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    • 专利摘要:
    spraying and liquid dispensing devices for spraying a liquid, and a method for manufacturing a spraying device. spraying device, as well as a method for manufacturing a spraying device, comprises mounting at least one spray plate (1) on a thermoplastic holder (2), while controlling the temperature of the spray plate (1) and/or the support (2) and, as a result, at least locally thermoplastically deform the support (2) permanently. after thermoplastic deformation of a seat (5) of the bracket (2), a diameter of the seat (5) of the bracket (2) upstream of the spray nozzle plate (1) exceeds a diameter of the seat (5) of the bracket ( 5) downstream of the nozzle plate (1). the thermoplastic support may have a tapered seat, where the smallest cross section of the tapered seat is smaller than the spray nozzle plate, the method comprising: - heating the spray nozzle plate; - pressing the spray nozzle plate onto the tapered seat of the holder leading the nozzle plate towards a smaller side of the tapered seat, thereby thermoplastically deforming a wall of the tapered seat; - forming a spray device from a spray nozzle plate and thermoplastic holder assembly, while a wider side of the tapered seat is pointed towards a liquid supply side.
    公开号:BR112016029844B1
    申请号:R112016029844-6
    申请日:2015-06-19
    公开日:2021-06-01
    发明作者:Henri Van Egmond；Wilhelmus Petrus Johannes De Kruijf；Wietze Nijdam；Jeroen Mathijn Wissink；Cornelis Johannes Maria Van Rijn
    申请人:Medspray B.V.；
    IPC主号:
    专利说明:

    [001] The invention describes a spray device for generating a fine spray, a spray nozzle unit comprising a spray nozzle plate and methods of manufacturing the same.
    [002] Microspray nozzle plates with orifices a few micrometers or less, created through semiconductor manufacturing techniques, need to be packaged for connection to, for example, a spray pump or syringe in accordance with product manufacturing protocols pharmacists. Liquids, which must be sprayed through spray nozzles with small holes, often require the use of one or a series of pre-filter plates to prevent clogging of the spray holes. It is known to manufacture prefilter plates also by means of semiconductor fabrication or micromachining. For medicinal or pharmaceutical purposes, it is not preferable to use glue, solvents or sealing agents to mount a spray nozzle plate and/or a pre-filter on a spray nozzle unit. The plastic materials to be used in spray nozzle units are typically medical grade plastics which have an acceptable low profile of extractables and leachables. Most medical grade plastics are thermoplastic materials such as polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polyetheretherketone (PEEK), cyclic olefin polymer (COP), polysulfone (PS), polyoxymethylene (POM). ), polycarbonate (PC), or polyamide (PA) and can be applied as part of the primary packaging of a medical fluid. The spray nozzle unit therefore comprises a medical grade thermoplastic package containing the nozzle plate with one or more pre-filter plates, and still needs to be packaged in accordance with pharmaceutical manufacturing protocols in a Boas environment. Manufacturing Practices (GMP) controlled in biological loads. The spray nozzle unit would ideally be used in an aerosol or spray device where no preservatives are added to the medicinal liquid. In that case, a spray nozzle unit needs to function as an impenetrable barrier for microbes in order to prevent them from entering the spray device container through the side of the nozzle plate.
    [003] In operation, the spray nozzle unit is subjected to high pressures of operating liquid at various temperatures and there is a risk of internal leakage and loss of bacterial integrity between the polymer parts of the package and the plate or pre-filter. Furthermore, being able to withstand high operating pressures, it is important to ensure that the spray nozzle plate cannot become loosened or even ejected, thus potentially hitting a person using the device. Typical operating pressures for aerosol and spray devices are between 100 and 5000 kPa (1 and 50 bar), with possibly higher peak pressures at the start and end of the spray mode.
    [004] It is an object of the invention to provide a spraying device that is capable of, at least partially, meeting one or more of the above needs.
    [005] In order to achieve this goal, a spraying device is provided comprising a nozzle plate with a spray nozzle orifice, and a seat having a seat, the seat supporting the nozzle plate, wherein the seat is made of a material thermoplastic and wherein the seat comprises a first collar, the first collar being formed of the thermoplastic material and being an integral part of the seat, the first collar sealingly engaging a downstream surface of the nozzle plate and extending along a a circumferential edge of the downstream surface of the nozzle plate.
    [006] As the first ring sealingly engages a downstream surface of the nozzle plate and extends along a circumferential edge of the downstream surface of the nozzle plate, it operates as a kind of O-ring, whereby a The force of the pressurized liquid in operation presses the nozzle plate against the rim, so as to seal the nozzle plate, thereby preventing liquid from leaking around the nozzle plate.
    [007] Surprisingly, it was found that when a specific polymer bead was present extending over the silicone nozzle plate on the outlet (or downstream) side, a good liquid-tight connection of the nozzle plate packaged over a wide range of work in relation to temperature and pressure was obtained. When in use, spray generating liquid is forced into the holder and presses against the nozzle plate which in turn presses against the rim. The liquid-tight sealing ring according to the invention can probably be better compared to sealing an O-ring on a flat surface. It is known in the art to use a thin collar on the downstream side to mechanically secure the nozzle plate, however, no specific measure is known to ensure a good liquid tight seal without the use of glue, solvent or sealing agent. The term upstream and downstream herein refers to a direction of flow of liquid through the spray device when in use. According to the invention, the higher the operating pressure, the greater the operating force that the nozzle plate will induce on this “O-ring”, thus creating a good liquid tight seal.
    [008] The nozzle plate is provided with at least one opening, also referred to as orifice, spray orifice, spray nozzle or similar words. In use, on an upstream side of the nozzle plate, a pressurized liquid is provided. As a result of pressurizing the liquid, spraying the liquid through the spray nozzle orifice will occur. Depending on the sizing (orifice size, pressure, liquid viscosity, etc.) a continuous stream or preferably - using a small orifice diameter) a sequence of small droplets will be sprayed. The support can be of any suitable shape, such as a cup, block, etc. Furthermore, the support can be integrated with a liquid reservoir to retain the liquid from which the aerosol is to be generated, etc. The support can be made of a thermoplastic material such as a thermoplastic. The term thermoplastic is to be understood as a material which is solid at room temperature and which obtains some degree of plasticity when the temperature is high. After decreasing the temperature, the thermoplastic material returns to a solid state again, whereby it retains a shape like that obtained at elevated temperature. The thermoplastic material can be, for example, PE, PP, PVC, PEEK, COP, PS, POM, PA. The elevated temperature at which a plasticity increases can be, for example, 50 to 300°C. The nozzle plate may comprise a single hole or a plurality of holes, for example arranged in a pattern. The holes can extend from one face of the orifice plate to the other, opposite face of the orifice plate, that is, extend through the orifice plate. The orifice plate can be made of a metal or ceramic material, for example a semiconductor, for example silicon.
    [009] The seat may be formed by an opening in the cradle, or any other suitable recess in the cradle. The seat can be open on 2 sides, ie extend through the support or through a part of it.
    [0010] In this document, the terms spray device, spray nozzle, spray nozzle unit, aerosol generator all refer to a device that, when supplied with pressurized liquid on an upstream side thereof, generates on a downstream side thereof a spraying of the liquid via at least one orifice in the nozzle plate. The hole can be referred to as an opening,
    [0011] The nozzle plate comprises one or more orifices and thus can also be referred to as an orifice plate or as a spray nozzle plate. The spray device can generate any spray, such as an aerosol. Consequently, the spray device can be an aerosol generator.
    [0012] The support comprises a through opening extending from the upstream side to the downstream side, whereby the seat is provided in the opening and whereby the nozzle plate closes the opening by snapping in with the ring in the seat (from so that one or more nozzle orifices form a single discharge path for the liquid).
    [0013] In one embodiment, a width of the first rim in a direction parallel to the downstream surface of the nozzle plate is at least 25% of a thickness of the nozzle plate. It was found that the rim should not be so wide; otherwise, the operating force becomes distributed over a larger contact area between the edge and the nozzle plate. Otherwise, the rim must not be too small or too thin, because in this case the structure becomes mechanically weak. Typically, the extent of the rim over the nozzle plate should be at least 50 micrometers and preferably less than 250 micrometers. The width of the first hoop, respectively, the extent of the first hoop is to be understood as an average width seen along a circumference of the first hoop.
    [0014] In one embodiment, the first hoop extends, in total, between 10% and 25% of a surface area of a nozzle plate on the downstream surface.
    [0015] In one embodiment, in a direction perpendicular to the downstream surface of the nozzle plate, the first rim has a thickness of at least 50% and at most 250% of a thickness of the nozzle plate. Thickness is to be understood as a depth in a direction perpendicular to the surface of the nozzle plate.
    [0016] The thickness of the rim must be at least 100 micrometers and maximum 500 micrometers. If the rim is too thick, it becomes too rigid and will lose its sealing properties. With these dimensions, a good liquid-tight seal can be guaranteed. The exact dimensions of the rim depend, of course, on the size and thickness of the nozzle plate. For a 1mm x 1mm x 0.2mm nozzle plate, typically the extension of the rim over the nozzle plate should be at least 25% of the thickness of the nozzle plate and the rim thickness should be at least 50% and at most 250% of the nozzle plate thickness. In addition, the rim must not obstruct the passage of liquid jets or impede the supply of air. Typically, the cavity that is formed by the rim and the mouthpiece plate should have an aspect ratio (width/depth) greater than 1. This cavity can be tapered, rounded or chamfered to allow for a smaller aspect ratio.
    [0017] In one embodiment, the spray device further comprises an adapter having an inner surface that fitably supports an upper outer support. In one embodiment, a stiffness of the adapter exceeds the stiffness of the bearing so as to promote a reduction in bearing deformation by the pressurized liquid. In other embodiments, an adapter stiffness may be the same as a bearing stiffness. According to the invention, the spray nozzle unit, comprising a plastic casing or backing and a spray nozzle plate with an upstream and a downstream (outlet) side, is distinguished by a polymer rim extending over the nozzle plate on the downstream side by at least 50 micrometers and preferably less than 250 micrometers.
    [0018] The spray nozzle unit is further distinguished by the fact that the extension of the rim over the spray nozzle plate on the downstream side has a thickness of at least 100 micrometers and maximum 500 micrometers.
    [0019] Preferably, the spray nozzle unit will be placed in an adapter of a relatively rigid and resistant material such as PEEK, POM or a metal that is capable of counterbalancing the pressure forces during operation of the spray nozzle unit. In particular, the adapter further comprises an adapter collar for supporting the support collar to reinforce the spray nozzle assembly during operation and aid in liquid tight sealing during operation. In other words, the adapter may comprise an adapter ring extending on a downstream side of the bearing and substantially parallel to the downstream surface of the mouthpiece plate, so as to support the first bearing ring during operation. The dimensions of the adapter support ring extending over the support collar must correspond to each other, being distinguished by the fact that the length of the adapter collar is between 50% and 200% of the support collar and the thickness is also between 50% and 200% of the support frame. Accordingly, in one embodiment, a width of the adapter collar as viewed in a direction along the downstream surface of the nozzle plate is between 50% and 200% of a width of the first bearing collar. Still, in one embodiment, in a direction perpendicular to the downstream surface of the nozzle plate, the adapter collar has a thickness between 50% and 200% of the bearing collar.
    [0020] The spray nozzle unit can be tapered on the outside. This means the spray nozzle unit has a tapered fit around it. To prevent the plastic mount from inflating at higher pressures, leading to internal leakage between the nozzle plate and the plastic mount, this tapered fitting has an ideal angle range. The angle is defined here as the angle of the taper fit, measured towards the center axis of the spray nozzle unit. If the angle is chosen too small, for example 5 degrees, tolerances on the outside diameter of the spray nozzle unit and the inside diameter of its surrounding environment will give a large positioning tolerance in the direction of the center axis. Material flexibilities or plastic deformation due to relaxation will have the same effect. Thus, the angle can be chosen smaller for more rigid materials. If the angle is chosen too large, for example 45 degrees or greater, the force exerted by the liquid due to the operating pressure in the direction of the central axis will not be translated into a greater lateral force preventing the expansion of the plastic support walls, leading to to internal leaks between the nozzle plate(s) and the plastic backing.
    [0021] In one embodiment of the invention, the outer surface of the bearing and the inner surface of the adapter both have a tapered section that tapers positively in a downstream direction, preferably a taper angle being between 5° and 45° at with respect to an orthogonal direction. Consequently, the spray nozzle unit has a conical shape and is placed in a corresponding conical adapter. The taper is positive in the downstream direction, and should be between 5° and 45°, and preferably between 10° and 20°. In this way, during operation, inward-facing forces are created, also sealing the side walls of the nozzle plate in the support.
    [0022] In one embodiment, at least part of the seat tapers toward a downstream end thereof, thus providing additional support to the nozzle plate and rim to withstand a force applied to the nozzle plate by pressurized liquid on the side. upstream of the nozzle plate.
    [0023] A second polymer collar extending over the upstream side of the nozzle plate will not necessarily aid in sealing because the fluid presses equally hard on such an upstream collar as on the upstream side of the nozzle plate. The aforementioned explanation for the “O ring” will not be considered valid here. However, it can help mechanically lock the spray nozzle plate into the holder.
    [0024] In one embodiment, the spraying device further comprises a pre-filter plate, the pre-filter plate being placed on the support at a distance from the nozzle plate and on an upstream side of the nozzle plate, the support comprising a second collar, the second collar extending along and engaging along a circumferential edge of a downstream surface of the prefilter plate between the nozzle and the prefilter plate. Surprisingly, however, it has been found that when a silicon-based pre-filter plate is placed in the package within a specific distance from the nozzle plate on the upstream side, allowing for the presence of a polymer rim between the nozzle plate and the pre-filter plate, a strong contribution to the liquid tight connection of the packaged spray nozzle unit is found. It is thought that the presence of polymer between the silicon spray nozzle plate and the first silicon pre-filter plate also acts as a sealing ring, in accordance with the above mentioned "O-ring" explanation. The greater the operating pressure on the upstream side of the prefilter, the greater the operating force that the downstream side of the prefilter will induce on the polymer rim between the prefilter and the nozzle plate. Likewise, it was found that this second hoop should not be too wide; instead, the operating force becomes distributed over a larger contact area between the second rim and the pre-filter. Otherwise, the second rim must not be too small or too thin, otherwise the structure becomes mechanically weak. Typically, the extension of the second rim over the prefilter should be at least 50% of the thickness of the prefilter and preferably less than 250% of the thickness of the prefilter. The thickness of the rim must be at least 50% and at most 250% of the thickness of the prefilter, in particular with a thickness of at least 100 and maximum 500 micrometers. Also, if the second rim is too thick, it becomes too rigid and will lose its sealing properties, and also the total dead volume increases a lot between the nozzle and the pre-filter plate.
    [0025] With the second rim according to the invention, a hermetically closed seal is obtained between the upstream side of the nozzle plate and the downstream side of the pre-filter, thus contributing strongly to the microbial integrity of the nozzle unit. pulverization. As spray pores generally need to be micron in size in order to generate the desired droplet size, the nozzle plate generally does not prevent microbial growth. The holes in the pre-filter can be chosen smaller, for example, 0.35 micron or 0.22 micron or even smaller, down to 0.1 micron. In this way, the pre-filter becomes a barrier to microbial growth inside the device container. In this case, it is essential that the sides of the prefilter are sealed perfectly within the plastic support.
    [0026] In one embodiment, the support, on the upstream side of the pre-filter plate, comprises a clamping ring for securing the pre-filter plate to the support. A third rim, according to a possible embodiment of the invention, can be created on the upstream side of the pre-filter plate, which helps in fixing the pre-filter plate to the holder and improves the sealing between the plastic holder and the pre-filter plate.
    [0027] In one embodiment, at least one of the nozzle plate and the pre-filter is provided with a coating with molecules with end groups that has a strong interaction with molecules of the support. A good bond between the polymer and the nozzle plate (and/or between the polymer and the pre-filter plate(s)) is obtained according to the invention in that such plate can be provided with a coating with molecules with end groups that have a strong interaction with the polymer molecules, eg a silane with non-polar end groups to couple the silicon oxide/nitride surfaces to PP or other material.
    [0028] In one embodiment, the at least one of the nozzle plate and the pre-filter plate are provided with anisotropic locking features on the downstream or upstream surface thereof, the anisotropic locking features to mechanically anchor the skin at least one of the nozzle plate and the pre-filter plate in the bearing, preferably the anisotropic locking features with a width between 2 and 200 micrometers and a depth/width aspect ratio of at least 2, more preferably by minus 5. Accordingly, another modality to obtain a good bond with the bearing polymer is distinguished, wherein the nozzle plate and/or the pre-filter plate are provided with anisotropic locking characteristics on the downstream side or upstream of the plates around their edges to mechanically anchor the plates to the support, in particular anisotropic locking characteristics with a width between 2 and 20 micrometers and an aspect ratio to depth/width of at least 2, and preferably at least 5.
    [0029] One modality to ensure bacterial integrity is distinguished by a first, second or third pre-filter plate being present with a pore size smaller than 450 nanometers, in particular 220 nanometers, or in particular 100 nanometers. Thus, in one embodiment, the prefilter plate has a pore size smaller than 450 nanometers, in particular 220 nanometers, or in particular 100 nanometers.
    [0030] In order to extend the operating temperature range of the spray nozzle unit, an embodiment of the invention is further distinguished by the fact that the polymer has a reduced temperature expansion coefficient, such as 5 x 10-5°C or smaller.
    [0031] In order to meet GMP manufacturing protocols, the spray nozzle unit is further distinguished by the fact that all the different components have at least one trace and trace feature.
    [0032] In one embodiment, the spray device comprises an identification feature with a dimension between 0.01 and 10 microns, the identification feature being identifiable with microscopy or fluorescence methods. In order to combat counterfeits, the spray nozzle unit is further distinguished by having at least one hidden identification feature having a dimension between 0.01 and 10 microns, which can be identified with microscopy of fluorescence methods. In one embodiment, the prefilter comprises a plurality of pores, wherein at least one of the pores of the prefilter is a different size than the remaining pores, preferably about 10-50 nanometers smaller or larger than the other pores, a location of at least one of the pores having different size providing the identifying feature. For example, at least one of the pores in the silicon prefilter has a different size, in particular about 10-50 nanometers, smaller or larger than the other pores, and the location of that pore is encrypted with a code on the same plate. of pre-filter.
    [0033] Preferably, a method for manufacturing a spray nozzle unit is used, distinguished by the fact that the components are placed in a polymer package with a thermoplastic deformation process. In particular, the method for making a spray device according to one aspect of the invention can be used as described below.
    [0034] The spray device, in one or more of its described modalities, can, for example, be applied in a compatible spray nozzle unit, following good manufacturing practices (GMP). The spray device may comprise a polymer package with an acceptable leachable and extractable profile, a spray nozzle plate and one or more pre-filters, which withstand high operating spray pressure over a wide range of temperatures. In the prior art, the liquid-tight bonding or molding of a micromachined silicon-based nozzle or prefilter plate to a pharmaceutical-type thermoplastic material is severely hampered by the low adhesion between the materials, the deformability and relaxation of the thermoplastic under mechanical pressure and the large difference in temperature expansion of plastic and silicon. These problems can be solved in accordance with various embodiments of the spray device as described above. In order to achieve the present invention, various designs and sealing strategies were carried out, also with different thermoplastic materials with different molding techniques, such as injection molding, over molding and hot welding methods.
    [0035] The invention is further based on a method for mounting a nozzle plate to a thermoplastic support while controlling the temperature of the nozzle plate and/or support.
    [0036] According to one aspect of the invention, there is provided a method for manufacturing a spraying device, the method comprising: providing a nozzle plate and a thermoplastic seat having a tapered seat, wherein the smallest cross-section of the tapered seat is smaller than the nozzle plate, the method comprising: - heating the nozzle plate; - pressing the nozzle plate onto the tapered seat of the support, pushing the nozzle plate towards a smaller side of the tapered seat, thereby thermoplastically deforming a tapered seat wall;- forming a spray device from a nozzle plate and thermoplastic seat assembly, while a wider side of the tapered seat is pointed towards a liquid supply side. Thus, a tapered seat is provided in the thermoplastic support. At least one nozzle plate is provided, wherein a smaller cross section of the tapered seat is smaller than the nozzle plate. The nozzle plate and/or seat is heated, followed by pressing the nozzle plate into the seat, bringing this nozzle plate to the smaller side of the tapered seat, in order to thermoplastically deform the seat wall. This forms a spray device from the nozzle plate with support, while the wider side of the tapered seat is pointing towards the liquid supply side.
    [0037] According to the invention, a dimension of the orifice plate exceeds a dimension of the seat in the intended position of the orifice plate in the seat. The intended position of the orifice plate is to be understood as the position in which the orifice plate is to be placed in the seat. The dimension of the orifice plate can be a length, width, diameter etc. of the orifice plate. The seat dimension can be a seat size measured at the location where the orifice plate is intended to be positioned. Thus, dimension is to be understood as a dimension that is substantially perpendicular to a direction of insertion of the orifice plate into the seat when placing the orifice plate in the seat. As a result, the orifice plate is oversized with respect to the opening in the seat at the intended position of the orifice plate. The orifice plate is heated before being placed in the bearing seat. Thus, the thermoplastic material of the bearing will increase in temperature when the heated orifice plate contacts the thermoplastic material after placing the orifice plate in the seat. When the orifice plate is placed in the seat, the thermoplastic material of the seat, for example a seat wall, will deform as the orifice plate is oversized, causing the orifice plate to interact with the seat, for example, scraping seat wall material and/or pushing seat wall material forward in an orifice plate placement direction.
    [0038] As a result of seat deformation, the seat, as deformed, will enclose an outer edge of the orifice plate, thus allowing compensation for larger tolerances in one dimension of the orifice plate. As the thermoplastic material tends to shrink during cooling, the seat material enclosing the outer edge of the orifice plate will form around the outer edge of the orifice plate, thus sealing the orifice plate thereby preventing leakage of the liquid from which the aerosol is to be generated. Some of that tension will drain away. The creep process is influenced by the type of thermoplastic material and by the storage time and temperature. However, the voltage never completely goes down to zero and thus improves the seal. The deformation of the seat can also provide a ridge of thermoplastic material at the edges of the orifice plate, in particular in front of the orifice plate in the direction of movement, when placing the orifice plate on the seat. Seat deformation can even lead to a ridge just behind the orifice plate.
    [0039] Thus, the orifice plate is being placed free of leakage and fixed in a single process step, without adding any glues or sealants.
    [0040] The dimension can refer to a circumference, diameter, length and/or width: thus, the outer dimension of the orifice plate can be an outer circumference, diameter, length and/or width of the orifice plate and the inner dimension of seat can be an inner circumference, diameter, length and/or width of the seat. In this way, an orifice plate seal around its circumference can be provided by the circumferential edge of the orifice plate thermoplastically deforming the seat. Consequently, a length and width of the orifice plate may exceed the corresponding internal dimensions of the seat at the intended position of the orifice plate in the seat. The step of forming a spray device from assembling the nozzle plate and thermoplastic support may comprise: active or passive cooling of the assembly after deformation occurs, placing the assembly on a support, or any other suitable manufacturing step.
    [0041] A pressure on the spray nozzle unit in use, applied from the supply side, works in the right direction to compress the seal between the nozzle plate and seat even tighter during operation. The tapered configuration also prevents the nozzle plate from being pushed through the plastic, the release of which could potentially eject the nozzle plate at high speed with the possibility of personal injury.
    [0042] Instead of the plastic housing parts being tapered as described above, or as an additional feature, the sides of the nozzle plate may have locking features, for example also tapered or with local protrusions. Their potential modalities will be described in the drawings. Thus, the seat may have a constant cross-sectional contour towards the discharge opening along at least part of a length of the seat from the inlet opening to the discharge opening. This can be beneficial for plastic injection molding tools for thermoplastic support.
    [0043] To prevent the nozzle plate from becoming loose when no spray pressure is applied, it is possible to locally heat and deform the wider side of the tapered seat to create a rivet-type flange or rim or rim behind the nozzle plate , as further illustrated in the drawings. Such a flange will also hold the nozzle plate in position during temperature cycles, causing thermal expansion, which may likely differ for the plastic backing and the nozzle plate.
    [0044] Another potential embodiment of the invention comprises multiple nozzle plates, each with a different function in the liquid stream. The nozzle plate closest to the outside world can function as a nozzle plate, generating spray. The middle nozzle plate can serve as a last-chance filter, with plenty of small holes, for example half the diameter of the spray holes in the nozzle plate. The third nozzle plate, closest to the liquid supply side, can serve as a pre-filter, featuring an abundance of larger holes, filtering larger particles out of the liquid. The nozzle plate closest to the outside world has the smallest surface area. The nozzle plate closest to the liquid supply side has the largest surface area. The nozzle plate and the middle nozzle plate are both held in position by a rivet-type flange, or rim, creating, by assembly, the next nozzle plate or microsieve.
    [0045] Such an embodiment of the invention comprises a method for manufacturing a spray device with two or more nozzle plates, wherein a first of the nozzle plates has a smaller surface area than a second of the nozzle plates, the method comprising: - placing the first of the nozzle plates in a thermoplastic support seat, - placing the second of the nozzle plates at controlled temperature in the thermoplastic support seat, the thermoplastic support being thus locally thermoplastically deformed in a flange (for example , rivet type), thus securing the first of the nozzle plates. The rim can thus follow a surface of the nozzle chip. A diameter of the second of the nozzle plates may be larger than a diameter of the seat in the bearing, so as to scrape material from a wall of the bearing to form a flange. Thus, two or more nozzle plates or microsieves are being placed on a plastic support in a tapered pile. The nozzle plate that is placed first has a smaller surface area than the last nozzle plate (closer to the liquid supply side). When the second nozzle plate is placed at an elevated temperature, the plastic support is locally thermoplastically deformed and forms a flange or rim of the rivet or rim type, securing the first nozzle plate. The rivet-type flange or rim or rim forms a tight seal against the surface of the first nozzle plate, perfectly following small imperfections in the surface.
    [0046] Instead of using a subsequent nozzle plate to create the flange or rivet-type rim or rim by thermoplastic deformation of the bearing, a THERMODE can be used. A THERMODE is a heated object that can be cooled and removed after the flange is formed. Or, alternatively, a non-stick coating on this THERMODE makes cooling superfluous, allowing for faster processing times.
    [0047] The shape of the nozzle plates can be symmetrical (eg square, triangular, circular, hexagonal) or non-symmetrical (eg rectangular). The nozzle plate can be very small, for example for a square 1 x 1 mm nozzle plate, preferably 0.7 x 0.7 mm, more preferably 0.5 x 0.5 mm or even smaller.
    [0048] Such a nozzle plate can be fitted with a heated connecting head. This causes the nozzle plate to fuse in its path into the thermoplastic support, therefore perfectly following the imperfections of the side surfaces of the nozzle plate. Seat tolerances on the plastic seat are less critical using this heated connection. The temperature of the heated connection head can be varied between 50 and 300°C for different plastics with different melting temperatures. Thus, in one embodiment, the orifice plate is heated by a heated connecting head, placing the orifice plate in the bearing seat being held by the heated connecting head. The aerosol generator can thus be manufactured using existing fabrication devices, allowing you to reliably and quickly scale an aerosol generator fabrication.
    [0049] Heating the thermoplastic support before placing the nozzle plate and cooling it after placing it at room temperature will improve the seal around the nozzle plate. Some of that tension will drain away. This relaxation process is being influenced by the type of thermoplastic material and the storage time and temperature. However, the voltage never completely goes down to zero and thus improves the seal.
    [0050] Through this method of assembly, no glues or sealants are used, which is essential for primary packaging components for pharmaceutical applications. The manufacturing methods described provide an ideal seal that cannot be penetrated by microbes.
    [0051] The outside of the plastic support may be tapered. Thus, when pressurizing the nozzle, the housing that retains the assembled nozzle plate creates a net inward force during use, further sealing the nozzle plate.
    [0052] To secure the nozzle plate retainer, a second object can be placed directly behind it, as described above. For example, a plastic piece (for example a retaining ring) can be snapped into position, or a second nozzle plate or microsieve with, for example, a very large hole can be placed with a heated connection head. This can, for example, also be a simple metal ring or a porous metal frit. The placement of such a second element creates a rivet-type flange or rim that seals the first nozzle plate in position, as illustrated in more detail in the drawings.
    [0053] The heated placement of the second object creates a rivet-type flange or rim that seals the first nozzle plate. Behind the second object, a second flange or rivet-type rim can be created as described above, but this may not be necessary.
    [0054] In a similar way, three or more plates or microsieves can be placed on a support. When using two (or more) nozzle plates or micro sieves on a plastic support, the nozzle plates can each have a different function. The tapered stack of nozzle plates or microsieves can be used for different filtration steps for the spray device or to prevent microbial growth inside the container.
    [0055] The shape of the plates can be symmetrical (eg square, triangular, circular, hexagonal) or non-symmetrical (eg rectangular). If the shape is not a symmetrical center point, an angled stack can be formed without increasing the size of each subsequent nozzle plate, but resulting in the creation of a rivet-type rim or flange in an equal way. The nozzle plate that has the highest pressure drop, the spray nozzle plate that sprays in the outside world, typically has the smallest size and is the strongest.
    [0056] An example: when using two nozzle plates, the second, placed just behind the first nozzle plate, the spray nozzle plate with the spray holes towards the outside world, can be a nozzle plate with a microsieve function. Sealing such a second nozzle plate with a second flange or rivet-type rim (or a subsequent nozzle plate) may be especially desired in the case where this micro sieve nozzle plate forms an antimicrobial barrier from the outside world towards the contents of the sterile container. The microsieve can be equipped with small pores, smaller than 1 μm, smaller than 0.45 μm, smaller than 0.33 μm or even smaller than 0.22 μm to prevent microbial growth through the spray device inside from the fluid container of the device.
    [0057] In one embodiment, at least 3 orifice plates are placed on the support, the at least 3 orifice plates forming a stack. The stack can, for example, provide a pre-filter, a last-chance filter and a spray nozzle. Having three nozzle plates in the liquid path can be beneficial to the filtration strategy: for example, a 5 µm pre-filter microsieve, then a 1 µm last-chance filter microsieve, and then a nozzle plate with pores of 2 µm. The pre-filter filters out large particles of contamination, thus preventing them from reaching the last-chance filter and nozzle. The last chance filter removes small particles of contamination thus preventing a clogging of the spray nozzle.
    [0058] This assembly method makes it possible to choose an ideal manufacturing process for each function. The thickness of the boards may vary depending on the role of the board in the stack. It can, for example, also be used to make a triple stack of nozzle plates on the same plastic support as used for a double stack of nozzle plates. The first nozzle plate may be stronger and may be made from another material than the micro sieve nozzle plates in the stack. The membrane surface of a nozzle plate with a microsieve function can be chosen as large as possible to provide the maximum sieve surface and sieve capacity. Much smaller nozzle plate membrane(s) can be chosen to optimize strength. A microsieve nozzle plate may have an optimally widened sieve surface, for example by introducing pillars or other two- or three-dimensional microstructures. The surfaces of different nozzle plates can be smooth or very rough if desired.
    [0059] Between the nozzle plates, cavities are formed in the assembled spray device. These wells can contain an antimicrobial coating or a canister of antimicrobial material can be mounted in this well between two mouthpiece plates. The use of a plastic material with antimicrobial additives for plastic support will also result in the availability of an antimicrobial agent between the nozzle plates.
    [0060] One of the benefits of this way of assembling a spraying device is that the nozzle plates, for example silicon nozzle plates, can be coated on a wafer scale. A liner deposited on the "outside" of an insert, in this assembly, becomes the "inside" of the cavity between two nozzle plates. The coated surfaces may terminate on the outside of the aerosol generator or inside a cavity between two orifice plates, or inside the aerosol generator, facing the liquid supply.
    [0061] Each nozzle plate in a mounted spray device may have a different coating with a different function (eg antifouling or antimicrobial or ultra-hydrophobic on the outside of the nozzle plate, antimicrobial on the inside of the cavity between two plates with holes).
    [0062] Coatings can be leachate (eg as silver, copper, or other ion-forming metals) or stationary (eg as QAS, quaternary ammonium salt or titanium dioxide coatings). Even an "inkjet printed" coating of biological or chemical origin (eg benzalkonium chloride) can be deposited on a tile and by this method of assembly become part of the interior of a cavity.
    [0063] Nozzle plates can be coated on one or both sides, in which case the coating ends on an "inner surface" and an "outer surface" simultaneously.
    [0064] Holes in subsequent nozzle plates in the stack can be placed asymmetrically to influence the aspect ratio of the liquid path, for example to prevent microbial growth inside. In this way, bacteria need to travel a longer path in a narrow cavity from one series of holes to the series of holes in the next mouthpiece plate, while the cavity may contain an antimicrobial agent.
    [0065] Other materials that might otherwise be difficult to assemble in a spray device can now be trapped between two nozzle plates (or between a nozzle plate and a retaining ring, made of metal, ceramic or other material) . Here, complex stacked sandwiches of materials can be prepared with filtering capabilities or antimicrobial properties. Also, a deposit of antimicrobial material can be placed in the stack, for example a piece of metal or a porous frit (for example from an antimicrobial treated plastic, metal or ceramic). Even a material, which then slowly dissolves in the sprayed formulation, for example an antimicrobial agent, can be incorporated into the heap.
    [0066] Additionally, the spraying device can be equipped with depth filters from various materials, for example, as sintered porous plastic or non-woven filters.
    [0067] The spray nozzle plate (furthest downstream, closest and spraying to the outside world) can be used to incorporate an overpressure safety feature. For example, a larger hole that is covered by the plastic housing can be created as a well-defined breaking point in the system. There, a leak can be introduced at overpressure, reducing the risk of silicon fragments being thrown into the patient's eyes in the case of an eye spray device or into the lungs in the case of an inhaler device.
    [0068] In one embodiment, the nozzle plate comprises a metal or a ceramic material such as silicon. Micromachined silicon nozzle plates can be equipped with very small holes, micron-sized or even smaller, eg 0.22 micron or smaller, to create liquid passages that trap bacteria.
    [0069] In one embodiment, a method of manufacturing a spraying device comprises - providing a nozzle plate with a diameter; - providing a thermoplastic support having a seat, wherein the diameter of the nozzle plate exceeds a diameter of the seat at a desired position of the nozzle plate on the seat, - heating at least one of the nozzle plates and the thermoplastic support; - placing the nozzle plate on the seat in the desired position, thus providing a thermoplastic deformation of at least a part of the seat, and- form a spray nozzle unit from a nozzle plate and thermoplastic holder assembly. Given the smaller initial dimension of the seat in the intended position of the nozzle plate, a thermoplastic deformation is provided which causes a conformation of the seat to retain and seal the nozzle plate.
    [0070] In one embodiment, the nozzle plate is placed on the support in a direction of movement of the nozzle plate relative to the support, which direction corresponds to a liquid flow direction from which the spray is to be generated in use of the spray device. After thermoplastic seat deformation, a seat diameter upstream of the nozzle plate may exceed a seat seat diameter downstream of the nozzle plate. The smaller diameter on the downstream side can be provided by inserting the nozzle plate thermoplastically forcing the softened material from the seat wall to be pushed forward (when inserting the nozzle plate from the upstream direction), possibly in combination with the seat having a tapered shape narrowing in the downstream direction. The term upstream and downstream refers to a direction of flow of liquid through the aerosol generator when in use. When in use, aerosol generating liquid is forced into the bearing and presses against the orifice plate, the smaller diameter of the bearing seat upstream of the orifice plate retains the orifice plate against pressure applied by the liquid.
    [0071] According to another aspect of the invention, there is provided an aerosol generator manufactured in accordance with the method according to the invention. The aerosol generator can, for example, be configured to generate an aerosol from a medical fluid. The aerosol generator can also be used for non-medical applications such as home sprays, semiconductor machine cleaning machines, perfumes and beauty care sprays.
    [0072] According to another aspect of the invention, there is provided a liquid administering device for spraying a liquid, the administering device comprising - a container for holding the liquid, - the spraying device according to the invention or the device a sprayer manufactured in accordance with the method of the invention, and a pressurizing device for propagating the liquid under pressure from the container to the spraying device.
    [0073] The liquid comprises a substantially sterile liquid, whereby the good sealing properties and reducing bacterial growth tend to keep the liquid sterile. The liquid may comprise a medicinal liquid.
    [0074] Note that, although some of the modalities are described in the context of the spraying device according to the invention or in the context of the manufacturing method according to the invention, the characteristics and effects as described with reference to the method according to the invention with the invention can apply to the spraying device according to the invention and vice versa.
    [0075] The method according to the invention can be applied to manufacture the spraying device according to the invention. The bearing ring that fits a downstream edge of the nozzle plate can thus be provided by the step of the thermoplastic seat deformation method. Thus, the rim can also be referred to as a protrusion. BRIEF DESCRIPTION OF THE FIGURES
    [0076] Other modalities, characteristics and effects will appear from the attached drawings and corresponding description, in which non-limiting modalities are described, in which:- Figure 1 shows a cross-sectional view of a set of plates with holes and support according to one aspect of the invention, for use in an aerosol generator or other spraying device; Figures 2, 3a, 3b, 4, 5a - 5c, 6 and 7 show a cross-sectional view of various possible stages of manufacturing the assembly according to Figure 1; - Figure 8a shows a cross-sectional view of plates with holes; - Figure 8b shows a cross-sectional view of an orifice plate and support assembly, making use of a plate of orifice, as shown in Figure 8a; - Figure 9 shows a cross-sectional view of a set of plates with holes and support according to another aspect of the invention, for use in an aerosol generator; - Figure 10 illustrates a sectional view cross-sectional view of a plate assembly with holes and support according to another aspect of the invention, for use in an aerosol generator; Figures 11a - 11c illustrate a cross-sectional view of various possible stages of manufacturing a plate assembly with holes and support according to another aspect of the invention, for use in an aerosol generator; - Figures 12 - 14 illustrate cross-sectional pathways of the spray device according to embodiments of the invention; - Figure 15 illustrates a view in cross section of a spray device according to embodiments of the invention to illustrate a fabrication of the spray device using a THERMODE;- Figure 16 shows a graph with microbial test results;- Figure 17 explains an effect of a taper fit (tapering) ; and Figure 18 illustrates a schematic perspective view of a nozzle plate comprising protrusions. DETAILED DESCRIPTION OF THE FIGURES
    [0077] Figure 1 shows a part of an aerosol generator according to a potential embodiment of the invention, with three plates with holes (1, 10 and 11) and a sintered porous plastic pre-filter (12). A spray nozzle orifice plate (1) is mounted on a thermoplastic mount (2). A second orifice plate (10) and a third orifice plate (11) are being assembled with heat and pressure so as to locally thermoplastically deform the tapered seat wall (5), creating rivet-like flanges (8) . These two orifice plates form a filter of last chance (orifice plate 10), preferably with holes that are half the diameter of the spray pore diameter in the orifice plate of the spray nozzle (1) and a pre-filter (plate 11) with orifices larger than the last chance filter. A sintered porous plastic pre-filter (12-depth filter) is mounted and is being held in place by a simple snap fit.
    [0078] Figure 2 shows an embodiment of the invention with an orifice plate (1) mounted on a thermoplastic support (2). The support (2) is provided with an originally tapered seat (3). The seat tapers from an inlet opening (seat bottom side opening) to a discharge opening (seat upper side opening). When inserting the orifice plate into the seat, the seat is locally thermoplastically deformed (5), which may tend to perfectly follow the contours of the orifice plate (1). In the intended position of the orifice plate in the seat of the support, that is, in the position as shown in Figure 2, before inserting the orifice plate into the support, so before deformation of the seat, the outer dimension of the orifice plate (for example , the outer width, diameter or circumference) exceeds a corresponding inner dimension of the seat (e.g., the inner width, diameter or circumference) of the bearing, causing the seat to thermoplastically deform where it contacts the orifice plate when the heated orifice plate is inserted and makes contact with and because the orifice plate is oversized in relation to the seat, exerts a force on the seat. The dimension of the orifice plate and seat are to be understood as dimensions in a direction substantially perpendicular to the insertion direction (as indicated by the arrow in Figure 3a and 3b, as described below).
    [0079] Figure 3a shows a partially tapered seat (3) in a thermoplastic support (2). An orifice plate (1) is provided, and inserted into the seat (an insertion direction being indicated by the arrow in Figure 3a), the insertion being carried out in a tapering direction of the seat, i.e. in a direction to an opening of seat discharge outlet that is smaller than the inlet opening. In the outlet opening, the smaller cross section of the tapered seat (3) is smaller than the orifice plate (1).
    [0080] Figure 3b shows that the orifice plate (1), after being heated or while being heated, was inserted into the seat followed by pressing the orifice plate (1) into the support (2), leading the hole (1) on the wider side (7) of the tapered seat (3) towards the smaller side (4) of the tapered seat (3), thus thermoplastically deforming the seat wall (5). The insertion direction is indicated by the arrow in Figure 3b. This forms an aerosol generator from the bearing orifice plate, while the wider side (6) of the tapered seat is pointing towards the liquid supply side (7).
    [0081] Figure 4 shows another potential embodiment of the invention, in which an orifice plate (1) is mounted on a thermoplastic support (2). The orifice plate may have been mounted to the thermoplastic support using the method described with reference to figures 2 and 3a - 3b. As an additional step it can be carried out as follows: having locally heated and deformed the wider cross section (6) of the tapered seat, a rivet-type flange (8) was created, which fixes the position of the orifice plate (1 ). The rivet-type flange can be created by temporarily pushing (in the direction of insertion of the orifice plate) an object into the seat, the object having a size (eg diameter, circumference, length and/or width) that exceeds that of the plate of hole, causing the seat to deform in the rivet-type flange. The object can be heated to facilitate local thermoplastic deformation to form the flange. Alternatively, the object can be inserted after mounting the orifice plate while the thermoplastic seat material next to the orifice plate is still hot and it still exhibits a degree of thermoplastic plasticity. A fabrication of the aerosol generator as shown in Figure 4 is illustrated with reference to Figures 5a-5c, as described below.
    [0082] Figure 5a shows a tapered seat (3) in a thermoplastic support (2). An orifice plate (1) is provided, wherein the smaller cross section of the tapered seat (3) is smaller than the orifice plate (1). The orifice plate is heated prior to insertion or is inserted into the seat by a heated object such as a heated connection head (not shown in Figure 5a-5c.
    [0083] Figure 5b shows the orifice plate (1) placed on the thermoplastic support (2) in one direction as indicated by the arrow shown. As the seat tapers toward a dimension that is smaller than the orifice plate, the orifice plate pushes against the tapered seat, thereby locally plastically deforming the tapered seat wall (5)
    [0084] Figure 5c shows the creation of the rivet flange (8) using an object, such as, in this example, a THERMODE (20) to locally plastically deform the wider end (6) of the tapered seat. There, the THERMODE is pushed into the seat in the insertion direction. THERMODE can be heated to promote local thermoplastic deformation of the seat.
    [0085] Figure 6 shows a potential embodiment of the invention. An orifice plate (1) is mounted on a thermoplastic mount (2). A second object (9), in this case a piece in the form of a metal ring, is placed immediately behind the first orifice plate (1), creating a rivet-type flange (8) to hold the orifice plate (1) . The second object 9 can be mounted on the seat in a similar way to the THERMODE insert as described with reference to figure 5c, whereby the second object is left in the seat and the thermoplastic material is allowed to cool.
    [0086] Figure 7a shows a potential embodiment of the invention with two orifice plates. A first orifice plate (1), which serves as the orifice plate of the spray nozzle, is mounted on a thermoplastic support (2). A second orifice plate (10), for example with a micro-sieve function, is placed just behind the first orifice plate (1), creating a rivet-like flange (8). The second orifice plate (10) can be mounted on the seat after having mounted the first orifice plate, whereby the second orifice plate is mounted similarly to the mounting of the first orifice plate. In order to deform the seat again while assembling the second orifice plate, the second orifice plate can be larger (in terms of, for example, diameter, circumference, length and/or width) then the first orifice plate. By means of the assembly method, according to the invention, a cavity (20) was formed between the first and second orifice plates. The first and/or second orifice plate may be provided with a recess to form an area in the recess where the thickness of the orifice plate is reduced. The recess can be generated by any appropriate technique. For example, in case the orifice plate is made of a semiconductor material such as silicon, the recess can be chemically attacked in the orifice plate. In the part of the orifice plate where the thickness is reduced, one or more openings can be provided to form holes to generate an aerosol, respectively to form a filter.
    [0087] Figure 7b shows a potential modality with the same orifice plates, where the second orifice plate (10) has been mounted differently, thus creating a larger cavity (20). In Figure 7a the recesses in the first and second orifice plates are provided on the same side (upstream), while in Figure 7b the recesses face each other so as to form the larger cavity.
    [0088] Figure 8a shows two silicon wafers. The first insert (13) contains several hundred spray nozzle orifice plates (4 being shown in Figure 8a) and the second insert (14) holds several hundred microsieve orifice plates (4 being shown in Figure 8a). The first insert is being coated on its top surface with an ultra-hydrophobic coating (30). The second insert is being coated on its top surface with an antimicrobial coating (31).
    [0089] Figure 8b shows an aerosol generator assembly using orifice plates from the two silicon wafers described in Figure 8a. The first orifice plate, the nozzle orifice plate (1), has the ultra-hydrophobic coating (30) on the outside (i.e., on the downstream side). The second orifice plate, the microsieve plate (10) has an antimicrobial coating which has now ended up inside the cavity (20).
    [0090] Figure 9 shows a potential embodiment of the invention with two orifice plates plus a deposit (32) of an antimicrobial material, placed in the cavity (20) between the two orifice plates (10 and 11). Depot 32 can be formed of an absorbent structure that absorbs the antimicrobial material, or it can be formed of the antimicrobial material itself.
    [0091] Figure 10 shows a potential embodiment of the invention with three orifice plates. The spray nozzle orifice plate (1) faces the outside world on the downstream side of the aerosol generator. The hole pattern in the second orifice plate, a microsieve plate (10), is placed asymmetrically with respect to a central axis of the support extending from the inlet to the discharge opening. The hole pattern in the third orifice plate, also a microsieve plate (11), is also placed asymmetrically on the other side, i.e. on the other side with respect to the central axis. In this way, the cavity (20) and the liquid path (21) between the two groups of microsieve holes have become very long and narrow as it extends through the holes in the third orifice plate which are located on the side. left in the figure 10 drawing, while the holes in the second orifice plate are located on the right side in the figure 10 drawing. The cavity has been further narrowed, with the recesses in the second and third orifice plates being spaced apart , bringing the thin parts of the orifice plate closer together to form a narrower space between them. An antimicrobial coating (22) applied to both chips of the microsieves (10 and 11) prevents bacteria (23) from growing in the container (24) of the device. The container, only a part of which is shown in Figure 10, holds the liquid from which the aerosol is to be generated.
    [0092] Figure 11a shows a thermoplastic support (2). Two orifice plates (1) and (10) are provided, wherein the smaller cross section of the tapered seat (3) is smaller than the orifice plate (1). In contrast to the seats as shown and described with reference to figures 1 - 10, the seat in the mode, as shown in figure 11, tapers gradually rather than continuously. The first and second orifice plates (1 and 10) are placed in the seat by inserting them in the direction of the arrow in Figure 11a. The first and second orifice plates may or may not be heated and may - but need not necessarily - cause thermoplastic seat deformation.
    [0093] Figure 11b shows the temperature-controlled placement of a third orifice plate (11), locally thermoplastically deforming (5) the support seat (2) inserting the third orifice plate into the seat in the direction of the arrow ( figure 11b). Part of the thermoplastic material of the bearing is being scraped from a seat wall (5) in front of the third orifice plate (11) to form a 5-way flange between the second orifice plate and the third orifice plate.
    [0094] Figure 11c shows a possible embodiment of an aerosol generator according to the invention, as obtained by placing orifice plates, as described with reference to figures 11a and 11b, in which a first orifice plate (1) , functioning as a spray nozzle orifice plate is provided and a second orifice plate (10) which functions as a last chance filter. The temperature-controlled placement of a third orifice plate (11), functioning as a pre-filter, created a rivet-type flange (8), securing the first two orifice plates (1 and 10).
    [0095] Figure 12 shows an embodiment of a spray nozzle unit (1) with a nozzle plate (2) with a thickness of 200 µm and a size of 1 x 1 mm. The nozzle plate (2) is made with silicon micromachining. For this, a 200 μm thick silicon wafer is used as support and a 1 μm thick silicon nitride layer for the provision of the nozzle holes. Silicon nitride nozzle holes here are 2 µm in diameter. The spray nozzle nozzle plate (2) is mounted on a thermoplastic bearing or medical certified polypropylene casing (3) which is distinguished by having a collar (4) extending over the silicone nozzle nozzle plate on the side. output or downstream (5). The collar (4) extends horizontally over the nozzle plate (2) on the downstream side (5) with a length of 200 µm and has a thickness of 200 µm. The spray nozzle unit (1) further comprises an adapter (6) with a tapered section (7) to counterbalance the thermal expansion and pressure of the thermoplastic support (3). The adapter (6) may further comprise a support collar (8) for supporting the collar (4) of the support (3) to reinforce the spray nozzle unit (1) during operation. Here, the support ring (8) extends about 150 µm and has a thickness of 200 µm.
    [0096] Figure 13 shows an embodiment of a spray nozzle unit (1) with a nozzle plate (2), a thermoplastic support (3) and a microsieve pre-filter (9). The microsieve (9) is made with a silicon micromachining method similar to the manufacture of the nozzle plate (2) with a thickness of 200 µm and has pores with a diameter of 0.45 µm. Between the nozzle plate (2) and the pre-filter (9) there is a second polymer ring (10) which extends over the mouth plate of the silicone nozzle (2) on the upstream side. Here the second polymer ring has a thickness of 100 µm and extends to a length of 200 µm. The membrane side of the microsieve (9) is here positioned on the upstream side of the spray nozzle unit (1), but it can also be placed inverted.
    [0097] Figure 14 shows an embodiment of a spray nozzle unit (1) with a nozzle plate (2), a thermoplastic support (3), a micro sieve pre-filter (9) and a pre-filter of sintered porous plastic (11), here with a pore size of approximately 10 µm. Likewise, a third filter (12) can be placed to collect particles from the fluid on the upstream side.
    [0098] Figure 15 shows a method for fabricating a spray nozzle unit (1) using a THERMODE (13).
    [0099] Figure 16 shows a graph with microbial test results, comparing a single-nozzle unit with a pre-filter and a tapered adapter, in accordance with the present invention, with a single-nozzle unit without the use of an adapter tapered. The nozzles are challenged over a period of one week, then the contents of the container with a nutrient solution are evaluated for bacterial growth.
    Previous nozzles unexpectedly show ingrowth of 0.22 microsieve pores, new nozzles according to the invention do not, which indicates that the microsieve plates are now mounted in a way that seals them perfectly.
    [00101] Figure 17 shows the importance of a tapered fit of the spray nozzle unit mounted in its vicinity. The plastic material used for the plastic backing used to generate this data is polypropylene, the surrounding adapters A and B are made of a harder plastic (adapter A fast prototyped polyamide, adapter B ground from polyoxymethylene). The graph shows that, at higher pressures, the polypropylene pad can inflate, causing internal leaks between the nozzle plate and the plastic pad.
    [00102] Figure 18 shows a schematic perspective view of a nozzle plate. Local protrusions are provided on each edge of the nozzle plate. Various protrusion profiles are shown. For illustrative purposes, in order to illustrate different possibilities of the protrusion profiles, each edge of the illustrated nozzle plate is provided with a different profile.
    权利要求:
    Claims (34)
    [0001]
    1. Spray device, comprising a nozzle plate with a downstream surface and a spray nozzle orifice and comprising a support having a seat, which is open at an upstream end and a downstream end thereof and, supporting the nozzle plate. nozzle in said seat, wherein the seat is made of a thermoplastic material and wherein the seat comprises a first ram, which is formed from said thermoplastic material as an integral part of said seat, and wherein the first ram sealingly engages said surface downstream of the nozzle plate and extends along a circumferential edge of the surface downstream of the ram of the nozzle plate, characterized in that at least part of said seat tapers towards said end downstream thereof and in which said nozzle plate is seated on said taper part of said seat of said support.
    [0002]
    2. Spray device according to claim 1, characterized in that it comprises a width of the first ram in a direction parallel to the downstream surface of the nozzle plate is at least 25% of a thickness of the nozzle plate.
    [0003]
    3. Spray device according to claim 1 or 2, characterized in that in the direction perpendicular to the surface downstream of the nozzle plate, the first ram has a thickness of at least 50% and at most 250% of a thickness of the nozzle plate.
    [0004]
    4. Spraying device according to any one of the preceding claims, characterized in that it further comprises an adapter having an inner surface that fitably supports an outer surface of the support, preferably a stiffness of the adapter that exceeds the stiffness of the support.
    [0005]
    5. Spray device according to claim 4, characterized in that the adapter comprises an adapter ram that extends on a downstream side of the support and substantially parallel to the downstream surface of the nozzle plate so that it supports the first support ram during operation.
    [0006]
    6. Spray device according to claim 5, characterized in that a width of the adapter ram seen in a direction along the downstream surface of the nozzle plate is between 50% and 200% of the width of the first ram of the support.
    [0007]
    7. Spraying device according to any one of claims 4 to 6, characterized in that in a direction perpendicular to the downstream surface of the nozzle plate, the adapter ram has a thickness between 50% and 200% of the support ram .
    [0008]
    8. Spray device according to any one of claims 4 to 7, characterized in that the outer surface of the support and the inner surface of the adapter both have a tapered section that tapers positively in a downstream direction, preferably having a taper angle between 5° and 45°.
    [0009]
    9. Spraying device according to any one of the preceding claims, characterized in that at least part of the seat tapers towards a downstream end thereof.
    [0010]
    10. Spray device according to any of the preceding claims, characterized in that the nozzle plate is mounted on the support with a thermoplastic deformation process.
    [0011]
    11. A spray device comprising a nozzle plate having a downstream surface and a spray nozzle orifice, and comprising a seat having a seat, said seat supporting said nozzle plate, wherein the seat is made of a material thermoplastic, wherein the seat comprises a first ram that is formed from said thermoplastic material as an integral part of said bearing, and wherein the first ram sealably engages said surface downstream of the mouthpiece plate and extends along of a circumferential edge of said surface downstream of the nozzle plate, characterized in that it further comprises a pre-filter plate, wherein the pre-filter plate is placed on said support seat at a distance from the nozzle plate and on an upstream side of the nozzle plate, wherein the bearing comprises a second ram between the nozzle plate and the prefilter plate, said second ram extending along and engaging along an edge circumferential surface of a downstream surface of the prefilter plate.
    [0012]
    12. Spray device according to claim 11, characterized in that in a direction perpendicular to the downstream surface of the nozzle plate, the second ram has a thickness of at least 50% and a maximum of 250% of a thickness of the pre-filter plate, in particular with a minimum thickness of 100 and a maximum of 500 micrometers.
    [0013]
    13. Spraying device according to claim 11 or 12, characterized in that the support on the upstream side of the pre-filter plate comprises a clamping ram for fixing the pre-filter plate to the support.
    [0014]
    14. Spray device according to claims 11 to 13, characterized in that at least one of the nozzle and pre-filter plates is provided with a coating having molecules with end groups that have a strong interaction with the molecules of the support.
    [0015]
    15. Spraying device according to claims 11 to 14, characterized in that at least one of the nozzle plate and the pre-filter plate has anisotropic locking characteristics on the surface downstream or upstream thereof, the characteristics of anisotropic locking to mechanically anchor at least one of the nozzle plate and pre-filter plate to the support, preferably the anisotropic locking features with a width between 2 and 20 micrometers and a depth/width aspect ratio of at least 2 , more preferably at least 5.
    [0016]
    16. Spraying device according to any of claims 11 to 15, characterized in that the pre-filter plate has a pore size of less than 450 nanometers, in particular less than 220 nanometers or in particular less than 100 nanometers.
    [0017]
    17. Spraying device according to any of claims 11 to 16, characterized in that said nozzle plate and said pre-filter plate are mounted on the support with a thermoplastic deformation process
    [0018]
    18. A spray device comprising a nozzle plate having a downstream surface and a spray nozzle orifice, and comprising a seat having a seat, said seat supporting said nozzle plate, wherein the seat is made of a material thermoplastic, wherein the seat comprises a first ram that is formed from said thermoplastic material as an integral part of said bearing, and wherein the first ram sealably engages said surface downstream of the mouthpiece plate and extends along of a circumferential edge of said surface downstream of the nozzle plate, characterized in that the spray nozzle unit has at least one track and trace feature.
    [0019]
    19. Spraying device according to claim 18, characterized in that it comprises an identification feature having a dimension between 0.01 and 10 microns, the identification feature being identifiable with microscopy or fluorescence methods.
    [0020]
    20. Spraying device according to claim 19, characterized in that it further comprises a pre-filter comprising a plurality of pores, wherein at least one of the pores of the pre-filter has a different size than the remaining pores, preferably about 10 to 50 nanometers smaller or larger than the other pores, a location of at least one of the pores having the different size providing the identifying characteristic.
    [0021]
    21. Method for manufacturing a spraying device, the method characterized in that it comprises: providing a nozzle plate; providing a thermoplastic support having a tapered seat that is tapered over at least a portion of a length thereof, having a smaller cross section that is smaller than a nozzle plate cross section and- forming a spray device from a nozzle plate and thermoplastic backing assembly by:- heating the nozzle plate; e - press the nozzle plate onto the tapered seat of the support, leading the nozzle plate towards said smaller cross section of the tapered seat, thereby thermoplastically deforming a tapered seat wall; - wherein a wider end of the tapered seat is on one side of the supply of a liquid.
    [0022]
    22. A method for manufacturing a spray device according to claim 21, characterized in that at least one additional nozzle plate having a cross section that is wider than said cross section of the first nozzle plate is placed: under controlled temperature in the thermoplastic bearing seat, the thermoplastic bearing being thereby locally thermoplastically deformed in a flange, thus securing said first nozzle plate.
    [0023]
    23. Method for manufacturing a spray device according to claim 20 or 21, characterized in that the thermoplastic backing is heated before assembly of the nozzle plate(s) and cooled again after assembly to improve the seal around the nozzle plate(s).
    [0024]
    24. Method for manufacturing a spraying device according to claim 22, characterized in that the rivet-shaped flange or ram is created by heating and deforming the wider end of the tapered seat of the thermoplastic support, so that the nozzle trim position is fixed.
    [0025]
    25. Method for manufacturing a spray device according to claim 24, characterized in that while the ram or rivet-shaped flange is created by temperature-controlled placement of an object other than a nozzle plate such as a metal ring, which remains on the spray device assembly.
    [0026]
    26. Method for manufacturing a spray device according to any one of claims 21 to 25, characterized in that 3 or more nozzle plates are placed in the spray device assembly, thus forming a balanced functional stack, for example a stack of a pre-filter, a last-chance filter and a spray nozzle.
    [0027]
    27. Method for manufacturing a spray device according to claim 25 or 26, characterized in that an antimicrobial agent is present in one of the cavities in the spray device assembly.
    [0028]
    28. Method for manufacturing a spray device according to claim 22, characterized in that at least one of the nozzle plates is coated.
    [0029]
    29. Method for manufacturing a spray device according to claim 28, characterized in that the coating agent is an antimicrobial coating.
    [0030]
    30. Method for manufacturing a spray device according to claims 21 to 29, characterized in that at least one nozzle plate has tapered sides or has local protuberances for anchoring purposes.
    [0031]
    31. Method for manufacturing a spraying device, characterized in that it comprises:- providing a nozzle plate with a diameter; - provide a thermoplastic support having a seat, where the diameter of the nozzle plate exceeds a seat diameter at a desired position of the nozzle plate on the seat, - heat at least one of the nozzle plates and the thermoplastic support; - place the nozzle plate on the seat of the seat in the desired position, thus providing a thermoplastic deformation of at least a portion of the seat, and forming a spray nozzle unit from a nozzle plate and thermoplastic seat assembly.
    [0032]
    32. Method according to claim 31, characterized in that the nozzle plate is placed in relation to the support in a direction, which corresponds to a flow direction in relation to the support of the liquid from which the spray should be generated while using the spray device
    [0033]
    33. Method according to claim 31 or 32, characterized in that after the thermoplastic deformation of the seat, a seat diameter upstream of the nozzle plate exceeds a seat diameter of the support seat downstream of the nozzle plate.
    [0034]
    34. Use of the spray device, characterized in that it is manufactured in accordance with the method as defined in any one of claims 21 to 33.
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    同族专利:
    公开号 | 公开日
    US20170281880A1|2017-10-05|
    BR112016029844A8|2021-03-16|
    CN106573134A|2017-04-19|
    CN106573134B|2021-04-06|
    US10632265B2|2020-04-28|
    US20200215276A1|2020-07-09|
    EP3157681A1|2017-04-26|
    WO2015194962A1|2015-12-23|
    BR112016029844A2|2017-08-22|
    WO2015194962A9|2016-03-10|
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    法律状态:
    2020-05-05| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2021-05-04| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-06-01| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 19/06/2015, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    NL2013044|2014-06-20|
    NL2013044|2014-06-20|
    PCT/NL2015/050455|WO2015194962A1|2014-06-20|2015-06-19|Aerosol or spray device, spray nozzle unit and method of manufacturing the same|
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