High mass throughput particle generation using multiple nozzle spraying

• US 20020007869A1
• Filed: 05/16/2001
• Published: 01/24/2002
• Est. Priority Date: 05/16/2000
• Status: Active Grant

• Current Assignee: Regents of The University of Minnesota (University of Minnesota)
• Original Assignee: Regents of The University of Minnesota (University of Minnesota)
• Inventors: Chen, Da-Ren, Pui, David Y.H.
• Granted Patent: US 6,764,720 B2
• Time in Patent Office: Days
• US Class Current: 141/173
• CPC Class Codes: A61F 2/86 Stents in a form characterised by the wire-like elements; Stents in the form characterised by a net-like or mesh-like structure
• CPC Class Codes: B05B 1/14 with multiple outlet openings B05B1/02, B05B1/26 take precedence; with strainers in or outside the outlet opening
• CPC Class Codes: B05B 13/06 specially designed for treating the inside of hollow bodies spray heads B05B1/00 - B05B7/00; devices for covering leaks in pipes or hoses, e.g. hose-menders, from inside the pipe F16L55/162; sprayed layers of rubber or plastics for internal protection of pipes or pipe fittings against corrosion or incrustation F16L58/1027
• CPC Class Codes: B05B 5/025 Discharge apparatus, e.g. electrostatic spray guns
• CPC Class Codes: B05B 5/0255 spraying and depositing by electrostatic forces only
• CPC Class Codes: B05B 5/032 for spraying particulate materials
• CPC Class Codes: B05B 5/08 Plant for applying liquids or other fluent materials to objects
• CPC Class Codes: B05B 5/087 Arrangements of electrodes, e.g. of charging, shielding, collecting electrodes B05B5/12, B05B5/14 take precedence; arrangements of electrodes on the discharge apparatus B05B5/0533
• CPC Class Codes: B05B 7/0408 with arrangements for mixing two or more liquids
• CPC Class Codes: B05B 7/066 with an inner liquid outlet surrounded by at least one annular gas outlet

Abstract

Spraying apparatus and methods that employ multiple nozzle structures for producing multiple sprays of particles, e.g., nanoparticles, for various applications, e.g., pharmaceuticals, are provided. For example, an electrospray dispensing device may include a plurality of nozzle structures, wherein each nozzle structure is separated from adjacent nozzle structures by an internozzle distance. Sprays of particles are established from the nozzle structures by creating a nonuniform electrical field between the nozzle structures and an electrode electrically isolated therefrom.

Claims

1. An electrospraying method, the method comprising:

providing a plurality of nozzle structures, wherein each nozzle structure comprises at least one opening defined along a center axis of the nozzle structure and terminating at a dispensing end thereof from which a spray of particles having an electrical charge applied thereto is dispensed, wherein each nozzle structure is separated from adjacent nozzle structures by at least an internozzle distance (L) defined by the distance between center axes of the nozzle structures, wherein the ratio of the internozzle distance (L) to a diameter (D) of the opening at the dispensing end is equal to or greater than 2; and

dispensing the spray of particles from each nozzle structure by creating a nonuniform electrical field between the dispensing ends from which the sprays are established and an electrode electrically isolated from the dispensing ends.

2. The method of claim 1, wherein each of the nozzle structures comprises a capillary tube comprised of a body portion and a tapered capillary tip at the dispensing end of the capillary tube.

3. The method of claim 1, wherein each of the nozzle structures comprises a tapered portion used to define the opening, and further wherein at least a part of each of the nozzle structures extend from an integral multiple nozzle structure conductive portion.

4. The method of claim 1, wherein each of the nozzle structures comprises a solid post along the center axis extending through the opening at the dispensing end.

5. The method of claim 1, wherein each of the dispensing ends of the nozzle structures are positioned in an x-y plane and have the center axis thereof aligned along the z axis.

6. The method of claim 1, wherein dispensing the spray of particles includes dispensing a spray of microdroplets including an active ingredient, and further wherein the electrical charge is concentrated on the active ingredient as the microdroplet evaporates.

7. The method of claim 1, wherein providing a plurality of nozzle structures comprises providing a circular configuration of nozzle structures comprising an outer multiple nozzle structure ring and one or more inner multiple nozzle structure rings, wherein each of the outer multiple nozzle structure ring and the inner multiple nozzle structure rings are concentric about a center nozzle structure, and further wherein each of the nozzle structrues of the one or more inner multiple nozzle structure rings are at a substantially equal internozzle distance (L) from adjacent nozzle structures.

8. The method of claim 7, wherein the dispensing ends of the plurality of nozzle structures lie in a plane.

9. The method of claim 7, wherein the dispensing end of the center nozzle structure lies in a first plane and at least the dispensing ends of the nozzle structures of at least one of the multiple nozzle structure rings lie in at least a second plane.

10. The method of claim 9, wherein the dispensing ends of the nozzle structures form a conical configuration with the dispensing end of the center nozzle structure at a tip of the conical configuration.

11. The method of claim 1, wherein the method further comprises isolating the dispensing ends of the nozzle structures from one another such that a cone jet is allowed to form at the dispensing end of each nozzle structure.

12. The method of claim 1, wherein isolating the dispensing ends of the nozzle structures from one another comprises positioning one or more separation structures between nozzle structures.

13. The method of claim 1, wherein the particles have a nominal diameter of about 1 nanometers to about 2000 nanometers.

14. The method of claim 1, wherein each of the nozzle structures comprise at least a first and second opening terminating at the dispensing end of each nozzle structure.

15. The method of claim 14, wherein the method further comprises:

providing a first flow of a first fluid composition at the first opening;

providing a second flow of a second fluid composition at the second opening; and

establishing a spray of particles from the first and second fluid compositions.

16. The method of claim 15, wherein the first fluid composition comprises an active ingredient and the second fluid composition comprises a coating component, and further wherein dispensing the spray of particles comprises dispensing a spray of coated active ingredients.

17. The method of claim 1, wherein the method further comprises:

providing excipient material; and

combining the spray of particles with the excipient material.

18. The method of claim 1, wherein the method further comprises:

providing a charged pattern; and

collecting the spray of particles on the charged pattern.

19. The method of claim 1, wherein dispensing the spray of particles comprises dispensing the spray of particles into a container operable for inhalation by a user.

20. The method of claim 1, wherein dispensing the spray of particles comprises dispensing the spray of particles at a rate in the range of 2 grams/minute to 50 grams/minute.

21. The method of claim 1, wherein the center axes of two or more nozzles are not parallel to one another.

22. An electrospraying method, the method comprising:

providing a circular configuration of nozzle structures comprising an outer ring of nozzle structures and one or more inner rings of nozzle structures, wherein each of the outer ring and the inner rings are concentric about a center nozzle structure, and further wherein the center nozzle structure and each of the nozzle structures of the one or more inner rings is at a substantially equal internozzle distance (L) from adjacent nozzle structures, and further wherein each of the nozzle structures comprises at least one opening defined along a center axis of the nozzle structure and terminating at a dispensing end thereof from which a spray of particles having an electrical charge applied thereto is dispensed; and

dispensing the spray of particles from each nozzle structure by creating a nonuniform electrical field between the dispensing ends from which the sprays are established and an electrode electrically isolated from the dispensing ends.

23. The method of claim 22, wherein the dispensing ends of the plurality of nozzle structures lie in a plane.

24. The method of claim 22, wherein each of the nozzle structures comprises a capillary tube comprised of a body portion and a tapered capillary tip at the dispensing end of the capillary tube.

25. The method of claim 22, wherein each of the nozzle structures comprises a tapered portion used to form define the opening, and further wherein at least a part of each of the nozzle structures extend from an integral multiple nozzle structure conductive portion.

26. The method of claim 22, wherein each of the dispensing ends of the nozzle structures are positioned in an x-y plane and have the center axis thereof aligned along the z axis.

27. The method of claim 22, wherein dispensing the spray of particles includes dispensing a spray of microdroplets including active ingredient, and further wherein the electrical charge is concentrated on the active ingredient as the microdroplet evaporates.

28. The method of claim 22, wherein the method further comprises isolating the dispensing end of the nozzle structures from one another such that a cone jet is allowed to form at the dispensing end of each nozzle structure.

29. The method of claim 22, wherein the particles have a nominal diameter of about 1 nanometers to about 2000 nanometers.

30. The method of claim 22, wherein each of the nozzle structures comprise at least a first and second opening terminating at the dispensing end of each nozzle structure.

31. The method of claim 22, wherein the method further comprises:

providing a first flow of a first fluid composition at the first opening;

providing a second flow of a second fluid composition at the second opening; and

establishing a spray of particles from the first and second fluid compositions.

32. The method of claim 31, wherein the first fluid composition comprises an active ingredient and the second fluid composition comprises a coating component, and further wherein dispensing the spray of particles comprises dispensing a spray of coated active ingredients.

33. The method of claim 22, wherein the method further comprises:

providing excipient material; and

combining the spray of particles with the excipient material.

34. The method of claim 22, wherein the method further comprises:

providing a charged pattern; and

collecting the spray of particles on the charged pattern.

35. The method of claim 22, wherein dispensing the spray of particles comprises dispensing the spray of particles into a container operable for inhalation by a user.

36. The method of claim 22, wherein dispensing the spray of particles comprises dispensing the spray of particles at a rate in the range of 2 grams/minute to 50 grams/minute.

37. An electrospraying method, the method comprising:

providing a plurality of nozzle structures, wherein each nozzle structure comprises at least one opening defined along a center axis of the nozzle structure at a dispensing end thereof from which a spray of particles having an electrical charge applied thereto is dispensed, wherein each nozzle structure is separated from adjacent nozzle structures by a distance;

structurally isolating the nozzle structures from one another such that a cone jet is allowed to form at the dispensing end of each nozzle structure; and

dispensing the spray of particles from each nozzle structure by creating a nonuniform electrical field between the dispensing ends from which the sprays are established and an electrode electrically isolated from the dispensing ends.

38. The method of claim 37, wherein structurally isolating the nozzle structures from one another comprises positioning one or more separation structures between nozzle structures.

39. The method of claim 37, wherein each of the nozzle structures comprises a capillary tube comprised of a body portion and a tapered capillary tip at the dispensing end of the capillary tube.

40. The method of claim 37, wherein each of the nozzle structures comprises a tapered portion used to form the opening, and further wherein at least a part of each of the nozzle structures extends from an integral multiple nozzle structure conductive portion.

41. The method of claim 37, wherein each of the nozzle structures comprises a solid post along the center axis extending through the opening at the dispensing end.

42. The method of claim 37, wherein each of the dispensing ends of the nozzle structures are positioned in an x-y plane and have the center axis thereof aligned along the z axis.

43. The method of claim 37, wherein the particles have a nominal diameter of about 1 nanometers to about 2000 nanometers.

44. The method of claim 37, wherein each of the nozzle structures comprise at least a first and second opening terminating at the dispensing end of each nozzle structure.

45. The method of claim 44, wherein the method further comprises:

providing a first flow of a first fluid composition at the first opening;

providing a second flow of a second fluid composition at the second opening; and

establishing a spray of particles from the first and second fluid compositions.

46. The method of claim 45, wherein the first fluid composition comprises an active ingredient and the second fluid composition comprises a coating component, and further wherein dispensing the spray of particles comprises dispensing a spray of coated active ingredients.

47. The method of claim 37, wherein the method further comprises:

providing excipient material; and

combining the spray of particles with the excipient material.

48. The method of claim 37, wherein the method further comprises:

providing a charged pattern; and

collecting the spray of particles on the charged pattern.

49. The method of claim 37, wherein dispensing the spray of particles comprises dispensing the spray of particles into a container operable for inhalation by a user.

50. The method of claim 37, wherein dispensing the spray of particles comprises dispensing the spray of particles at a rate in the range of 2 grams/minute to 50 grams/minute.

51. An apparatus for electrospraying particles, the apparatus comprising:

a particle source; and

a dispensing device configured to receive source material from the particle source, wherein the dispensing device comprises a plurality of nozzle structures, wherein each nozzle structure comprises at least one opening defined along a center axis of the nozzle structure and terminating at a dispensing end thereof, wherein each nozzle structure is separated from adjacent nozzle structures by at least an internozzle distance (L) defined by the distance between center axes of nozzle structures, wherein the ratio of the internozzle distance (L) to a diameter (D) of the opening at the dispensing end is equal to or greater than 2; and

an electrode isolated from the dispensing end, wherein a nonuniform electrical field is created between the dispensing ends and the electrode such that a spray of particles having an electrical charge applied thereto is dispensed from the dispensing end of each nozzle structure.

52. The apparatus of claim 51, wherein the electrode is a grounded target.

53. The apparatus of claim 51, wherein each of the nozzle structures comprises a capillary tube comprised of a body portion and a tapered capillary tip at the dispensing end of the capillary tube.

54. The apparatus of claim 51, wherein each of the nozzle structures comprises a tapered portion used to form the opening at the dispensing end, and further wherein at least a part of each of the nozzle structures extend from an integral multiple nozzle structure conductive portion.

55. The apparatus of claim 51, wherein each of the nozzle structures comprises a solid post along the center axis extending through the opening at the dispensing end.

56. The apparatus of claim 51, wherein each dispensing end of the nozzle structures are positioned in an x-y plane and have the center axis thereof aligned along the z axis.

57. The apparatus of claim 51, wherein the plurality of nozzle structures comprises providing a circular configuration of nozzle structures comprising an outer multiple nozzle structure ring and one or more inner multiple nozzle structure rings, wherein each of the outer multiple nozzle structure ring and the inner multiple nozzle structure rings are concentric about a center nozzle structure, and further wherein each of the nozzle structrues of the one or more inner multiple nozzle structure rings are at a substantially equal internozzle distance (L) from adjacent nozzle structures.

58. The apparatus of claim 51, wherein the dispensing ends of the plurality of nozzle structures lie in a plane.

59. The apparatus of claim 51, wherein the dispensing end of the center nozzle structure lies in a first plane and at least the dispensing ends of the nozzle structures of at least one of the multiple nozzle structure rings lie in at least a second plane.

60. The apparatus of claim 59, wherein the dispensing ends of the nozzle structures form a conical configuration with the center nozzle structure at a tip of the conical configuration.

61. The apparatus of claim 51, wherein the dispensing device further comprises one or more separation structures positioned between nozzle structures and configured such that cone jets are allowed to form at the dispensing end of each nozzle structure.

62. The apparatus of claim 51, wherein the particles have a nominal diameter of about 1 nanometers to about 2000 nanometers.

63. The apparatus of claim 51, wherein each of the nozzle structures comprise at least a first and second opening terminating at the dispensing end of each nozzle structure.

64. The apparatus of claim 63, wherein the particle source comprises a first particle source of at least a first fluid composition comprising an active ingredient to be dispensed through the first opening and a second particle source of at least a second fluid composition comprising a coating component to be dispensed through the second opening, and further wherein the sprays of particles comprise sprays of coated active ingredients.

65. The apparatus of claim 51, wherein the apparatus further comprises an excipient material provided on a target surface, the target surface positioned such that the sprays of particles are directed for contact with the excipient material.

66. The apparatus of claim 51, wherein the apparatus further comprises a charged pattern, the charged pattern positioned such that the sprays of particles is directed for contact with the charged pattern.

67. The apparatus of claim 51, wherein the apparatus further comprises a container operable by a user for inhalation of contents therein, the container positioned such that the sprays of particles are directed therein.

68. The apparatus of claim 51, wherein the sprays of particles are dispensed at a rate in the range of 2 grams/minute to 50 grams/minute.

69. The apparatus of claim 51, wherein the center axes of two or more nozzles are not parallel to one another.

70. The apparatus of claim 51, wherein each of the nozzle structures comprise a first capillary tube having a first opening terminating at the dispensing end and a second capillary tube concentric with at least a portion of the first capillary tube having a second opening terminating at the dispensing end.

71. An apparatus for electrospraying particles, the apparatus comprising:

a particle source; and

a dispensing device configured to receive source material from the particle source, wherein the dispensing device comprises a circular configuration of nozzle structures comprising an outer ring of nozzle structures and one or more inner rings of nozzle structures, wherein each of the outer ring and the inner rings are concentric about a center nozzle structure, and further wherein the center nozzle structure and each of the nozzle structures of the inner rings are at a substantially equal internozzle distance (L) from adjacent nozzle structures, and further wherein each of the nozzles structures comprise an opening defined along a center axis of the nozzle structure and terminating at a dispensing end thereof from which a spray of particles having an electrical charge applied thereto is dispensed; and

an electrode isolated from the dispensing end, wherein a nonuniform electrical field is created between the dispensing ends and the electrode such that a spray of particles having an electrical charge applied thereto is dispensed from the dispensing end of each nozzle structure.

72. The apparatus of claim 71, wherein the electrode is a grounded target.

73. The apparatus of claim 71, wherein each of the nozzle structures comprises a capillary tube comprised of a body portion and a tapered capillary tip at the dispensing end.

74. The apparatus of claim 71, wherein each of the nozzle structures comprises a tapered portion used to form the opening, and further wherein at least a part of each of the nozzle structures extend from an integral multiple nozzle structure conductive portion.

75. The apparatus of claim 71, wherein each of the dispensing ends of the nozzle structures are positioned in an x-y plane and have the center axis thereof aligned along the z axis.

76. The apparatus of claim 71, wherein the openings defined at the center axis of the plurality of nozzle structures lie in a plane.

77. The apparatus of claim 71, wherein the dispensing device further comprises one or more separation structures positioned between nozzle structures and configured such that cone jets are allowed to form at the dispensing end of each nozzle structure.

78. The apparatus of claim 71, wherein the particles have a nominal diameter of about 1 nanometers to about 2000 nanometers.

79. The apparatus of claim 71, wherein each of the nozzle structures comprise at least a first and second opening terminating at the dispensing end of each nozzle structure.

80. The apparatus of claim 79, wherein the particle source comprises a first particle source of at least a first fluid composition comprising an active ingredient to be dispensed through the first opening and a second particle source of at least a second fluid composition comprising a coating component to be dispensed through the second opening, and further wherein the sprays of particles comprise sprays of coated active ingredients.

81. The apparatus of claim 71, wherein the apparatus further comprises an excipient material provided on a target surface, the target surface positioned such that the sprays of particles are directed for contact with the excipient material.

82. The apparatus of claim 71, wherein the apparatus further comprises a charged pattern, the charged pattern positioned such that the sprays of particles are directed for contact with the charged pattern.

83. The apparatus of claim 71, wherein the apparatus further comprises a container operable by a user for inhalation of contents therein, the container positioned such that the sprays of particles are directed therein.

84. The apparatus of claim 71, wherein each of the nozzle structures comprise a first capillary tube having a first opening terminating at the dispensing end and a second capillary tube concentric with at least a portion of the first capillary tube having a second opening terminating at the dispensing end.

85. An apparatus for electrospraying particles, the apparatus comprising:

a particle source;

a dispensing device configured to receive source material from the particle source, wherein the dispensing device comprises a plurality of nozzle structures, wherein each nozzle structure comprises an opening defined along a center axis of the nozzle structure and terminating at a dispensing end thereof, and further wherein the dispensing device comprises one or more separation structures positioned between one or more of the nozzle structures and configured such that cone jets are allowed to form at the dispensing end of each nozzle structure; and

an electrode isolated from the dispensing end, wherein a nonuniform electrical field is created between the dispensing ends and the electrode such that a spray of particles having an electrical charge applied thereto is dispensed from the dispensing end of each nozzle structure.

86. The apparatus of claim 85, wherein the electrode is a grounded target.

87. The apparatus of claim 85, wherein each of the nozzle structures comprises a capillary tube comprised of a body portion and a tapered capillary tip at the dispensing end.

88. The apparatus of claim 85, wherein each of the nozzle structures comprises a tapered portion used to form the opening, and further wherein at least a part of each of the nozzle structures extend from an integral multiple nozzle structure conductive portion.

89. The apparatus of claim 85, wherein each of the nozzle structures comprises a solid post along the center axis extending through the opening at the dispensing end.

90. The apparatus of claim 85, wherein each of the dispensing ends of the nozzle structures are positioned in an x-y plane and have the center axis thereof aligned along the z axis.

91. The apparatus of claim 85, wherein the dispensing ends of the plurality of nozzle structures lie in a plane.

92. The apparatus of claim 85, wherein the particles have a nominal diameter of about 1 nanometers to about 2000 nanometers.

93. The apparatus of claim 85, wherein each of the nozzle structures comprise at least a first and second opening terminating at the dispensing end of each nozzle structure.

94. The apparatus of claim 93, wherein the particle source comprises a first particle source of at least a first fluid composition comprising an active ingredient to be dispensed through the first opening and a second particle source of at least a second fluid composition comprising a coating component to be dispensed through the second opening, and further wherein the sprays of particles comprise sprays of coated active ingredients.

95. The apparatus of claim 85, wherein the apparatus further comprises an excipient material provided on a target surface, the target surface positioned such that the sprays of particles are directed for contact with the excipient material.

96. The apparatus of claim 85, wherein the apparatus further comprises a charged pattern, the charged pattern positioned such that the sprays of particles are directed for contact with the charged pattern.

97. The apparatus of claim 85, wherein the apparatus further comprises a container operable by a user for inhalation of contents therein, the container positioned such that the sprays of particles are directed therein.