High Mass Throughput Particle Generation Using Multiple Nozzle Spraying

Abstract

Spraying apparatus and methods that employ multiple nozzle structures for producing multiple sprays of particles, e.g., nanoparticles, for various applications, e.g., pharmaceuticals, are provided. For example, an electrospray dispensing device may include a plurality of nozzle structures, wherein each nozzle structure is separated from adjacent nozzle structures by an interozzle distance. Sprays of particles are established from the nozzle structures by creating a nonuniform electrical field between the nozzle structures and an electrode electrically isolated therefrom.

1 - 50 . (canceled) 
     
     
         51 . An apparatus for electrospraying particles, the apparatus comprising:
 a particle source; and   a dispensing device configured to receive source material from the particle source, wherein the dispensing device comprises a plurality of nozzle structures, wherein each nozzle structure comprises at least one opening defined along a center axis of the nozzle structure and terminating at a dispensing end thereof, wherein each nozzle structure is separated from adjacent nozzle structures by at least an internozzle distance (L) defined by the distance between center axes of nozzle structures, wherein the ratio of the internozzle distance (L) to a diameter (D) of the opening at the dispensing end is equal to or greater than 2; and   an electrode isolated from the dispensing end, wherein a nonuniform electrical field is created between the dispensing ends and the electrode such that a spray of particles having an electrical charge applied thereto is dispensed from the dispensing end of each nozzle structure.   
     
     
         52 . The apparatus of  claim 51 , wherein the electrode is a grounded target. 
     
     
         53 . The apparatus of  claim 51 , wherein each of the nozzle structures comprises a capillary tube comprised of a body portion and a tapered capillary tip at the dispensing end of the capillary tube. 
     
     
         54 . The apparatus of  claim 51 , wherein each of the nozzle structures comprises a tapered portion used to faun the opening at the dispensing end, and further wherein at least a part of each of the nozzle structures extend from an integral multiple nozzle structure conductive portion. 
     
     
         55 . The apparatus of  claim 51 , wherein each of the nozzle structures comprises a solid post along the center axis extending through the opening at the dispensing end. 
     
     
         56 . The apparatus of  claim 51 , wherein each dispensing end of the nozzle structures are positioned in an x-y plane and have the center axis thereof aligned along the z axis. 
     
     
         57 . The apparatus of  claim 51 , wherein the plurality of nozzle structures comprises providing a circular configuration of nozzle structures comprising an outer multiple nozzle structure ring and one or more inner multiple nozzle structure rings, wherein each of the outer multiple nozzle structure ring and the inner multiple nozzle structure rings are concentric about a center nozzle structure, and further wherein each of the nozzle structrues of the one or more inner multiple nozzle structure rings are at a substantially equal internozzle distance (L) from adjacent nozzle structures. 
     
     
         58 . The apparatus of  claim 51 , wherein the dispensing ends of the plurality of nozzle structures lie in a plane. 
     
     
         59 . The apparatus of  claim 51 , wherein the dispensing end of the center nozzle structure lies in a first plane and at least the dispensing ends of the nozzle structures of at least one of the multiple nozzle structure rings lie in at least a second plane. 
     
     
         60 . The apparatus of  claim 59 , wherein the dispensing ends of the nozzle structures form a conical configuration with the center nozzle structure at a tip of the conical configuration. 
     
     
         61 . The apparatus of  claim 51 , wherein the dispensing device further comprises one or more separation structures positioned between nozzle structures and configured such that cone jets are allowed to form at the dispensing end of each nozzle structure. 
     
     
         62 . The apparatus of  claim 51 , wherein the particles have a nominal diameter of about 1 nanometers to about 2000 nanometers. 
     
     
         63 . The apparatus of  claim 51 , wherein each of the nozzle structures comprise at least a first and second opening terminating at the dispensing end of each nozzle structure. 
     
     
         64 . The apparatus of  claim 63 , wherein the particle source comprises a first particle source of at least a first fluid composition comprising an active ingredient to be dispensed through the first opening and a second particle source of at least a second fluid composition comprising a coating component to be dispensed through the second opening, and further wherein the sprays of particles comprise sprays of coated active ingredients. 
     
     
         65 . The apparatus of  claim 51 , wherein the apparatus further comprises an excipient material provided on a target surface, the target surface positioned such that the sprays of particles are directed for contact with the excipient material. 
     
     
         66 . The apparatus of  claim 51 , wherein the apparatus further comprises a charged pattern, the charged pattern positioned such that the sprays of particles is directed for contact with the charged pattern. 
     
     
         67 . The apparatus of  claim 51 , wherein the apparatus further comprises a container operable by a user for inhalation of contents therein, the container positioned such that the sprays of particles are directed therein. 
     
     
         68 . The apparatus of  claim 51 , wherein the sprays of particles are dispensed at a rate in the range of 2 grams/minute to 50 grams/minute. 
     
     
         69 . The apparatus of  claim 51 , wherein the center axes of two or more nozzles are not parallel to one another. 
     
     
         70 . The apparatus of  claim 51 , wherein each of the nozzle structures comprise a first capillary tube having a first opening terminating at the dispensing end and a second capillary tube concentric with at least a portion of the first capillary tube having a second opening terminating at the dispensing end. 
     
     
         71 - 97 . (canceled)