Aperture plate and methods for its construction and use
First Claim
Patent Images
1. A method for forming an aperture plate, the method comprising:
- providing a mandrel comprising a plate body having a conductive surface and a plurality of non-conductive islands disposed on the conductive surface, wherein the islands extend above the conductive surface and are sloped relative to the conductive surface;
placing the mandrel within a solution containing a material that is to be deposited onto the mandrel;
applying electrical current to the mandrel to form an aperture plate on the mandrel, wherein the apertures have an exit angle that is in the range from about 30°
to about 60°
.
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Abstract
A method for performing an aperture plate comprises providing a mandrel that is constructed of a mandrel body having a conductive surface and a plurality of nonconductive islands disposed on the conductive surface. The mandrel is placed within a solution containing a material that is to be deposited onto the mandrel. Electrical current is applied to the mandrel to form an aperture plate on the mandrel, with the apertures having an exit angle that is in the range from about 30° to about 60°.
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Citations
35 Claims
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1. A method for forming an aperture plate, the method comprising:
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providing a mandrel comprising a plate body having a conductive surface and a plurality of non-conductive islands disposed on the conductive surface, wherein the islands extend above the conductive surface and are sloped relative to the conductive surface;
placing the mandrel within a solution containing a material that is to be deposited onto the mandrel;
applying electrical current to the mandrel to form an aperture plate on the mandrel, wherein the apertures have an exit angle that is in the range from about 30°
to about 60°
. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. An aperture plate comprising:
a plate body having a top surface, a bottom surface, and a plurality of apertures extending from the top surface to the bottom surface, wherein the apertures are tapered in a direction from the top surface to the bottom surface, and wherein the apertures have an exit angle that is in the range from about 30°
to about 60°
, and a diameter that is in the range from about 1 micron to about 10 microns at the narrowest portion of the taper.- View Dependent Claims (11, 12, 13, 14)
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15. A mandrel for forming an aperture plate, the mandrel comprising:
a mandrel body having a conductive, generally flat top surface and a plurality of non-conductive islands disposed on the conductive surface, wherein the islands extend above the conductive surface and have a geometry approaching a generally conical shape. - View Dependent Claims (16, 17, 18)
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19. A method for producing a mandrel that is adapted to form an aperture plate, the method comprising:
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a) providing an electroforming mandrel body;
b) applying a photoresist film to the mandrel body;
c) placing a mask having a pattern of circular regions over the photoresist film;
d) developing the photoresist film to form an arrangement of nonconductive islands corresponding to the location of the holes in the pattern; and
e) heating the mandrel body to permit the islands to melt and flow into a desired shape. - View Dependent Claims (20, 21, 22, 23, 24, 25, 26)
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27. A method for aerosolizing a liquid, the method comprising:
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providing an aperture plate comprising a plate body having a top surface, a bottom surface, and a plurality of apertures that taper in a direction from the top surface to the bottom surface, wherein the apertures have an exit angle that is in the range from about 30°
to about 60°
, and a diameter that is in the range from about 1 micron to about 10 microns at the narrowest portion of the taper;
supplying a liquid to the bottom surface of the aperture plate; and
vibrating the aperture plate to eject liquid droplets from the top surface. - View Dependent Claims (28, 29, 30)
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31. An aperture plate comprising:
a plate body having a top surface, a bottom surface, and a plurality of apertures extending from the top surface to the bottom surface, wherein the apertures each include an upper portion and a lower portion, wherein the lower portion extends upwardly from the bottom surface and is generally concave in geometry, and wherein the upper portion is tapered in a direction from the top surface to the bottom surface and intersections with the lower portion. - View Dependent Claims (32, 33, 34)
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35. A method for ejecting droplets of liquid, the method comprising:
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providing an aperture plate comprising a plate body having a top surface, a bottom surface, and a plurality of apertures that taper in a direction from the top surface to the bottom surface, wherein the apertures have an exit angle that is in the range from about 30°
to about 60°
, and a diameter that is in the range from about 1 micron to about 10 microns at the narrowest portion of the taper; and
forcing liquid through the apertures to eject liquid droplets from the front surface.
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Specification