Volatile propellant droplet evaporation measurements in metered dose inhaler sprays

Many aerosol products rely on the rapid vaporization of volatile propellants to produce a fine spray. In the simplest case, these are binary mixtures of propellant and a delivered product which undergo a flash-evaporation process leaving only the less volatile product in the resultant droplet. In more complex applications, such as pressurized metered-dose inhalers, the non-propellant component may contain dissolved or suspended drug which precipitates or dries to form a matured particle. The size and morphology of the particles depend strongly on the time-history of the droplet as the propellant evaporates. However, measuring the dynamic evaporation processes that occur in dense sprays containing millions of droplets is challenging. In this paper, we demonstrate a novel application of Ultra Small Angle X-ray Scattering to measure the bulk composition of volatile HFC134a–ethanol sprays and compare the obtained results with simple evaporation models in a dry nitrogen environment. The data reveal that diffusion-limiting processes inside the droplet are equally important as external convection and mixing-limited factors in determining evaporative timescales.