Droplet sizes and delivery rates from film breakup aerosolisation mode in porous materials

Abstract A novel two-phase aerosolisation mode utilizing porous materials is investigated, aiming to improve aerosol delivery for medical inhalation. Sintered stainless steel filters with varied pore sizes (PS) from 0.2 μm to 7 μm were used to generate aerosols from a 0.9 wt.% sodium chloride solution. Droplet sizes and delivery rates were measured using laser diffraction spectroscopy. Further measurements included shadow imaging. Results indicate that aerosolisation occurs within a specific range of PS with droplet sizes increasing with increasing PS. The droplets generated are suitable for inhalation therapies. A hypothesis is established about the process of droplet formation which states that different PS within the porous material serve distinct functions that contribute to the breakup of liquid films into aerosol particles. Droplet formation is the result of film breakup in pores filled with fluid. This low-energy aerosolisation method has the potential to be used in handheld devices for sensitive drug formulations, overcoming the limitations of current technologies. Further research is needed to optimize the pore size distribution and enhance aerosol generation efficiency.