EP1037858A1

EP1037858A1 - Device and method for creating spherical particles of uniform size

Info

Publication number: EP1037858A1
Application number: EP98960045A
Authority: EP
Inventors: Alfonso Ganan Calvo
Original assignee: Universidad de Sevilla
Current assignee: Universidad de Sevilla
Priority date: 1997-12-17
Filing date: 1998-12-17
Publication date: 2000-09-27
Also published as: AU1572799A; AU745904B2; WO1999031019A1; CA2315048A1; JP2002508250A

Abstract

Spherical particles having a size on the order of 0.1 to 100 microns in size are created by systems and devices of several types. The device includes a source of a stream of gas which is forced through a liquid held under pressure in a pressure chamber with an exit opening therein. The stream of gas surrounded by the liquid in the pressure chamber flows out of an exit orifice of the chamber into a liquid thereby creating a monodispersion of bubbles with substantially uniform diameter. The bubbles are small in size and produced with a relatively small amount of energy relative to comparable systems. Small particles of liquid may also be produced. Applications of the technology range from oxygenating sewage with monodispersions of bubbles to inhalation therapy with monodisperse aerosol dispersions of pharmaceutically active drugs.

Description

DEVICE AND METHOD FOR CREATING SPHERICAL PARTICLES OF UNIFORM SIZE

FIELD OF THE INVENTION The invention relates generally to the field of small particle formation and more specifically to fields where (1) it is important to create solid particles, liquid particles or gas bubbles which are very small and uniform in size and/or (2) it is important to avoid nozzle clogging when small nozzle openings are used to expel a fluid over a long period of time.

BACKGROUND OF THE INVENTION Monodispersed sprays of droplets of micrometric size have attracted the interest of scientist and engineers because of their potential applications in many fields of science and technology. Recently, the possibility of getting medicines into patients via pulmonary inhalation is being actively investigated by pharmaceutical companies around the world R.F. Service (1997), "Drug Delivery Takes a Deep Breath," Science 277: 1199-1200. Classifying a polydispersed aerosol (for example, by using a differential mobility analyzer, B.Y. Liu et al. (1974), "A Submicron Standard and the Primary Absolute Calibration of the Condensation Nuclei Counter," J. Coloid Interface Sci. 47: 155-171 or breakup process of Rayleigh's type of a capillary microjet Lord Rayleigh (1879), "On the instability of Jets," Proc. London Math. Soc. 1Q:4-13, are the current methods to produce the monodispersed aerosols of micrometric droplets needed for such applications. The substantial loss of the aerosol sample during the classification process can severely limit the use of this technique for some applications. On the other hand, although in the capillary break up the size distribution of the droplets can be very narrow, the diameter of the droplets is determined by the jet diameter (approximately twice the jet diameter). Therefore, the generation and control of capillary microjets are essential to the production of sprays of micrometric droplets with very narrow size distribution.

Capillary microjets with diameters ranging from tens of nanometers to hundred of micrometers are successfully generated by employing high electrical fields (several kV) to form the well-known cone-jet electrospray. Theoretical and experimental results and numerical calculations on electrosprays can be obtained from M. Cloupean et al. (1989), "Electrostatic Spraying of Liquids in Cone Jet Mode," J. Electrostat 22: 135-159, Fernandez de la Mora et al. (1994), "The Current Transmitted through an Electrified Conical Meniscus," J. Fluid Mech.T ϊ: 155-184 and Loscertales (1994), A.M. Ganan- Calvo et al. (1997), "Current and Droplet Size in the Electrospraying of Liquids: Scaling Laws, " J. Aerosol Sci. 2£:249-275, Hartman et al. (1997), "Electrohydrodynamic Atomization in the Cone-Jet Mode, " Paper presented at the ESF Workshop on Electrospray, Sevilla, 28 Feb.-l Mar. 1997 among others [see also the papers contained in the Special Issue for Electrosprays (1994)]. In the electrospray technique the liquid to be atomized is slowly injected through a capillary electrified needle. For a certain range of values of the applied voltage and flow rate an almost conical meniscus is formed at the needle's exit from whose vertex a very thin, charged jet is issued. The jet breaks up into a fine aerosol of high charged droplets characterized by a very narrow droplet size distribution. Alternatively, the use of purely mechanical means to produce capillary microjets is limited in most of applications for several reasons: the high-pressure values required to inject a liquid through a very narrow tube (typical diameters of the order of few micrometers) and the easy clogging of such narrow tubes due to impurities in the liquid.

The present invention provides a new technique for generating steady microcapillary jets exclusively based on mechanical means which does not present the above inconveniences and can compete advantageously with electrospray atomizers. The jet diameters produced with this technique can be easily controlled and range from below one micrometer to several tens of micrometers.

SUMMARY OF THE INVENTION Spherical particles of liquid in the form of a monodispersion as well as spherical particles of bubbles in the form of a monodispersion are disclosed wherein the particles have a size on the order of 0.1 to 100 microns. The particles are created by various types of systems and devices disclosed herein. The device includes a primary source of a stream of liquid or gas which is forced through, respectively, a gas or liquid held under pressure in a pressure chamber. The pressure chamber has an exit opening through which the stream is allowed to flow surrounded by the surrounding gas or liquid. As the stream flows toward the exit opening it forms a stable capillary microjet which jet disassociates upon exiting the chamber. When certain parameters are correctly chosen the particles or bubbles formed are all substantially uniform in size with a very small degree of deviation, e.g., +3 % to + 10% . The particles and bubbles are produced using a relatively small amount of energy compared with the amount of energy used to produce such in comparable systems. Small particles of liquid may be used in a variety of applications including fuel injection engines and the production of aerosols for the delivery of drugs by inhalation. Small bubbles may be used for a variety of uses including decontamination of gases and oxygenation of sewage or water in which fish or other plant or animal life is present and in need of oxygen.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a schematic view showing the basic components of one embodiment of the invention with a cylindrical feeding needle as a source of formulation.

Figure 2 is a schematic view of another embodiment of the invention with two concentric tubes as a source of formulation.

Figure 3 is a schematic view of yet another embodiment showing a wedge- shaped planar source of formulation. Figure 3a illustrates a cross-sectional side view of the planar feeding source and the interaction of the fluids. Figure 3b show a frontal view of the openings in the pressure chamber, with the multiple openings through which the atomizate exits the device. Figure 3c illustrates the channels that are optionally formed within the planar feeding member. The channels are aligned with the openings in the pressure chamber.

Figure 4 is a schematic view of a stable capillary microjet being formed and flowing through an exit opening to thereafter form a monodisperse aerosol. Figure 5 is a graph of data where 350 measured values of djd₀ versus OIQ₀ are plotted.

Figure 6 is a schematic view of the critical area of a device of the type shown in Figure 1 showing gas surrounded by liquid expelled into a liquid to form bubbles.

Figure 7 is a schematic view as in Figure 6 but with the bubbles flowing into a gas.

Figure 8 is a schematic view as in Figure 6 but with two immiscible liquids flowing into a gas. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Before the present aerosol device and method are described, it is to be understood that this invention is not limited to the particular components and steps described, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims.

It must be noted that as used herein and in the appended claims, the singular forms

"a", "and," and "the" include plural referents unless the context clearly dictates otherwise.

Thus, for example, reference to "a particle" includes a plurality of particles and reference to "a fluid " includes reference to a mixture of fluids, and equivalents thereof known to those skilled in the art, and so forth.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods and materials are now described. All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited.

The publications discussed herein are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention. Further, the dates of publication provided may be different from the actual publication dates which may need to be independently confirmed.

DEVICE IN GENERAL

Different embodiments are shown and described herein (see Figures 1, 2 and 3) which could be used in producing the stable capillary microjet and/or a dispersion of particles which are substantially uniform in size. Although various embodiments are part of the invention, they are merely provided as exemplary devices which can be used to convey the essence of the invention, which is the formation of a stable capillary microjet and/or uniform dispersion of particles. A basic device comprises (1) a means for supplying a first fluid and (2) a pressure chamber supplied with a second fluid which flows out of an exit opening in the pressure chamber. The exit opening of the pressure chamber is aligned with the flow path of the means for supplying the first fluid. The embodiments of Figures 1, 2 and 3 clearly show that there can be a variety of different means for supplying the first fluid. Other means for supplying a first fluid flow stream will occur to those skilled in the art upon reading this disclosure.

Further, other configurations for forming the pressure chamber around the means for supplying the first fluid will occur to those skilled in the art upon reading this disclosure. Such other embodiments are intended to be encompassed by the present invention provided the basic conceptual results disclosed here are obtained, i.e. a stable capillary microjet is formed and/or a dispersion of particle highly uniform in size is formed. Further description provided below shows that a stable microjet can be obtained when parameters are adjusted to obtain a Weber number of 1 or more but the disassociation of that microjet will not provide a desired monodispersion unless the parameters are adjusted so that the Weber number is less than 40.

To simplify the description of the invention, the means for supplying a first fluid is often referred to as a cylindrical tube (see Figure 1) and the first fluid is generally referred to as a liquid. The liquid can be any liquid depending on the overall device which the invention is used within. For example, the liquid could be a liquid formulation of a pharmaceutically active drug used to create an aerosol for inhalation or, alternatively, it could be a hydrocarbon fuel used in connection with a fuel injector for use on an internal combustion engine or heater or other device which burns hydrocarbon fuel. Further, for purposes of simplicity, the second fluid is generally described herein as being a gas and that gas is often preferably air. However, the first fluid may be a gas and second fluid a liquid or both fluids may be liquid provided the first and second fluid are sufficiently different from each other (immiscible) so as to allow for the formation of a stable microjet of the first fluid moving from the supply means to an exit port of the pressure chamber. Notwithstanding these different combinations of gas-liquid, liquid-gas, and liquid-liquid, the invention is generally described with a liquid formulation being expelled from the supply means and forming a stable microjet due to interaction with surrounding air flow focusing the microjet to flow out of an exit of the pressure chamber. Formation of the microjet and its acceleration and ultimate particle formation are based on the abrupt pressure drop associated with the steep acceleration experienced by the liquid on passing through an exit orifice of the pressure chamber which holds the second fluid (i.e. the gas). On leaving the chamber the flow undergoes a certain pressure difference between the liquid and the gas, which in turn produces a highly curved zone on the liquid surface near the exit port of the pressure chamber and in the formation of a cuspidal point from which a steady microjet flows, provided the amount of the liquid withdrawn through the exit port of the pressure chamber is replenished. Thus, in the same way that a glass lens or a lens of the eye focuses light to a given point, the flow of the gas surrounds and focuses the liquid into a stable microjet. The focusing effect of the surrounding flow of gas creates a stream of liquid which is substantially smaller in diameter than the diameter of the exit orifice of the pressure chamber. This allows liquid to flow out of the pressure chamber orifice without touching the orifice, providing advantages including (1) clogging of the exit orifice is virtually eliminated, (2) contamination of flow due to contact with substances (e.g. bacteria or particulate residue) on the orifice opening is virtually eliminated, and (3) the diameter of the stream and the resulting particles are smaller than the diameter of the exit orifice of the chamber. This is particularly desirable because it is difficult to precisely engineer holes which are very small in diameter. Further, in the absence of the focusing effect (and formation a stable microjet) flow of liquid out of an opening will result in particles which have about twice the diameter of the exit opening. An additional advantage is that the particles are not prone to agglomeration following exit from the chamber owing to the accelerating effect of the surrounding gas stream, which has a velocity larger than the liquid velocity.

These advantages are all obtained with a system which uses a very small amount of energy as compared to other systems for creating either aerosolized particles of liquid in a gas or a monodispersion of bubbles in a liquid. More specifically, a given ideal minimum amount of energy is needed to move a stream of gas through a liquid or a stream of liquid through a gas. Further energy is needed (based on characteristics such as surface tensions) to form small spherical particles or bubbles. By using methodology disclosed here a capillary supercritical flow is obtained creating a stable capillary microjet. These characteristics move the flow stream and create the particles or bubbles using an amount of energy which is substantially closer to the minimum amount of energy required in an ideal system, i.e. it is closer to the ideal minimum amount of energy needed in other systems for obtaining such results. This is particularly important in some applications. For example, to treat sewage large amount of gas (air or oxygen) must be forced into the sewage to oxygenate the water. The smaller the bubbles and the greater the number of bubbles the more energy that is required. However, smaller bubbles present a greater surface area to the water resulting in greater diffusion of oxygen into the water. Further, smaller bubbles rise less quickly and thereby provide contact between the air and water for a greater period of time - further enhancing the oxygenation of the water.

The description provided here generally indicates that the fluid leaves the pressure chamber through an exit orifice surrounded by the gas and thereafter enters into a gaseous surrounding environment which may be air held at normal atmospheric pressure, or, alternatively, the gas (heated pressurized air) inside an internal combustion engine. However, when the first fluid is a gas and the second fluid is a liquid the fluid present outside of the chamber may also be a liquid. This configuration is particularly useful when it is necessary to create very small highly uniform bubbles which are moved into a liquid surrounding exit opening of the pressure chamber. The need for the formation of very small highly uniform bubbles into a gas occurs in a variety of different industrial applications. For example, water needs to be oxygenated in a variety of situations including small at home fish tanks and large volume fisheries. The additional oxygen can aid the rate of growth of the fish and thereby improve production for the fishery. In the embodiment described above, oxygen or air bubbles can be forced into liquid sewage in order to aid in treatment. In yet another application of the invention, contaminated gases such as a gas contaminated with toxins such as a radioactive material can be formed into small uniformed bubbles and blown into a liquid where the contamination in the gas will diffuse into the liquid, thereby cleaning the gas. The liquid will, of course, occupy substantially less volume and therefore be substantially easier to dispose of than contaminated toxic gas.

Those skilled in the art will recognize that variations on the different embodiments disclosed below will be useful in obtaining particularly preferred results. Specific embodiments of devices are now described. EMBODIMENT OF FIGURE 1

A first embodiment of the invention where the supply means is a cylindrical feeding needle supplying liquid into a pressurized chamber of gas is described below with reference to

Figure 1. The components of the embodiment of Figure 1 are as follows:

1. Feeding needle - also referred to generally as a fluid source and a tube.

2. End of the feeding needle used to insert the liquid to be atomized.

3. Pressure chamber.

4. Orifice used as gas inlet. 5. End of the feeding needle used to evacuate the liquid to be atomized.

6. Orifice through which withdrawal takes place.

7. Atomizate (spray) - also referred to as aerosol.

D] = diameter of the feeding needle; D₀ = diameter of the orifice through which the microjet is passed; e - axial length of the orifice through which withdrawal takes place; H = distance from the feeding needle to the microjet outlet; P₀ = pressure inside the chamber; P_a = atmospheric pressure. Although the device can be configured in a variety of designs, the different designs will all include the essential components shown in Figure 1 or components which perform an equivalent function and obtain the desired results. Specifically, a device of the invention will be comprised of at least one source of a first fluid (e.g., a feeding needle with an opening 2) into which a first fluid such as liquid flowable formulation can be fed and an exit opening 5 from which the formulation can be expelled. The feeding needle 1, or at least its exit opening 5, is encompassed by a pressure chamber 3. The chamber 3 has inlet opening 4 which is used to feed a second fluid (e.g. a gas) into the chamber 3 and an exit opening 6 through which gas from the pressure chamber and liquid formulation from the feeding needle 3 are expelled. When the first fluid is a liquid it is expelled into gas to create an aerosol. When the first fluid is a gas it is expelled into a liquid to create bubbles.

In Figure 1, the feeding needle and pressure chamber are configured to obtain a desired result of producing an aerosol wherein the particles are small and uniform in size or bubbles which are small and uniform in size. The particles or bubbles have a size which is in a range of 0.1 to 100 microns. The particles of any given aerosol or bubbles will all have about the same diameter with a relative standard deviation of ±10% to ±30% or more preferably ±3% to ±10%. Stating that particles of the aerosol have a particle diameter in a range of 1 to 5 microns does not mean that different particles will have different diameters and that some will have a diameter of 1 micron while others of 5 microns. The particles in a given aerosol will all (preferably about 90% or more) have the same diameter ±3% to ±30%. For example, the particles of a given aerosol will have a diameter of 2 microns ±3% to ±10%.

The same deviations are also correct for the formation of bubbles.

Such a monodisperse aerosol is created using the components and configuration as described above. However, other components and configurations will occur to those skilled in the art. The object of each design will be to supply fluid so that it creates a stable capillary microjet which is accelerated and stabilized by tangential viscous stress exerted by the second fluid on the first fluid surface. The stable microjet created by the second fluid leaves the pressurized area (e.g., leaves the pressure chamber and exits the pressure chamber orifice) and splits into particles or bubbles which have the desired size and uniformity. The parameter window used (i.e. the set of special values for the liquid properties, flow-rate used, feeding needle diameter, orifice diameter, pressure ratio, etc.) should be large enough to be compatible with virtually any liquid (dynamic viscosities in the range from 10^"4 to 1 kg m^'V¹); in this way, the capillary microjet that emerges from the end of the feeding needle is absolutely stable and perturbations produced by breakage of the jet cannot travel upstream. Downstream, the microjet splits into evenly shaped drops simply by effect of capillary instability (see, for example, Rayleigh, "On the instability of jets", Proc. London Math. Soc, 4-13, 1878), similar in a manner to a laminar capillary jet falling from a half-open tap.

When the stationary, steady interface is created, the capillary jet that emerges from the end of the drop at the outlet of the feeding point is concentrically withdrawn into the nozzle. After the jet emerges from the drop, the liquid is accelerated by tangential sweeping forces exerted by the gas stream flowing on its surface, which gradually decreases the jet cross-section. Stated differently the gas flow acts as a lens and focuses and stabilizes the microjet as it moves toward and into the exit orifice of the pressure chamber. The forces exerted by the second fluid flow on the first fluid surface should be steady enough to prevent irregular surface oscillations. Therefore, any turbulence in the gas motion should be avoided; even if the gas velocity is high, the characteristic size of the orifice should ensure that the gas motion is laminar (similar to the boundary layers formed on the jet and on the inner surface of the nozzle or hole).

STABLE CAPILLARY MICROJET Figure 4 illustrates the interaction of a liquid and a gas to form atomizate using the method of the invention. The feeding needle 60 has a circular exit opening 61 with an internal radius R, which feeds a liquid 62 out of the end, forming a drop with a radius in the range of R, to Rj plus the thickness of the wall of the needle. Thereafter, the drop narrows in circumference to a much smaller circumference as is shown in the expanded view of the tube (i.e. feeding needle) 5 as shown in Figures 1 and 4. The exiting liquid flow comprises an infinite amount of liquid streamlines 63 that after interaction of the liquid with the surrounding gas to form a stable cusp at the interface 64 of the two fluids. The surrounding gas also forms an infinite number of gas streamlines 65, which interact with the solid surfaces and the exiting liquid to create the effect of a virtual focusing funnel 66. The exiting liquid is focused by the focusing funnel 66 resulting in a stable capillary microjet 67, which remains stable until it exits the opening 68 of the pressure chamber 69. After exiting the pressure chamber, the microjet begins to break-up, forming monodispersed particles 70.

The gas flow, which affects the liquid withdrawal and its subsequent acceleration after the jet is formed, should be very rapid but also uniform in order to avoid perturbing the fragile capillary interface (the surface of the drop that emerges from the jet).

As illustrated in Figure 4, the exit opening 61 of the capillary tube 60 is positioned close to an exit opening 68 in a planar surface of a pressure chamber 69. The exit opening 68 has a minimum diameter D₀ and is in a planar member with a thickness e. The diameter D₀ is referred to as a minimum diameter because the opening may have a conical configuration with the narrower end of the cone positioned closer to the source of liquid flow. Thus, the exit opening may be a funnel-shaped nozzle although other opening configurations are also possible, e.g. an hour glass configuration. Gas in the pressure chamber continuously flows out of the exit opening. The flow of the gas causes the liquid drop expelled from the tube to decrease in circumference as the liquid moves away from the end of the tube in a direction toward the exit opening of the pressure chamber.

In actual use, it can be understood that the opening shape which provokes maximum gas acceleration (and consequently the most stable cusp and microjet with a given set of parameters) is a conically shaped opening in the pressure chamber. The conical opening is positioned with its narrower end toward the source of liquid flow.

The distance between the end 61 of the tube 60 and the beginning of the exit opening 68 is H. At this point it is noted that R_b D₀, H and e are all preferably on the order of hundreds of microns. For example, R, = 400μm, D₀ = 150μm, H = 1mm, e = 300μm.

However, each could be 1/100 to lOx these sizes.

The end of the liquid stream develops a cusp-like shape at a critical distance from the exit opening 68 in the pressure chamber 69 when the applied pressure drop ΔP_g through the exit opening 68 overcomes the liquid-gas surface tension stresses γ/R^* appearing at the point of maximum curvature — e.g. 1/R^* from the exit opening.

A steady state is then established if the liquid flow rate Q ejected from the drop cusp is steadily supplied from the capillary tube. This is the stable capillary cusp which is an essential characteristic of the invention needed to form the stable microjet. More particularly, a steady, thin liquid jet with a typical diameter d_j is smoothly emitted from the stable cusp- like drop shape and this thin liquid jet extends over a distance in the range of microns to millimeters. The length of the stable microjet will vary from very short (e.g. 1 micron) to very long (e.g. 50 mm) with the length depending on the (1) flow-rate of the liquid and (2) the Reynolds number of the gas stream flowing out of the exit opening of the pressure chamber. The liquid jet is the stable capillary microjet obtained when supercritical flow is reached. This jet demonstrates a robust behavior provided that the pressure drop ΔP_g applied to the gas is sufficiently large compared to the maximum surface tension stress (on the order of γ/d_j) that act at the liquid-gas interface. The jet has a slightly parabolic axial velocity profile which is, in large part, responsible for the stability of the microjet. The stable microjet is formed without the need for other forces, i.e. without adding force such as electrical forces on a charged fluid. However, for some applications it is preferable to add charge to particles, e.g. to cause the particles to adhere to a given surface. The shaping of liquid exiting the capillary tube by the gas flow forming a focusing funnel creates a cusp-like meniscus resulting in the stable microjet. This is a fundamental characteristic of the invention.

The stable capillary microjet is maintained stably for a significant distance in the direction of flow away from the exit from the tube. The liquid is, at this point, undergoing "supercritical flow." The microjet eventually destabilizes due to the effect of surface tension forces. Destabilization results from small natural perturbations moving downstream, with the fastest growing perturbations being those which govern the break up of the microjet, eventually creating a uniform sized monodisperse aerosol 70 as shown in Figure 4.

The microjet, even as it initially destabilizes, passes out of the exit orifice of the pressure chamber without touching the peripheral surface of the exit opening. This provides an important advantage of the invention which is that the exit opening 68 (which could be referred to as a nozzle) will not clog from residue and/or deposits of the liquid. Clogging is a major problem with very small nozzles and is generally dealt with by cleaning or replacing the nozzle. When fluid contacts the surfaces of a nozzle opening some fluid will remain in contact with the nozzle when the flow of fluid is shut off. The liquid remaining on the nozzle surface evaporates leaving a residue. After many uses over time the residue builds up and clogging takes place. The present invention substantially reduces or eliminates this clogging problem.

MATHEMATICS OF A STABLE MICROJET Cylindrical coordinates (r,z) are chosen for analyzing the shape of a stable microjet, i.e. a liquid jet undergoing "supercritical flow." The cusp-like meniscus formed by the liquid coming out of the tube is pulled toward the exit of the pressure chamber by a pressure gradient created by the flow of gas.

The cusp-like meniscus formed at the tube's mouth is pulled towards the hole by the pressure gradient created by the gas stream. From the cusp of this meniscus, a steady liquid thread with the shape of radius r = ξ is withdrawn through the hole by the action of both the suction effect due to ΔP_g, and the tangential viscous stresses τ_s exerted by the gas on the jet's surface in the axial direction. The averaged momentum equation for this configuration may be written

where Q is the liquid flow rate upon exiting the feeding tube, P_x is the liquid pressure, and pi is the liquid density, assuming that the viscous extensional term is negligible compared to the kinetic energy term, as will be subsequently justified. In addition, liquid evaporation effects are neglected. The liquid pressure P_l is given by the capillary equation.

where γ is the liquid-gas surface tension. As shown in the Examples, the pressure drop ΔP_g is sufficiently large as compared to the surface tension stress γ/ξ to justify neglecting the latter in the analysis. This scenario holds for the whole range of flow rates in which the microjet is absolutely stable. In fact, it will be shown that, for a given pressure drop ΔP_g, the minimum liquid flow rate that can be sprayed in steady jet conditions is achieved when the surface tension stress γ/ξ is of the order of the kinetic energy of the liquid pι<2²/(2π²ξ⁴), since the surface tension acts like a "resistance" to the motion (it appears as a negative term in the right-hand side term of Eq. (1)). Thus,

For sufficiently large flow rates Q compared to Q_nύn, the simplified averaged momentum equation in the axial direction can be expressed as

where one can identify the two driving forces for the liquid flow on the right-hand side. This equation can be integrated provided the following simplification is made: if one uses a thin plate with thickness L of the order or smaller than the hole's diameter D (which minimizes downstream perturbations in the gas flow), the pressure gradient up to the hole exit is on the average much larger than the viscous shear term 2τ_s/ξ owning to the surface stress. On the other hand, the axial viscous term is of the order 0[μ²QID²d²], since the hole diameter D is actually the characteristic distance associated with the gas flow at the hole's entrance in both the radial and axial directions. This term is very small compared to the pressure gradient in real situations, provided that Δ-P_g » μ²/D²p (which holds, e.g., for liquids with viscosities as large as 100 cpoises, using hole diameters and pressure drops as small as D ~ 10 μm and ΔP_g > 100 mbar). The neglect of all viscous terms in Eq. (4) is then justified. Notice that in this limit on the liquid flow is quasi-isentropic in the average (the liquid almost follows Bernoulli equation) as opposed to most micrometric extensional flows. Thus, integrating (4) from the stagnation regions of both fluids up to the exit, one obtains a simple and universal expression for the jet diameter at the hole exit:

which for a given pressure drop Δ _g is independent of geometrical parameters (hole and tube diameters, tube-hole distance, etc.), liquid and gas viscosities, and liquid-gas surface tension. This diameter remains almost constant up to the breakup point since the gas pressure after the exit remains constant.

MONODISPERSE PARTICLES Above the stable microjet undergoing "supercritical flow" is described and it can be seen how this aspect of the invention can be made use of in a variety of industrial applications — particularly where the flow of liquid through small holes creates a clogging problem. An equally important aspect of the invention is obtained after the microjet leaves the pressure chamber.

When the microjet exits the pressure chamber the liquid pressure P_l becomes (like the gas pressure E_g) almost constant in the axial direction, and the jet diameter remains almost constant up to the point where it breaks up by capillary instability. Defining a Weber number We = (p_gv_g ²fi?_j)/γ - 2 ΔE_{g j}/γ (where v_g is the gas velocity measured at the orifice), below a certain experimental value We_c~ 40 the breakup mode is axisymmetric and the resulting droplet stream is characterized by its monodispersity provided that the fluctuations of the gas flow do not contribute to droplet coalescence (these fluctuations occur when the gas stream reaches a fully developed turbulent profile around the liquid jet breakup region). Above this We_c value, sinuous nonaxisymmetric disturbances, coupled to the axisymmetric ones, become apparent. For larger We numbers, the nonlinear growth rate of the sinuous disturbances seems

14 -

SUBSTITUTΕ SHEET (RULE 26) to overcome that of the axisymmetric disturbances. The resulting spray shows significant polydispersity in this case. Thus, it can be seen that by controlling parameters to keep the resulting Weber number to 40 or less, allows the particles formed to be all substantially the same size. The size variation is about ±3% to ±30% and move preferably ±3% to ±10%. These particles can have a desired size e.g. 0.1 microns to 50 microns.

The shed vorticity influences the breakup of the jet and thus the formation of the particles. Upstream from the hole exit, in the accelerating region, the gas stream is laminar. Typical values of the Reynolds number range from 500 to 6000 if a velocity of the order of the speed of sound is taken as characteristic of the velocity of the gas. Downstream from the hole exit, the cylindrical mixing layer between the gas stream and the stagnant gas becomes unstable by the classical Kelvin-Helmholtz instability. The growth rate of the thickness of this layer depends on the Reynolds number of the flow and ring vortices are formed at a frequency of the order of v_g D, where D is the hole diameter. Typical values of v_g and D as those found in our experimental technique lead to frequencies or the order of MHZ which are comparable to the frequency of drop production (of order of t_b ^_1).

Given the liquid flow rate and the hole diameter, a resonance frequency which depends on the gas velocity (or pressure difference driving the gas stream) can be adjusted (tuned) in such a way that vortices act as a forcing system to excite perturbations of a determined wavelength on the jet surface. Experimental results obtained clearly illustrates the different degree of coupling between the two gas-liquid coaxial jets. In one set of experimental results the particle sizes are shown to have a particle size of about 5.7 microns with a standard deviation of 12%. This results when the velocity of the gas has been properly tuned to minimize the dispersion in the size of droplets resulting from the jet breakup. In this case, the flow rate of the liquid jet and its diameter are 0.08μl s^"1 and 3 μm, respectively. Data have been collected using a MASTERSIZER from MALVERN Instruments. As the degree of coupling decreases, perturbations at the jet surface of different wavelengths become excited and, as it can be observed from the size distributions, the dispersion of the spray increases.

It is highly desirable in a number of different industrial applications to have particles which are uniform in size or to create aerosols of liquid particles which are uniform in size. For example, particles of a liquid formation containing a pharmaceutically active drug could be created and designed to have a diameter of about 2 microns ±3%. These particles could be inhaled into the lungs of a patient for intrapulmonary drug delivery. Moreover, particle size can be adjusted to target a particular area of the respiratory tract.

Upstream of the orifice exit the gas flow should be laminar in order to avoid a turbulent regime - turbulent fluctuations in the gas flow which have a high frequency and would perturb the liquid-gas interface. The Reynolds numbers reached at the orifice are

^{v d} _n Re = -LI ~ 4000 v z

where v.- is the kinematic viscosity of the gas. Even though this number is quite high, there are large pressure gradients downstream (a highly convergent geometry), so that a turbulent regime is very unlikely to develop.

The essential difference from existing pneumatic atomizers (which possess large Weber numbers) and the present invention is that the aim of the present invention is not to rupture the liquid-gas interface but the opposite, i.e. to increase the stability of the interface until a capillary jet is obtained. The jet, which will be very thin provided the pressure drop resulting from withdrawal is high enough, splits into drops the sizes of which are much more uniform than those resulting from disorderly breakage of the liquid-gas interface in existing pneumatic atomizers.

The proposed atomization system obviously requires delivery of the liquid to be atomized and the gas to be used in the resulting spray. Both should be fed at a rate ensuring that the system lies within the stable parameter window. Multiplexing is effective when the flow-rates needed exceed those on an individual cell. More specifically, a plurality of feeding sources or feeding needles may be used to increase the rate at which aerosols are created. The flow-rates used should also ensure the mass ratio between the flows is compatible with the specifications of each application.

The gas and liquid can be dispensed by any type of continuous delivery system (e.g. a compressor or a pressurized tank the former and a volumetric pump or a pressurized bottle the latter). If multiplexing is needed, the liquid flow-rate should be as uniform as possible among cells; this may entail propulsion through several capillary needles, porous media or any other medium capable of distributing a uniform flow among different feeding points.

Each individual atomization device should consist of a feeding point (a capillary needle, a point with an open microchannel, a microprotuberance on a continuous edge, etc.) 0.002-2 mm (but, preferentially 0.01-0.4 mm) in diameter, where the drop emerging from the microjet can be anchored, and a small orifice 0.002-2 mm (preferentially 0.01-0.25 mm) in diameter facing the drop and separated 0.01-2 mm (preferentially 0.2-0.5 mm) from the feeding point. The orifice communicates the withdrawal gas around the drop, at an increased pressure, with the zone where the atomizate is produced, at a decreased pressure. The atomizer can be made from a variety of materials (metal, polymers, ceramics, glass).

Figure 1 depicts a tested prototype where the liquid to be atomized is inserted through one end of the system 2 and the propelling gas in introduced via the special inlet 4 in the pressure chamber 3. The prototype was tested at gas feeding rates from 100 to 2000 mBar above the atmospheric pressure P_a at which the atomized liquid was discharged. The whole enclosure around the feeding needle 1 was at a pressure P₀ > P_a. The liquid feeding pressure, P_h should always be slightly higher than the gas propelling pressure, P₀. Depending on the pressure drop in the needle and the liquid feeding system, the pressure difference (Pj - P₀ > 0) and the flow-rate of the liquid to be atomized, Q, are linearly related provided the flow is laminar - which is indeed the case with this prototype. The critical dimensions are the distance from the needle to the plate (H), the needle diameter (D₀), the diameter of the orifice through which the microjet 6 is discharged (d₀) and the axial length, e, of the orifice (i.e. the thickness of the plate where the orifice is made). In this prototype, H was varied from 0.3 to 0.7 mm on constancy of the distances (D₀ = 0.45 mm, d₀ - 0.2 mm) and e - 0.5 mm. The quality of the resulting spray 7 did not vary appreciably with changes in H provided the operating regime (i.e. stationary drop and microjet) was maintained. However, the system stability suffered at the longer H distances (about 0.7 mm). The other atomizer dimensions had no effect on the spray or the prototype functioning provided the zone around the needle (its diameter) was large enough relative to the feeding needle.

WEBER NUMBER Adjusting parameters to obtain a stable capillary microjet and control its breakup into monodisperse particle is governed by the Weber number and the liquid-to-gas velocity ratio or a which equal VJV_e. The Weber number or "We" is defined by the following equation:

wherein p_g is the density of the gas, dis the diameter of the stable microjet, γ is the liquid-gas surface tension, and V² is the velocity of the gas squared.

When carrying out the invention the parameters should be adjusted so that the Weber number is greater than 1 in order to produce a stable capillary microjet. However, to obtain a particle dispersion which is monodisperse (i.e. each particle has the same size ±3 to ±30%) the parameters should be adjusted so that the Weber number is less than about 40. The monodisperse aerosol is obtained with a Weber number in a range of about 1 to about 40 (1 < We < 40).

OHNESORGE NUMBER

A measure of the relative importance of viscosity on the jet breakup can be estimated from the Ohnesorge number defined as the ratio between two characteristic times: the viscous time t_v and the breaking time t_b. The breaking time t_b is given by [see Rayleigh (1878)]

Perturbations on the jet surface are propagated inside by viscous diffusion in times t_v of the order of

where μ_l is the viscosity of the liquid. Then, the Ohnesorge number, Oh, results

μ₁

Oh = (4)

%

(P_/Yc If this ratio is much smaller than unity viscosity plays no essential role in the phenomenon under consideration. Since the maximum value of the Ohnesorge number in actual experiments conducted is as low as 3.7 ^χl0^"2, viscosity plays no essential role during the process of jet breakup.

EMBODIMENT OF FIGURE 2 A variety of configurations of components and types of fluids will become apparent to those skilled in the art upon reading this disclosure. These configurations and fluids are encompassed by the present invention provided they can produce a stable capillary microjet of a first fluid from a source to an exit port of a pressure chamber containing a second fluid. The stable microjet is formed by the first fluid flowing from the feeding source to the exit port of the pressure chamber being accelerated and stabilized by tangential viscous stress exerted by the second fluid in the pressure chamber on the surface of the first fluid forming the microjet. The second fluid forms a focusing funnel when a variety of parameters are correctly tuned or adjusted. For example, the speed, pressure, viscosity and miscibility of the first and second fluids are chosen to obtain the desired results of a stable microjet of the first fluid focused into the center of a funnel formed with the second fluid. These results are also obtained by adjusting or tuning physical parameters of the device, including the size of the opening from which the first fluid flows, the size of the opening from which both fluids exit, and the distance between these two openings.

The embodiment of Figure 1 can, itself, be arranged in a variety of configurations. Further, as indicated above, the embodiment may include a plurality of feeding needles. A plurality of feeding needles may be configured concentrically in a single construct, as shown in Figure 2. The components of the embodiment of Figure 2 are as follows:

21. Feeding needle - tube or source of fluid.

22. End of the feeding needle used to insert the liquids to be atomized.

23. Pressure chamber.

24. Orifice used as gas inlet. 25. End of the feeding needle used to evacuate the liquid to be atomized.

26. Orifice through which withdrawal takes place.

27. Atomizate (spray) or aerosol. 28. First liquid to be atomized (inner core of particle).

29. Second liquid to be atomized (outer coating of particle). 30. Gas for creation of microj et.

31. Internal tube of feeding needle. 32. External tube of feeding needle.

D = diameter of the feeding needle; d = diameter of the orifice through which the microjet is passed; e - axial length of the orifice through which withdrawal takes place; H = distance from the feeding needle to the microjet outlet; γ=surface tension; P₀ = pressure inside the chamber; P_a = atmospheric pressure. The embodiment of Figure 2 is preferably used when attempting to form a spherical particle of one substance coated by another substance. The device of Figure 2 is comprised of the same basic component as per the device of Figure 1 and further includes a second feeding source 32 which is positioned concentrically around the first cylindrical feeding source 31.

The second feeding source may be surrounded by one or more additional feeding sources with each concentrically positioned around the preceding source. The outer coating may be used for a variety of purposes, including: coating particles to prevent small particles from sticking together; to obtain a sustained release effect of the active compound (e.g. a pharmaceutically active drug) inside, and/or to mask flavors; and to protect the stability of another compound (e.g. a pharmaceutically active drug) contained therein.

The process is based on the microsuction which the liquid-gas or liquid-liquid interphase undergoes (if both are immiscible), when said interphase approaches a point beginning from which one of the fluids is suctioned off while the combined suction of the two fluids is produced. The interaction causes the fluid physically surrounded by the other to form a capillary microjet which finally breaks into spherical drops. If instead of two fluids (gas-liquid), three or more are used that flow in a concentric manner by injection using concentric tubes, a capillary jet composed of two or more layers of different fluids is formed which, when it breaks, gives rise to the formation of spheres composed of several approximately concentric spherical layers of different fluids. The size of the outer sphere (its thickness) and the size of the inner sphere (its volume) can be precisely adjusted. This can allow the manufacture of coated particles for a variety of end uses. For example the thickness of the coating can be varied in different manufacturing events to obtain coated particles which have gradually decreasing thicknesses to obtain a controlled release effect of the contents, e.g. a pharmaceutically active drug. The coating could merely prevent the particles from degrading, reacting, or sticking together. The method is based on the breaking of a capillary microjet composed of a nucleus of one liquid or gas and surrounded by another or other liquids and gases which are in a concentric manner injected by a special injection head, in such a way that they form a stable capillary microjet and that they do not mix by diffusion during the time between when the microjet is formed and when it is broken. When the capillary microjet is broken into spherical drops under the proper operating conditions, which will be described in detail below, these drops exhibit a spherical nucleus, the size and eccentricity of which can be controlled.

In the case of spheres containing two materials, the injection head 25 consists of two concentric tubes with an external diameter on the order of one millimeter. Through the internal tube 31 is injected the material that will constitute the nucleus of the microsphere, while between the internal tube 31 and the external tube 32 the coating is injected. The fluid of the external tube 32 joins with the fluid of tube 31 as the fluids exit the feeding needle, and the fluids (normally liquids) thus injected are accelerated by a stream of gas that passes through a small orifice 24 facing the end of the injection tubes. When the drop in pressure across the orifice 24 is sufficient, the liquids form a completely stationary capillary microjet, if the quantities of liquids that are injected are stationary. This microjet does not touch the walls of the orifice, but passes through it wrapped in the stream of gas or funnel formed by gas from the tube 32. Because the funnel of gas focuses the liquid, the size of the exit orifice 26 does not dictate the size of the particles formed.

When the parameters are correctly adjusted, the movement of the liquid is uniform at the exit of the orifice 26 and the viscosity forces are sufficiently small so as not to alter either the flow or the properties of the liquids; for example, if there are biochemical molecular specimens having a certain complexity and fragility, the viscous forces that would appear in association with the flow through a micro-orifice might degrade these substances

Figure 2 shows a simplified diagram of the feeding needle 21, which is comprised of the concentric tubes 30, 31 through the internal and external flows of the fluids 28, 29 that are going to compose the microspheres comprised of two immiscible fluids. The difference in pressures P₀ - P_α (P₀ > ?_a) through the orifice 26 establishes a flow of gas present in the chamber 23 and which is going to surround the microjet at its exit. The same pressure gradient that moves the gas is the one that moves the microjet in an axial direction through the hole 26, provided that the difference in pressures P₀ - P„ is sufficiently great in comparison with the forces of surface tension, which create an adverse gradient in the direction of the movement.

There are two limitations for the minimum sizes of the inside and outside jets that are dependent (a) on the surface tensions γl of the outside liquid 29 with the gas 30 and γ2 of the outside liquid 29 with the inside liquid 28, and (b) on the difference in pressures ΔP = P₀ - P-- through the orifice 26. In the first place, the jump in pressures ΔP must be sufficiently great so that the adverse effects of the surface tension are minimized. This, however, is attained for very modest pressure increases: for example, for a 10 micron jet of a liquid having a surface tension of 0.05 N/m (tap water), the necessary minimum jump in pressure is in the order of 0.05 (N/m) / 0.00001 m = ΔP= 50 mBar. But, in addition, the breakage of the microjet must be regular and axilsymmetric, so that the drops will have a uniform size, while the extra pressure ΔP cannot be greater than a certain value that is dependent on the surface tension of the outside liquid with the gas γl and on the outside diameter of the microjet. It has been experimentally shown that this difference in pressures cannot be greater than 20 times the surface tension γl divided by the outside radius of the microjet.

Therefore, given some inside and outside diameters of the microjet, there is a range of operating pressures between a minimum and a maximum; nonetheless, experimentally the best results are obtained for pressures in the order of two to three times the minimum.

The viscosity values of the liquids must be such that the liquid with the greater viscosity u--.^ verifies, for a diameter d of the jet predicted for this liquid and a difference through the orifice ΔP , the inequality:

I ≤ A Pd²D Q

With this, the pressure gradients can overcome the extensional forces of viscous resistance exerted by the liquid when it is suctioned toward the orifice.

Moreover, the liquids must have very similar densities in order to achieve the concentricity of the nucleus of the microsphere, since the relation of velocities between the liquids moves according to the square root of the densities vl/v2 = (p2/pl)^{1 2} and both jets, the inside jet and the outside jet, must assume the most symmetrical configuration possible, which does not occur if the liquids have different velocities (Figure 2). Nonetheless, it has been experimentally demonstrated that, on account of the surface tension γ2 between the two liquids, the nucleus tends to migrate toward the center of the microsphere, within prescribed parameters.

When two liquids and gas are used on the outside, the distance between the planes of the mouths of the concentric tubes can vary, without the characteristics of the jet being substantially altered, provided that the internal tube 31 is not introduced into the external one 32 more than one diameter of the external tube 32 and provided that the internal tube 31 does not project more than two diameters from the external tube 32. The best results are obtained when the internal tube 31 projects from the external one 32 a distance substantially the same as the diameter of the internal tube 31. This same criterion is valid if more than two tubes are used, with the tube that is surrounded (inner tube) projecting beyond the tube that surrounds (outer tube) by a distance substantially the same as the diameter of the first tube.

The distance between the plane of the internal tube 31 (the one that will normally project more) and the plane of the orifice may vary between zero and three outside diameters of the external tube 32, depending on the surface tensions between the liquids and with the gas, and on their viscosity values. Typically, the optimal distance is found experimentally for each particular configuration and each set of liquids used.

The proposed atomizing system obviously requires fluids that are going to be used in the resulting spray to have certain flow parameters. Accordingly, flows for this use must be:

- Flows that are suitable so that the system falls within the parametric window of stability. Multiplexing (i.e. several sets of concentric tubes) may be used, if the flows required are greater than those of an individual cell.

- Flows that are suitable so that the mass relation of the fluids falls within the specifications of each application. Of course, a greater flow of gas may be supplied externally by any means in specific applications, since this does not interfere with the functioning of the atomizer.

Therefore, any means for continuous supply of gas (compressors, pressure deposits, etc.) and of liquid (volumetric pumps, pressure bottles) may be used. If multiplexing is desired, the flow of liquid must be as homogeneous as possible between the various cells, which may require impulse through multiple capillary needles, porous media, or any other medium capable of distributing a homogeneous flow among different feeding points. Each atomizing device will consist of concentric tubes 31, 32 with a diameter ranging between 0.05 and 2 mm, preferably between 0.1 and 0.4 mm, on which the drop from which the microjet emanates can be anchored, and a small orifice (between 0.001 and 2 mm in diameter, preferably between 0.1 and 0.25 mm), facing the drop and separated from the point of feeding by a distance between 0.001 and 2 mm, preferably between 0.2 and 0.5 mm. The orifice puts the suction gas that surrounds the drop, at higher pressure, in touch with the area in which the atomizing is to be attained, at lower pressure.

EMBODIMENT OF FIGURE 3 The embodiments of Figures 1 and 2 are similar in a number of ways. Both have a feeding piece which is preferably in the form of a feeding needle with a circular exit opening. Further, both have an exit port in the pressure chamber which is positioned directly in front of the flow path of fluid out of the feeding source. Precisely maintaining the alignment of the flow path of the feeding source with the exit port of the pressure chamber can present an engineering challenge particularly when the device includes a number of feeding needles. The embodiment of Figure 3 is designed to simplify the manner in which components are aligned. The embodiment of Figure 3 uses a planar feeding piece, which by virtue of the withdrawal effect produced by the pressure difference across a small opening through which fluid is passed permits multiple microjets to be expelled through multiple exit ports of a pressure chamber thereby obtaining multiple aerosol streams. Although a single planar feeding member is shown in Figure 3 it, of course, is possible to produce a device with a plurality of planar feeding members where each planar feeding member feeds fluid to a linear array of outlet orifices in the surrounding pressure chamber. In addition, the feeding member need not be strictly planar, and may be a curved feeding device comprised of two surfaces that maintain approximately the same spatial distance between the two pieces of the feeding source. Such curved devices may have any level of curvature, e.g. circular, semicircular, elliptical, hemi-elliptical, etc. The components of the embodiment of Figure 3 are as follows:

41. Feeding piece.

42. End of the feeding piece used to insert the fluid to be atomized.

43. Pressure chamber. 44. Orifice used as gas inlet.

45. End of the feeding needle used to evacuate the liquid to be atomized.

46. Orifices through which withdrawal takes place.

47. Atomizate (spray) or aerosol.

48. first fluid containing material to be atomized. 49. second fluid for creation of microjet.

50. wall of the propulsion chamber facing the edge of the feeding piece.

51. channels for guidance of fluid through feeding piece. d_j = diameter of the microjet formed; p_A= liquid density of first fluid (48); p_B= liquid density of second fluid (49). v_A= velocity of the first liquid (48); v_B=velocity of the second liquid (49); e = axial length of the orifice through which withdrawal takes place; H = distance from the feeding needle to the microjet outlet; P₀ = pressure inside the chamber;

£φ_g- change in pressure of the gas; P_a = atmospheric pressure; flow rate The proposed dispersing device consists of a feeding piece 41 which creates a planar feeding channel through which a where a first fluid 48 flows. The flow is preferably directed through one or more channels of uniform bores that are constructed on the planar surface of the feeding piece 41. A pressure chamber 43 that holds the propelling flow of a second liquid 49, houses the feeding piece 41 and is under a pressure above maintained outside the chamber wall 50. One or more orifices, openings or slots (outlets) 46 made in the wall 52 of the propulsion chamber face the edge of the feeding piece. Preferably, each bore or channel of the feeding piece 41 has its flow path substantially aligned with an outlet 46.

Formation of the microjet and its acceleration are based on the abrupt pressure drop resulting from the steep acceleration undergone by the second fluid 49 on passing through the orifice 46, similarly to the procedure described above for embodiments of Figures 1 and 2 when the second fluid 49 is a gas. When the second fluid 49 is a gas and the first fluid 48 is a liquid, the microthread formed is quite long and the liquid velocity is much smaller than the gas velocity. In fact, the low viscosity of the gas allows the liquid to flow at a much lower velocity; as a result, the microjet is actually produced and accelerated by stress forces normal to the liquid surface, i.e. pressure forces. Hence, one effective approximation to the phenomenon is to assume that the pressure difference established will result in the same kinetic energy per unit volume for both fluids (liquid and gas), provided gas compressibility effects are neglected. The diameter d_j of the microjet formed from a liquid density p, that passes at a volumetric flow-rate Q through an orifice across which a pressure difference ΔP_g exists will be given by

See Ganan-Calvo, Physical Review Letters, 80:285-288 (1998).

The relation between the diameter of the microjet, d_p and that of the resulting drops, d, depends on the ratio between viscous forces and surface tension forces on the liquid on the one hand, and between dynamic forces and surface tension forces on the gas on the other (i.e. on the Ohnesorge and Weber numbers, respectively) (Hinds (Aerosol Technology, John & Sons, 1982), Lefevre (Atomization and Sprays, Hemisphere Pub. Corp., 1989) and Bayvel & Orzechowski (Liquid Atomization, Taylor & Francis, 1993)). At moderate to low gas velocities and low viscosities the relation is roughly identical with that for capillarity instability developed by Rayleigh: d = 1 .89d_j Because the liquid microjet is very long, at high liquid flow-rates the theoretical rupture point lies in the turbulent zone created by the gas jet, so turbulent fluctuations in the gas destabilize or rupture the liquid microjet in a more or less uneven manner. As a result, the benefits of drop size uniformity are lost.

On the other hand, when the second fluid 49 is a liquid and the first fluid 48 is a gas, the facts that the liquid is much more viscous and that the gas is much less dense provide that the gas microthread formed is much shorter; however, because its rupture zone is almost invariably located in a laminar flowing stream, dispersion in the size of the microbubbles formed is almost always small. At a volumetric gas flow-rate Q_g and a liquid overpressure ΔEj, the diameter of the gas microjet is given by:

where p_g is the gas density. The low liquid velocity and the absence of relative velocities between the liquid and gas lead to the Rayleigh relation between the diameters of the microthread and those of the bubbles (i.e. d= 1.89^).

If both fluids 48, 49 are liquid and scarcely viscous, then their relative velocities will be given by their densities ratio:

The diameter of a microjet of the first liquid at a volumetric flow-rate of Q_A and an overpressure of ΔP_B will be given by

At viscosities such that the velocities of both fluids 48, 49 will rapidly equilibrate in the microjet, the diameter of the microjet of the first liquid will be given by

a

The proposed atomization system obviously requires delivery of the fluids 48, 49 to be used in the dispersion process at appropriate flow-rates. Thus:

(1) Both flow-rates should be adjusted for the system so that they lie within the stable parameter window. (2) The mass ratio between the flows should be compatible with the specifications of each application. Obviously, the gas flow-rate can be increased by using an external means in special applications (e.g. burning, drug inhalation) since this need not interfere with the atomizer operation.

(3) Therefore, the gas and liquid can be dispensed by any type of continuous delivery system (e.g. a compressor or a pressurized tank the former and a volumetric pump or a pressurized bottle the latter).

(4) The atomizer can be made from a variety of materials (metal, polymers, ceramics, glass).

DRUG DELIVERY DEVICE A device of the invention may be used to provide particles for drug delivery, e.g. the pulmonary delivery of aerosolized pharmaceutical compositions. The device would produce aerosolized particles of pharmaceutically active drug for delivery to a patient by inhalation. The device is comprised of a liquid feeding source such as a channel to which formulation is added at one end and expelled through an exit opening. The feeding channel is surrounded by a pressurized chamber into which gas is fed and out of which gas is expelled from an opening. The opening from which the gas is expelled is positioned directly in front of the flow path of liquid expelled from the feeding channel. Various parameters are adjusted so that pressurized gas surrounds liquid flowing out of the feeding channel in a manner so as to maintain a stable capillary microjet of liquid until the liquid exits the pressure chamber opening and is aerosolized. The aerosolized particles having a uniform diameter in the range of about 1 to 5 microns are inhaled into a patient's lungs and thereafter reach the patient's circulatory system.

PRODUCTION OF DRY PARTICLES The method of the invention is also applicable in the mass production of dry particles. Such particles are useful in providing a highly dispersible dry pharmaceutical particles containing a drug suitable for pulmonary delivery. The particles formed of pharmaceutical are particularly useful in a dry powder inhaler due to the small size of the particles (e.g. 1, 2, 3, 4, or 5 microns in diameter) and conformity of size (e.g. 3 to 30% difference in diameter) from particle to particle. Such particles should improve dosage by providing accurate and precise amounts of dispersible particles to a patient in need of treatment. Dry particles are also useful because they may serve as a particle size standard in numerous applications.

For the formation of dry particles, the first fluid is preferably a liquid, and the second fluid is preferably a gas, although two liquids may also be used provided they are generally immiscible. Atomized particles within a desired size range (e.g., 1 micron to about 5 microns) The first fluid liquid is preferably a solution containing a high concentration of solute. Alternatively, the first fluid liquid is a suspension containing a high concentration of suspended matter. In either case, the liquid quickly evaporates upon atomization (due to the small size of the particles formed) to leave very small dry particles.

FUEL INJECTION APPARATUS

The device of the invention is useful to introduce fuel into internal combustion engines by functioning as a fuel injection nozzle, which introduces a fine spray of aerosolized fuel into the combustion chamber of the engine. The fuel injection nozzle has a unique fuel delivery system with a pressure chamber and a fuel source. Atomized fuel particles within a desired size range (e.g., 5 micron to about 500 microns, and preferably between 10 and 100 microns) are produced from a liquid fuel formulation provided via a fuel supply opening. The fuel may be provided in any desired manner, e.g., forced through a channel of a feeding needle and expelled out of an exit opening of the needle. Simultaneously, a second fluid contained in a pressure chamber which surrounds at least the area where the formulation is provided, e.g., surrounds the exit opening of the needle, is forced out of an opening positioned in front of the flow path of the provided fuel, e.g. in front of the fuel expelled from the feeding needle. Various parameters are adjusted to obtain a stable fuel-fluid interface and a stable capillary microjet of the fuel, which allows formation of atomized fuel particles on exiting the opening of the pressurized chamber. Fuel injectors of the invention have three significant advantages over prior injectors. First, fuel never contacts the periphery of the exit orifice from which it is emitted because the fuel stream is surrounded by a gas (e.g. air) which flows into the exit orifice. Thus, clogging of the orifice is eliminated or substantially reduced. Second, the fuel exits the orifice and forms very small particles which are substantially uniform in size, thereby allowing faster and more controlled combustion of the fuel. Third, by using the methods described herein, the amount of energy needed to produce aerosolized particles of fuel is substantially less than that required by other methods.

MICROFABRICATION

Molecular assembly presents a 'bottom-up' approach to the fabrication of objects specified with incredible precision. Molecular assembly includes construction of objects using tiny assembly components, which can be arranged using techniques such as microscopy, e.g. scanning electron microspray. Molecular self-assembly is a related strategy in chemical synthesis, with the potential of generating nonbiological structures with dimensions as small as 1 to 100 nanometers, and having molecular weights of 10⁴ to 10¹⁰ daltons. Microelectro-deposition and microetching can also be used in microfabrication of objects having distinct, patterned surfaces.

Atomized particles within a desired size range (e.g., 0.001 micron to about 0.5 microns) can be produced to serve as assembly components to serve as building blocks for the microfabrication of objects, or may serve as templates for the self-assembly of monolayers for microassembly of objects. In addition, the method of the invention can employ an atomizate to etch configurations and/or patterns onto the surface of an object by removing a selected portion of the surface.

AERATION OF WATER

More fish die from a lack of oxygen than any other cause. Fish exposed to low oxygen conditions become much more vulnerable to disease, parasites and infection, since low oxygen levels will (1) lower the oxidation/reduction potential (ORP) (2) favor growth of disease causing pathogens and (3) disrupt the function of many commercially available biofilters. Moreover, stress will reduce the fish activity level, growth rate, and may interfere with proper development. A continuous healthy minimum of oxygen is approximately a 6 parts per million (ppm) oxygen:water ratio, which is approximately 24 grams of dissolved oxygen per 1000 gallons of water. Fish consume on average 18 grams of oxygen per hour for every ten pounds of fish. Low level stress and poor feeding response can be seen at oxygen levels of 4-5 ppm. Acute stress, no feeding and inactivity can be seen at oxygen levels of 2-4 ppm, and oxygen levels of approximately 1-2 ppm generally result in death. These numbers are merely a guideline since a number of variable (e.g., water temperature, water quality, condition of fish, level of other gasses, etc.) all may impact on actual oxygen needs.

Proper aeration depends primarily on two factors: the gentleness and direction of water flow and the size and amount of the air bubbles. With respect to the latter, smaller air bubbles are preferable because they (1) increase the surface are between the air and the water, providing a larger area for oxygen diffusion and (2) smaller bubbles stay suspended in water longer, providing a greater time period over which the oxygen may diffuse into the water.

The technology of the invention provides a method for aerating water for the proper growth and maintenance of fish. A device of the invention for such a use would provide an oxygenated gas, preferably air, as the first fluid, and a liquid, preferably water, as the second fluid. The air provided in a feeding source will be focused by the flow of the surrounding water, creating a stable cusp at the interface of the two fluids. The particles containing the gas nucleus, and preferably air nucleus, are expelled into the liquid medium where aeration is desired. When the first fluid of the invention is a liquid, and the second fluid is a gas, the inertia of the first fluid is low, and the gas abruptly decelerates very soon after it issues from the cusp of the attached droplet. In such an instance, the microjet is so short that it is almost indistinguishable from the stable cusp.

SPECTROGRAPHIC ANALYSIS An embodiment of the type shown in Figure 1 can be modified to provide an analytical device. A signal emitter (e.g. infrared) is positioned such that the signal is directed at and through the stable capillary microjet of fluid coming from the feeding source 1. A signal receiving component is positioned opposite the emitter. Thus, the flow stream out of the feeding needle 1 is positioned directly between the emitter and receiver. Two feeding needles may be used so that one can provide a flow stream of, for example, the solvent in which the material to be analyzed is dissolved. Two readings are made simultaneously and the reading of the solvent is subtracted away by microprocessor devices of the type known to those skilled in the art to obtain a true analysis of only the material of interest.

In addition to analysis of any compound dissolved or suspended in a solvent the methodology can be used to analyze materials such as body fluids e.g. blood or urine. The methodology can be adapted to work in a wide range of different systems, e.g. see U.S. Patent 5,126,022 issued June 30, 1992 and patents and publications cited therein. The present invention does not need to use electrical fields to move charged molecules as is required by many other systems. Thus, non-polar molecules can be moved, via the present invention, through the capillary microjet. Because of the manner in which the stable capillary microjet is formed and maintained materials such as large proteins, nucleotide sequences, cells, and other biomaterials are not destroyed by physical stresses.

BUBBLES INTO LIQUID OR GAS

Figures 6 and 7 are useful in showing how bubbles may be formed in either a liquid (Figure 6) or a gas (Figure 7). In Figure 6 a tubular feeding source 71 is continually supplied with a flow of gas which forms a stable cusp 72 which is surrounded by the flow of liquid 73 in the pressure chamber 74 which is continually supplied with a flow of liquid 73. The liquid 73 flows out of the chamber 74 into a liquid 75 which may be the same as or different from the liquid 73. The cusp 72 of gas narrows to a capillary supercritical flow 76 and then enter the exit opening 77 of the chamber 74. At a point 78 in the exit opening 77 the supercritical flow 76 begins to destabilize but remains as a critical capillary flow until leaving the exit opening 77. Upon leaving the exit opening 77 the gas stream breaks apart and forms bubbles 79 each of which are substantially identical to the others in shape and size. The uniformity of bubbles is such that one bubble differs from another (in terms of measured physical diameter) in an amount in a range of standard deviation of ±0.01% to ±30% with a preferred deviation being less than 1%. Thus, the uniformity in size of the bubbles is greater than the uniformity of the particles formed as described above in connection with Figure 1 when liquid particles are formed. Gas in the bubbles 79 will diffuse into the liquid 75. Smaller bubbles provide for greater surface area contact with the liquid 75. Smaller bubbles provide for greater surface area contact with the liquid 75 thereby allowing for a faster rate of diffusion then would occur if the same volume of gas were present in a smaller number of bubbles. For example, ten bubbles each containing 1 cubic mm of gas would diffuse gas into the liquid much more rapidly than one bubble containing 10 cubic mm of gas. Further, smaller bubbles rise to the liquid surface more slowly than larger bubbles. A slower rate of ascent in the liquid means that the gas bubbles are in contact with the liquid for a longer period of time thereby increasing the amount of diffusion of gas into the liquid. Thus, smaller bubbles could allow a greater amount of oxygen to diffuse into water (e.g., to sewage or where fish are raised) or allow a greater amount of a toxic gas (e.g., a radioactive gas) to diffuse into a liquid thereby concentrating the toxin for disposal. Because the bubbles are so uniform in size the amount of gas diffusing into the liquid can be uniformly calculated which is important in certain applications such as when diffusing CO₂ into carbonated drinks.

Figure 7 shows the same components as shown in Figure 6 except that the liquid 75 is replaced with a gas 80. When the stream of bubbles 79 disassociate the liquid 73 forms an outer spherical cover thereby providing hollow droplets 81 which will float in the gas 80. The hollow droplets 81 have a large physical or actual diameter relative to their aerodynamic diameter. Hollow droplets fall in air at a much slower rate compared to liquid droplets of the same diameter. Because the hollow droplets 81 do not settle or fall quickly in air they can be inhaled into the lungs. Eventually the hollow droplets 81 will burst and form many smaller particles which can be drawn even deeper into the lungs. Thus, it is understood that the aerodynamic diameter of the hollow droplets is very small compared to their actual physical diameter. The creation of hollow droplets 81 which burst and form very small particles is applicable in a wide range of different applications including internal combustion engines where the hollow droplets are formed using fuel (e.g., gasoline, diesel fuel, jet fuel) as the liquid 73 and injecting the hollow droplets 81 into the combustion chamber where the hollow droplets burst, from smaller particles and undergo combustion. The amount of fuel needed to create hollow droplets which burst and form a fine mist is minimal compared to any other existing pneumatic method.

EMULSIONS Figure 8 is similar to Figures 6 and 7. However, rather than a gas 72 as in Figure

6 the feeding source 71 provides a stream of liquid 82 which may be miscible but is preferably immiscible in the liquid 73. Further the liquid 73 may be the same as or different from the liquid 75 but is preferably immiscible in the liquid 75 The oieaticr-. of emulsions using such a configuration of liquids has applicability in a variety of fields particularly because the liquid particles formed can have a size in the range of from about 1 to about 200 microns with a standard deviation in size of one particle to another being as little as 0.01%). The size deviation of one particle to another can vary up to about 30% and is preferably less than ±5% and more preferably less than ±1%.

In one application the configuration of Figure 8 is used in flow hemato-cytology sorting. The liquid 82 is a liquid such as blood, plasma, or other suitable flowable iiquid containing cells of any type e.g., red and white blood cells, HIV infected cells, or cells from a biopsy which may be malignant. The liquid 73 is a liquid which can be the same or different from that of the liquid 82 but is preferably immiscible in the liquid 82 e.g., an oil which is immiscible in an aqueous liquid 82.

The system then operates to expel the liquid 82 out of the exit orifice 77 to form spheres 83 of liquid 82. Each sphere 83 has an actual physical diameter which deviates from other spheres 83 by a standard deviation of ±0.01% to ±30%, preferably 10% or less and more preferably 1% or less. The size of the spheres 83 and flow rate of liquid 82 is controlled so that each sphere 83 contain a single particle (e.g. a single cell) to be examined. The stream of spheres 83 is caused to flow past a sensor and/or energy source of any desired type thereby allowing for cell-by-cell analysis of the sample of liquid 82 or more particularly particle-by- particle analysis of each particle (e.g., cell) in each sphere 83. The liquid 73 should be one that does not significantly interfere with analysis of any particle in a sphere 83.

Single cells in spheres 83 could be analyzed or treated via laser-sorting cell techniques in Micro Electro Mechanisms (MEMs).

In one embodiment the sorting allows for undesirable particles (e.g., infected or cancerous cells) to be identified and discarded. The remaining cells are then re-injected back into the patient (e.g., human) from which they were extracted. The size of the spheres 83 is not controlled by the size of the exit orifice 77 and as such clogging of the orifice 77 is prevented and the spheres 83 can be made very small - approximately the diameter of a cell of the type being analyzed.

- 34

RECTIFIED SHEET (RULE ISA/EP FOOD AND COSMETICS

Creating emulsions of small (1 micron to 200 microns) particles of uniform size

(0.01% to 30%) standard deviation) is important to the creation of high quality foods and cosmetics. An emulsions of small spheres 83 of oil is important to the taste, mouth feel or texture, and overall homogeneity of foods such as salad dressings, milk, mayonnaise and chocolate. Further, the system shown in Figure 8 is useful in the even distribution of color and preservatives into the foods and cosmetics. By decreasing particle size and increasing uniformity smaller amounts of necessary (but undesirable) component can be added and obtain the same effect as if larger amounts were added via conventional technologies.

FUEL EMULSIONS

In Figure 8 the liquid 75 can be a gas (e.g., air) inside a combustion chamber of an internal combustion engine. The liquid 82 could be water which is surrounded by a second liquid 73 which is a hydrocarbon fuel. The system then forms particles 83 which have a water center and an outer coating of fuel. Such water/fuel particles will undergo combustion while decreasing both the overall combustion temperature and formation of undesirable emissions without decreasing the compression rate or compromising the efficiency of the thermodynamic cycle of the engine. This system allows for temperature to be a readily adjustable parameter effected by the ratio of water to fuel. Adjusting the fuel/water ratio and thereby the temperature makes it possible to redesign the thermodynamic cycle thereby optimizing the ratio of power output to cleanliness.

The systems could also use two different types of fuel at the same time. A high octane fuel (gasoline) is used as the liquid 73 to surround a low octane fuel (desired fuel). Spheres 83 of cheaper lower octane fuel of any type are coated with a layer of more expensive high octane fuel of any type. When these spheres enter the combustion chamber the high octane fuel undergoes combustion first and causes a reaction which causes the lower octane fuel to also undergo combustion. This system could be used with 92 octane gasoline coating an inner core of 87 octane gasoline to obtain substantially the same performance as with all 92 octanes but at a lower cost. Hollow droplets of fuel as in Figure 7 could also be created with the advantage of obtaining a fine mist of fuel when the droplets burst as shown in Figure 7. EXAMPLES

The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how to make and use the present invention, and are not intended to limit the scope of what the inventors regard as their invention nor are they intended to represent that the experiments below are all or the only experiments performed. Efforts have been made to ensure accuracy with respect to numbers used (e.g. amounts, temperature, etc.) but some experimental errors and deviations should be accounted for. Unless indicated otherwise, parts are parts by weight, molecular weight is weight average molecular weight, temperature is in degrees Centigrade, and pressure is at or near atmospheric.

The properties of sixteen different liquids are provided in Table 1

TABLE 1 : Liquids used and some of their physical properties at 24.5° C (p: kg/m³, μ: cpoise, γ: N/m). Also given, the symbols used in the plots. Liquid P μ γ Symbol

Heptane 684 0.38 0.021 o

Tap Water 1000 1.00 0.056 0

Water + glycerol 90/10 v/v 1026 1.39 0.069 Δ

Water + glycerol 80/20 v/v 1052 1.98 0.068 V Isopropyl alcohol 755.5 2.18 0.021 X

Water + glycerol 70/30 v/v 1078 2.76 0.067 0

Water + glycerol 60/40 v/v 1104 4.37 0.067 •

Water + glycerol 50/50 v/v 1030 6.17 0.066 o

1-Octanol 827 7.47 0.024 0 Water + glycerol 40/60 v/v 1156 12.3 0.065 Δ

Water + glycerol 35/65 v/v 1167 15.9 0.064 V

Water + glycerol 30/70 v/v 1182 24.3 0.064 X

Water + glycerol 25/75 v/v 1195 38.7 0.063 +

Propylene glycol 1026 41.8 0.036 • The liquids of Table 1 were forced through a feeding needle of the type shown in Figure 1. The end 5 of the feeding needle had an internal radius R₀. The exit orifice 6 had a diameter -D and the wall of the pressure chamber 3 had a thickness of L. Three different devices were tested having the following dimensions: (D = 0.15, 0.2, and 0.3 mm; L = 0.1- 0.2 and 0.35 mm; R₀ + 0.2, 0.4, and 0.6 mm, respectively), and several distances H from the tube mouth to the orifice ranging from H = 0.5 mm to H = 1.5 mm have been used. The jet diameter was measured at the hole exit and was plotted as a function of the pressure difference ΔE_g and flow rate Q respectively. Although this technique allows for jet diameters even below one micron, larger flow rates and diameters have been used in this study to diminish the measuring errors.

In order to collapse all of the data, we define a reference flow rate Q₀ and diameter d₀ based on the minimal values, from expressions (3) and (5), that can be attained in stable regime for a given ΔE :

These definitions provide the advantage of a nondimensional expression for (5), as

which allows for a check for the validity of neglecting the surface tension term in (4) (i.e.,

QIQ₀ should be large).

Notice that if the measured fiζ follows expression (5), the surface tension cancels out in (7). Also notice that djd₀ ~ We/2. 350 measured values of <- <-/-, versus QIQ₀ are plotted in Fig. 5. A continuous line represents the theoretical prediction (7), independent of liquid viscosity and surface tension.

The use of different hole and tube diameters as well as tube-hole distances does not have any appreciable influence on d_y The collapse of the experimental data and the agreement with the simple theoretical model is excellent. Finally, the experimental values of Q are at least four times large than Q₀ (being in most cases several hundreds times larger), which justifies the neglect of the surface tension term in Eq. (4). While the present invention has been described with reference to the specific embodiments thereof, it should be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the true spirit and scope of the invention. In addition, many modifications may be made to adapt a particular situation, material, composition of matter, process, process step or steps, to the objective, spirit and scope of the present invention. All such modifications are intended to be within the scope of the claims appended hereto.

Claims

What is claimed is:

1. A monodispersion of bubbles of a gas in a first liquid, the bubbles characterized by having the same diameter with a standard deviation in diameter from one particle to another in a range of from about ┬▒0.01% to about ┬▒30%.

2. The monodispersion of bubbles as claimed in claim 1, wherein the deviation in diameter from one bubble to another is less than ┬▒5%; wherein the monodispersion comprises more than one thousand bubbles; wherein the bubbles have a diameter in a range of from about 0.1 micron to about 100 microns; and wherein the gas is selected from the group consisting of air and oxygen and the liquid is aqueous.

3. The monodispersion of claim 1, wherein the gas is contaminated with a toxin which toxin is soluble in the liquid which is aqueous.

4. The monodispersion of claim 3, wherein the aqueous liquid is sewage.

5. The monodispersion of claim 1, wherein the bubbles are created by a flow stream of gas from a source through a second liquid in a pressure chamber wherein the second liquid is forced out of an exit orifice of the pressure chamber while surrounding and focusing the flow stream of gas into the first liquid where the focused flow stream of gas breaks up to form the bubbles.

6. A method of diffusing molecules of a gas into a liquid, comprising the steps of: forcing a gas from a source opening into a first liquid in a manner so as to create a flow stream of the gas through the first liquid wherein the gas is comprised of molecules to be diffused into the first liquid and a second liquid; moving the first liquid, in a pressure chamber surrounding the source opening, out of an exit orifice in the pressure chamber wherein the flow stream of the gas flows out the exit orifice into the second liquid wherein the flow stream breaks up forming bubbles of the gas in the second liquid; and allowing molecules in the gas bubbles to diffuse into the first and second liquids.

7. The method of claim 6, wherein the bubbles have a size in a range of from about 0.1 micron to about 100 microns; wherein the bubbles are characterized by having substantially the same diameter with a deviation in diameter from one particle to another in a range of from about ┬▒0.01% to about ┬▒30%; and wherein the bubbles are emitted at regularly spaced intervals from the exit orifice of the pressure chamber.

8. The method of claim 7, wherein the bubbles have a diameter in a range of from about 1 micron to about 20 microns and are comprised of a gas selected from the group consisting of air and oxygen.

9. A device for creating aerosolized particles, comprising: a first means for providing a first fluid comprising a first fluid entrance port and a first fluid exit port; a pressure chamber for providing a pressurized second fluid to an area surrounding the first fluid exit port, the pressure chamber comprising a second fluid entrance port and a second fluid exit port; wherein the first means for providing the first fluid is a feeding needle having a cylindrical channel therein whereby the first fluid entrance port and first fluid exit port are each circular; and wherein the feeding needle exit port has a diameter in the range of from about 0.002 to about 2 mm, and the pressure chamber exit port has a diameter in the range of about 0.002 mm to about 2 mm.

10. The device of claim 9, wherein the feeding needle exit port has a diameter in the range of from about 0.01 mm to about 0.4 mm and the pressure chamber exit port has a diameter in the range of about 0.01 mm to about 0.25 mm the device having inserted therein a first fluid having a dynamic viscosity in the range of from about 10^" to about 1 kg/m/sec.

11 The device of claim 9 wherein the first fluid is liquid having a viscosity in a range of from about 0.3 x 10 3 to about 5 x 10^" 2 kg/m/sec; and wherein the liquid is forced through the channel at a rate in a range of about 0.01 nl/sec to about 100 ╬╝l/sec and further wherein the gas is forced through the opening of the pressure chamber at a rate in the range of from about 50 m/sec to about 2000 m/sec.

12. The device of claim 9, wherein the first fluid is a liquid and is forced through the channel at a rate in a range of about 1 nl/sec to about 10 ╬╝l/sec and further wherein the second fluid is a gas and is forced through the opening of the pressure chamber at a rate in the range of from about 100 to 500 m/sec.