The atomizer assembly contains an oscillatory chamber containing: a cavity that contains the liquid to be sprayed; a liquid inlet for supplying a liquid to be sprayed into the cavity; an elastically deformable element and a mesh element containing a plurality of nozzles. The sprayer assembly also contains an actuator configured to communicate vibrations to the elastically deformable element. The oscillating chamber and the liquid contained in the cavity of the oscillating chamber form an oscillatory system, and due to the communication of vibrations to the elastically deformable element by means of the actuating device, the pressure inside the cavity changes. The actuating device is configured to communicate vibrations to the elastically deformable element at the resonant frequency of the oscillatory system to push the liquid contained in the cavity out of the cavity through the nozzles of the mesh element.

During use of the atomizer assembly, the liquid to be atomized is supplied to the cavity through the liquid inlet. The actuating device communicates vibrations to the elastically deformable element, pushing at least part of the liquid inside the cavity through a plurality of nozzles of the mesh element. The liquid pushed through the many nozzles of the mesh element forms a lot of droplets. The force pulse of the liquid pushed through the plurality of nozzles to form the plurality of drops carries the drops away from the mesh member. Therefore, during use, the atomizer assembly generates an aerosol containing liquid droplets expelled through the mesh member.

In the context of this document, the term "resonance" refers to forced vibration at the natural frequency of the system. Similarly, the term "resonant frequency" refers to an exciting oscillation at the natural frequency of the system. In other words, the actuator assembly of the atomizer is configured to impart vibrations to the elastically deformable element at the natural frequency of the oscillatory system.

The inventors of the present invention have determined that the atomizer assembly according to the present invention comprises an oscillatory system having a natural frequency that can be driven at resonance. Preferably, driving the vibrating system at resonance causes an increase in the amplitude of vibrations of the vibrating system compared to vibrations at other frequencies. This increase in the amplitude of oscillations of the oscillatory system provides a decrease in the amplitude of the excitatory oscillations supplied to the actuator, for example, the amplitude of the voltage or current supplied to the actuator, while maintaining the necessary amplitude of the oscillations of the oscillatory system to push fluid out of the nozzles of the mesh element at the required speed. Advantageously, a decrease in the amplitude of the excitatory vibrations applied to the actuating device may make it possible to reduce the power required to communicate vibrations to the elastically deformable element. Advantageously, actuating the vibrating system at resonance may also provide a reduction in the size of the actuator and the compliant element, since one or more of the actuator and the compliant element may be required to be larger at other frequencies in order to achieve the necessary oscillation amplitude to expel fluid from the nozzles. mesh element at the required speed.

An oscillatory system can have many natural frequencies, which can be called resonant modes or harmonics. The lowest natural frequency of an oscillatory system is usually called the fundamental frequency or the first harmonic of the oscillatory system. The actuator may be configured to oscillate the elastically deformable element at any suitable resonant frequency or harmonic. The actuating device can be configured to impart oscillations to the elastically deformable element at the resonant frequency of the oscillatory system, which is equal to the first harmonic. The actuating device can be configured to impart oscillations to the elastically deformable element at the resonant frequency of the oscillatory system, which is equal to or greater than the second harmonic of the oscillatory system. The actuating device can be configured to impart oscillations to the elastically deformable element at the highest harmonic of the oscillatory system.

Advantageously, the second harmonic drive oscillation of the oscillatory system may allow the atomizer assembly to eject droplets at a higher rate than when the system is driven at the first harmonic. The excitation oscillation of the oscillating system at higher harmonics can further increase the speed of ejection of droplets from the atomizer assembly. Increasing the droplet ejection rate from the nebulizer assembly may increase the volume of aerosol generated by the nebulizer assembly. Increasing the droplet ejection rate from the atomizer assembly may also allow the number of nozzles provided in the mesh member to be reduced without reducing the volume of aerosol generated by the atomizer assembly.

The actuator may be configured to oscillate the elastically deformable element at any suitable frequency to achieve resonance of the oscillatory system. For example, the actuator may be configured to oscillate the elastically deformable element at a frequency of from about 0.05 MHz to about 10.0 MHz, from about 0.1 MHz to about 5.0 MHz, from about 0.2 MHz to about 4 .5 MHz, about 0.3 MHz to about 3 MHz, about 0.4 MHz to about 2.5 MHz, or about 0.5 MHz to about 2 MHz.

One or more of the resonant frequencies or harmonics of the vibrating system may be determined during the calibration step. The calibration step may be performed prior to the user's first use of the atomizer assembly, for example, before the atomizer assembly leaves the factory. At the calibration stage, the vibration frequency of the elastically deformable element can be changed and the vibration amplitude of the oscillatory system at each frequency can be recorded. The resonant frequencies or harmonics of an oscillatory system can be determined by identifying peaks in the amplitude of the oscillating system at certain frequencies.

One or more of the determined resonant frequencies may be stored as resonant frequency calibration data. In some embodiments, the atomizer assembly may include a memory device that stores resonant frequency calibration data. In some embodiments, the control circuit may be associated with the nebulizer assembly and the control circuit may include a memory device storing resonant frequency calibration data. The control circuit may represent a control circuit for an aerosol generating device that includes or is configured to be used with an atomizer assembly.

The vibration chamber may be of any suitable shape. The oscillatory chamber, as a rule, can be formed from the body of the atomizer assembly, a mesh element and an elastically deformable element.

The atomizer assembly may include a housing. The housing may be formed from any suitable materials. Examples of suitable materials include metals, alloys, plastics or composite materials containing one or more of these materials, or thermoplastic materials suitable for use in the food or pharmaceutical industry, such as polypropylene, polyether ether ketone (PEEK) and polyethylene. The material may be lightweight and non-fragile.

The atomizer assembly may comprise one or more walls at least partially defining a cavity between the mesh element and the elastically deformable element. The atomizer housing assembly may include at least one side wall. The cavity may be limited by a mesh element, elastically deformable element and at least one side wall. The liquid inlet may pass through at least one side wall.

Preferably, the elastically deformable element is located opposite the mesh element. Preferably, the actuator is configured to oscillate the elastically deformable element towards and away from the mesh element.

The nebulizer cavity assembly may be of any suitable shape and size. The cavity of the atomizer assembly may be substantially cylindrical.

The capacity of the cavity of the oscillation chamber can be from about 0.30 microliter to about 50 microliter, from about 0.35 microliter to about 25 microliter, from about 0.40 microliter to about 12 microliter, or from about 0.45 microliter to about 9 microliter.

In some embodiments, the cavity of the atomizer assembly includes a central region located directly between the mesh element and the elastic element, and a radially outer region between the elastic element and the body of the atomizer assembly, located radially outside the central region. The cavity may further comprise a delimited region between the central region and the radially outer region. The restricted region may comprise a narrow region between the central region and the radially outer region that restricts fluid flow between the central region and the radially outer region. Providing a restricted area may allow the pressure generated in the central area to be greater than the pressure in a cavity without a limited area. The restricted area can also help to prevent the fluid in the cavity from being forced out of the cavity through the fluid inlet when the elastically deformable member oscillates. The central region may be substantially cylindrical. The radially outer region may be substantially annular or tubular. The radially outer region may extend into at least one side wall of the atomizer assembly. The radially outer region may provide storage for liquid that can be immediately available to replenish the central region when liquid is expelled from the central region through the nozzles of the mesh member.

The fluid inlet may extend through at least one side wall of the atomizer body assembly to a radially outer region. The fluid inlet may be located in at least one side wall such that the fluid inlet is offset from the central region of the cavity.

In some embodiments, the atomizer assembly may have a proximal end, a distal end opposite the proximal end, and a longitudinal axis extending between the proximal end and the distal end. The mesh element may be located at the proximal end. The cavity may comprise a central region between the mesh element and the elastically deformable element. The cavity may further comprise a radially outer region that extends at least partially along the side wall of the atomizer assembly in a longitudinal axis direction towards the distal end of the atomizer assembly. The fluid inlet may extend through the side wall of the nebulizer assembly into the radially outer region of the cavity. The liquid inlet may be located at a distance from the central region of the cavity along the longitudinal axis. In other words, the fluid inlet may be offset from the central region of the cavity. This fluid inlet arrangement can reduce the likelihood of fluid being forced out of the cavity through the fluid inlet when subjected to vibrations from the elastically deformable member. This fluid inlet arrangement can also reduce the likelihood of air entering the cavity center region from the fluid inlet.

The elastically deformable element may comprise any suitable elastically deformable material. For example, the elastically deformable element may contain plastic, rubber or silicone. In some preferred embodiments, the elastically deformable element contains silicone. In some embodiments, the elastically deformable element may comprise a metal or a metal alloy such as nickel, palladium, or a nickel-palladium alloy. The elastically deformable element may contain platinum or titanium. In some embodiments, the elastically deformable element may comprise stainless steel. In some embodiments, the elastically deformable element is formed from the same material as the atomizer body. In some embodiments, the elastically deformable element is formed from a material different from the material of the atomizer body. In some embodiments, the elastically deformable element is formed from the same material as the mesh element.

In preferred embodiments, the elastically deformable member is formed from a material that is chemically inert to the aerosol generating substrate.

The elastically deformable element may be substantially planar. In some embodiments, the elastically deformable element has a substantially constant thickness. In some embodiments, the compliant member has a thickness that varies across the compliant member. Part of the elastically deformable element may be in contact with the actuating device. Part of the elastically deformable element in contact with the actuating device may have a thickness that is greater than the thickness of other parts of the elastically deformable element.

In embodiments in which the vibrating chamber cavity comprises a central region between the mesh element and the compliant element, the compliant element may have a central region lying on top of the mesh element and a radially outer region located radially outside the central region. The thickness of the central region of the elastically deformable element may be greater than the thickness of the radially outer region of the elastically deformable element. In these embodiments, the actuator may lie on top of the central region of the elastically deformable element and the central region of the cavity. The actuating element can contact the elastically deformable element in the central region.

The actuator may include any suitable type of actuator. In some embodiments, the actuator may include a piezoelectric element. In some embodiments, the actuator may comprise an ultrasonic sonotrode.

The atomizer assembly may contain a preload element configured to compress the actuator between the preload element and the elastically deformable element. The preload element can be adjusted to change the compression of the actuator between the preload element and the elastically deformable element. In embodiments containing a piezoelectric element as an actuator, compressing the piezoelectric element using a preload element may increase the force generated by the actuator. It has been found that compressing or "preloading" a piezoelectric element by half the compressibility of the piezoelectric element can cause the piezoelectric element to exert a force that is ten times greater than that generated by an uncompressed piezoelectric element. The preload element can be adjustable. The preload element may include a screw. The preload element can be adjusted manually. The preload element can be adjusted automatically. The atomizer assembly may include a motor configured to move the preload element to change the compression of the actuator between the preload element and the elastically deformable element.

The preload member may be movably attached to the atomizer body assembly. Changing the position of the preload element relative to the atomizer body assembly can change the degree of compression of the actuator between the preload element and the elastically deformable element. For example, the preload element may include external screw threads and the atomizer assembly may include internal screw threads, and rotation of the preload element relative to the atomizer body may change the compression ratio of the actuator between the preload element and the elastically deformable element.

In particular, in embodiments where the actuator is a piezoelectric element, the piezoelectric element may be located between the preload element and the elastically deformable element. The piezoelectric element may be compressed between the preload element and the elastically deformable element. The preload element may be adjustable to change the degree of compression of the piezoelectric element between the preload element and the elastically deformable element.

The mesh element contains a plurality of nozzles. In the context of this document, the term "nozzle" refers to an opening, slot or hole in the mesh element, which provide a passage for fluid to move through the mesh element.

The mesh element may comprise an inner surface and an outer surface, wherein a plurality of nozzles extend between the inner surface and the outer surface. The inner surface of the mesh element may be facing the cavity of the oscillating chamber. The outer surface of the mesh element can be turned away from the cavity of the oscillation chamber.

The mesh element may be of any suitable size and shape. The mesh element may be substantially flat. The mesh element may be substantially circular.

The plurality of mesh element nozzles may be arranged in any suitable manner along the mesh element. In some embodiments, a plurality of nozzles may be arranged in a repeating pattern on the screen element. In some embodiments, a plurality of nozzles may be randomly positioned on the mesh element.

The mesh element may have a thickness between the inner surface and the outer surface. The thickness of the mesh element may be at least about 1 micrometer, at least about 2 micrometers, at least about 3 micrometers, at least about 4 micrometers, at least about 5 micrometers, at least about 6 micrometers, at least about 7 micrometers, at least about 8 micrometers, or at least about 9 micrometers. The thickness of the mesh element may be less than about 50 micrometers, less than about 45 micrometers, less than about 40 micrometers, less than about 35 micrometers, less than about 30 micrometers, less than about 25 micrometers, less than about 20 micrometers, less than about 15 micrometers, or less than about 12 micrometers. micrometers. The mesh element may have a thickness of approximately 10 micrometers.

Each nozzle may have a length, with the length of each nozzle being the shortest distance along the nozzle between the inner surface and the outer surface. The length of each nozzle may be the same as the thickness of the mesh element. The length of each nozzle may be at least about 1 micrometer, at least about 2 micrometers, at least about 3 micrometers, at least about 4 micrometers, at least about 5 micrometers, at least about 6 micrometers, at least about 7 micrometers, at least about 8 micrometers, or at least about 9 micrometers. The length of each nozzle may be less than about 50 micrometers, less than about 45 micrometers, less than about 40 micrometers, less than about 35 micrometers, less than about 30 micrometers, less than about 25 micrometers, less than about 20 micrometers, less than about 15 micrometers, or less than about 12 micrometers. Each nozzle may be approximately 10 micrometers long.

Each nozzle may have a maximum cross-sectional area. The maximum cross-sectional area of each nozzle may be perpendicular to the length of the nozzles. The maximum cross-sectional area of each nozzle may be at least about 0.01 square micrometer, at least about 0.05 square micrometer, at least about 0.1 square micrometer, at least about 0.2 square micrometer, at least at least about 0.3 square micrometer, at least about 0.4 square micrometer, at least about 0.5 square micrometer, at least about 0.6 square micrometer, at least about 0.7 square micrometer, or at least measure approximately 0.8 square micrometer. The maximum cross-sectional area of each nozzle may be less than about 20 square micrometers, less than about 19 square micrometers, less than about 18 square micrometers, less than about 17 square micrometers, less than about 16 square micrometers, less than about 15 square micrometers, less than about 14 square micrometers, less than about 13 square micrometers, less than about 12 square micrometers, less than about 11 square micrometers, or less than about 10 square micrometers.

Each nozzle may have a minimum cross-sectional area, wherein the minimum cross-sectional area of the nozzle is equal to or less than the maximum cross-sectional area of the nozzle. The minimum cross-sectional area of each nozzle may be at least about 0.01 square micrometer, at least about 0.05 square micrometer, at least about 0.1 square micrometer, at least about 0.2 square micrometer, at least at least about 0.3 square micrometer, at least about 0.4 square micrometer, at least about 0.5 square micrometer, at least about 0.6 square micrometer, at least about 0.7 square micrometer, or at least measure approximately 0.8 square micrometer. The minimum cross-sectional area of each nozzle may be less than about 20 square micrometers, less than about 19 square micrometers, less than about 18 square micrometers, less than about 17 square micrometers, less than about 16 square micrometers, less than about 15 square micrometers, less than about 14 square micrometers, less than about 13 square micrometers, less than about 12 square micrometers, less than about 11 square micrometers, or less than about 10 square micrometers.

Each nozzle may have any suitable cross-sectional shape.

Each nozzle may have a first cross-sectional shape along a second line parallel to the length of the nozzle. The first cross-sectional shape of each nozzle may be circular, elliptical, oval, triangular, square, rectangular, or any other polygonal shape. Preferably the first cross-sectional shape of each nozzle is triangular. The term "triangular" in the context of this document is used to refer to shapes containing a triangle or triangular elements. For example, the first cross-sectional shape may comprise a triangle, a truncated triangle, a truncated triangle with a square or rectangular portion extending from the truncated portion of the triangle, and the like. The predominantly triangular first cross-sectional shape may include converging flow region nozzles. Advantageously, the converging flow region can reduce or minimize the pressure required to force fluid through the nozzle, while also providing the required minimum cross-sectional area of the nozzle.

Each nozzle may have a second cross-sectional shape perpendicular to the second length of the nozzle. In other words, the second cross-sectional shape forms the maximum cross-sectional area of the nozzle. The second cross-sectional shape of each nozzle may be circular, elliptical, oval, triangular, square, rectangular, or any other polygonal shape. Preferably the second cross-sectional shape of each nozzle is circular.

Each nozzle may have a maximum width or diameter. The maximum diameter of each nozzle may be at least about 0.1 micrometer, at least about 0.25 micrometer, at least about 0.5 micrometer, at least about 0.75 micrometer, or at least about 1 micrometer. The maximum diameter of each nozzle may be less than about 10 micrometers, less than about 9 micrometers, less than about 8 micrometers, less than about 7 micrometers, less than about 6 micrometers, less than about 5 micrometers, or less than about 4 micrometers.

Each nozzle may have a minimum width or diameter, wherein the minimum diameter of each nozzle is equal to or less than the maximum nozzle diameter. The minimum diameter of each nozzle may be at least about 0.1 micrometer, at least about 0.25 micrometer, at least about 0.5 micrometer, at least about 0.75 micrometer, at least about 1 micrometer. The minimum diameter of each nozzle may be less than about 10 micrometers, less than about 9 micrometers, less than about 8 micrometers, micrometers, less than about 7 micrometers, less than about 6 micrometers, less than about 5 micrometers, or less than about 4 micrometers.

In embodiments where the mesh element comprises an outer surface and an inner surface, the mesh element may comprise a hydrophobic coating on the outer surface. The term "hydrophobic" in the context of this document is used to refer to a material that exhibits a water contact angle greater than 90 degrees. Advantageously, in embodiments in which the aqueous liquid is distributed through the mesh element, the hydrophobic coating advantageously increases or maximizes the contact angle between the aqueous liquid and the outer surface. Advantageously, an increased or maximally increased contact angle improves the release of liquid droplets from the outer surface. Advantageously, improving the release of liquid droplets from the outer surface can help reduce or minimize the size of the liquid droplets.

A hydrophobic coating may be provided in one or more regions of the outer surface. For example, the hydrophobic coating may include at least one annular region of hydrophobic material surrounding each nozzle.

The hydrophobic coating may be provided on the entire outer surface of the mesh element.

The hydrophobic coating may comprise at least one of polyurethane (PU), fluorocarbon (PFC), polytetrafluoroethylene (PTFE), and a superhydrophobic metal. Suitable superhydrophobic metals include microporous metals and metal meshes functionalized with carbon chains. Examples of metals include copper and aluminum.

The hydrophobic coating can be formed by surface modification. For example, the outer surface may be chemically modified to provide the desired degree of hydrophobicity.

The hydrophobic coating may be formed by depositing a hydrophobic material on the outer surface. For example, a hydrophobic material may be deposited on the outer surface using at least one of a physical vapor deposition process and a chemical vapor deposition process.

In some embodiments, the implementation of the mesh element contains a hydrophilic coating on the inner surface. The mesh element may contain a hydrophilic coating on at least one surface of the nozzle.

The term "hydrophilic" in the context of this document is used to refer to a material that has a water contact angle of less than 90 degrees. Advantageously, in embodiments in which the aqueous liquid is distributed through the mesh element, the hydrophilic coating may allow the aqueous liquid to flow to the first layer through at least one channel and at least one nozzle.

The hydrophilic coatings may contain at least one of 3: polyamide, polyvinyl acetate (PVAc), cellulose acetate, cotton, and one or more hydrophilic oxides. Suitable hydrophilic oxides include silica, alumina, titanium dioxide and tantalum pentoxide.

Hydrophilic coatings can be formed by surface modification. For example, the surface may be chemically modified to provide the desired degree of hydrophilicity. In embodiments in which the hydrophilic coating comprises at least one hydrophilic oxide, the hydrophilic coating may be formed by oxidizing the mesh-forming material.

Hydrophilic coatings can be formed by depositing a hydrophilic material on the surface of the mesh element. For example, the hydrophilic material may be deposited using at least one of the following methods: a physical vapor deposition method and a chemical vapor deposition method.

The outer surface of the mesh element may form an annular portion extending around each nozzle, wherein the thickness of the mesh element on each annular portion is greater than the thickness of the mesh element between adjacent annular portions. Advantageously, the annular portion can assist in separating the drop of liquid from the liquid remaining within each nozzle. In embodiments in which the mesh element comprises a hydrophobic coating, preferably at least a portion of the hydrophobic coating is provided on the annular portion. In embodiments in which the hydrophobic coating comprises one or more annular regions of hydrophobic material, preferably each annular region of hydrophobic material is located on the annular portion.

The annular portion may have a rounded shape. The advantageously rounded shape may further assist in separating the liquid drop from the liquid remaining within the nozzle. The annular part may have a semicircular shape in cross section.

In some embodiments, the mesh element may comprise a first layer and a second layer. The second layer may lie on top of the first layer. The first layer may form at least one channel. The second layer may form a plurality of nozzles. Each nozzle may lie on top of at least one channel. At least one channel may have a minimum cross-sectional area. Each nozzle may have a maximum cross-sectional area. The maximum cross-sectional area of each nozzle may be less than the minimum cross-sectional area of at least one channel.

The first layer may include a first surface and a second surface, with at least one channel extending between the first surface and the second surface. The second layer may comprise an inner surface and an outer surface, with at least one nozzle extending between the inner surface and the outer surface. Preferably, the inner surface of the second layer faces the second surface of the first layer. Preferably, the outer surface of the second layer is turned away from the first layer.

At least one channel may have a first length. The first length is the shortest distance along at least one channel between the first surface and the second surface. The first length of at least one channel is greater than the second length of the nozzles.

Preferably the first layer has a first thickness extending between the first surface and the second surface. Preferably the second layer has a second thickness extending between the inner surface and the outer surface. Preferably the first thickness is greater than the second thickness.

Preferably the first layer has a first thickness of at least about 0.1 mm, preferably at least about 0.15 mm, preferably at least about 0.2 mm, preferably at least about 0.25 mm, preferably at least about 0.3 mm. Preferably the first layer has a first thickness of less than about 1 mm, preferably less than about 0.95 mm, preferably less than about 0.9 mm, preferably less than about 0.85 mm, preferably less than about 0.8 mm, preferably less than about 0.75 mm , preferably less than about 0.7 mm, preferably less than about 0.65 mm, preferably less than about 0.6 mm.

The second layer preferably has a second thickness of at least about 1 micrometer, preferably at least about 2 micrometers, preferably at least about 3 micrometers, preferably at least about 4 micrometers, preferably at least about 5 micrometers, preferably at least about 6 micrometers, preferably at least about 7 micrometers, preferably at least about 8 micrometers, preferably at least about 9 micrometers. The second layer preferably has a second thickness of less than about 50 micrometers, preferably less than about 45 micrometers, preferably less than about 40 micrometers, preferably less than about 35 micrometers, preferably less than about 30 micrometers, preferably less than about 25 micrometers, preferably less than about 20 micrometers, preferably less than about 15 micrometers, preferably less than about 12 micrometers. The second layer may have a second thickness of approximately 10 micrometers.

Preferably, the at least one channel has a first length, the first length being the shortest distance along the at least one channel between the first surface and the second surface. In embodiments where the first layer has a first thickness, the first length of the at least one channel may be the same as the first thickness of the first layer. Preferably the first length is at least about 0.1 mm, preferably at least about 0.15 mm, preferably at least about 0.2 mm, preferably at least about 0.25 mm, preferably at least about 0, 3 millimeters. Preferably the first length is less than about 1 mm, preferably less than about 0.95 mm, preferably less than about 0.9 mm, preferably less than about 0.85 mm, preferably less than about 0.8 mm, preferably less than about 0.75 mm, preferably less than than about 0.7 mm, preferably less than about 0.65 mm, preferably less than about 0.6 mm. Preferably, the minimum cross section of the at least one channel is orthogonal to the first length of the at least one channel.

Preferably the at least one nozzle has a second length, the second length being the shortest distance along the at least one nozzle between the inner surface and the outer surface. In embodiments where the second layer has a second thickness, the second length of at least one nozzle may be the same as the second thickness of the second layer. Preferably the second length is at least about 1 micrometer, preferably at least about 2 micrometers, preferably at least about 3 micrometers, preferably at least about 4 micrometers, preferably at least about 5 micrometers, preferably at least about 6 micrometers. , preferably at least about 7 micrometers, preferably at least about 8 micrometers, preferably at least about 9 micrometers. Preferably the second length is less than about 50 micrometers, preferably less than about 45 micrometers, preferably less than about 40 micrometers, preferably less than about 35 micrometers, preferably less than about 30 micrometers, preferably less than about 25 micrometers, preferably less than about 20 micrometers, preferably less than about 15 micrometers , preferably less than about 12 micrometers. The second layer may have a second thickness of approximately 10 micrometers. Preferably, the maximum cross section of the at least one nozzle is orthogonal to the second length of the at least one nozzle.

Preferably the first length of at least one channel is greater than the second length of at least one nozzle.

A plurality of nozzles may lie on top of at least one channel.

At least one channel may be a single channel, with a plurality of nozzles overlying the single channel.

At least one channel may contain a plurality of channels, with each channel lying under at least two nozzles. The plurality of channels may comprise a first channel underlying the first plurality of nozzles and a second channel underlying the second plurality of nozzles.

Advantageously, providing a plurality of nozzles overlying each channel can simplify the fabrication of the mesh element by reducing the number of channels needed in the first layer.

Preferably, each channel lies under at least about 5 nozzles, preferably at least about 10 nozzles, preferably at least about 15 nozzles, preferably at least about 20 nozzles. Preferably, each channel lies under less than about 150 nozzles, preferably less than about 140 nozzles, preferably less than about 130 nozzles, preferably less than about 120 nozzles, preferably less than about 110 nozzles, preferably less than about 100 nozzles.

Preferably, the minimum cross-sectional area of at least one channel is at least about 0.01 square millimeters, preferably at least about 0.02 square millimeters, preferably at least about 0.03 square millimeters, preferably at least about 0, 04 square millimeters, preferably at least about 0.05 square millimeters. Preferably, the minimum cross-sectional area of at least one channel is less than about 0.5 square millimeters, preferably less than about 0.45 square millimeters, preferably less than about 0.4 square millimeters, preferably less than about 0.35 square millimeters, preferably less than about 0 .3 square millimeters.

At least one channel may have any suitable cross-sectional shape.

At least one channel may have a first cross-sectional shape along a first line parallel to the first length of at least one channel. The first cross-sectional shape of at least one channel may be circular, elliptical, oval, triangular, square, rectangular, or any other polygonal shape. Preferably the first cross-sectional shape of at least one channel is square or rectangular.

The at least one channel may have a second cross-sectional shape orthogonal to the first length of the at least one channel. In other words, the second cross-sectional shape defines the minimum cross-sectional area of at least one channel. The second cross-sectional shape of the at least one channel may be circular, elliptical, oval, triangular, square, rectangular, or any other polygonal shape. Preferably the second cross-sectional shape of the at least one channel is circular. At least one channel may have a minimum diameter. The minimum diameter of at least one channel may be at least about 0.1 mm, at least about 0.15 mm, at least about 0.2 mm, or at least about 0.25 mm. The minimum diameter of at least one channel may be less than about 1 mm, less than about 0.95 mm, less than about 0.9 mm, less than about 0.85 mm, less than about 0.8 mm, less than about 0.75 mm, less than about 0.7 mm, less than about 0.65 mm, or less than about 0.6 mm.

The first layer and the second layer can be made in one piece. In other words, the first layer and the second layer may be formed as a single element.

The second layer can be made separately from the first layer. Preferably the second layer is attached to the first layer. For example, the second layer may be attached to the first layer by at least one of the following methods: interference fit, adhesive, and welding.

The mesh element may comprise any suitable material. For example, the mesh element may comprise a silicon-on-dielectric plate. In embodiments comprising a mesh element having a first layer and a second layer, the first layer may comprise a first silicon wafer and the second layer may comprise a second silicon wafer. The mesh element may include a deep oxide layer between the first silicon wafer and the second silicon wafer. The deep oxide layer may be formed by oxidizing the surface of at least one of the first silicon wafer and the second silicon wafer before the first and second silicon wafers are bonded to each other.

A plurality of nozzles may be formed in the screen element using any suitable process. The plurality of nozzles may be formed using at least one of laser perforation and electrical discharge machining.

In embodiments comprising a mesh element having a first layer and a second layer, at least one channel may be formed in the first layer using any suitable process. At least one channel may be formed using at least one of laser perforation and electrical discharge machining.

The liquid to be sprayed may be an aerosol-forming liquid substrate. The liquid substrate forming the aerosol may contain nicotine. The liquid substrate forming the nicotine-containing aerosol may be a nicotine salt matrix. The aerosol-forming liquid substrate may contain material of vegetable origin. The aerosol-forming liquid substrate may contain tobacco. The aerosol-forming liquid substrate may comprise homogenized tobacco material. The aerosol-forming liquid substrate may comprise a non-tobacco material. The aerosol-forming liquid substrate may contain homogenized plant material.

The aerosol-forming liquid substrate may contain at least one aerosol-forming agent. An aerosol generating agent is any suitable compound or mixture of compounds known to the art which, when used, promotes the formation of a dense and stable aerosol. Suitable aerosol forming agents are well known in the art and include, but are not limited to: polyhydric alcohols such as triethylene glycol, 1,3-butanediol, and glycerol; polyhydric alcohol esters such as glycerol mono-, di-, or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. Aerosol forming agents are polyhydric alcohols or mixtures thereof, such as triethylene glycol, 1,3-butanediol and glycerol. The aerosol-forming liquid substrate may contain other additives and ingredients such as flavors.

The aerosol-forming liquid substrate may contain water.

The aerosolizing liquid substrate may contain nicotine and at least one aerosolizing agent. The aerosol forming agent may contain glycerin. The aerosol generating agent may contain propylene glycol. The aerosol forming agent may contain both glycerin and propylene glycol. The aerosol-forming liquid substrate may contain a nicotine concentration of from about 2% to about 10%.

The present inventors have determined that the eigenfrequencies of an oscillating system depend on the characteristics and properties of the liquid to be evaporated. In particular, the natural frequencies depend on the viscosity of the liquid to be evaporated.

In some embodiments, the liquid to be sprayed may have a specific viscosity. For example, the liquid to be sprayed may have a viscosity at 20 degrees Celsius that is equal to or less than about 40 centipoise (mPa⋅s), preferably equal to or less than about 35 centipoise (mPa⋅s), preferably equal to or less than about 30 centipoise ( mPa⋅s), preferably equal to or less than about 25 centipoise (mPa⋅s), preferably equal to or less than about 20 centipoise (mPa⋅s), preferably equal to or less than about 15 centipoise (mPa⋅s).

As used herein, viscosities refer to viscosities measured using a classic Brookfield viscometer, which measures the viscosity of a fluid by measuring the resistance to rotation of a spindle in the fluid at a specific speed or shear rate. Unless otherwise noted, the viscosity values given herein are the viscosity of an 8 milliliter (mL) sample volume of an aerosol-forming liquid substrate sample, measured using a Brookfield RVDV-II +Pro viscometer equipped with a Brookfield small sample adapter containing an SC4-13R cylindrical sample chamber; and an SC4-21 cylindrical spindle at 100 revolutions per minute (RPM).

The atomizer assembly may be configured to control the temperature of the liquid to be sprayed to control the viscosity of the liquid. Advantageously, lowering the viscosity of the atomized fluid to be atomized reduces the pressure required to force the fluid through the nozzles of the screen element. Increasing the temperature of the liquid to be vaporized can reduce the viscosity of the liquid. The atomizer assembly may be provided with a heater to heat the liquid to be sprayed. The heater may be configured to heat the liquid to be sprayed in the cavity to a predetermined temperature. The preset temperature may be from about 20 degrees Celsius to about 100 degrees Celsius, from about 70 degrees Celsius to about 90 degrees Celsius, and may preferably be about 80 degrees Celsius.

The aerosol-forming liquid substrate may have a viscosity at 80 degrees Celsius equal to or less than about 20 centipoise (mPa⋅s), preferably equal to or less than about 15 centipoise (mPa⋅s), preferably equal to or less than about 10 centipoise (mPa⋅s). ), preferably equal to or less than about 7 centipoise (mPa⋅s), preferably equal to or less than about 5 centipoise (mPa⋅s).

The nebulizer assembly may include a heater to heat fluid in the cavity. The heater may be configured to heat the fluid in the cavity to a predetermined temperature to control the viscosity of the fluid. The heater may be any suitable type of heater. Preferably the heater is an electrical heater.

Advantageously, heating the liquid can reduce the viscosity of the liquid. Advantageously, reducing the viscosity of the liquid can reduce or minimize the size of the liquid droplets formed by forcing the liquid through the nozzles.

The mesh element may include an electrical heating element located on the surface of the mesh element. Advantageously, an electrical heating element can be used to heat the liquid to be pushed through the nozzles of the mesh element.

The electrical heating element may be configured to directly heat the liquid to be extruded through the plurality of nozzles. An electric heating element may be located on the outer surface of the mesh element. In embodiments comprising a mesh element having a first layer and a second layer, an electrical heating element may be located on the outer surface of the second layer. In other embodiments, an electrical heating element may be located on the first surface of the first layer.

The electrical heating element may be configured to indirectly heat the liquid to be expelled through the nozzles. An electrical heating element may be located on the outer surface of the second layer.

The electrical heating element may include any suitable type of heating element. For example, an electrical heating element may include a heating element of a microelectromechanical system.

The electrical heating element may include an adhesive layer. The adhesive layer may assist in the adhesion of the electric heating element to the mesh element. The adhesive layer may comprise any suitable material. The adhesive layer may contain metal. The adhesive layer may contain tantalum.

The electrical heating element may include one or more resistive heating tracks. One or more resistive heating tracks may contain metal. One or more resistive heating tracks may contain at least one of the following materials: platinum, nickel and polysilicon.

The electrical heating element may comprise a passivation layer. The passivation layer may comprise at least one of the following materials: metal oxide and metal nitride. The passivating layer may contain at least one of the following materials: silicon nitride, silicon dioxide, titanium dioxide and alumina.

According to a second aspect of the present invention, an aerosol generating system is provided, comprising an atomizer assembly according to the first aspect of the present invention. The aerosol generating system further comprises a liquid reservoir containing a supply of liquid to be sprayed.

In some embodiments, the liquid reservoir and the nebulizer are contained in the same unit. In these devices, the liquid outlet of the liquid reservoir is in fluid communication with the liquid inlet of the oscillating chamber to supply liquid from the liquid reservoir to the cavity of the oscillating chamber.

In some embodiments, the aerosol generating system comprises a cartridge containing a liquid reservoir and an aerosol generating device configured to receive the cartridge in a retractable manner. The aerosol generating device may include a cartridge receiving device connector.

In some specific embodiments, the cartridge may further comprise an atomizer assembly. In these specific embodiments, the fluid outlet of the fluid reservoir may be in fluid communication with the fluid inlet of the nebulizer assembly. The nebulizer actuator assembly may be electrically coupled to the aerosol generating device when the cartridge is placed in the aerosol generating device. If the nebulizer assembly comprises an electrical heater, then the electrical heater may also be configured to be electrically connected to the aerosol generating device when the cartridge is placed in the aerosol generating device. In these particular embodiments, the cartridge may include a device connector comprising one or more electrical connectors for electrically connecting the cartridge to the aerosol generating device. The aerosol generating device may include an appropriate device connector comprising one or more electrical connectors for electrically connecting the device to the cartridge.

In some embodiments, the aerosol generating device may include an atomizer assembly. In these particular embodiments, the liquid reservoir of the cartridge may have a liquid outlet that is located in fluid communication with the liquid inlet of the nebulizer assembly of the aerosol generating device when the cartridge is placed in the aerosol generating device. In these particular embodiments, the cartridge may comprise a device connector comprising one or more liquid outlets for fluidly connecting the cartridge to an aerosol generating device. The aerosol generating device may include a suitable device connector comprising one or more fluid inlets for fluidly connecting the device to the cartridge.

The device connectors in the aerosol generating device and the cartridge may include at least one of a bayonet connector, a screw connector, a magnetic connector, and an interference fit connector.

The liquid reservoir may contain a container, wherein the liquid to be sprayed is held within the container. The container may be made from any suitable material. The container may be made of at least one of glass, metal or plastic. The container may be transparent. The container may be translucent.

The container may form an opening through which the aerosol-forming liquid substrate may flow out of the container. Preferably, the liquid reservoir comprises a seal overlying the opening to seal the aerosol-forming liquid substrate within the container. Preferably, the seal is at least one of the following: removable and breakable. The aerosol generating device may include a piercing element configured to pierce the seal when the fluid reservoir is at least partially contained in the connector of the device.

The aerosol generating device comprises a power source and a controller configured to control the power supply from the power source to the sprayer assembly actuator.

During use, the controller controls the power supply from the power source to the actuator to push liquid droplets through the mesh element, as described in this document.

In embodiments where the atomizer assembly comprises an electrical heating element, the controller is preferably configured to control the supply of power from a power source to the electrical heating element. The aerosol generating device may be configured to heat the electrical heating element during use to any suitable temperature, such as about 20 degrees Celsius to about 100 degrees Celsius, or about 70 degrees Celsius to about 90 degrees Celsius. The aerosol generating device is preferably configured to heat the electrical heating element during use to a temperature of approximately 80 degrees Celsius.

The power source may be a constant voltage source. In preferred embodiments, the power supply is a battery. For example, the power source may be a nickel-metal hydride battery, a nickel-cadmium battery, or a lithium-based battery such as a lithium cobalt, lithium iron phosphate, or lithium polymer battery. The power supply may contain another form of charge storage device such as a capacitor. The power supply may need to be recharged and may have a capacity that allows it to store enough energy to use the aerosol generating device with one or more liquid reservoirs.

An aerosol generating device may include a housing. The controller and power supply can be located inside the case. The connector of the device for accommodating the liquid reservoir may be located inside the housing. In those embodiments in which the device includes a nebulizer assembly, the nebulizer assembly may be located within the housing.

The body of the device may comprise any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics or composite materials containing one or more of these materials, or thermoplastic materials suitable for use in the food or pharmaceutical industry, such as polypropylene, polyether ether ketone (PEEK) and polyethylene. The material may be lightweight and non-fragile.

In some embodiments, the device body may define an aerosol chamber configured to receive liquid droplets expelled from the mesh element during use of the aerosol generating device. The aerosol generating device may include an air inlet in fluid communication with the aerosol chamber. The aerosol generating device may include an air outlet in fluid communication with the aerosol chamber.

The cartridge may include a housing. The cartridge body may comprise any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics or composite materials containing one or more of these materials, or thermoplastic materials suitable for use in the food or pharmaceutical industry, such as polypropylene, polyether ether ketone (PEEK) and polyethylene. The material may be light and non-fragile.

In some embodiments, the cartridge housing may define an aerosol chamber configured to receive liquid droplets expelled from the mesh element during use of the aerosol generating device. In these embodiments, the cartridge includes an air inlet in fluid communication with the aerosol chamber. The cartridge may include an air outlet in fluid communication with the aerosol chamber.

The aerosol generating device may include a mouthpiece in fluid communication with an air outlet. The mouthpiece can be made in one piece with the body. The mouthpiece may be detachable from the housing.

During use, the user puffs on the mouthpiece to draw air into the aerosol chamber through the air inlet. The air flows through the aerosol chamber, in which liquid droplets expelled from the mesh element are entrained in the air stream to form an aerosol. The aerosol exits the aerosol chamber through the air outlet and is delivered to the user through the mouthpiece.

The aerosol generating device may include a sensor for detecting airflow indicative of a user taking a puff. The air flow sensor may be an electromechanical device. The air flow sensor can be any of: a mechanical device, an optical device, an optical-mechanical device, and a microelectromechanical systems (MEMS) sensor. The controller may be configured to provide power from a power source to the atomizer actuator assembly in response to a signal from an airflow sensor indicating that the user is taking a puff.

In some embodiments, the aerosol generating device further comprises a liquid identification system for identifying the liquid to be sprayed contained in the liquid reservoir of the cartridge. The fluid identification system may include any suitable type of identification system.

The cartridge may further comprise an identifier for identifying the liquid that is contained in the liquid reservoir. The liquid identification system of the aerosol generating device may include a detector for detecting the cartridge identifier when the cartridge is placed in the aerosol generating device. For example, the cartridge may include an RFID tag and the device may include an RFID sensor. For example, the cartridge may contain a barcode, and the device may contain an optical sensor.

In some embodiments, the liquid identification system may include a sensor for measuring a property or characteristic of the liquid to be sprayed. The sensor may be supplied with a sample of the liquid to be sprayed from the liquid reservoir of the cartridge.

The controller of the aerosol generating device may be configured to control the power supply from the power source to the nebulizer assembly based on information received by the controller from the identification system.

In embodiments where the cartridge contains an identifier, reference data corresponding to known identifiers may be stored in the controller's memory. In these embodiments, the controller may be configured to compare information received from the identification system with stored reference data to determine whether the identifier detected by the identification system is a known identifier.

If the information received from the identification system matches the known identifier, this indicates that the cartridge is a genuine or approved manufacturer's cartridge that contains the correct liquid to be sprayed. If the information received from the identification system matches the known identifier, the controller may be configured to supply power from a power source to the sprayer assembly.

If the identifier is not a known identifier, the controller may determine that the cartridge is not a genuine or approved cartridge, which may not contain a suitable or approved fluid to be sprayed. In the event that the information received from the information detection system does not match the known identifier, the controller may be configured to prevent power from being supplied to the sprayer assembly from the power source.

In some embodiments, the controller may store reference data corresponding to a plurality of known identifiers. Each known identifier may also be associated with a specific fluid to be sprayed, which may require a certain amount of power to be supplied from the power source to the sprayer assembly. The controller may be configured to supply a particular power to the atomizer assembly based on a particular identifier, which is determined to be detected by the identification system.

In those embodiments in which a characteristic or property of the liquid stored in the liquid reservoir of the cartridge is measured or detected by the identification system, the controller may be configured to compare the information received from the identification system with one or more predefined threshold values to determine at least one of whether the liquid stored in the liquid reservoir is suitable for use with the atomizer assembly and the power to be supplied to the atomizer assembly.

The aerosol generating device may include a manually operated switch to initiate a puff by the user. The controller may be configured to supply power from a power source to the actuator of the sprayer assembly in response to a signal from a manually operated switch.

The aerosol generating device preferably includes an indicator to indicate that power is being supplied from the power source to the nebulizer actuator assembly. The indicator may include an indicator light that illuminates when power is applied from the power source to the sprayer actuator assembly.

The aerosol generating device may include at least one of the following: an external plug or connector and at least one external electrical contact, allowing the aerosol generating device to be connected to another electrical device. For example, the aerosol generating device may include a USB plug or USB connector to allow the aerosol generating device to be connected to another USB equipped device. The USB plug or USB connector may allow the aerosol generating device to be connected to a USB charger to charge the rechargeable power source in the aerosol generating device. The USB connector or plug may support data transfer to or from the aerosol generating device, or both to and from the device. The aerosol generating device may be connected to a computer to transmit data to the aerosol generating device.

In embodiments where the aerosol generating device includes a USB plug or socket, the aerosol generating device may further comprise a removable cover to cover the USB plug or socket when not in use. In embodiments in which the USB plug or USB connector is a USB plug, the USB plug may additionally or alternatively be selectively retractable from the device.

According to a third aspect of the present invention, an aerosol generating device is provided, comprising an atomizer assembly according to the first aspect of the present invention. The aerosol generating device also includes a power source and a controller configured to control the power supply from the power source to the sprayer assembly actuator. The aerosol generating device also includes a device connector for receiving a liquid reservoir and configured to supply liquid from the liquid reservoir to the liquid inlet of the nebulizer assembly.

According to a fourth aspect of the present invention, a method for controlling an atomizer assembly is provided. The atomizer assembly contains: an oscillatory chamber having: a cavity that contains the liquid to be sprayed; a liquid inlet for supplying a liquid to be sprayed into the cavity; an elastically deformable element and a mesh element containing a plurality of nozzles, and an actuating device configured to impart vibrations to the elastically deformable element. The method includes actuating an actuating device for imparting vibrations to the elastically deformable element at the resonant frequency of the oscillating system for pushing the liquid contained in the cavity out of the cavity through the nozzles of the mesh element.

In some embodiments, the implementation of the method includes actuating an actuator for communicating vibrations to an elastically deformable element at a resonant frequency of the oscillatory system, which is equal to or greater than the second harmonic of the oscillatory system.

It should be understood that any feature described in relation to one aspect of the present invention may also be applicable to another aspect of the present invention. Any aspect described with respect to the first aspect may be equally applicable to the second, third and fourth aspects, and vice versa. Any aspect described with respect to the second aspect may be equally applicable to the third and fourth aspects, and vice versa. Any aspect described in relation to the third aspect may be equally applicable to the fourth aspect, and vice versa.

The present invention will also be described solely by way of example with reference to the accompanying drawings, in which:

in fig. 1 is a cross-sectional view of a nebulizer screen assembly according to an embodiment of the present invention;

in fig. 2 is a plan view of the mesh element shown in FIG. one;

in fig. 3 is an enlarged cross-sectional view of a portion of the mesh element shown in FIG. one;

in fig. 4 is a cross-sectional view of one nozzle of the screen element shown in FIG. one;

in fig. 5 is a cross-sectional view of one nozzle of the mesh element shown in FIG. 1 illustrating an alternate outer surface of the second layer;

in fig. 6 is a cross-sectional perspective view of an atomizer assembly according to an embodiment of the present invention which has the screen element shown in FIG. one; and

in fig. 7 is a partial exploded cross-sectional view of an aerosol generating system according to an embodiment of the present invention.

In FIG. 1 and 2 show a screen assembly 10 for an atomizer according to an embodiment of the present invention. The mesh element 10 includes a first layer 12 defining a plurality of cylindrical channels 14 and a second layer 16 defining a plurality of nozzles 18. The nozzles 18 are grouped, with each group of nozzles 18 lying above one of the channels 14.

The mesh element 10 also includes an electrical heating element 19 located on the second layer 16. During use, the electrical heating element 19 heats the mesh element 10, which heats the fluid expelled through the nozzles 18.

In FIG. 3 and 4 show enlarged sectional views of one of the channels 14 and one of the nozzles 18. The first layer 12 includes a first surface 20 and a second surface 22. The second layer 16 includes an inner surface 24 facing the second surface 22 of the first layer 12. The second layer 16 also contains an outer surface 26 on which a hydrophobic coating 28 is provided. The first and second layers 12, 16 are made of silicon wafers. The deep oxide layer 30 is made by oxidizing the second surface 22 of the first layer 12 before bonding the first and second layers 12, 16 in place during the fabrication of the mesh element 10.

Each channel 14 has a minimum diameter 32 and a length corresponding to the thickness 33 of the first layer 12. The minimum diameter 32 of each channel 14 is significantly larger than the maximum diameter 34 of each overlying nozzle 18. Therefore, each channel 14 has a minimum cross-sectional area that is greater than the maximum cross-sectional area of each nozzle 18. As such, the length of the passage 14 does not affect the length of each nozzle 18 in determining the pressure required to force a given fluid through each nozzle 18. Advantageously, the thickness 33 of the first layer 12 may be chosen to provide the mesh element with the desired strength and stiffness. , without affecting the pressure required to push liquid drops out of the nozzles 18.

Each nozzle 18 has a triangular cross section so that each nozzle 18 has a maximum diameter of 34 on the inner surface 24 of the second layer 16 and a minimum diameter of 36 on the outer surface 26 of the second layer 16. The minimum diameter 36 of each nozzle 18 is selected according to the required droplet size. liquids expelled through the nozzle 18 during use. Each nozzle 18 has a length corresponding to the thickness 38 of the second layer 16. The thickness 38 of the second layer 16 is significantly less than the thickness 33 of the first layer 12 to minimize the length of each nozzle 18. The triangular cross-sectional shape of each nozzle 18 and the minimum length of each nozzle 18 reduce or minimize the pressure required to force a given fluid through each nozzle 18.

As shown in FIG. 5, the outer surface 26 of the second layer 16 may include an annular portion 40 of increased thickness surrounding each nozzle 18. The semicircular cross-sectional shape of each annular portion 40 facilitates the separation of liquid droplets from the liquid remaining within each nozzle 18 during use.

In FIG. 6 is a cross-sectional perspective view of an atomizer assembly 50 comprising a screen element 10 shown in FIG. 1. The mesh element 10 is placed inside the housing 52 of the mesh element. The atomizer assembly 50 also includes an elastically deformable element 54 and an actuator 56 configured to communicate vibrations to the elastically deformable element 54. The actuator 56 is a piezoelectric actuator.

The atomizer assembly 50 also includes a preload element 58 configured to compress the actuator 56 between the preload element 58 and the elastically deformable element 54. The preload element 58, the actuator 56 and the elastically deformable element 54 are located inside the housing 60 of the actuator. The actuator housing 60 is attached to the mesh element housing 52 to form a cavity 62 between the mesh element 10 and the resiliently deformable element 54. The actuator housing 60 defines a liquid inlet 64 to provide liquid to be sprayed into the cavity 62.

The elastically deformable element 54 extends radially outward from the mesh element 10 over the mesh element housing 52 to the actuator housing 60 . The region of the cavity 62 between the mesh element 10 and elastically deformable element 54 is essentially circular. The mesh body 52 includes a raised region 63 around the circumference of the mesh element 10 such that the gap between the mesh body 52 and the resilient element 54 narrows around the circumference of the mesh element 10. The narrow gap between the raised region 63 of the mesh body 52 and the resilient element 54 restricts the flow liquid into the area of the cavity 62 directly between the mesh element 10 and elastically deformable element 54, which contributes to the creation of high fluid pressure in this area. An outer cavity region 62 extending radially outward from the raised region 63 of the mesh element body 52 extends partially into the actuator body 60 to provide an area of the cavity 62 that is capable of holding a small volume of fluid outside the region immediately between the mesh element 10 and the elastically deformable element 54. This the outer region of the cavity 62 provides a reserve supply of liquid to the region between the mesh element 10 and elastically deformable element 54 as the consumption of fluid from this area during operation. A fluid inlet 64 is provided in the body actuator body 60 for supplying fluid to the outer region of the cavity 62. The fluid inlet 64 is positioned offset from the cavity region 62 between the mesh member 10 and the elastically deformable member 54. This fluid inlet arrangement can reduce the probability of expulsion of the liquid from the cavity through the inlet for the liquid when exposed to fluctuations from the elastically deformable element. This may also reduce the likelihood of air being drawn directly into this area from the fluid inlet 64.

During use, the liquid to be sprayed is supplied to the cavity 62 through the liquid inlet 64. Actuator 56 oscillates elastically deformable element 54 by forcing at least a portion of the liquid within cavity 62 through channels 14 and nozzles 18 of mesh element 10. Liquid pushed through nozzles 18 of mesh element 10 forms droplets. The force pulse of the liquid forced through the droplet nozzles 18 carries the droplets away from the screen element 10. Therefore, during use, the atomizer assembly 50 generates an aerosol containing liquid droplets pushed through the screen element 10.

In FIG. 7 shows a cross-sectional view of an aerosol generating system 70 according to an embodiment of the present invention. The aerosol generating system 70 includes an aerosol generating device 72 and a liquid reservoir 74 .

The aerosol generating device 72 includes a housing 76 comprising a first housing part 78 and a second housing part 80. The controller 82 and the power supply 84, providing the battery, are located inside the first part 78 of the housing. The mouthpiece 85 forming the mouthpiece channel 87 is configured to be connected to the second body part 80.

The second housing part 80 defines a liquid reservoir chamber 86 for receiving the liquid reservoir 74 . The first housing part 78 is detachable from the second housing part 80 to allow the fluid reservoir 74 to be replaced.

The aerosol generating device 72 also includes a device connector 88 located within the fluid reservoir chamber 86 for engagement with a reservoir connector 90 that forms part of the fluid reservoir 74.

The aerosol generating device 72 includes the nebulizer assembly 50 of FIG. 6, located in the second part 80 of the body. The fluid inlet 64 of the atomizer assembly 50 is in fluid communication with the connector 88 of the device. The mesh element 10 of the atomizer assembly 50 is located inside the aerosol chamber 92 formed by the second body part 80.

The fluid reservoir 74 comprises a container 94 and an aerosol-forming liquid substrate 96 disposed within the container 94. When the reservoir connector 90 is engaged with the device connector 88, the aerosol-forming liquid substrate 96 from the fluid reservoir 74 is supplied to the cavity 62 of the atomizer assembly 50 through the reservoir connector 90, the device connector 88, and the atomizer fluid inlet 64 assembly 50.

When the first housing part 78 is connected to the second housing part 80, the controller 82 controls the supply of power from the power source 84 to the actuator 56 for pushing droplets of the aerosol-forming liquid substrate 96 into the aerosol chamber 92 from the mesh member 10. The controller 82 includes a memory A that stores frequency calibration data. The frequency calibration data contains information corresponding to the power required to supply the actuator 56 to vibrate the elastically deformable element 54 at the resonant frequency of the oscillatory system. During operation, the controller 82 accesses the frequency calibration data stored in the memory and controls the power supply to the actuator 56 based on the frequency calibration data so that the elastically deformable element 54 oscillates at the resonant frequency of the vibrating system.

The second housing portion 80 defines an air inlet 98 and an air outlet 100, each of which is in fluid communication with the aerosol chamber 92. During use, the user puffs through the mouthpiece 85 to draw air into the aerosol chamber 92 through the air inlet 98 . The air passes through the aerosol chamber 92 where the aerosol-forming liquid substrate droplets 96 expelled from the mesh member 10 are entrained in the air stream to form an aerosol. The aerosol flows out of the aerosol chamber 92 through the air outlet 100 and is delivered to the user through the mouthpiece channel 87 .

The aerosol generating device 72 also includes an air flow sensor 102 located within the aerosol chamber 92. The air flow sensor 102 is configured to provide a signal to the controller 82 indicating that the user is puffing through the mouthpiece 85. The controller 82 is configured to supply power from the power source 84 to the actuator 56 of the atomizer assembly 50 only when the controller receives a signal from the sensor 102 airflow indicating that the user is puffing through the mouthpiece 85.

Claims (51)

1. Sprayer assembly, containing: an oscillatory chamber containing: a cavity containing a liquid to be sprayed; a liquid inlet for supplying a liquid to be sprayed into the cavity; elastically deformable element; and a mesh element containing a plurality of nozzles; and an actuating device configured to communicate vibrations to an elastically deformable element, wherein: the oscillating chamber and the liquid contained in the cavity of the oscillating chamber form an oscillating system; due to the communication of oscillations to the elastically deformable element by means of the actuating device, the pressure inside the cavity changes; and the actuating device is configured to communicate oscillations to the elastically deformable element at the resonant frequency of the oscillatory system to push the liquid contained in the cavity out of the cavity through the nozzles of the mesh element. 2. Atomizer assembly according to claim 1, characterized in that the actuating device is configured to communicate vibrations to the elastically deformable element at the resonant frequency of the oscillatory system, which is equal to the second harmonic of the oscillatory system or greater than it. 3. The sprayer assembly according to claim 1, characterized in that the actuator is configured to communicate vibrations to the elastically deformable element at the resonant frequency of the oscillatory system, which is equal to the first harmonic of the oscillatory system. 4. Sprayer assembly according to any one of paragraphs. 1, 2 or 3, characterized in that the actuator is configured to communicate vibrations to the elastically deformable element at a frequency of from about 0.05 MHz to about 10.0 MHz, or from about 0.1 MHz to about 5.0 MHz, or from about 0.2 MHz to about 4.5 MHz, or about 0.3 MHz to about 3 MHz, or about 0.4 MHz to about 2.5 MHz, or about 0.5 MHz to about 2 MHz. 5. Sprayer assembly according to any one of paragraphs. 1-4, characterized in that the elastically deformable element is located opposite the mesh element and the actuating device is configured to impart vibrations to the elastically deformable element to and from the mesh element. 6. Sprayer assembly according to any one of paragraphs. 1-5, characterized in that the oscillatory chamber contains walls forming a cavity for accommodating the liquid to be sprayed, and at the same time: the first of the walls contains elastically deformable element; the second of the walls, opposite the first wall, contains a mesh element; and one of the walls contains a fluid inlet. 7. Sprayer assembly according to claim 6, characterized in that the actuating device is configured to impart vibrations to the elastically deformable element to and from the mesh element. 8. Sprayer assembly according to any of the previous paragraphs, characterized in that the actuator contains a piezoelectric element. 9. Sprayer assembly according to claim 8, characterized in that it additionally contains a preload element, while the piezoelectric element is located between the preload element and the elastically deformable element. 10. The atomizer assembly according to claim 9, characterized in that the piezoelectric element is compressed between the preload element and the elastically deformable element and the preload element is adjustable to change the degree of compression of the piezoelectric element between the preload element and the elastically deformable element. 11. An atomizer assembly according to any one of the preceding claims, further comprising a heater configured to heat the liquid to be atomized contained in the cavity of the oscillation chamber. 12. Sprayer assembly according to claim 11, characterized in that the heater is located in or on the mesh element. 13. An aerosol generating system, comprising: sprayer assembly according to any one of paragraphs. 1-12 and a liquid reservoir containing a supply of liquid to be sprayed, the liquid reservoir in fluid communication with a fluid inlet of the oscillating chamber to supply liquid from the liquid reservoir to a cavity of the oscillating chamber. 14. An aerosol generating system according to claim 13, characterized in that the system comprises a cartridge containing a reservoir for liquid, and an aerosol generating device adapted to receive the cartridge with the possibility of removal. 15. An aerosol generating system according to claim 14, characterized in that the cartridge contains an atomizer assembly. 16. An aerosol generating system according to claim 14, characterized in that the aerosol generating device comprises an atomizer assembly. 17. An aerosol generating system according to claim 16, wherein the aerosol generating device further comprises a liquid identification system for identifying the liquid to be sprayed contained in the liquid reservoir of the cartridge. 18. The aerosol generating system according to claim 17, characterized in that the cartridge further comprises an identifier for identifying the liquid contained in the liquid reservoir, and the liquid identification system of the aerosol generating device comprises a detector for detecting the cartridge identifier when the cartridge is placed in aerosol generating device. 19. An aerosol generating device, comprising: sprayer assembly according to any one of paragraphs. 1-12; source of power; a controller configured to control the supply of power from the power source to the actuator; and a connector for receiving the liquid reservoir and configured to supply liquid from the liquid reservoir to the liquid inlet. 20. An aerosol generating device according to claim 19, characterized in that the aerosol generating device is configured to receive a cartridge containing a liquid reservoir, and wherein the aerosol generating device further comprises a liquid identification system for identifying the liquid to be sprayed contained in the cartridge fluid reservoir. 21. A method for controlling an atomizer assembly, the atomizer assembly comprising: an oscillatory chamber containing: a cavity containing a liquid to be sprayed; a liquid inlet for supplying a liquid to be sprayed into the cavity; elastically deformable element and a mesh element containing a plurality of nozzles; and an actuating device configured to communicate vibrations to an elastically deformable element, wherein the oscillatory chamber and the liquid contained in the cavity of the oscillatory chamber form an oscillatory system, and the method includes actuating an actuator to impart vibrations to the elastically deformable element at the resonant frequency of the oscillatory system to push the liquid contained in the cavity out of the cavity through the nozzles of the mesh element. 22. The method according to claim 21, characterized in that the method includes actuating an actuator to communicate vibrations to an elastically deformable element at a resonant frequency of the oscillatory system, which is equal to or greater than the second harmonic of the oscillatory system. 23. The method according to claim 21, characterized in that the method includes actuating an actuator to communicate vibrations to an elastically deformable element at a resonant frequency of the oscillatory system, which is equal to the first harmonic of the oscillatory system. 24. The method according to any one of paragraphs. 21, 22 or 23, characterized in that the actuator is configured to vibrate the elastically deformable element at a frequency of from about 0.05 MHz to about 10.0 MHz, or from about 0.1 MHz to about 5.0 MHz, or from about 0.2 MHz to about 4.5 MHz, or about 0.3 MHz to about 3 MHz, or about 0.4 MHz to about 2.5 MHz, or about 0.5 MHz to about 2 MHz. 25. The method according to any one of paragraphs. 21-24, characterized in that the elastically deformable element is located opposite the mesh element and the actuating device is configured to impart vibrations to the elastically deformable element to and from the mesh element.

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