WO2019032758A1

WO2019032758A1 - Ultrasonic atomizer with removable cartridge for the dispersal of a liquid

Info

Publication number: WO2019032758A1
Application number: PCT/US2018/045885
Authority: WO
Inventors: William Tan; Liat Keng KANG
Original assignee: William Tan; Kang Liat KENG
Priority date: 2017-08-08
Filing date: 2018-08-08
Publication date: 2019-02-14

Abstract

The apparatus has an atomizer for the dispersal of a liquid and has an enclosed removable cartridge assembly with a reservoir of liquid and a wick or a silicone membrane with one end in communication with the liquid and a vibrating transducer in contact with another end of the wick; the transducer, wick and cartridge of liquid are arranged to allow a capillary volume of liquid from the wick to vibrate together to disperse the liquid in a direction away from the wick.

Description

PCT Patent Application

Title: ULTRASONIC ATOMIZER WITH REMOVABLE CARTRIDGE FOR THE

DISPERSAL OF A LIQUID

This application claims the benefit of U.S. Provisional Patent Appl. No.: 62/542715, filed on Aug. 8, 2017 and U.S. Provisional Patent Appl. No. 62672555, filed on May 16, 2018. In addition, for the purposes of the U.S., this application is a continuation in part of U.S. Patent Application No. 15004920, filed on January 23, 2016 and U.S. Patent Application No.

15472223, filed on March 28, 2017. This application is related to U.S. Provisional Patent Appl. No. 62/106,852, filed on Jan. 23, 2015 and 62/142,464, filed on April 2, 2015;

PCTUS2016014646, filed on Jan. 23, 2016; U.S. Provisional Patent Appl. No. 62314380, filed on March 28, 2016; and U.S. Provisional Patent Appl. No. 62343086, filed on May 30, 2016, which are all incorporated by reference in entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention:

The present invention relates to an atomizer for the dispersal of a liquid.

2. Description of Related Art

Atomizers for dispensing of liquids are well known in the art. A common ultrasonic atomizer such as SC Johnson's Glade Wisp air freshener typically comprises a wick which is placed in the reservoir of material to be dispensed. The wick leads to a position adjacent to a vibrating plate which is provided with a plurality of fine holes. Liquid from the wick is held in a gap between the wick and plate. As the plate is vibrated, this liquid is dispersed through the holes in the orifice plate.

Cartridge with pre-filled liquid fragrance can be replaced when the old ones are used up. However, the mesh plate is permanently attached to the transducer and cannot be easily removed for cleaning. When the atomizer is not used for a long period of time, the fine holes on the plates may be clogged with dried particulates, diminishing vapor output. The Omron NE-U22 medical nebulizer is another example of the use of a vibrating mesh. The mesh is spaced from the transducer with a gap between the two. This gap provides a capillary space along which liquid medicine flows in order to cover the surface of the transducer. As the transducer vibrates, it pushes the liquid through the orifices in the mesh thereby dispensing the medicine for inhalation.

The mesh plate in the Omron NE-U22 nebulizer is attached to a liquid reservoir, which is designed to be removable and washable. However, it is troublesome to sterilize after each use. A sterile reservoir and mesh plate is important because of potential contamination of the inhalation medicine. Replacing the mesh plate after each use is also impractical due to the high cost of replacement parts.

Another example of a vibrating media is described in application PCT/GB 2007/002863. Rather than a metallic mesh plate, the application describes the use of a wick made of a fibrous material, which is in contact with the transducer and vibrates with it. Liquid is drawn by the wick from a liquid reservoir and delivered to the transducer by capillary action. As the transducer vibrates, the acoustic energy from the transducer on one side of the wick causes liquid to disperse from the opposite side, away from the transducer.

The use of a fibrous material is better suited for a disposable design, as materials like cotton or polymer fiber wicks are easier and cheaper to manufacture than metal mesh plates. However, the fibrous material needs to be thin enough for the acoustic energy to sufficiently penetrate to atomize the liquid. A thick material will dampen the wave energy and affect vapor output. On the other hand, a thin material is ineffective in drawing sufficient liquid from the reservoir to be delivered to the transducer. After the initial amount of material is atomized, the wick section adjacent to the transducer becomes dry. The atomizer needs to pause for several seconds for the wick to soak up enough liquid for the next cycle. This is obviously impractical in applications requiring constant vapor output, such as spray painting or inhalation of lung medication.

It is an object of the present invention to address one or more of the above-mentioned problems. In particular, it is an object of the present invention to provide an improved design of an atomizer. From the preceding descriptions, it is apparent that the devices currently being used have significant disadvantages. Thus, important aspects of the technology used in the field of invention remain amenable to useful refinement.

SUMMARY OF THE INVENTION

There is presented a preferred embodiment for a vaporizing device or an apparatus for ultrasonic atomizing of a liquid, comprising: a housing with a power source and an ultrasonic transducer; the housing has a mouthpiece and a removable cartridge with the liquid for atomizing; the removable cartridge has a wick or silicone membrane for drawing the liquid to a probe on the ultrasonic transducer; the cartridge can be moved from a first non-engaged position to a second engaged position, in the second engaged position, the probe of the transducer engages the wick or the silicone membrane and can allow for a displacement of greater than 10 micrometers. The ultrasonic transducer is connected to the power source (external or internal battery) and a circuit board with a signal generator and a microprocessor; whereby when the cartridge is moved to the second engaged position, the ultrasonic transducer is activated and vibrates the probe, and the liquid from the wick is atomized, and vapor of the atomized liquid exits the mouthpiece. In the first non-engaged position, the cartridge is positioned away from the transducer probe with a first magnet and a second magnet; the first magnet is attached to the removable cartridge, and the second magnet is attached to the circuit board; and in the first non- engaged position, the first magnet is substantially aligned with the second magnet, and the probe does not engage the wick of the removable cartridge. In the second engaged position, the first magnet on the removable cartridge is pushed away from the second magnet on the circuit board, whereby there is magnetic attraction between the first magnet and the second magnet to push back the removable cartridge to the first non-engaged position.

The circuit board can have at least one sensor, including optical or special sensor, which senses when the removable cartridge is in the first non-engaged position or the second engaged position; in the first non-engaged position, the microprocessor turns off the ultrasonic transducer; in the second engaged position, the microprocessor turns on the ultrasonic transducer. In addition or in substitute for a magnet, the apparatus can use at least one spring to provide resistance to the removable cartridge from the first non-engaged position to the second engaged position. The power source can be an internal battery or an external power source; and the ultrasonic transducer can be activated by an activation switch or an activation button. The ultrasonic transducer can have multiple piezoelectric elements, a transduction portion, an anvil bearing member and a sonotrode amplification member, and the ultrasonic transducer can be acoustically coupled; the housing can have acoustic isolators to dampen vibrations emitted from the ultrasonic transducer to the housing; the wick of the removable cartridge is a silicone membrane.

The removable cartridge can have a verification electronic chip or an authentication chip, which communicates with the microprocessor and allows for verification of the removable cartridge for said apparatus; whereby when the removable cartridge is verified with the authentication chip, the cartridge is moved to the second engaged position, and the ultrasonic transducer is activated and vibrates the probe, and the liquid from the wick is atomized, and vapor of the atomized liquid exits the mouthpiece; the verification chip can communicate with the microprocessor to log in a specific user and to record usage, time of use, frequency or dosage; and the verification chip has an encoded profile of the removable cartridge; the microprocessor and the verification chip can use encryption software to record usage and user information and to keep said user information as confidential and to provide password access; and the

microprocessor and the verification chip can record name, date of birth, identification code or bio-characteristics; the verification chip on the removable cartridge and the microprocessor record a log of the cartridge contents and usage of the cartridge; the verification chip and the microprocessor can relay level of the liquid and enables alerts to when the removable cartridge needs to be replaced or reordered.

All of the foregoing operational principles and advantages of the present invention will be more fully appreciated upon consideration of the following detailed description, with reference to the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a cross-sectional view of one preferred embodiment of the invention. In Figure 1, a transducer has a flat surface on one end in contact with the wick; when the cartridge is placed vertically on top of the transducer, the droplets will be expelled in all directions away from wick and transducer tip. Figure 2 a cross-sectional view of another preferred embodiment of the invention; in Figure 2, the transducer has a rounded end and this allows the cartridge to be placed at an angle from the vertical axis; the droplets are similarly expelled away from the wick and transducer tip.

Fig 3: Similar to the embodiment shown in Figure 1 and Figure 2, except for the silicone membrane 303 with a small orifice 306, and the viscous media 302. The membrane 303 can be vibrated by the transducer 306 and heat up due to vibration, which causes the temperature of the media 302 adjacent to the membrane 303 to rise, and to consequently become less viscous and to allow flow through the orifice 306 for vaporization.

Figure 4 A and 4B: Part No. 400 describes a cartridge embodiment with authentication function. A circuit board 410 is integrated with the cartridge body 401. Two contact pads 411 on the circuit board 410 provides electrical connection to the ultrasonic device to read/decode. The authentication chip 412 is embedded in the circuit board 410. An example of a verification or authentication chip 412 is Infineon brand Optiga Trust B SLE95250.

Figures 5A and 5B shows setup embodiments of the cartridge/transducer. In Figure 5A, the cartridge is positioned away from the transducer 506 and kept in this position by magnets 523/522. Magnet 523 is attached to the cartridge 501, and magnet 522 is attached to a circuit board 520. Contact pins 521 are in contact with the circuit board 511 of the cartridge 501. An optical sensor 524 on the circuit board 520 senses that the cartridge is not in position, thus turning the transducer 506 OFF. Wires 526 from the circuit board and wires 507 from the transducer is connected to a signal generator 530 that also comprises an MCU to read the authentication chip of the cartridge.

In Figure 5B, the cartridge 501 is pushed towards the transducer 506 so that the wick is now in contact. Sensor 524 now "sees" that the cartridge is in position to turn ON the transducer. Magnet 523 on the cartridge is now pushed away from magnet 522, such that there is now a magnetic force wanting to pull magnet 523 (and consequently the cartridge 501) back to the resting position in Figure 5 A. At least one or multiple contact pins 521 are still contacting the circuit board 511, sending the usage time and other information to the MCU on the signal generator 530 for data logging.

Figures 6A and 6B shows another embodiment of the cartridge and the transducer. In Figure 6A, the cartridge is positioned away from the transducer and kept in this position by at least one spring; in Figure 6B, a force is applied to the removable cartridge so that the spring is compressed, and the wick or silicone membrane of the cartridge engages or touches the probe on the transducer. DESCRIPTION OF THE PREFERRED EMBODIMENTS

According to the present invention, there is provided an atomizer for the dispersal of a liquid; the atomizer uses an enclosed removable cartridge assembly with a reservoir of liquid; a wick with one end in communication with the liquid; and a vibrating transducer in contact with another end of the wick; the cartridge, wick and transducer are arranged to allow a capillary volume of liquid from the wick to vibrate together and to disperse the liquid in a direction away from the wick, so that the vapor can escape and be inhaled by the user.

Further, the reservoir may have a pluggable opening to allow filling of liquid, or the liquid can be pre-filled and completely sealed without any opening for refilling. When the wick made wet by the liquid, there is limited or no air exchange with the outside environment.

When the atomizer is inactive, the reservoir is able to hold the liquid without the liquid dripping out through the fibrous wick material. This phenomenon is similar to a drinking straw holding a volume of water with one end covered by a finger-tip. Without air entering the reservoir, the outside air pressure creates an upward force on the liquid on the wick greater than the force of gravity pulling down on the liquid. Surface tension of the fibrous wick material also creates capillary forces to keep the liquid from dripping out of the reservoir.

The volume of the reservoir is calculated such that capillary forces and atmospheric pressure is able to support the weight of the liquid, even when the reservoir is completely full. This volume equates to the weight of the liquid at any amount less than one atmosphere pressure at sea level. If the liquid is heavier than one atmosphere, it will overcome the air pressure outside the reservoir and leak out.

When the wick is placed on the transducer, liquid flows within the capillary space between the wick and transducer. As the transducer is activated, the liquid is expelled in the form of droplets from the capillary space between the wick and transducer as depicted by the arrows 110 and 210. In Figure 1, a transducer has a flat surface on one end in contact with the wick. When the cartridge is placed vertically on top of the transducer, the droplets will be expelled in all directions away from wick and transducer tip.

In Figure 2, the transducer has a rounded end, and this rounded shape of the transducer allows the cartridge to be placed at an angle from the vertical axis. The droplets are similarly expelled away from the wick and transducer tip. It is important to note that the atomized liquid is not dispersed through any orifice as described in the prior art, but rather, between the capillary space of the wick and transducer.

As liquid is atomized and expelled, a phenomenon known as cavitation occurs.

Microscopic gas bubbles in the liquid are forced to oscillate due to the applied acoustic field from the transducer. As the bubbles collapse, droplets are expelled. At the same time, the gas from the collapsed bubbles is forced through the wick and enters the reservoir. These gas bubbles take up the volume of the liquid that are dispersed and allows more liquid to flow out of the reservoir constantly. Thus, the pressure inside the reservoir is always kept at equilibrium, even when the liquid level drops as it is being dispersed. When the transducer is turned off, no bubbles enter the reservoir, and liquid continues to be held within the reservoir.

Thus, with the construction described above, a low-cost reservoir or cartridge can be manufactured and cheaply replaced without the need for washing or sterilization. The invention therefore provides a simple, cost-effective and reliable atomizer with constant vapor output in comparison with the prior art.

The atomizer is suitable for use with any liquid to be atomized. In particular, it may be used for products such as medicine, fragrances, pesticides, detergents, malodor counteractants, water (for a humidifier), or any other type of liquid or combination of liquids dispersed by atomization. It is understood that this atomizer is suitable for liquids that are more viscous than water.

According to one embodiment, the wick is made of any fibrous material that allows the good rate of liquid flow to be dispersed by the transducer. The preferred rate is 100 mg per minute or more. A high temperature material for the fibers, such as PET (Polyethylene

Terephthalate), nylon or glass is preferred, since the vibrating transducer causes friction against the wick and may melt low temperature plastic polymers. Ceramic wicks can also be used. Cotton wicks can also be used because they do not melt. Alternatively, a plurality of fibrous materials can be used. For example, the wick can be made from two or multiple layers of material. On one end of the wick, a high temperature thin glass fiber layer is used for contacting the transducer, and a thicker low temperature material with good capillary flow on the other end to absorb liquid from the reservoir.

The reservoir can be made of plastic, glass, ceramic or metal, although transparency is preferred so a user can see the remaining volume of liquid inside the reservoir.

It is also preferred according to the present invention that the transducer is a piezo electric transducer, including without limitation: a Langevin type transducer. The transducer is connected to a control circuit (not shown) and a suitable power source, preferably a battery (not shown) is provided to power the transducer. The activation of the transducer may be determined by the user by activating an appropriate activation switch.

An apparatus for vaporizing a liquid comprising: a cartridge with a first end and a second end; the first end of the cartridge is a fill end; the second end of the cartridge having a wick; the cartridge holding the liquid; without being limiting, a Langevin type transducer (horn, piezo, anvil) being in contact with the wick; a power source and a signal generator are connected to the Langevin type transducer; whereby the Langevin type transducer is activated and vibrates to cause gas bubbles to be forced into the wick and the liquid, which contacts the transducer, is atomized, and the atomized liquid is a vapor.

The cartridge can be sealed; the wick can be cotton, glass fiber, ceramic, polypropylene, polyethylene, nylon, wood, paper, felt, or porous plastics; the viscosity of the liquid is more than water.

Improvements:

1. Authentication chip:

In conjunction with the microprocessor and computing device on the main vaporizer apparatus, there can be an authentication chip on the cartridge to allow for verification of the cartridge for the correct type or authorized type of vaporizer; this chip can also be used with the main vaporizer's microprocessor to log in a specific user, record and document usage, including time of use, frequency and dosage used. The microprocessor uses encryption software to keep the vaporizer's user and usage information confidential; password access; the microprocessor chip can record the user's name, date of birth, identification code and bio-characteristics (gender, weight, age, height, etc.).

The cartridge chip also allows for communicating to the vaporizer's microprocessor chip, which can keep a log of the cartridge contents and usage; for example, the chip on the cartridge can relay the level of contents within the cartridge, which enables the user to be alerted to when the cartridge needs to be replaced or reordered.

As described, the chip on the cartridge will have an encoded profile of the contents of the cartridge, such as manufacturer, type of liquid etc. The device will keep a log of usage of the cartridge, such as when it is turned on/off, and any errors. Therefore, a profile of the cartridge use can be generated, and prevents non-genuine cartridges from being used.

2. Silicone membrane (with or without openings) instead of using a wick for very viscous fluids that do not or does not easily flow through the pores of a wick.

In addition to the wicks mentioned earlier in this application, the cartridge can also be capped off with a silicone membrane webbing or porous opening. The silicone web will allow very viscous fluids or substances to pass through the web to the transducer.

3. The transducer tip can also be rounded instead of flat.

4. The removable cartridge can be angled between 0-90 degrees (vertical to horizontal) against the tip.

5. Different positions for the Cartridge:

Cartridge can be positioned so it moves towards the tip during vaporization, and away when not in use. For example, a first or resting position, wherein the cartridge does not contact the tip of the transducer; a second or active position, wherein the cartridge is moved so that the cartridge's web or wick contacts the tip of the transducer. The first or resting position prevents capillary action between the wick and tip when not in use that may cause unwanted flow/leak. The movement from a first to a second position can be controlled by springs or magnets.

Figures 6A and 6B shows setup embodiments of the cartridge/transducer. In Figure 6A, the cartridge 601 is positioned away from the transducer 606 and kept in this position by spring 622. Spring 622 can be attached to the circuit board 620. Contact pins 621 are in contact with the circuit board 611 of the cartridge 601. An optical sensor 624 on the circuit board 620 senses that the cartridge is not in position, thus turning the transducer 606 OFF. Wires 626 from the circuit board and wires 607 from the transducer is connected to a signal generator 630 that also comprises an MCU to read the authentication chip of the cartridge.

In Figure 6B, the cartridge 601 is pushed towards the transducer 606 so that the wick is now in contact (i.e., the second engaged position). Sensor 624 now "sees" that the cartridge is in position to turn ON the transducer. Spring 622 is compressed, such that there is a spring force wanting to expand the spring 622 back to the first non-engaged position (and consequently the cartridge 601) back to the resting position (non-engaged) in Figure 6A. At least one or multiple contact pins 621 are still contacting the circuit board 611, sending the usage time and other information to the MCU on the signal generator 530 for data logging.

There can be multiple circuit boards and microprocessors (MCU) on both the apparatus (vaporizer) and also on the removable cartridge; a first circuit board or a second circuit board; or multiple circuit boards in the apparatus. Radio Frequency tags or chips can also be employed on the apparatus or the removable cartridges for further identification and tracking. 6. ACTIVATION:

The unit can be activated with an on/off button; in addition, the power on/off activation can be done with a sensor/switch, so that when the cartridge is depressed (into the second or active position), the unit is activated so that there is one action rather than having to power on the transducer and depress the cartridge at the same time.

Detailed embodiments of the present invention are disclosed; however, the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms; specific structural and functional details disclosed are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. The title, headings, terms and phrases used are not intended to limit the subject matter or scope; but rather, to provide an understandable description of the invention. The invention is composed of several sub-parts that serve a portion of the total functionality of the invention independently and contribute to system level functionality when combined with other parts of the invention. The terms "a" or "an" are defined as: one or more than one. The term "plurality" is defined as: two or more than two. The term "another" is defined as: at least a second or more. The terms

"including" and/or "having" are defined as comprising (i.e., open language). The term "coupled" is defined as connected, although not necessarily directly, and not necessarily mechanically.

Any element in a claim that does not explicitly state "means for" performing a specific function, or "step for" performing a specific function, is not be interpreted as a "means" or "step" clause as specified in 35 U.S.C. Sec. 112, Paragraph 6. In particular, the use of "step of in the claims herein is not intended to invoke the provisions of 35 U.S.C. Sec. 112, Paragraph 6.

Incorporation by Reference: All publications, patents, patent applications and Internet website addresses mentioned in this specification are incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference; U.S. Patent Appl. 61/921,906, filed on Dec. 30, 2013; 61/928,823, filed on Jan. 17, 2014; 61/928,797, filed on Jan. 17, 2014;

14/271,442, filed on May 6, 2014; and 14/272,414, filed on May 7, 2014; US 6278218; US 5702360; US 8257377; US 6325811; US 5954736; PCT/GB 2007/002863; US 2010/0044460 Al (Sauzade); US 5950619 Van Der Linden; US 7784712 Wang; US 7975688 Truitt; WO 2008/015394 Al Reckitt Benckiser, which are all incorporated by reference in entirety.

Claims

We claim:

1. An apparatus for ultrasonic atomizing of a liquid, comprising:

a housing with a power source and an ultrasonic transducer;

the housing has a mouthpiece and a removable cartridge with the liquid for atomizing; the removable cartridge has a wick for drawing the liquid to a probe on the ultrasonic transducer;

the cartridge can be moved from a first non-engaged position to a second engaged position,

in the second engaged position, the probe engages the wick and allows for a displacement of greater than 10 micrometers;

the ultrasonic transducer is connected to the power source and a circuit board with a signal generator and a microprocessor;

whereby when the cartridge is moved to the second engaged position, the ultrasonic transducer is activated and vibrates the probe, and the liquid from the wick is atomized, and vapor of the atomized liquid exits the mouthpiece.

2. The apparatus of claim 1, wherein in the first non-engaged position, the cartridge is positioned away from the transducer probe with a first magnet and a second magnet;

the first magnet is attached to the removable cartridge, and the second magnet is attached to the circuit board; and

in the first non-engaged position, the first magnet is substantially aligned with the second magnet, and the probe does not engage the wick of the removable cartridge.

3. The apparatus of claim 2, wherein in the second engaged position, the first magnet on the removable cartridge is pushed away from the second magnet on the circuit board, whereby there is magnetic attraction between the first magnet and the second magnet to push back the removable cartridge to the first non-engaged position.

4. The apparatus of claim 1, wherein the circuit board has an optical sensor, which senses when the removable cartridge is in the first non-engaged position or the second engaged position; in the first non-engaged position, the microprocessor turns off the ultrasonic transducer; in the second engaged position, the microprocessor turns on the ultrasonic transducer.

5. The apparatus of claim 1, wherein a spring provides resistance to the removable cartridge from the first non-engaged position to the second engaged position.

6. The apparatus of claim 1, wherein the power source is an internal battery or an external power source; and the ultrasonic transducer is activated by an activation switch or an activation button.

7. The apparatus of claim 1, wherein the ultrasonic transducer has multiple piezoelectric elements, a transduction portion, an anvil bearing member and a sonotrode amplification member, and the ultrasonic transducer is acoustically coupled.

8. The apparatus of claim 1, wherein the housing has acoustic isolators to dampen vibrations emitted from the ultrasonic transducer to the housing.

9. The apparatus of claim 1, wherein the wick of the removable cartridge is a silicone membrane.

10. The apparatus of claim 1, wherein the removable cartridge has an authentication chip, which communicates with the microprocessor and allows for verification of the removable cartridge for said apparatus;

whereby when the removable cartridge is verified with the authentication chip, the cartridge is moved to the second engaged position, and the ultrasonic transducer is activated and vibrates the probe, and the liquid from the wick is atomized, and vapor of the atomized liquid exits the mouthpiece.

11. The apparatus of claim 10 wherein the verification chip communicates with the microprocessor to log in a specific user and to record usage, time of use, frequency or dosage; and the verification chip has an encoded profile of the removable cartridge.

12. The apparatus of claim 10, wherein the microprocessor and the verification chip use encryption software to record usage and user information and to keep said user information as confidential and to provide password access; and

the microprocessor and the verification chip can record name, date of birth, identification code or bio-characteristics.

13. The apparatus of claim 10, wherein the verification chip on the removable cartridge and the microprocessor records a log of the cartridge contents and usage of the cartridge;

the verification chip and the microprocessor can relay level of the liquid and enables alerts to when the removable cartridge needs to be replaced or reordered.