STAMFORD DEVICES LIMITED

A method of producing an aperture plate for a nebuliser is described. A substrate ( 2 ) is patterned with a resist ( 5, 6 ) and a metal ( 10 ) is applied by electroless deposition so that the resist forms a desired aperture pattern. The substrate ( 2 ) has an array of domes ( 2 ( b )) to provide aperture plates ( 16 ) with domes ( 101 ) and flanges ( 102 ) without need for application of mechanical force pressing after deposition. The substrate is shaped for simultaneous manufacture of a plurality of aperture plates in which the resist pattern provides a deposition region for each aperture plate. By using electroless plating the aperture plate accuracy is excellent, especially for defining apertures having a diameter in the rang of only less than 10 μm, and having improved corrosion and fracture resistance for high frequency nebulizer operation.

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

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

A nebulizer comprises a controller linked at its output to a nebulizer head, and at its input to a USB cable and USB plug for connection to a host system. The link between the USB plug and the controller is a USB cable with power and data channels. The controller comprises a boost circuit, a microcontroller 11 , and a drive circuit. The latter provides power and control signals via a cable and proprietary plug to the nebulizer head. These signals provide power and control for a vibrating membrane receiving a liquid to be aerosolised. The controller has a housing with LED status lamps, and an ON/OFF button. The controller can be controlled via a host, either locally or remotely.

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

A coupling part with integrated aerosol generator for use in a breathing circuit, comprising a housing ( 10 ) enclosing a cavity (V), having a first opening at a first end prepared for direct or indirect connection to a ventilator, a second opening at a second end, which is suitable for direct or indirect connection to a patient line or an endotracheal tube, wherein an aerosol generator ( 20 ) is integrated in one side of the housing and is suitable for delivering an aerosolised liquid, in particular a medicament.

A nebulizer comprises a controller linked at its output to a nebulizer head, and at its input to a USB cable and USB plug for connection to a host system. The link between the USB plug and the controller is a USB cable with power and data channels. The controller comprises a boost circuit, a microcontroller 11 , and a drive circuit. The latter provides power and control signals via a cable and proprietary plug to the nebulizer head. These signals provide power and control for a vibrating membrane receiving a liquid to be aerosolised. The controller has a housing with LED status lamps, and an ON/OFF button. The controller can be controlled via a host, either locally or remotely.

A nebulizer has an aerosol generator, a reservoir, and an aerosol outlet. A piezoelectric vibration generator is on a downstream side of a support washer, and power to the piezo is provided by a spring contact assembly. The assembly has upstanding electrical terminals for contact with electrical supply conductors. There are spring terminals extending around a rim of the spring contact assembly to engage an exposed underside of the washer, and a resilient ridge extending in the upstream direction to engage the underside of the piezo, which itself is on the downstream side of the washer.

A gas therapy system ( 1 ) has a flow line ( 3, 2 ), a coupler ( 6 ) to a gas source, and an aerosol generator ( 4 ) for aerosol delivery, and a patient interface such as a nasal interface ( 2 ). A controller ( 10 ) is configured to modulate gas flow and aerosol delivery in real time. The controller changes gas flow rate and dynamically reduces aerosol delivery during upper gas flow rates such as 60 LPM, and activates aerosol delivery during lower gas flow rates of for example 10 LPM. The control may also include sensors to detect breathing, so that there is a bias towards increased aerosol delivery during inhalation in addition to during lower level gas flow.

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