Multiple Dose Condensation Aerosol Devices and Methods of Forming Condensation Aerosols

Abstract

Devices and methods of entraining a substance within an airflow are disclosed. Condensation aerosol delivery devices and methods of consistently producing multiple doses of a substance, such as a drug, having high purity, high yield, characterized by a particle size distribution appropriate for pulmonary delivery, and which can be administered to a user in a single dose are also disclosed.

1 . An electrically resistive heating element comprising a metal foil for vaporizing a substance disposed thereon to produce a condensation aerosol comprising the substance; wherein the metal foil is in an arched configuration. 
     
     
         2 . The heating element of  claim 1 , wherein the metal foil is stainless steel. 
     
     
         3 . The heating element of  claim 1 , wherein the thickness of the metal foil is less than 0.01 inches. 
     
     
         4 . The heating element of  claim 1 , wherein the thickness of the metal foil is less than 0.001 inches. 
     
     
         5 . The heating element of  claim 1 , wherein the thickness of the metal foil is less than 0.0005 inches. 
     
     
         6 . The heating element of  claim 1 , wherein the surface area of the metal foil ranges from 0.01 cm 2  to 50 cm 2 . 
     
     
         7 . The heating element of  claim 1 , wherein the metal foil comprises a metal layer plated on the metal foil. 
     
     
         8 . The heating element of  claim 7 , wherein the metal layer is chosen from gold, silver, nickel, and copper. 
     
     
         9 . The heating element of  claim 7 , wherein the metal layer is gold. 
     
     
         10 . The heating element of  claim 7 , wherein the thickness of the metal layer ranges from 0.001 μm to 3 μm. 
     
     
         11 . The heating element of  claim 1 , wherein the height of the arch ranges from 0.5 mm to 2 mm. 
     
     
         12 . The heating element of  claim 1 , wherein an impedance of the heating element is closely matched to an impedance of a power source for heating the heating element. 
     
     
         13 . The heating element of  claim 12 , wherein the difference between the impedance of the heating element and the impedance of the power source is less than 50% of the impedance of the power source. 
     
     
         14 . The heating element of  claim 12 , wherein the difference between the impedance of the heating element and the impedance of the power source is less than 10% of the impedance of the power source. 
     
     
         15 . The heating element of  claim 12 , wherein the difference between the impedance of the heating element and the impedance of the power source is less than 2% of the impedance of the power source. 
     
     
         16 . The heating element of  claim 1 , wherein the ratio of the surface area of the heating element, to the thermal mass of the heating element is greater than 10 cm 2 /J/° C. 
     
     
         17 . The heating element of  claim 1 , wherein the ratio of the surface area of the heating element, to the thermal mass of the heating element is greater than 100 cm 2 /J/° C. 
     
     
         18 . The heating element of  claim 1 , wherein the ratio of the surface area of the heating element, to the thermal mass of the heating element is greater than 500 cm 2 /J/° C. 
     
     
         19 . The heating element of  claim 1 , wherein the heating element can reach a temperature of at least 250° C. in less than 500 msec. 
     
     
         20 . The heating element of  claim 1 , wherein the heating element can reach a temperature of at least 250° C. in less than 250 msec. 
     
     
         21 . The heating element of  claim 1 , wherein the heating element can reach a temperature of at least 250° C. in less than 100 msec. 
     
     
         22 . The heating element of  claim 1 , wherein the amount of energy to vaporize one milligram of a substance disposed on the heating element is less than 250 joules. 
     
     
         23 . The heating element of  claim 1 , wherein the amount of energy to vaporize one milligram of a substance disposed on the heating element is less than 10 joules.