Factors that influence spray pattern measurements of pressurized, metered-dose inhalers have been evaluated. Spray patterns were correlated with changes in actuator orifice diameter, particle size profiles, and calculated estimates of particle-size dynamics of plumes during a spray. Spray patterns, regardless of actuator orifice size, were ellipsoid in the vertical direction. Measures of elliptical ratio, major axis, and minor axis were significantly influenced by orifice size in a non-linear fashion over the range of orifice sizes investigated. Spray patterns also correlated with particle size profile and spray geometry measurements. Spray distribution asymmetry may be related to droplet evaporation and sedimentation processes. However, the spray patterns did not appear sensitive to changes in gravitational force acting on the plume. Instead, it is postulated that elliptical spray patterns may have dependence on fluid dynamic processes within the inhaler actuator. Developing an understanding of these processes may provide a basis for developing spray pattern tests with relevance to product performance
