Nebulizer

Claim 2

A nebulizer for converting liquid into aerosol, comprising; a housing having a liquid reservoir and an outlet opening through which aerosol passes; a spray nozzle having an end wall defining an orifice and having liquid inlet means in communication with said reservoir; a gas nozzle positioned within said spray nozzle having gas inlet means and an orifice spaced from and co-axial with said spray orifice; said spray nozzle and said gas nozzle defining a passage therebetween extending from said liquid inlet means to said space between said orifices; a diffuser having a nose portion spaced from and adjacent said orifices with the furthermost extension of said nose portion coaxial with said orifices, said nose portion having a surface or revolution diverging from said furthermost extension away from said orifices; and said end wall having an outer surface extending outwardly from said spray orifice in a direction substantially parallel to the diverging surface of said nose portion with said outer surface of said end wall and said diverging surface of said nose portion defining a narrow path through which spray passes from said spray orifice.

Claim 3

The nebulizer of claim 1, wherein the distance between the outer surface and the inner surface of said spray nozzle at the edge of said spray orifice is about 0.015 inch to minimize noise.

Claim 4

The nebulizer of claim 1, wherein said spray orifice is defined by an end wall of said spray nozzle, said end wall having a recess coaxial with said spray orifice on the outer surface of said end wall to reduce the thickness of said end wall at the edge of said spray orifice to prevent noise while permitting injection-molding of said end wall.

Claim 5

The nebulizer of claim 1, wherein the distance between said furthermost extension of said nose portion and said spray orifice is about 0.030 inch.

Claim 6

The nebulizer of claim 1, wherein the distance between the inner surface of said end wall of said spray nozzle and the outer surface of said end wall of said gas nozzle at said space between said orifices is between about 0.012 inch and 0.015 inch.

Claim 7

The nebulizer of claim 1, wherein the distance between the inner surace of said end wall of said spray nozzle and the outer surface of said end wall of said gas nozzle in said passage is less than the diameter of said spray orifice.

Claim 8

The nebulizer of claim 1, wherein a baffle plate is provided, said baffle plate being positioned in the path of spray emanating from said spray orifice and adjacent said aerosol outlet to prevent oversize droplets of liquid from escaping the nebulizer.

Claim 9

The nebulizer of claim 1, wherein said gas inlet means is provided with a check valve to prevent a back flow of liquid through said gas nozzle.

Claim 10

The nebulizer of claim 1, wherein the inner surface of said end wall extending from said spray orifice is parallel to the outer surface of said end wall extending radially from said gas orifice.

Claim 11

A nebulizer for converting liquid into aerosol, compressing; an enclosed container having a liquid supply reservoir and an aerosol outlet; a nozzle assembly extending into said container including an inner gas nozzle and an outer spray nozzle encircling said gas nozzle; said gas nozzle having an end wall defining a gas orifice and said spray nozzle having an end wall defining a spray orifice spaced from and coaxial with said gas orifice; said end walls having a passage therebetween extending to said space between said orifices; said gas nozzle having a gas inlet means in communication with said gas orifice and said spray nozzle having liquid inlet means in communication with said reservoir and said passage; a diffuser in said container having a nose portion adjacent said orifices with the furthermost extension of said nose portion sapced from and coaxial with said spray orifice, said nose portion having a surface of revolution diverging from said furthermost extension away from said spray orifice; and said end wall of said spray nozzle having an outer surface extending outwardly from said spray orifice in a direction substantially parallel to said diverging surface of said nose portion with said outer surface of said end wall and said diverging surface of said nose portion defining a narrow path through which spray passes from said spray orifice.

Claim 12

A nebulizer for converting liquid into aerosol, compressing; an enclosed container having a liquid supply reservoir and an aerosol outlet; a nozzle assembly extending into said container including an inner gas nozzle and an outer spray nozzle encircling said gas nozzle; said gas nozzle having an end wall defining a gas orifice and said spray nozzle having an end wall defining a spray orifice spaced from and coaxial with said gas orifice; said end walls having a passage therebetween extending to said space between said orifices; said gas nozzle having a gas inlet means in communication with said gas orifice and said spray nozzle having liquid inlet means in communication with said reservoir and said passage; a diffuser in said container having a nose portion adjacent said orifices with the furthermost extension of said nose portion sapced from and coaxial with said spray orifice, said nose portion having a surface of revolution diverging from said furthermost extension away from said spray orifice; and said end wall of said spray nozzle having an outer surface extending outwardly from said spray orifice in a direction substantially parallel to said diverging surface of said nose portion with said outer surface of said end wall and said diverging surface of said nose portion defining a narrow path through which spray passes from said spray orifice.

Claim 13

The nebulizer of claim 10, wherein the outer surface of said end wall of said spray nozzle is provided with a recess coaxial with and surrounding said spray orifice.

Claim 14

The nebulizer of claim 11, wherein said nose portion of said diffuser extends into said recess.

Claim 15

The nebulizer of claim 10, wherein the distance between said furthermost extension of said nose portion and said spray orifice is about 0.030 inch.

Claim 16

The nebulizer of claim 10, wherein the distance between the inner surface of said end wall of said spray nozzle and the outer surface of said end wall of said gas nozzle at said space between said orifices is between about 0.012 inch and 0.015 inch.

Claim 17

The nebulizer of claim 10, wherein the diameter of said gas orifice is between about 0.024 inch and 0.028 inch and the diameter of said spray orifice is between about 0.036 inch and 0.042 inch.

Claim 18

The nebulizer of claim 10, wherein the distance between the inner surface of said end wall of said spray nozzle and the outer surface of said end wall of said gas nozzle in said passage is less than the diameter of said spray orifice.

Claim 19

The nebulizer of claim 10, wherein a baffle plate is provided, said baffle plate being positioned in the path of spray emanating from said spray orifice and adjacent said aerosol outlet to prevent oversize droplets of liquid from escaping the nebulizer.

Claim 20

The nebulizer of claim 10, wherein said gas inlet means is provided with valve means to preVent a back flow of liquid passing through said gas nozzle.

Claim 21

The nebulizer of claim 10, wherein the inner surface of said spray nozzle is provided with at least three ribs engaging the outer surface of said gas nozzle to position and maintain said gas orifice with respect to said spray orifice.

Claim 22

A disposable, preferably plastic nebulizer unit for converting liquid medicament into aerosol, comprising: four separately molded components comprising an outlet component, a cover component, a bowl component, and a gas nozzle component; said outlet component having an aersol outlet end, an aerosol inlet end, and an aerosol passageway therebetween; said cover component and said bowl component each having sidewalls connected together at one end, said sidewalls together defining a container having an upper mixing area and a lower reservoir area; said gas nozzle component and said bowl component being connected together with a section of said gas nozzle component extending into said container, said gas nozzle component having a gas orifice inside said container and a gas inlet end outside said container in communication with said gas orifice; said bowl component having an integral spray nozzle within said container, said spray nozzle having an end wall defining an orifice and liquid inlet means in communication with said reservoir area and said spray orifice, said spray orifice being positioned above said reservoir area and spaced from and coaxial with said gas orifice; said cover component being connected to said aerosol inlet end and having an outlet opening for communication of aerosol between said mixing area and said aerosol inlet end, said cover component further including an integral diffuser-baffle assembly positioned within said container between said outlet opening and said coaxial orifices; and said diffuser-baffle having a nose portion spaced from and adjacent said orifices with the furthermost extension of said nose portion coaxial with said orifices, said nose portion having a surface or revolution diverging from said futhermost extension away from said orifices; and said end wall having an outer surface extending outwardly from said spray orifice in a direction substantially parallel to the diverging surface of said nose portion with said outer surface of said end wall and said diverging surface of said nose portion defining a narrow path through which spray passes from said spray orifice.

Claim 23

A disposable, preferably plastic nebulizer unit for converting liquid medicament into aerosol, comprising: four separately molded components comprising an outlet component, a cover component, a bowl component, and a gas nozzle component; said outlet component having an aersol outlet end, an aerosol inlet end, and an aerosol passageway therebetween; said cover component and said bowl component each having sidewalls connected together at one end, said sidewalls together defining a container having an upper mixing area and a lower reservoir area; said gas nozzle component and said bowl component being connected together with a section of said gas nozzle component extending into said container, said gas nozzle component having a gas orifice inside said container and a gas inlet end outside said container in communication with said gas orifice; said bowl component having an integral spray nozzle within said container, said spray nozzle having an end wall defining an orifice and liquid inlet means in communication with said reservoir area and said spray orifice, said spray orifice being positioned above said reservoir area and spaced from and coaxial with said gas orifice; said cover component being connected to said aerosol inlet end and having an outlet opening for communication of aerosol between said mixing area and said aerosol inlet end, said cover component further including an integral diffuser-baffle assembly positioned within said container between said outlet opening and said coaxial orifices; and said diffuser-baffle having a nose portion spaced from and adjacent said orifices with the furthermost extension of said nose portion coaxial with said orifices, said nose portion having a surface or revolution diverging from said futhermost extension away from said orifices; and said end wall having an outer surface extending outwardly from said spray orifice in a direction substantially parallel to the diverging surface of said nose portion with said outer surface of said end wall and said diverging surface of said nose portion defining a narrow path through which spray passes from said spray orifice.