A METHOD AND APPARATUS FOR
NEBULIZING A LIQUID PARTICULARLY USEFUL
FOR THE AEROSOL DELIVERY OF BIOPHARMACEUTICALS
FIELD AND BACKGROUND OF THE INVENTION
The present invention relates to a method and apparatus for nebulizing a liquid to produce a small-particle aerosol. The invention is particularly useful for the aerosol delivery of biopharmaceuticals, and is therefore described below with respect to this application.
Many techniques are known for nebulizing liquids. In one technique, high pressure air is forced through a nozzle to exit in the form of a high-velocity jet which creates a low-pressure region, causing the liquid to be nebulized to rise in a feed tube and to be sheared into droplets. Such a nebulizer, however, is not suitable for the aerosol delivery of biopharmaceuticals since it produces high shear stresses which degrade or destroy the pharmaceuticals within the droplets. In addition, the resulting droplets cover a wide range of particle sizes.
Another known technique is a bubbling technique, in which bubbles are formed by passing air through a medium-velocity fretted disc immersed in the liquid near the bottom of the reservoir, to produce bubbles which burst and are dried by tangential injection of drying air. As a result, the droplets rapidly shrink in size and are carried out of the generator in an upward swirl ingly motion. A drawback of such an aerosol generator, however, is the difficulty in controlling the size distribution range of the particles in the aerosol.
Other known techniques are based on the ultrasonic generation of aerosols by an ultrasonic transducer, such as a pizeoelectric device driven at ultrasonic frequencies. In one type generator, the piezoelectric device is submerged in the liquid to be nebulized and its ultrasonic vibrations produce bubbles which burst and are dried by air, similar to the bubble type generator. In another type generator, the
piezoelectric device is mounted on a main body and disperses the liquid in small droplets through a central hole, or through a perforated membrane having an array of holes. Examples of the later types are described in US Patents 4,850,534, 5,152,456, and 5,261,601. Such piezoelectric type generators, however, also suffer from one or more of the foregoing drawbacks, particularly the production of shear stresses and the difficulty in controlling the particle size distribution.
OBJECTS AND BRIEF SUMMARY OF THE INVENTION
An object of the present invention is to provide a method and apparatus for nebulizing liquids having advantages in the above respects. More particularly, an object of the present invention is to provide a method and apparatus for nebulizing liquids which produce relatively low stresses in the particles of the produced aerosol, and which also permit close control of the particle size distribution, such as to make the method and apparatus especially (but not exclusively) useful for the aerosol delivery of biopharmaceuticals.
According to one aspect of the present invention, there is provided a method for nebulizing a liquid to produce a small -particle aerosol, comprising: providing a reservoir with a rigid porous body; introducing liquid to be nebulized into the reservoir to contact the upper face of the rigid porous body; introducing a pressurized gas to be applied to another face of the rigid porous body; and vibrating the rigid porous body at an ultrasonic frequency.
According to a preferred important feature of the novel method, the rigid porous body is a microporous body having pores of micron size, up to several hundred microns in size. Preferably, the rigid porous body is a ceramic, glass, or a metal .
According to further features in the described preferred embodiments, the rigid porous body is vibrated by
a pizeoelectric mechanism. Preferably, the rigid porous body is vibrated by a pizeoelectric device in contact with the rigid porous body. The rigid porous body may also be vibrated by a pizeoelectric material incorporated in a porous matrix and integrated with the rigid porous body according to known techniques as will be described more ful ly below.
According to another aspect of the present invention, there is provided an aerosol generator for nebulizing a liquid to produce a smal 1 -particle aerosol, comprising: a reservoir for receiving liquid to be nebulized; a rigid porous body within the reservoir; a liquid inlet for introducing liquid to be nebulized into the reservoir to contact the upper face of the rigid porous body therein; a source of pressurized gas for introducing a pressurized gas into the reservoir to be applied to another face of the rigid porous body; and a vibrator for vibrating the rigid porous body at an ultrasonic frequency.
As will be described below, such a method and generator is particularly suitable for the aerosol delivery of biopharmaceuticals since the method and apparatus produce low stresses in the particles of the aerosol, and also permit close control of the particles size distribution in the produced aerosol . When the method and apparatus are to be used for the aerosol delivery of biopharmaceuticals, the liquid introduced in the reservoir is preferably a mixture of the biopharmaceutical and a liposome in a buffered solution.
Further features and advantages of the invention will be apparent from the description below.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is herein described, by way of example only, with reference to the accompanying drawings, wherein:
Fig. 1 is a block diagram illustrating one form of aerosol generator constructed in accordance with the present invention;
Fig. 2 is a block diagram illustrating modifications in the construction of the aerosol generator of Fig. 1; and
Fig. 3 and Fig. 4 are block diagrams illustrating two further modifications int he construction of the aerosol generator.
DESCRIPTION OF PREFERRED EMBODIMENTS
The aerosol generator illustrated in Fig. 1 comprise a reservoir 2 provided with a rigid microporous body 3 and a piezoelectric device 4. The rigid microporous body 3 is in the form of a layer secured within reservoir 2 slightly raised from its bottom wall 2a, so as to define a chamber 5 above the microporous layer 3, and another chamber 6 below the microporous layer. Reservoir 2 is provided with an inlet, shown at 7 in a top wall 2b for inletting the liquid to be nebulized, and with an outlet 8 for outletting the nebulized liquid in the form of a small -particle aerosol. When the nebulized liquid is a pharmaceuthical , e.g., to be inhaled by a patient, outlet 8 includes a face mask 9 to be applied over the face of the patient.
The piezoelectric device 4 is in contact with the rigid microporous layer 3 so as to vibrate that layer by ultrasonic vibrations. Piezoelectric device 4 is driven by an electrical power supply, schematically shown by block 10, under the control of a control circuit, schematically shown by block 11.
Chamber 6 underlying the rigid microporous layer 3 within reservoir 2 includes an inlet 12 for inletting the compressed air into chamber 6. The compressed air is supplied by a compressor 13 via a conduit 14 and is also under the control of the control circuit 11.
The liquid to be nebulized is introduced via inlet 7 into chamber 5 so as to contact the upper face of the rigid microporous layer 3, whereas the compressed air is introduced into chamber 6 so that it is applied to the lower face of the rigid microporous layer 3. Accordingly, when the piezoelectric device 4 is driven at ultrasonic frequencies, the vibrations produced by it, as applied to the microporous layer 3, generate a small-particle aerosol within chamber 5 which is outletted via the outlet 8.
The frequency and intensity at which the piezoelectric device 4 is driven by the driving unit 10, and the rate of air flow from the compressor 13, can be controlled to provide the desired particle size, particle size distribution, and flow rate in the produced aerosol. In addition, the shear stresses in the particles in the produced aerosol are relatively low as compared to the other known techniques briefly described above. These advantages make the described generator particularly useful for the aerosol delivery of biopharmaceuticals. In such cases, the liquid within chamber 5 would be the desired pharmaceutical to be delivered mixed with a liposome in a buffer solution, as known in this art.
The control circuit shown by block 11 in Fig. 1 could be a personal computer. The parameters concerning the aerosol to be delivered (e.g., particle size, delivery rate, delivery period, etc.) can be inputted into the computer to control the piezoelectric driver 10, and the air compressor 13, to obtain the desired results. Preferably, the piezoelectric driver 10 would be operated within the range of from 10 to 100 KHz, with an output power of from 100 milliwatts to a few watts. The microporous layer 3 is preferably a microporous ceramic or glass, but could also be a microporous metal. Preferably, the pores are of micron size, up to several hundred microns.
Instead of using a separate piezoelectric unit 4 for vibrating the rigid microporous layer 3, the microporous
layer may incorporate piezoelectric material within it. For example, a porous ceramic material may be imparted with piezoelectric properties by incorporating piezoelectric material within a porous matrix of the ceramic and integrating it into a rigid microporous body. Techniques for accomplishing the foregoing are known, as described in Ting. PIEZOELECTRIC PROPERTIES OF A POROUS PZT CERAMIC, Ferroelectric, 1985, Vol.65., pp.12-20; Kahn et al . PREPARATION AND PIEZOELECTRIC RESPONSE OF PZT CERAMICS WITH ANISOTROPIC PORES, Advanced Ceramic Materials, Vol.l, (1) 1996, p.33; and the references cited in such articles.
Fig. 2 illustrates an aerosol generator including such a rigid microporous body incorporating piezoelectric material within it, rather than providing a separate piezoelectric device in contact with the rigid microporous body. Thus, the generator illustrated in Fig. 2 includes a reservoir 22 containing the integrated rigid microporous body 23 incorporating the piezoelectric material within it, and dividing the interior of the reservoir into an upper liquid compartment 25 and lower air compartment 26. The other elements in Fig. 2 common with those described above in Fig. 1 carry the same reference numerals to facilitate understanding the construction and operation of the generator of Fig. 2.
The generator of Fig. 2, however, includes several other modifications. One such modification is the addition of an air supply inlet 35 for inletting drying air into chamber 25 above the liquid being nebulized, to remove water from the aerosol which is discharged from outlet 8. Another modification is the provision of a heater 36 in the outlet conduit 8 also for removing water from the discharged aerosol. In addition, the air generator illustrated in Fig. 2 includes a flow meter 37 in the conduit 14 supplying air from compressor 13 into the air chamber 26 of the reservoir 22.
Fig. 3 illustrates a generator similar to that of Fig. 1, except the piezoelectric device 34 is attached directly to the reservoir 2; and Fig. 4 illustrates a similar generator except the piezoelectric device 44 is submerged within the liquid in the reservoir 2.
In all other respects, the generators illustrated in Figs. 2, 3 and 4 are constructed and operate in the same manner as described above with respect to Fig. 1.
While the invention has been described with respect to several preferred embodiments, it will be appreciated that these are set forth merely for purposes of examples, and that many other variations, modifications and applications of the invention may be made.