Enhancing the Proportion of Sub-5 μm Atomized Droplet Size in Medical Air-Compression Nebulizer

Medical air-compression nebulizers deliver atomized medication to the lungs, providing rapid and painless treatment for respiratory diseases. However, the size of most atomized droplets is around 10 μm, limiting drug deposition in the lower airways and alveoli, with increasing the proportion of sub-5 μm droplets remaining challenging. In this work, finite element analysis was employed to model the effects of gas flow rate, liquid channel width, and broken baffle structure on droplet size distribution, aiming to optimize structure symmetrical parameters and operating conditions. A novel compression atomizer was developed and experimentally evaluated, incorporating an improved symmetrical structure for the crushing baffle. Following this modification, the proportion of sub-5 μm droplets increased from 54.6% to 59.25%, representing a 4.65% enhancement in the generation of sub-5 μm droplets. The effects of gas flow rate and liquid concentration on droplet size distribution were systematically investigated to further optimize the atomization performance. The results demonstrated a significant increase in the proportion of sub-5 μm droplets, thereby enhancing drug delivery efficiency to the lower respiratory tract and improving treatment efficacy for respiratory diseases.