Aerosol generator having a sandwich construction
An aerosol generator includes a carrier structure having an opening, a mesh membrane covering the opening and overlaying an upper surface of the carrier structure, and a closing ring arranged on an upper surface of the mesh membrane that faces away from the carrier structure. The mesh membrane includes at least two gluing openings extending through the mesh membrane and distributed evenly around a circumference of the mesh membrane. Cured adhesive columns protrude through the gluing openings and mechanically connect an adhesive layer located below the mesh membrane that is bonded to the upper surface of the carrier structure to an adhesive layer located above the mesh membrane that is bonded to a lower surface of the closing ring. The adhesive columns mechanically connect the mesh membrane to the carrier structure and the closing ring.
1 . An aerosol generator for use in a nebulizer for aerosolization of a fluid comprising:
a carrier structure having a concentric, continuous opening;
a mesh membrane covering the opening and overlaying an upper surface of the carrier structure;
a closing ring arranged on an upper surface of the mesh membrane that faces away from the carrier structure,
wherein:
the mesh membrane includes at least two gluing openings extending from the upper surface of the mesh membrane to a lower surface of the mesh membrane that faces the carrier structure and distributed evenly around a circumference of the mesh membrane, and cured adhesive columns protruding through the gluing openings;
the adhesive columns mechanically connect a lower adhesive layer that lies below the lower surface of the mesh membrane and is bonded to the upper surface of the carrier structure facing the mesh membrane with an upper adhesive layer that lies above the upper surface of the mesh membrane and is bonded to a lower surface of the closing ring facing the mesh membrane;
the adhesive columns mechanically connect the mesh membrane to the carrier structure and the closing ring; and
wherein the mesh membrane is not adhesively bonded across its entire surface to either the upper or lower adhesive layer or the adhesive columns, and an introduction of a force from a piezo ceramic into the mesh membrane is affected exclusively via the adhesive columns protruding through the gluing openings.
2 . The aerosol generator according to claim 1 , wherein the mesh membrane is made of a material that is not bondable by means of an adhesive approved for contact with active ingredient solutions.
3 . The aerosol generator according to claim 2 , wherein the mesh membrane is made of nickel or a fluorine-containing plastic.
4 . The aerosol generator according to claim 1 , wherein the at least two gluing openings in the mesh membrane comprise three or more gluing openings in the mesh membrane.
5 . The aerosol generator according to claim 1 , wherein the mesh membrane has a circular outline.
6 . The aerosol generator according to claim 1 , wherein the at least two gluing openings are arranged on exactly one circle or on exactly two circles around a center point of the opening of the carrier structure.
7 . The aerosol generator according to claim 1 , wherein the carrier structure comprises a steel disk having an annular piezo ceramic attached on its lower surface facing away from the mesh membrane.
8 . The aerosol generator according to claim 1 , wherein the carrier structure comprises an annular piezo ceramic.
9 . The aerosol generator according to claim 1 , wherein the at least two gluing openings are round and a distance from a center of each gluing opening to an edge of the mesh membrane is not less than one and a half times a radius of the gluing openings.
10 . The aerosol generator according to claim 1 , wherein the adhesive columns and adhesive layers comprise an epoxy resin based adhesive.
11 . A method of manufacturing an aerosol generator comprising:
providing a mesh membrane, an annular closing ring having an opening and an annular carrier structure having and opening that is concentric to the opening of the annular closing ring,
introducing at least two gluing openings spaced evenly along a circumference of the mesh membrane in a desired pattern;
applying, on an upper surface of the carrier structure, a ring of adhesive, which encloses the opening, wherein a total adhesive volume of the ring of adhesive is dimensioned larger than the total volume of all the gluing openings of the mesh membrane;
placing the mesh membrane over the ring of adhesive and the carrier structure and pressing the mesh membrane toward the upper surface of the carrier structure, wherein the ring of adhesive is pressed and forms a lower adhesive layer between the carrier structure and the mesh membrane, and extends through the gluing openings and forms adhesive dots protruding above an upper surface of the mesh membrane facing away from the carrier structure;
placing and pressing the closing ring toward the upper surface of the mesh structure, wherein an upper adhesive layer is formed between the mesh membrane and the closing ring; and
allowing the adhesive to cure,
wherein the mesh membrane is not adhesively bonded across its entire surface to either the upper or lower adhesive layer, and the introduction of a force from a piezo ceramic into the mesh membrane is effected exclusively via the adhesive columns protruding through the gluing openings.
12 . The method according to claim 11 , further comprising, after allowing the adhesive to cure, removing protruding adhesive residue.