Aerosol processing and inhalation method and system for high dose rate aerosol drug delivery

A method for producing concentrated aerosols in a compact device suitable for inhalation therapy, said device comprising

• an aerosol generator;
• an aerosol evaporator engaged by and in communication with the aerosol generator;
• said aerosol evaporator having a chamber with a cylindrical chamber wall and a central axis;
• an aerosol concentrator engaged by and in communication with the aerosol evaporator;
• and
• an aerosol flow regulator that is connected to the aerosol concentrator, said method comprising:
• generating by means of the aerosol generator a large liquid aerosol flow and directing the large liquid aerosol flow into a first direction of flow extending along the central axis;
• reducing the velocity of the large liquid aerosol flow by directing a counterflow air jet into a second direction of flow that is opposed to the first direction of flow against the large liquid aerosol flow;
• generating a sheath air flow for minimizing aerosol deposition on the chamber;
• mixing the sheath air flow with the large liquid aerosol flow and counterflow for augmenting evaporation of the large liquid aerosol;
• generating at least one of convective heat and radiative heat and transferring this heat into the chamber, evaporating liquid contained in the large liquid aerosol by dry air mixing to form a flow comprising a dry aerosol powder having a particle size between 1 μm and 10 μm;
• concentrating the dry aerosol powder by virtual impaction removing most of the air and unwanted vapor as a major fraction from a remaining small fraction containing air, vapor and dry aerosol powder;
• providing stable dry particles of the dry aerosol powder containing up to 100% active agents.

A system for producing concentrated aerosols in a compact device suitable for inhalation therapy, said system comprising the elements of:

• a chamber with a cylindrical chamber wall and a central axis extending into a first direction of flow;
• means generating a sheath of dry air flow for minimizing aerosol deposition on the chamber;
• an aerosol generator having at least one orifice adapted to eject a large liquid aerosol flow into the chamber along the central axis in the first direction of flow;
• an aerosol evaporator engaged by and in communication with the aerosol generator;
• a coaxial counterflow air jet nozzle reducing the velocity of the aerosol by directing a counterflow air jet into a second direction of flow that is opposed to the first direction of flow and therefore directed against the aerosol;
• at least one of a convective or radiative heat transfer device heating at least one of dry air flowing into the chamber and being within said chamber;
• an aerosol concentrator engaged by and in communication with the aerosol evaporator, said concentrator being adapted to remove most of the air and unwanted vapor as a major fraction from a remaining small fraction containing air, vapor and dry aerosol powder;
• and
• an aerosol flow regulator that is connected to the aerosol concentrator.

A system for producing concentrated aerosols in a compact device, said system comprising the elements of:

• a chamber with a cylindrical chamber wall and a central axis extending into a first direction of flow;
• means generating a sheath of dry air flow for minimizing aerosol deposition on the chamber;
• an aerosol generator having at least one orifice adapted to eject a large liquid aerosol flow into the chamber along the central axis in the first direction of flow;
• an aerosol evaporator engaged by and in communication with the aerosol generator;
• a coaxial counterflow air jet nozzle reducing the velocity of the aerosol by directing a counterflow air jet into a second direction of flow that is opposed to the first direction of flow and therefore directed against the aerosol;
• at least one of a convective or radiative heat transfer device heating at least one of dry air flowing into the chamber and being within said chamber;
• an aerosol concentrator engaged by and in communication with the aerosol evaporator, said concentrator being adapted to remove most of the air and unwanted vapor as a major fraction from a remaining small fraction containing air, vapor and dry aerosol powder.