Patent ID: 11872573
Assignee: STAMFORD DEVICES LIMITED
Field: Chemical engineering (Chemistry)
Classification: CPC B  C  A | IPC A  B  C

Claim 6:
7. A method of manufacturing an aperture plate wafer, the method comprising:
applying a mask over a substrate in a pattern of columns, each column having a frustoconical bottom portion terminating in a convex top surface, wherein a height of each column is greater than a diameter of each column;
electroplating a palladium-nickel alloy matrix plating material around the columns to form a first thickness;
over-plating the plating material directly on the top surfaces of the pattern of columns to form a second thickness and so as to form a plurality of aerosol-forming apertures, wherein the first thickness is greater than the second thickness;
removing the palladium-nickel alloy matrix plated material from the mask and the substrate to provide a wafer of electroplated material with greater than 44,100 aerosol-forming apertures per 650 mm2 and a plurality of tapered droplet entrainment portions; and
forming the aperture plate wafer into a domed shape such that a size of an exit of the tapered droplet entrainment portions increases based on the forming.