Small volume nebulizer

• US 7,267,120 B2
• Filed: 08/19/2002
• Issued: 09/11/2007
• Est. Priority Date: 08/19/2002
• Status: Active Grant

• Current Assignee: SunMed Group Holdings LLC
• Original Assignee: Allegiance Corporation (Cardinal Health, Inc.)
• Inventors: Rustad, Andre, Rivera, David, Atlas, Charlie
• Primary Examiner(s): Dawson; Glenn K.
• Application Number:
  US10/223,394
• Publication Number:
  US 20040031485A1
• Time in Patent Office: 1,849 Days
• Field of Search: 12820014-20024, 128/203.12, 128/203.15, 12820714-20718, 239/338, 239/343, 239/370, 239/369
• US Class Current: 128/200.18
• CPC Class Codes: A61M 11/00 Sprayers or atomisers specially adapted for therapeutic purposes in general B05B; aerosol containers B65D83/14
• CPC Class Codes: A61M 11/002 by flow deviation causing inertial separation of transported particles
• CPC Class Codes: A61M 11/06 of the injector type
• CPC Class Codes: A61M 15/00 Inhalators drug delivery in endotracheal tubes A61M16/04
• CPC Class Codes: B05B 7/0012 Apparatus for achieving spraying before discharge from the apparatus
• CPC Class Codes: Y10S 261/65 Vaporizers

Abstract

An atomizing nebulizer for dispensing a substance or medicament is described. The nebulizer is formed with a reservoir base releasably secured to an effluent vent cap that together capture a diffuser and integral dispersing baffle that are further formed with an uptake lumen or channel terminating with a nozzle jet. The diffuser dispersing baffle is positioned relative to the jet nozzle to optimize atomization of any of a number of such substances so as to maximize disbursement of the substance. The reservoir base also incorporates a pressurized fluid-accelerating inlet tube terminated with a metering orifice that cooperates with the nozzle jet when the inlet tube is received within the diffuser uptake lumen or channel. When so received, the nozzle jet axially registers proximate and superior to the orifice to establish a vacuum space that is in fluid communication with a capillary interstice established between the walls of the exterior of the inlet tube and the confronting interior surface of the diffuser lumen or channel. When a pressurized fluid is communicated through the lumen, the orifice, and into the vacuum space towards the nozzle jet, a vacuum develops in the vacuum space that, in combination with the capillary action of the interstice, draws the fluid proximate to the orifice and disperses it into droplets that are then entrained into a fluid stream to be further atomized upon impact with the baffle and then dispensed.

Claims

1. A nebulizer, comprising:

a reservoir base formed with an inlet tube and adapted to receive a substance to be dispensed, the inlet tube incorporating an orifice about a distal end of the tube;

an effluent vent cap formed with an aerosol outlet and being removably secured to the reservoir base thereby defining an interior cistern with an upper recess and a lower substance storage vessel for containing the substance;

an interchangeable diffuser optimized to nebulize the substance, said diffuser being not directly connected to the vent cap, being releasably held within the cistern, and being formed with an uptake lumen having at one end a jet nozzle, the lumen configured to be removably engaged about the inlet tube to form a capillary interstice and to axially register the jet nozzle proximate to the orifice establishing a vacuum space therebetween;

wherein the diffuser further includes an integral baffle disperser substantially axially aligned superior to the jet nozzle and configured to deflect and nebulize particles of the substance traveling along a path passing through the orifice and the jet nozzle;

wherein, when the diffuser is held within the cistern, the orifice of the inlet tube is stationary relative to the jet nozzle, and

wherein the aerosol outlet of the effluent vent car is further formed with a baffle lumen projecting interiorly into the upper recess.

2. The nebulizer according to claim 1, wherein the diffuser is adapted for releasable engagement to the reservoir base to establish a precise arrangement of the jet nozzle relative to the orifice of the reservoir inlet tube.

3. The nebulizer according to claim 1, further comprising:

at least one support member incorporated onto the reservoir base to establish free-standing capability of the nebulizer on a substantially level surface.

4. The nebulizer according to claim 1, wherein the inlet tube is configured to project into the cistern above the top surface of the substance when received in the storage vessel of the cistern to establish an anti-siphon capability for the nebulizer.

5. The nebulizer according to claim 1, wherein the orifice of the inlet tube is sized to regulate the flow of a pressurized fluid communicated through the inlet tube and to communicate a stream of such fluid into the vacuum space in the direction of the jet nozzle.

6. The nebulizer according to claim 1, wherein the base reservoir includes at least one diffuser standoff adapted to seat the diffuser in the vessel portion of the cistern above a surface of the vessel portion.

7. The nebulizer according to claim 1, wherein the base reservoir includes at least one capture latch adapted to releasably secure the diffuser in the vessel portion of the cistern.

8. The nebulizer according to claim 1, wherein the orifice of the inlet tube is formed to have a cross-sectional area that is approximately less than or equal to the cross-sectional area of the jet nozzle of the diffuser.

9. The nebulizer according to claim 1, wherein the reservoir base is formed to have a generally diminishing lateral cross section from a superior portion to an inferior portion in the storage vessel whereby the substance received in the storage vessel pools about the inferior portion to maximize immersion of a footer disc of the diffuser in the pooled substance.

10. The nebulizer according to claim 1, wherein the diffuser also includes one or more baffle arms.

11. The nebulizer of claim 1, wherein the vent cap, diffuser, and reservoir base are separate components.

12. The nebulizer of claim 1, wherein the diffuser does not touch the vent cap.

13. A nebulizer, comprising:

a reservoir base formed with an inlet tube and adapted to receive a substance to be dispensed, the inlet tube incorporating an orifice about a distal end of the tube;

an effluent vent cap formed with an aerosol outlet and being removably secured to the reservoir base thereby defining an interior cistern with an upper recess and a lower substance storage vessel for containing the substance;

an interchangeable diffuser optimized to nebulize the substance, said diffuser being not directly connected to the vent cap, being releasably held within the cistern, and being formed with an uptake lumen having at one end a jet nozzle, the lumen configured to be removably engaged about the inlet tube to form a capillary interstice and to axially register the jet nozzle proximate to the orifice establishing a vacuum space therebetween;

wherein the diffuser further includes an integral baffle disperser substantially axially aligned superior to the jet nozzle and configured to deflect and nebulize particles of the substance traveling along a path passing through the orifice and the jet nozzle;

wherein, when the diffuser is held within the cistern, the orifice of the inlet tube is stationary relative to the jet nozzle, and

wherein at least one surface of the diffuser and the inlet tube is treated so as to increase adhesion forces between the at least one surface and the substance to be dispensed to amplify the capillary action of the interstice and whereby the adhesion forces are established to be greater than internal cohesion forces of the substance to be dispensed.

14. A nebulizer, comprising:

a reservoir base formed with an inlet tube and adapted to receive a substance to be dispensed, the inlet tube incorporating an orifice about a distal end of the tube;

an effluent vent cap formed with an aerosol outlet and being removably secured to the reservoir base thereby defining an interior cistern with an upper recess and a lower substance storage vessel for containing the substance;

an interchangeable diffuser optimized to nebulize the substance, said diffuser being not directly connected to the vent cap, being releasably held within the cistern, and being formed with an uptake lumen having at one end a jet nozzle, the lumen configured to be removably engaged about the inlet tube to form a capillary interstice and to axially register the jet nozzle proximate to the orifice establishing a vacuum space therebetween;

wherein the diffuser further includes an integral baffle disperser substantially axially aligned superior to the jet nozzle and configured to deflect and nebulize particles of the substance traveling along a path passing through the orifice and the jet nozzle;

wherein, when the diffuser is held within the cistern, the orifice of the inlet tube is stationary relative to the jet nozzle, and

wherein the jet nozzle is formed in a bulkhead of the uptake lumen that incorporates a substantially lateral channel defined by at least two generally confronting sidewalls, the channel being substantially registered about the jet nozzle to minimize the thickness of the bulkhead proximate to the nozzle and whereby the sidewalls are configured to control the divergence of a fluid stream being communicated from the jet nozzle.

15. A nebulizer, comprising:

a reservoir base formed with an inlet tube and adapted to receive a substance to be dispensed, the inlet tube incorporating an orifice about a distal end of the tube;

an effluent vent cap formed with an aerosol outlet and being removably secured to the reservoir base thereby defining an interior cistern with an upper recess and a lower substance storage vessel for containing the substance;

an interchangeable diffuser optimized to nebulize the substance, said diffuser being releasably held within the cistern and being formed with an uptake lumen having at one end a jet nozzle, the lumen configured to be removably engaged about the inlet tube to form a capillary interstice and to axially register the jet nozzle proximate to the orifice establishing a vacuum space therebetween; and

wherein the diffuser further includes an integral baffle disperser substantially axially aligned superior to the jet nozzle and configured to deflect and nebulize particles of the substance traveling along a path passing through the orifice and the jet nozzle,

wherein the jet nozzle is formed in a bulkhead of the uptake lumen that incorporates a substantially lateral channel defined by at least two generally confronting sidewalls, the channel being substantially registered about the jet nozzle to minimize the thickness of the bulkhead proximate to the nozzle and whereby the sidewalls are arranged to define an angle therebetween approximately in the range of between 5 and 47 degrees to thereby optimize the divergence of a fluid stream being communicated from the jet nozzle.

16. A nebulizer for atomizing and dispensing a substance into an effluent aerosolized airstream, comprising:

a reservoir base including an inlet tube formed in a distal end with an orifice and being adapted to receive the substance;

an effluent vent cap formed with an aerosol outlet and configured to be secured to the reservoir base to thereby define an interior cistern for containing the substance;

an interchangeable diffuser optimized to atomize the substance, said diffuser being not directly connected to the vent cap and being releasably held within the cistern, the diffuser formed with an uptake lumen having a jet nozzle at one end, the lumen being adapted to removably receive the inlet tube and forming an interstice therebetween sized to induce adhesion between molecules of the substance and the confronting walls of the diffuser and inlet tube, the lumen also being adapted to axially register the jet nozzle proximate to the orifice when received on the inlet tube to establish a vacuum space between the nozzle and the orifice;

wherein the diffuser further includes an integral baffle disperser substantially axially aligned superior to the jet nozzle and sized to obstruct, atomize, and deflect particles moving in a line of motion passing through both the orifice and the jet nozzle;

wherein, when the diffuser is held within the cistern, the orifice of the inlet tube is stationary relative to the jet nozzle, and

wherein the aerosol outlet of the effluent vent cap is further formed with a baffle lumen projecting interiorly into the upper recess.

17. The nebulizer according to claim 16, further comprising:

at least one support member incorporated onto the reservoir base to establish free-standing capability of the nebulizer on a substantially level surface.

18. The nebulizer according to claim 16, wherein the inlet tube is configured to project into the cistern above the top surface of the substance when received in the storage vessel of the cistern to establish an anti-siphon capability for the nebulizer.

19. The nebulizer according to claim 16, wherein the orifice of the inlet tube is sized to regulate the flow of a pressurized fluid communicated through the inlet tube and to communicate a stream of such fluid into the vacuum space in the direction of the jet nozzle.

20. The nebulizer according to claim 16, wherein the base reservoir includes at least one diffuser standoff adapted to seat the diffuser in the vessel portion of the cistern above a surface of the vessel portion.

21. The nebulizer according to claim 16, wherein the base reservoir includes at least one capture latch adapted to releasably secure the diffuser in the vessel portion of the cistern.

22. The nebulizer according to claim 16, wherein the orifice of the inlet tube is formed to have a cross-sectional area that is approximately less than or equal to the cross-sectional area of the jet nozzle of the diffuser.

23. The nebulizer according to claim 16, wherein the reservoir base is formed to have a generally diminishing lateral cross section from a superior portion to an inferior portion in the storage vessel whereby the substance received in the storage vessel pools about the inferior portion to maximize immersion of a footer disc of the diffuser in the pooled substance.

24. The nebulizer of claim 16, wherein the vent cap, diffuser, and reservoir base are separate components.

25. The nebulizer of claim 16, wherein the diffuser does not touch the vent cap.

26. A nebulizer for atomizing and dispensing a substance into an effluent aerosolized airstream, comprising:

a reservoir base including an inlet tube formed in a distal end with an orifice and being adapted to receive the substance;

an effluent vent cap formed with an aerosol outlet and configured to be secured to the reservoir base to thereby define an interior cistern for containing the substance;

an interchangeable diffuser optimized to atomize the substance, said diffuser being not directly connected to the vent cap and being releasably held within the cistern, the diffuser formed with an uptake lumen having a jet nozzle at one end, the lumen being adapted to removably receive the inlet tube and forming an interstice therebetween sized to induce adhesion between molecules of the substance and the confronting walls of the diffuser and inlet tube, the lumen also being adapted to axially register the et nozzle proximate to the orifice when received on the inlet tube to establish a vacuum space between the nozzle and the orifice;

wherein the diffuser further includes an integral baffle disperser substantially axially aligned superior to the jet nozzle and sized to obstruct, atomize, and deflect particles moving in a line of motion passing through both the orifice and the jet nozzle;

wherein, when the diffuser is held within the cistern, the orifice of the inlet tube is stationary relative to the jet nozzle, and

wherein at least one surface of the diffuser and the inlet tube is treated so as to increase adhesion forces between the at least one surface and the substance to be dispensed to amplify a capillary action of the interstice and whereby the adhesion forces are established to be greater than internal cohesion forces of the substance to be dispensed.

27. A nebulizer for atomizing and dispensing a substance into an effluent aerosolized airstream, comprising:

a reservoir base including an inlet tube formed in a distal end with an orifice and being adapted to receive the substance;

an effluent vent cap formed with an aerosol outlet and configured to be secured to the reservoir base to thereby define an interior cistern for containing the substance;

an interchangeable diffuser optimized to atomize the substance, said diffuser being not directly connected to the vent cap and being releasably held within the cistern, the diffuser formed with an uptake lumen having a jet nozzle at one end, the lumen being adapted to removably receive the inlet tube and forming an interstice therebetween sized to induce adhesion between molecules of the substance and the confronting walls of the diffuser and inlet tube, the lumen also being adapted to axially register the let nozzle proximate to the orifice when received on the inlet tube to establish a vacuum space between the nozzle and the orifice;

wherein the diffuser further includes an integral baffle disperser substantially axially aligned superior to the jet nozzle and sized to obstruct, atomize, and deflect particles moving in a line of motion passing through both the orifice and the jet nozzle;

wherein, when the diffuser is held within the cistern, the orifice of the inlet tube is stationary relative to the jet nozzle, and

wherein the jet nozzle is formed in a bulkhead of the uptake lumen that incorporates a substantially lateral channel defined by at least two generally confronting sidewalls, the channel being substantially registered about the jet nozzle to minimize the thickness of the bulkhead proximate to the nozzle and whereby the sidewalls are configured to control the divergence of a fluid stream being communicated from the jet nozzle.

28. A nebulizer for atomizing and dispensing a substance into an effluent aerosolized airstream, comprising:

a reservoir base including an inlet tube formed in a distal end with an orifice and being adapted to receive the substance;

an effluent vent cap formed with an aerosol outlet and configured to be secured to the reservoir base to thereby define an interior cistern for containing the substance;

an interchangeable diffuser optimized to atomize the substance, said diffuser being releasably held within the cistern, the diffuser formed with an uptake lumen having a jet nozzle at one end, the lumen being adapted to removably receive the inlet tube and forming an interstice therebetween sized to induce adhesion between molecules of the substance and the confronting walls of the diffuser and inlet tube, the lumen also being adapted to axially register the jet nozzle proximate to the orifice when received on the inlet tube to establish a vacuum space between the nozzle and the orifice; and

wherein the diffuser further includes an integral baffle disperser substantially axially aligned superior to the jet nozzle and sized to obstruct, atomize, and deflect particles moving in a line of motion passing through both the orifice and the jet nozzle,

wherein the jet nozzle is formed in a bulkhead of the uptake lumen that incorporates a substantially lateral channel defined by at least two generally confronting sidewalls, the channel being substantially registered about the jet nozzle to minimize the thickness of the bulkhead proximate to the nozzle and whereby the sidewalls are arranged to define an angle therebetween approximately in the range of between 5 and 47 degrees to thereby optimize the divergence of a fluid stream being communicated from the jet nozzle.

29. A nebulizer for dispensing a substance to be inhaled by a patient, comprising:

an effluent vent cap formed with an aerosol outlet;

a reservoir base configured to be removably secured to the effluent cap to define a cistern, the reservoir base being adapted to receive the substance and incorporating an inlet tube formed with an internal lumen terminating at a distal orifice;

a diffuser optimized for use with the substance and adapted to be secured within the cistern and formed with an uptake channel adapted to receive the inlet tube to substantially form a capillary interstice configured to maximize uptake of the substance through the interstice, the uptake channel terminating at one end with a jet nozzle sized to be approximately larger than or equal to the distal orifice and that, upon receipt of the inlet tube within the channel, is axially registered proximate with the orifice to establish a vacuum space between the nozzle and the orifice;

wherein the diffuser further includes an integral baffle disperser substantially axially aligned superior to the jet nozzle and sized to obstruct, break apart, and accelerate atomized particles of the substance moving in a line of motion passing through both the orifice and the jet nozzle; and

a substantially lateral groove formed in the terminating end of the uptake channel and defined by at least two generally confronting sidewalls and a substantially flat bottom, the groove being substantially registered about the jet nozzle to minimize the thickness of the terminating end proximate the nozzle and whereby the sidewalls define an angle therebetween selected to optimize the divergence of a fluid stream being communicated from the jet nozzle.

30. The nebulizer according to claim 29, wherein the aerosol outlet of the effluent vent cap is further formed with a baffle lumen projecting interiorly into the upper recess.

31. The nebulizer according to claim 29, further comprising:

at least one support member incorporated onto the reservoir base to establish free-standing capability of the nebulizer on a substantially level surface.

32. The nebulizer according to claim 29, wherein the inlet tube is configured to project into the cistern above the top surface of the substance when received in the storage vessel of the cistern to establish an anti-siphon capability for the nebulizer.

33. The nebulizer according to claim 29, wherein the orifice of the inlet tube is sized to regulate the flow of a pressurized fluid communicated through the inlet tube and to communicate a stream of such fluid into the vacuum space in the direction of the jet nozzle.

34. The nebulizer according to claim 29, wherein the base reservoir includes at least one diffuser standoff adapted to seat the diffuser in an inferior portion of the cistern above a bottom surface of the cistern.

35. The nebulizer according to claim 29, wherein the base reservoir includes at least one capture latch adapted to releasably secure the diffuser in the vessel portion of the cistern.

36. The nebulizer according to claim 29, wherein the reservoir base is formed to have a generally diminishing lateral cross section from a superior portion to an inferior portion in the storage vessel whereby the substance received in the storage vessel pools about the inferior portion to maximize immersion of a footer disc of the diffuser in the pooled substance.

37. The nebulizer according to claim 29, wherein at least one surface of the uptake channel and the inlet tube is treated so as to optimize the capillary action of the interstice for the substance.

38. The nebulizer according to claim 29, wherein the diffuser also includes one or more baffle arms.

39. The nebulizer of claim 29, wherein the confronting sidewalls do not intersect.

40. A nebulizer for dispensing a substance to be inhaled by a patient, comprising:

an effluent vent cap formed with an aerosol outlet;

a reservoir base configured to be removably secured to the effluent cap to define a cistern, the reservoir base being adapted to receive the substance and incorporating an inlet tube formed with an internal lumen terminating at a distal orifice;

a diffuser optimized for use with the substance and adapted to be secured within the cistern and formed with an uptake channel adapted to receive the inlet tube to substantially form a capillary interstice configured to maximize uptake of the substance through the interstice, the uptake channel terminating at one end with a jet nozzle sized to be approximately larger than or equal to the distal orifice and that, upon receipt of the inlet tube within the channel, is axially registered proximate with the orifice to establish a vacuum space between the nozzle and the orifice;

wherein the diffuser further includes an integral baffle disperser substantially axially aligned superior to the jet nozzle and sized to obstruct, break apart, and accelerate atomized particles of the substance moving in a line of motion passing through both the orifice and the jet nozzle; and

a substantially lateral groove formed in the terminating end of the uptake channel and defined by at least two generally confronting sidewalls, the groove being substantially registered about the jet nozzle to minimize the thickness of the terminating end proximate the nozzle and whereby the sidewalls define an angle therebetween selected to optimize the divergence of a fluid stream being communicated from the jet nozzle,

wherein the angle defined by the confronting sidewalls is approximately in the range of between 5 and 47 degrees.

41. A system for nebulization and dispensing at least two treatment substances, comprising:

a reservoir base adapted to receive a quantity of at least one of the substances, the reservoir base including a pressurized fluid inlet tube terminating in a distal metering orifice;

an effluent vent cap formed with an aerosol outlet and being coupled to the reservoir base to define an interior cistern with an upper recess and a lower substance storage vessel adapted to contain at least one of the substances;

a plurality of interchangeable diffusers each optimized for a different set of nebulization parameters and to be releasably secured to the reservoir base and being formed with an uptake lumen in fluid communication with the storage vessel and terminating at one end with a nozzle jet formed with a divergent spray guide, the lumen configured to be removably engaged about the inlet tube to substantially form a capillary interstice therewith and to axially register the nozzle jet proximate to the orifice to establish, during operation, a vacuum space between the nozzle jet and the orifice; and

wherein at least one diffuser of the plurality further includes an integral dispersing baffle substantially axially aligned superior to the jet nozzle and configured to obstruct, atomize, and accelerate particles of the at least one of the substances traveling along a path passing through both the orifice and the jet nozzle.

42. The nebulizer of claim 41, wherein the plurality of interchangeable diffusers have varying configurations.

43. A nebulizer, comprising:

a reservoir base formed with an inlet tube and adapted to receive a substance to be dispensed, the inlet tube incorporating an orifice about a distal end of the tube;

an effluent vent cap formed with an aerosol outlet and being removably secured to the reservoir base thereby defining an interior cistern with an upper recess and a lower substance storage vessel for containing the substance;

an interchangeable diffuser optimized to nebulize the substance, said diffuser being not directly connected to the vent cap, being releasably held within the cistern, and being formed with an uptake lumen having at one end a jet nozzle, the lumen configured to be removably engaged about the inlet tube to form a capillary interstice and to axially register the jet nozzle proximate to the orifice establishing a vacuum space therebetween;

wherein the diffuser further includes an integral baffle disperser substantially axially aligned superior to the jet nozzle and configured to deflect and nebulize particles of the substance traveling along a path passing through the orifice and the jet nozzle; and

wherein at least one surface of the diffuser and the inlet tube is treated so as to increase adhesion forces between the at least one surface and the substance to be dispensed.

44. The nebulizer of claim 43, wherein the at least one surface is treated to amplify the capillary action of the interstice, and whereby the adhesion forces are established to be greater than internal cohesion forces of the substance to be dispensed.

45. A nebulizer for atomizing and dispensing a substance into an effluent aerosolized airstream, comprising:

a reservoir base including an inlet tube formed in a distal end with an orifice and being adapted to receive the substance;

an effluent vent cap formed with an aerosol outlet and configured to be secured to the reservoir base to thereby define an interior cistern for containing the substance;

an interchangeable diffuser optimized to atomize the substance, said diffuser being not directly connected to the vent cap and being releasably held within the cistern, the diffuser formed with an uptake lumen having a jet nozzle at one end, the lumen being adapted to removably receive the inlet tube and forming an interstice therebetween sized to induce adhesion between molecules of the substance and the confronting walls of the diffuser and inlet tube, the lumen also being adapted to axially register the jet nozzle proximate to the orifice when received on the inlet tube to establish a vacuum space between the nozzle and the orifice;

wherein the diffuser further includes an integral baffle disperser substantially axially aligned superior to the jet nozzle and sized to obstruct, atomize, and deflect particles moving in a line of motion passing through both the orifice and the jet nozzle; and

wherein at least one surface of the diffuser and the inlet tube is treated so as to increase adhesion forces between the at least one surface and the substance to be dispensed.

46. The nebulizer according to claim 45, wherein the at least one surface is treated to amplify a capillary action of the interstice, and whereby the adhesion forces are established to be greater than internal cohesion forces of the substance to be dispensed.