Abstract: An aerosol delivery system has an aerosol generator with a vibrating aperture plate (10) and an actuator (11, 16, 17, 19), a controller (18, 19). The controller in real time monitors (201) the aerosol generator as it is driven for vibration of the aperture plate, and detects (202) a change in an electrical characteristic in response to a transition from a wet state to a dry state of the aperture plate. It automatically modifies (203, 205, 206), during the transition, operation of the aerosol generator in response to the detected change. The modification includes reducing applied power (203). The controller continues (204) to monitor during the transition, including monitoring the aperture plate for presence of residual liquid on the aperture plate first surface.

Abstract: A high flow nasal therapy system (1) has a gas supply (2), a nebulizer (12), and a nasal interface (7). There are two branches (11, 10) and a valve (6) linked with the controller, the branches including a first branch (11) for delivery of aerosol and a second branch (10) for delivery of non-aerosolized gas. The controller controls delivery into the branches (11, 10), in which flow is unidirectional in the first and second branches, from the gas supply towards the nasal interface. The first branch (11) includes the nebulizer (12) and a line configured to store a bolus of aerosol during flow through the second branch (10). The valve (6) comprises a Y-junction between the gas inlet on one side and the branches on the other side.

Abstract: An aerosol generator (100) has a vibratable plate (1) with apertures therein and an annular piezo (2) which causes movement of the vibratable plate (1). An annular support member (3) supports the piezo (2) and the vibratable plate (1). A first electrical power conducting pin (10) engages directly with a first, top, surface of the piezo (2). A second electrical power conducting pin (11) indirectly conducts electrical power to a second surface of the piezo (2), by contacting an extension tab (103) of the support member (20), also on its top side. There is a film of cured epoxy adhesive on the tab (103), providing excellent gripping force between the pin (11) and the support (3). The aerosol generator (100) avoids need for soldered joints for electrical contact, and the pins are conveniently mounted parallel to each on the same lateral and top side of the piezo and support member. The pins may have multi-point tips (50) for particularly effective electrical contact.

Abstract: In one embodiment, a method for manufacturing an aperture plate includes depositing a releasable seed layer above a substrate, applying a first patterned photolithography mask above the releasable seed layer, the first patterned photolithography mask having a negative pattern to a desired aperture pattern, electroplating a first material above the exposed portions of the releasable seed layer and defined by the first mask, applying a second photolithography mask above the first material, the second photolithography mask having a negative pattern to a first cavity, electroplating a second material above the exposed portions of the first material and defined by the second mask, removing both masks, and etching the releasable seed layer to release the first material and the second material. The first and second material form an aperture plate for use in aerosolizing a liquid. Other aperture plates and methods of producing aperture plates are described according to other embodiments.

Abstract: An aperture plate is manufactured by plating metal around a mask of resist columns having a desired size, pitch, and profile, which yields a wafer about 60 ?m thickness. This is approximately the full desired target aperture plate thickness. The plating is continued so that the metal overlies the top surfaces of the columns until the desired apertures are achieved. This needs only one masking/plating cycle to achieve the desired plate thickness. Also, the plate has passageways formed beneath the apertures, formed as an integral part of the method, by mask material removal. These are suitable for entrainment of aerosolized droplets exiting the apertures.

Abstract: A photo-resist (21) is applied in a pattern or vertical columns having the dimensions of holes or pores of the aperture plate to be produced. This mask pattern provides the apertures which define the aerosol particle size, having up to 2500 holes per square mm. There is electro-deposition of metal (22) into the spaces around the columns (21). There is further application of a second photo-resist mask (25) of much larger (wider and taller) columns, encompassing the area of a number of first columns (21). The hole diameter in the second plating layer is chosen according to a desired flow rate.

Abstract: An aerosol delivery system has an aerosol generator with a vibrating aperture plate (10) and an actuator (11, 16, 17, 19), a controller (18, 19). The controller in real time monitors (201) the aerosol generator as it is driven for vibration of the aperture plate, and detects (202) a change in an electrical characteristic in response to a transition from a wet state to a dry state of the aperture plate. It automatically modifies (203, 205, 206), during the transition, operation of the aerosol generator in response to the detected change. The modification includes reducing applied power (203). The controller continues (204) to monitor during the transition, including monitoring the aperture plate for presence of residual liquid on the aperture plate first surface.

Abstract: A high flow nasal therapy system (1) has a gas supply (2), a nebulizer (12), and a nasal interface (7). There are two branches (11, 10) and a valve (6) linked with the controller, the branches including a first branch (11) for delivery of aerosol and a second branch (10) for delivery of non-aerosolized gas. The controller controls delivery into the branches (11, 10), in which flow is unidirectional in the first and second branches, from the gas supply towards the nasal interface. The first branch (11) includes the nebulizer (12) and a line configured to store a bolus of aerosol during flow through the second branch (10). The valve (6) comprises a Y-junction between the gas inlet on one side and the branches on the other side.

Abstract: A system for delivery of aerosol therapy to spontaneously breathing patients comprises a housing which defines a chamber. The housing has a base, a top and a main body extending between the base and the top. An ambient air inlet is located adjacent to the base and is normally closed by an inlet valve. The housing also has a patient port for receiving a mouthpiece or a face mask. The mouthpiece has an exhaust outlet closed by an exhaust valve. Similarly, the face mask has an exhaust outlet closed by an exhaust valve. Exhaled air is exhausted through the valves and to prevent recirculation through the chamber which would adversely affect dose efficiencies. The housing also has an aerosol port for receiving a vibrating mesh aerosol generating device. The aerosol port is located in a side of the main body of the housing for delivery of aerosol into the chamber between the inlet valve and the patient port.

Abstract: A supplemental oxygen delivery system is described in which Aerosol is delivered into a housing 10, 20, which sits in the circuit from the supplemental oxygen supply and optional humidifier. The supplemental oxygen passes through this chamber 10, 20 in which the aerosol is located, and collects the aerosol transporting it to a patient via a nasal cannula 3 or a face mask 4. An aerosol generator 9 is mounted to the housing 10, 20 and delivers aerosol into an oxygen stream 13 flowing between an inlet 14 and an outlet 15 of the housing 10. The housing 10 also has a removable plug 16 in the base 17 thereof for draining any liquid that accumulates in the housing 10. There is no disruption of oxygen delivery to patients using nasal cannulas who currently have to use a separate face-mask when receiving nebulized medication.

Abstract: An aerosol delivery system has a nebulizer and a humidifier providing a gas flow to the nebulizer. A controller varies humidity level of the gas flow to the nebulizer so that if the nebulizer is not operating it has about 100% humidity and it is operating the value is less to allow for the humidification effect of the nebulizer. The control may be achieved by dynamically varying proportions of flow through a dry branch and a humidification branch.

Abstract: A patient interface (1) is for aerosol treatment, having a base (2) to surround the patients mouth and nose and engage the skin with a resilient seal, and with a strap (8) to attach to a patients head. There is a support (3) on and across the base for supporting an aerosol delivery head with prongs (4, 5). An enclosed volume is formed in the interface by attachment of a shell (10), which has an extraction port (11) for attachment of an extraction system (20) to extract gas from this volume. An HFNT system includes a patient interface surrounding the nose and mouth and an aerosol delivery apparatus (4, 6), an extraction apparatus (20), and a controller (100) to control delivery of aerosol and/or gas to the interface and to extract gases from a volume enclosed by the interface. Because of the fully sealed volume within the interface there are a wide range of control scenarios possible, using pressure sensing in the volume, bypass valves (201), dynamically-controllable nebulizer (203).

Abstract: A nebulizer has an aperture plate, a mounting, an actuator, and an aperture plate drive circuit (2-4). A controller measures an electrical drive parameter at each of a plurality of measuring points, each measuring point having a drive frequency; and based on the values of the parameter at the measuring points makes a determination of optimum drive frequency and also an end-of-dose prediction. The controller performs a short scan at regular sub-second intervals at which drive current is measured at two measuring points with different drive frequencies. According to drive parameter measurements at these points the controller determines if a full scan sweeping across a larger number of measuring points should be performed. The full scan provides the optimum drive frequency for the device and also an end of dose indication.

Abstract: A photo-resist (21) is applied in a pattern or vertical columns having the dimensions of holes or pores of the aperture plate to be produced. This mask pattern provides the apertures which define the aerosol particle size, having up to 2500 holes per square mm. There is electro-deposition of metal (22) into the spaces around the columns (21). There is further application of a second photo-resist mask (25) of much larger (wider and taller) columns, encompassing the area of a number of first columns (21). The hole diameter in the second plating layer is chosen according to a desired flow rate.

Abstract: A method for aerosolising a liquid comprises the steps of: —providing an aperture plate having at least 100 outlet holes per mm; delivering liquid to the aperture plate; and vibrating the aperture plate to produce an aerosol. The viscosity of the liquid is in the range of from 1 to 15 cP and the surface tension of the liquid is in the range of from 72 to 0.5 mN/m. The output rate of the generated aerosol is greater than 0.01 mL/min.

Abstract: A supplemental oxygen delivery system is described in which Aerosol is delivered into a housing 10, 20, which sits in the circuit from the supplemental oxygen supply and optional humidifier. The supplemental oxygen passes through this chamber 10, 20 in which the aerosol is located, and collects the aerosol transporting it to a patient via a nasal cannula 3 or a face mask 4. An aerosol generator 9 is mounted to the housing 10, 20 and delivers aerosol into an oxygen stream 13 flowing between an inlet 14 and an outlet 15 of the housing 10. The housing 10 also has a removable plug 16 in the base 17 thereof for draining any liquid that accumulates in the housing 10. There is no disruption of oxygen delivery to patients using nasal cannulas who currently have to use a separate face-mask when receiving nebulized medication.

Abstract: An aperture plate (1) is attached at its rim (203) to a support washer (3) by adhesive. Anchor grooves (204) having a zig-zag pattern in plan are machined in the lower surface of the rim (203 of the aperture plate before application of the adhesive. The grooves (204) extend out to the edge of the aperture plate (1). The anchor grooves have a depth in the range of 10 ?m to 40 ?m, and a width in the range of 20 ?m to 150 ?m, and an angular pitch in the range of 2.5° to 12.5°. Excellent bonding strength is achieved for long term reliable attachment in an environment of high frequency vibration and moisture and chemical corrosion.

Abstract: A nebulizer has an aperture plate, a mounting, an actuator, and an aperture plate drive circuit (2-4). A controller measures an electrical drive parameter at each of a plurality of measuring points, each measuring point having a drive frequency; and based on the values of the parameter at the measuring points makes a determination of optimum drive frequency and also an end-of-dose prediction. The controller performs a short scan at regular sub-second intervals at which drive current is measured at two measuring points with different drive frequencies. According to drive parameter measurements at these points the controller determines if a full scan sweeping across a larger number of measuring points should be performed. The full scan provides the optimum drive frequency for the device and also an end of dose indication.

Abstract: An aperture plate (1) is attached at its rim (203) to a support washer (3) by adhesive. Anchor grooves (204) having a zig-zag pattern in plan are machined in the lower surface of the rim (203 of the aperture plate before application of the adhesive. The grooves (204) extend out to the edge of the aperture plate (1). The anchor grooves have a depth in the range of 10 ?m to 40 ?m, and a width in the range of 20 ?m to 150 ?m, and an angular pitch in the range of 2.5° to 12.5°. Excellent bonding strength is achieved for long term reliable attachment in an environment of high frequency vibration and moisture and chemical corrosion.

Abstract: An aerosol generator with electrical power conducting pins has a vibratable plate with apertures therein and an annular piezo. An annular support member supports the piezo and the vibratable plate. A first electrical power conducting pin engages directly with a first, top, surface of the piezo. A second electrical power conducting pin indirectly conducts electrical power to a second surface of the piezo, by contacting an extension tab. There is a film of cured epoxy adhesive on the tab. The aerosol generator avoids need for soldered joints for electrical contact, and the pins are conveniently mounted parallel to each on the same lateral and top side of the piezo and support member. The pins may have multi-point tips for particularly effective electrical contact.