Patent Application
20250058059
The present invention relates to nebulizers and their operation.
Known nebulizers include those of the type having a vibrating mesh or “aperture plate” which is vibrated by a drive such as a piezoelectric device. The piezoelectric device may be annular and mounted on a washer-shaped support for the aperture plate. Examples are those described in our PCT publications WO2012/046220 and WO2021/191160, the contents of which are incorporated herein by reference.
The present invention addresses the problem of providing automatic sensing of operation of the nebulizer with reduced or no interference with its operation, and/or in a manner which is simple and/or inexpensive. For example, if a non-invasive sensing arrangement can be provided the requirement for re-validation of a nebulizer can be avoided.
The invention provides a nebulizer as set out in the appended claims.
We describe a nebulizer comprising:
In one example the nebulizer comprises an outlet conduit for flow of droplets from the aperture plate, and the aerosol plume is detected in a space within said outlet conduit.
The delivery means may be a reservoir or alternatively a conduit with a pump pumping liquid onto the plate.
Preferably, the nebulizer comprises an outlet conduit downstream of the aperture plate, and the sensor is arranged to pick up an acoustic signal through said conduit. Preferably, the sensor comprises an acoustic transducer located adjacent or in contact with an outer surface of said conduit. Preferably, the transducer is pressed against an outer surface of the conduit. Preferably, the sensor is at least partially housed by a housing which is removably engageable with said conduit. Preferably, the housing is in the shape of a housing surrounding at least part of the outlet conduit. In one example, the housing supports the aerosol generator of the nebulizer.
Preferably, the sensor is located in the range of 1 mm to 20 mm from the aperture plate as measured along a longitudinal axis of the aperture plate. Preferably, the sensor is configured to monitor an acoustic signal in a frequency range which is lower than the drive frequency. Preferably, the sensor is configured to monitor an acoustic signal in a frequency band in the range of one third to two thirds of the drive frequency.
Preferably, the processor is configured to automatically determine area under a curve of acoustic intensity and time for one or more transducer pickup frequencies. In one example, the intensity is represented by voltage.
In one example, the aperture plate is dome shaped.
Preferably, the aperture plate is attached to an internal rim of a washer-shaped support. Preferably, the nebulizer comprises an upstream annular seal between the reservoir and the support, and a downstream annular seal between the support and a housing component.
Preferably, the housing component comprises a retainer which fits into the outlet conduit (6) and is arranged to press the downstream annular seal towards the support.
In one example, the nebulizer further comprises a cap for the reservoir, arranged to cover an opening of the reservoir.
The nebulizer may further comprise a support for a chamber, and the controller is configured to drive the aperture plate to provide a single dose of aerosol per chamber, in which the outlet conduit engages an aerosol chamber and in which the sensor provides feedback of presence or absence of an aerosol plume.
The controller may be configured to provide a series of doses to a series of chambers which are presented to the nebulizer, and to determine when the aerosol has been fully delivered into a chamber when the detector detects that there is no plume.
We also describe a method of operation of a nebulizer of any example described herein, the method comprising a liquid being delivered to the aperture plate, the aperture plate being driven to vibrate at the drive frequency or frequencies to provide an aerosol plume, the controller determining plume presence or absence according to the sensor detecting an acoustic signal from a space downstream of the aperture plate.
The method may comprise the steps of providing a series of aerosol chambers to the nebulizer, the controller operating to provide aerosol to each in a series of discrete operations, and in which completion of each dispensing operation is determined when there is little or no plume detected by the sensor.
The liquid may be a vaccine, and each chamber is for inhalation of a single vaccine dose by a patient.
The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example only with reference to the accompanying drawings in which:
The invention provides for very effective and non-invasive monitoring of plume generated by a vibrating mesh or aperture plate aerosol generator of a nebulizer. In one example the aerosol generator comprises a vibratable aperture plate, an annular support supporting the aperture plate, a vibration generator attached to the annular support, a power conductor for transferring power to the vibration generator, a downstream resilient seal mounted between a housing and the annular support on a side of the aperture plate opposed to the liquid supply reservoir, and an upstream resilient seal mounted between the annular support and the housing reservoir, and having an opening forming part of a throat over the aperture plate.
The nebulizer 1 further comprises a housing 20 surrounding the sensor, in which a lower part supports the circuit 11 and a top part supports and surrounds the acoustic transducer 10.
Referring specifically to
The reservoir top part 22 is in fluid communication with the inclined funnel-shaped lower part 21 for delivering liquid onto the aperture plate (“AP”) 41. The aerosol delivery tubular outlet 6 is below the AP, is integral with the reservoir 3, and is co-axial with the AP 41. The axis of the funnel 21 is inclined to the AP 41 axis. This allows use of the nebulizer at a wide range of orientations with gravity fall of the liquid onto the AP.
The conducting pins 31 and 32 are for conducting power to a piezoelectric vibration generator 46 of the aerosol generator 5, and are retained within, and guided by, the pin housing part 4 of the housing body 2.
The retainer 16 is for carrying the aerosol generator assembly 5, pressed against a lower surface of the reservoir 3. The aerosol generator assembly 5 comprises, from top down, an upstream seal namely the gasket 48, the piezoelectric vibration generator (“piezo”) 46, an adhesive ring 47 under the piezo 46, the aperture plate 41, a braze ring on the rim of the AP 41, an annular washer-shaped aerosol generator support (“washer”) 40, and a downstream annular resilient seal, in this case an O-ring 43. This assembly is supported by the retainer 16 and is surrounded by the aerosol delivery tube 6. The adhesive ring 47 bonds the (annular) piezo 46 to the washer 40, attaching the piezo to the washer in a manner which conducts electrical power to the underside of the piezo 46. A braze ring is an integral part of the rim of the aperture plate (“AP”) 41 and the internal rim of the washer 40, attaching the AP to the washer. In other examples the attachment of the AP may be bonded rather than brazed.
This example involves an electroformed aperture plate 41 with “hourglass” shaped apertures. However, in other examples the aperture plate may be formed by photo-defined technology as described in our prior patent specification nos. WO2012/092163 or WO2013/186031. There may be a reservoir layer of liquid supply cavities leading into the aerosol-forming apertures, formed in a manner for example as described in these specifications, and these may have a diameter in the range of 20 μm to 400 μm. Each cavity overlies multiple aerosol-forming apertures.
The retainer 16 is configured so as to securely support and contain the components of the aerosol generator assembly 5. It has a circumferential wall with a top rim and a pair of lower depending legs 62 with toes which snap fit as clips into corresponding recesses 67 of the aerosol outlet tube 6. At the upper end, a series of circumferentially extending elongate tabs define the outer surface of a circular seat for the gasket 48.
The retainer 16 also forms an annular seat for the downstream O-ring 43. The washer 40 is supported underneath by the O-ring 43 housed within the groove 68 of the retainer 6, the washer 40 resting on the O-ring 43 and itself supporting the piezo 46 adhered to the washer 40 top surface. The AP 41 is attached by the braze ring 42 to the washer 40.
The liquid supply reservoir funnel 21 has an internal tapered surface 26 inclined inwardly towards the AP 41, defining a throat 28 over the AP together with the gasket inner surface. The latter is not overhung by the housing, forming a continuation of the housing surface. By having two components, the gasket and the housing forming a reservoir shape leading to the aperture plate, it is convenient and versatile to provide a combination of surface types to optimise liquid flow to the AP, with minimization of bubble formation.
As is described in more detail below, as the aperture plate 41 is driven to vibrate, in one example at a frequency of 128 kHz, and droplets having a size in the range of 2 μm to 6 μm break off the lower surface of the plate. On average it takes more than one and less than three vibrations to provide a droplet, and so the frequency of droplet formation is less than the AP drive frequency. The flow of the droplets gives rise to a characteristic sound at a frequency which is less than the AP drive frequency, and the transducer 10 picks up this acoustic signal. It is tuned to a number of frequencies around a value of half of the drive frequency, in this case 64 kHz. The aerosol droplets move vertically downwardly within the conduit 6 from the AP 41 in a space indicated by 70 in
The support 106 comprises a ring 119 at the end of an arm 120, the ring 119 being configured to surround the tubular outlet 114, and it acts as a housing for an acoustic sensor 121 having a cylindrical housing 122 for an acoustic transducer at its distal end (nearest the conduit 114) and a drive and signal circuit, with a power lead 125 and a helical spring 123. The sensor housing 122 is held in a chamber 124 of the ring 119, the chamber guiding the sensor into position abutting the outlet conduit 114 when the conduit is encompassed by the ring 119.The sensor components, namely the sensor element 122, the helical spring 123, and the power lead 125 are retained by a plastics clip 126.
The aerosol generator assembly of the nebulizer 100 is the same as that of the nebulizer 1. The manner of operation of the sensors 10/11 and 22 are the same, both being located in contact with the outlet conduit through which the generated aerosol droplets flow. It is envisaged, though not as effective, to position the transducer spaced from the conduit wall by a distance in the range of 0.5 mm to 5 mm in other examples.
The nebulizer 100 is suited to dispense aerosol of a medication such as a vaccine into a succession of chambers 103. In one example this is in a vaccine station for high-volume dispensing of vaccines with successive operations of filling the chambers 103. In this case the sensor detection of plume is particularly advantageous because it allows control at the delivery end of the nebulizer, allowing accurate control of when a chamber is brought into registry with the nebuliser outlet conduit for consistent dispensing into the chambers 103.
Advantageously, the controller is configured to drive the aperture plate 41 to provide a single dose of aerosol per chamber 103, with the outlet conduit114 engaging the aerosol chamber 103 and in which the sensor 121 provides feedback of presence or absence of an aerosol plume. The sensing does not depend on an upstream condition such as presence of liquid on the aperture plate, the plum e absence or presence providing clear feedback of start and end of a single discrete dispensing operation.
Advantageously, the controller is configured to provide a series of doses to a series in this manner to chambers (103) which are presented to the nebulizer, wither manually or automatically by a handling system. It determines when the aerosol has been fully delivered into a chamber when the detector detects that there is no plume.
The method of operation of the nebulizer 100 is particularly advantageous for determining plume presence or absence according to the sensor detecting an acoustic signal from the space (70) downstream of the aperture plate. It is particularly advantageous where there are steps of providing a series of aerosol chambers to the nebulizer, the controller operating to provide aerosol to each in a series of discrete operations, and in which completion of each dispensing operation is determined when there is little or no plume detected by the sensor.
In one particular example the liquid is a vaccine, and each chamber 103 is for inhalation of a single vaccine dose by a patient.
The sensor in positioned on the outlet of the nebulizer The signal strength increases with distance from the AP 41 due to the plume diverging as it leaves the plate. The sensor is preferably located in the range of 1 mm to 20 mm from the aperture plate as measured along a longitudinal axis of the aperture plate.
The signal that is picked up by the sensor is developed as a result of how the droplets are formed.
The movement of the plate 41 and its mode shape determines how a droplet is formed, the majority of droplets are formed from the centre and the shoulder area as shown in
The sensor monitors delivery of liquid drug through detection of a unique acoustic signature of when delivering dose compared to the signature when delivery has ceased. During operation, the nebulizer is driven at a drive frequency of at 128 kHz. In addition to the output at the operating frequency, a small signal can be observed at sub-harmonic of the operating frequencies during delivery. The sensor of one example functions by monitoring a signal at 64 kilohertz range and analyzing the output for a distinct signature that is only present during delivery. In general, it is preferred that the transducer picks up signals in the range of one third to two-thirds of the drive frequency, because the droplets are primarily formed for one to three AP vibrations.
This signal is a by-product of the droplet formation and also partially due to energy transfer through the liquid. Droplets are not always created on each individual plate cycles. Droplet breakoff can also occur on every second cycle producing a unique output at half the operating frequency i.e. 64 kHz. Acoustic energy from the vibrating plate will transfer through the liquid, where it is picked up on the outer surface of the device as an acoustic signal.
We have found the largest increase in sound intensity occurs in the 64 KHz frequency band when the nebulizer is generating a plume with the AP driven at 128 kHz. The sensor has a hardware element to pickup and amplify the very small signal and a software element to process the signal and make the determination of plate status. Importantly, the sensor is not directly monitoring liquid presence on the AP, rather presence of a plume on the opposed (downstream) side of the AP.
The detected acoustic signal is amplified, using a two-stage amplifier to increase the intensity. The sensor circuit removes the unwanted frequencies using a band-pass filter, to leave only the area indicated by the box in
The signal from the amplifier stage, in the time domain, looks like the plot of
The invention provides a simple and low-cost method of detecting delivery. The nebulizer delivery is not altered in any way, therefore there is no concern for invalidating a previously approved system. The sensing is not affected by rainout of liquid on the sidewall of the nebulizer as is the case with any visual system (visual detection systems require continuous cleaning).
The sensor size is very small (approximately 10 mm in diameter in one example) and can be placed close to the nebulizer body, with minimal interference.
The sensor can be an ancillary product that can be added to any existing system. It can be used for bespoke delivery stations where delivery status information is a requirement. It may be added to the T-piece element in a standard Ventilator circuit, as shown in
In other embodiments the transducer could be distal from the nebuliser and rely on the material properties of a T-piece or other coupler to transmit the signal to the transducer. It has been shown that a rigid acrylic sheet with a hole to accommodate a press fit insertion of the transducer can facilitate this. The T-piece could incorporate the necessary geometry to locate the PCB, the battery, the transducer and light guide/illumination features.
In the examples shown the transducer is in direct contact with the body of the nebuliser, and in some examples a compressed spring provides a constant pressure between the contact surfaces to ensure good and consistent transfer of energy from the nebuliser body to the transducer. The transducer is primarily only making contact with the nebuliser body and the spring. In an alternative embodiment the transducer would be rigidly coupled to the bracket, and the bracket would serve as an energy transfer medium between the nebulizer body and the transducer.
The sensor support is configured to position the transducer at the ‘lowest’ point on the body, furthest from the AP whilst still leaving a portion (˜4.5 mm) of the ISO port 6/114 protruding such that it can interface with the 22 mm hole in the coupler for delivery of the aerosol.
Components of embodiments can be employed in other embodiments in a manner as would be understood by a person of ordinary skill in the art. The invention is not limited to the embodiments described but may be varied in construction and detail. For example, the liquid may be delivered to the aperture plate by a conduit. In one such example the liquid may be pumped. In another example the liquid is delivered by capillary action, with the conduit being sized for capillary flow.
| Number | Date | Country | Kind |
|---|---|---|---|
| 21215755.6 | Dec 2021 | EP | regional |
| 21215761.4 | Dec 2021 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/083919 | 11/30/2022 | WO |
