An inhalation device assembled from several parts

Abstract

An inhaler article includes a front plug having a front plug tube body with an upstream end and downstream end, an external front plug surface, and an internal front plug surface defining a front plug cavity. The front plug having an internal diameter, a support member contained in the cavity of the front plug. A mouth plug includes a mouth plug tube body having an upstream end and downstream end, an external mouth plug surface and an internal mouth plug surface defining a mouth plug cavity. The mouth plug having an internal diameter greater than the internal diameter of the mouth plug. The inhaler article includes the front plug containing the support member forming an upstream portion of the inhaler article and the mouth plug forming a downstream portion of the inhaler article. The lesser inner diameter of the mouth plug forms a shoulder stop to retain the support member.

Description

[0001] INHALER ARTICLE ASSEMBLED FROM MULTIPLE PARTS

[0002] The present disclosure relates to an inhaler article. The present disclosure relates to a dry particle inhaler article. The present disclosure relates to an inhaler article assembled from multiple parts. The present disclosure relates to an inhaler article for use with a holder to form an inhaler system. The present disclosure relates to a method for assembling the inhaler article.

[0003] Inhaler articles are used to deliver dry powder to the lungs of a user. Inhaler articles provide an airflow path. The airflow path through an inhaler article begins at an airflow inlet, travels through the inhaler article, and exits the inhaler article at a mouth end or downstream end where the air traveling in the airflow path is inhaled by a user. Inhaler articles may contain a capsule containing dry powder. The dry powder may be a pharmaceutically active compound. The dry powder may comprise an active compound. The dry powder may comprise an active compound that is delivered to a user when the dry powder is released from the capsule, is entrained in the airflow traveling through the inhaler article and is inhaled by a user. To release the dry powder from the capsule and to introduce dry powder into an airflow so that the dry powder can be delivered to a user, the capsule may be pierced. The pierced capsule releases its dry powder contents into airflow as the air flows around and past the pierced capsule. The inhaler article is depleted when the contents of the capsule have been released into the airflow.

[0004] The dose of dry powder is limited by the contents of the capsule. The dose of dry powder is also limited by the degree to which all of the contents of the capsule can be released from the capsule and delivered to the user. It would be desirable provide an inhaler article structured to enable the release of the contents of the capsule.

[0005] Inhaler articles are manipulated before, during and after use. For example, inhaler articles may be subjected to longitudinal and radial pressures as they are manufactured, packaged, unpackaged, inserted into devices, activated, pierced, used and discarded. Inhaler articles are not always fully suitable to withstand this manipulation. For example, when inhaler articles are manufactured, multiple parts may be assembled to form the final inhaler articles. It would be desirable to provide inhaler articles structured to enable manufacture and assembly of the inhaler article without damaging or bending the parts.

[0006] When using the inhaler article, the capsule may be pierced. Another word for piercing the capsule is activating the capsule. For example, when the capsule is pierced, a piercing element is pressed into the capsule. The piercing element may be pressed into the capsule from the upstream side of the capsule. When the piercing element is pressed into the upstream end of the capsule, the capsule may move in response to the pressure of the piercing element. The pressure may be transmitted to structures downstream of the capsule. This may cause the downstream structures to deform. This may cause the pierced capsule to be pushed downstream in the inhaler article. This may cause the pierced capsule to be pushed out of the inhaler article. It would be desirable to provide an inhaler article structured to reduce the deformation of the structures of the inhaler article. It would be desirable to provide an inhaler article that is structured to prevent the capsule from being pushed out of the inhaler article. It would be desirable to prevent the pierced capsule from being pushed out of the inhaler article. It would be desirable to provide a support member that provides support member airways that allow airflow to pass from upstream of the support member where the capsule is located to downstream of the support member where the airflow outlet is located, so that the airflow may be inhaled by a user. This allows air to flow past the capsule, entraining particles of dry powder released from the capsule, through support member airways.

[0007] When support member airways have a smaller cross-section than the tubular inhaler article, air flowing through these airways having reduced diameter accelerates. It may be desirable to accelerate the airflow as it flows through the inhaler article. It may be desirable to provide a support member that has an upstream face that is closed in a central area. This closed central area may provide a flat surface to contact the downstream end of the capsule. When the capsule contacts the flat surface of this central area, it provides a single contact point between the capsule and internal structures of the inhaler article. This closed central area provides less contact points between the capsule and the internal structures of the inhaler article compared to a support member having support member airways in the center of the support member, for example. For example, if support member airways are located where the capsule contacts the support member, the capsule may contact the edges of the support member airways, forming more contact points between the capsule and the upstream face of the support member. Contact points create friction when the capsule moves. Contact points interfere with the movement of the capsule inside the inhaler article. If the support member airways are located where the capsule contacts the support member, the capsule may block airflow through the support member airways. It would be desirable to provide an inhaler article that doesn’t have support member airways in the center of the support member where the capsule may contact the support member. It would be desirable to provide an inhaler article having internal structures that minimize contact points with the capsule and allow the capsule to move and agitate more freely, thus releasing dry powder more freely.

[0008] The support member airways may form straight passageways from the upstream face to the downstream face of the support member along the longitudinal axis of the inhaler article. Or the support member airways may be straight passageways that are angled with respect to the central axis of the inhaler article. Or, the support member airways may form curved or angled passageways between the upstream face and the downstream face of the support member. The support member airways may form circuitous or convoluted passageways between the upstream face and the downstream face of the support member. These angled, circuitous or convoluted passageways may prevent dry powder from leaking from the inhaler article.

[0009] It may be desirable to provide an inhaler article having improved stability. It would be desirable to provide an inhaler article providing sufficient rigidity to resist longitudinal force, such as the force provided by the piercing of the capsule. It would be desirable to provide an inhaler article providing sufficient rigidity to resist radial force such as crushing forces against the sidewalls of the inhaler article which may occur during manufacturing, packaging or use. It would be desirable to provide an inhaler article with sufficient stability to withstand compression forces exerted during one or more of manufacturing, packaging and use of the article. It would be desirable to provide an article having sufficient rigidity to resist deforming or crushing of the inhaler article when the capsule of the inhaler article is pierced. It would be desirable to provide an inhaler article structured to provide enhanced rigidity. For example, if the inhaler article is bent or deformed, the ability of the capsule to move inside the inhaler article and release its contents to provide a dose of dry powder may be reduced. If the capsule cannot move inside the inhaler article, it may not fully release the dry powder contained in the capsule during use.

[0010] It would be desirable to provide an inhaler article to prevent the capsule from escaping from the inhaler article. If the capsule escapes from the inhaler article, the capsule containing dry powder may be dangerous if ingested. It would be desirable to provide an inhaler article that is simple and cost-effective to manufacture. It would be desirable to provide an article that can reliably contain the capsule before, during and after use, to prevent escape of the capsule containing dry powder. It would be desirable to provide an article offering improved sustainability. It would be desirable to provide a biodegradable article. It would be desirable to provide a biodegradable retainer portion. It would be desirable to provide a recyclable retainer portion. It would be desirable to provide a biodegradable retainer portion providing sufficient rigidity to the article during one or more of manufacturing, packaging and use of the article. It would be desirable to provide an article offering an improved user experience. It would be desirable to provide an article offering improved alignment of the capsule in the article.

[0011] It would be desirable to provide an inhaler article containing a support member to provide rigidity and stability. It would be desirable to provide an inhaler article containing a support member to provide rigidity and stability in the longitudinal direction. It would be desirable to provide an inhaler article containing a support member to provide rigidity and stability in radial direction. It would be desirable to provide an inhaler article containing a support member to hold the capsule inside the cavity of the inhaler article. It would be desirable to provide an inhaler article containing a support member to prevent the capsule from escaping from the inhaler article.

[0012] In a manufacturing environment, it can be difficult to predictably and reliably set a part within another part. It would be desirable to provide an inhaler article structured to predictably and reliably assemble a front plug containing a support member with a mouth plug so that the placement of the support member is predictable and reliable. It would be desirable to provide an inhaler article structured to predictably and reliably assemble a front plug containing a support member with a mouth plug so that additional parts and manufacturing steps are not needed. For example, it would be desirable to assemble the parts without requiring adhesive. It would be desirable to assemble the parts without pins or fasteners. Or, it would be desirable to assemble parts using adhesive where the structure of the inhaler article allows for placement of the adhesive in a location that is accessible during manufacture.

[0013] It would be desirable to provide an inhaler article containing a support member that is placed inside the inhaler article in a way that makes the manufacture of the inhaler article containing a support member easier and more predictable. Providing an inhaler article structured so that it is easier and more predictable to assemble the parts together and place the support member inside the cavity of the inhaler article would make manufacturing more efficient. In addition, providing an inhaler article structure so that it is easier and more predictable to assemble results in an inhaler article that is more rigid and more stable.

[0014] It would be desirable to provide an inhaler article to prevent dry powder from escaping from the inhaler article before, during or after use. It would be desirable to design an inhaler article that is cheaper and easier and more efficient to assemble. It would be desirable to provide an inhaler article that is cheaper and easier to manufacture. It would be desirable to provide an inhaler article having an airflow path that maximizes the emptying of the contents of a dry powder containing capsule.

[0015] According to an aspect of the disclosure, an inhaler is disclosed comprising: a front plug comprising a front plug tube body comprising an upstream end and a downstream end, an external front plug surface and an internal front plug surface, the internal front plug surface defining a front plug cavity, the front plug having an internal diameter, a support member contained in the cavity of the front plug; a mouth plug comprising a mouth plug tube body comprising an upstream end and a downstream end, an external mouth plug surface and an internal mouth plug surface, the internal mouth plug surface defining a mouth plug cavity, the mouth plug having an internal diameter; wherein the internal diameter of the front plug is greater than the internal diameter of the mouth plug; wherein the inhaler article comprises the front plug containing the support member forming an upstream portion of the inhaler article and the mouth plug forming a downstream portion of the inhaler article; and wherein the lesser inner diameter of the mouth plug forms a shoulder stop to retain the support member in the inhaler article during use.

[0016] According to an aspect of the disclosure, there is provided an inhaler article constructed from at least a front plug and a mouth plug. According to an aspect of the disclosure, the front plug comprises a front plug tube body comprising an upstream end and a downstream end, an external front plug surface and an internal front plug surface, the internal front plug surface defining a front plug cavity, the front plug the front plug cavity having a diameter. According to an aspect of the disclosure, the front plug contains a support member. The mouth plug comprises a mouth plug tube body comprising an upstream end and a downstream end, an external mouth plug surface and an internal mouth plug surface, the internal mouth plug surface defining a mouth plug cavity, the mouth plug cavity having a diameter. According to an aspect of the disclosure, the diameter of the front plug cavity is greater than the diameter of the mouth plug cavity. According to an aspect of the disclosure, the front plug containing the support member forms an upstream portion of the inhaler article and the mouth plug forms a downstream portion of the inhaler article. According to an aspect of the disclosure, the lesser diameter of the mouth plug cavity forms a shoulder stop to retain the support member in the inhaler article during use.

[0017] According to an aspect of the disclosure, as described above or as described elsewhere in this disclosure, an advantage of the disclosure is to provide an inhaler article having improved stability. Assembling the inhaler article from two sections, an upstream portion comprising the front plug which contains the support member, and a downstream front plug portion provides a more stable inhaler article compared to an inhaler article assembled from more than two portions. For example, the front plug containing the support member and the mouth plug may abutted against each other and may be wrapped by a wrapping paper to assemble the front plug and the mouth plug together. An inhaler article having two portions has fewer abutments than an inhaler article assembled from three portions, which may be, for example a front portion, a separate support member and a mouth portion. An inhaler article assembled from three portions has two abutments compared to an inhaler article assembled from two portions which has one abutment. The abutment may provide a weak area more prone to bending or crushing. Fewer abutments means fewer joints or fewer weak areas. Advantageously, having two plugs instead of three or more plugs makes manufacturing less complicated. Assembling together two parts and wrapping them with a wrapping paper is less complicated than assembling together three or more parts and wrapping them with a wrapping paper. Less complicated manufacture is generally faster, less expensive and requires less expensive equipment. Less expensive, faster manufacturing is desirable. Advantageously, the presence of a shoulder stop provided by the diameter of the mouth plug cavity being less than the diameter of the front plug cavity blocks the support member from moving downstream in response to longitudinal pressure. Because the support member is blocked from moving, the capsule is blocked from moving in a downstream direction in response to longitudinal pressure. Advantageously, the structure of the inhaler article according to an aspect of the disclosure provides an inhaler article that is more rigid, more structurally sound, and more resistant to longitudinal pressure.

[0018] According to an aspect of the disclosure, the external diameter of the front plug and the external diameter of the mouth plug are essentially equal. Advantageously, when the external diameter of the front plug and the external diameter of the mouth plug are essentially equal, when the two parts are assembled together and wrapped by a wrapping paper, an inhaler article having a uniform cylindrical shape and a uniform diameter is formed. Such a structure is advantageous because an inhaler article having a smooth, uniform shape is stronger and is less likely to bend at the joint or abutment between the front plug and the mouth plug. Advantageously, such a smooth, uniform shape is more likely to retain its shape in the face of longitudinal and radial pressures.

[0019] According to an aspect of the disclosure, the inhaler article is constructed from two parts, a front plug and a mouth plug. The front plug forms the upstream portion of the inhaler article. The mouth plug forms the downstream portion, the mouth-end, of the inhaler article. The front plug and the mouth plug are assembled together by a wrapping paper. The external diameter of the front plug and the mouth plug are essentially equal so that when the front plug is abutted against the mouth plug and the two parts, the front plug and the mouth plug, are abutted together and wrapped with a wrapping paper, an inhaler article having a uniform external diameter results. The internal diameter of the front plug is smaller than the internal diameter of the mouth plug. This difference of internal diameter of the two parts forms an annular shoulder stop where the two parts abut each other. That is, looking from the upstream end to the downstream end of the tube formed from the assembled front plug and mouth plug, the diameter of the downstream end of the tube is narrower than the diameter of the upstream end. This shoulder stop provides additional stability to the inhaler article.

[0020] A support member may be placed in the front plug cavity. The support member may be in the front plug at or near the downstream end of the front plug cavity. When the front plug, containing a support member at or near the downstream end of the front plug cavity, is assembled with the mouth plug, the front plug forms the upstream portion of the inhaler article and the mouth plug forms the downstream portion of the inhaler article. When the front plug containing the support member and the mouth plug are assembled together by a wrapping paper, the support member abuts the shoulder stop. The shoulder stop holds the support member in place.

[0021] The external diameter of the front plug and the mouth plug are essentially equal so that when the front plug is abutted against the mouth plug and the two parts, the front plug and the mouth plug, are abutted together and wrapped with a wrapping paper, an inhaler article having a uniform external diameter results. The internal diameter of the front plug is smaller than the internal diameter of the mouth plug. This difference of internal diameter of the two parts forms an annular shoulder stop where the two parts abut each other. That is, looking from the upstream end to the downstream end of the tube formed from the assembled front plug and mouth plug, the diameter of the downstream end of the tube is narrower than the diameter of the upstream end. This shoulder stop provides stability and rigidity to the inhaler article. Additionally and advantageously, the shoulder stop enables assembly of the inhaler article without the use of adhesive or fasteners. The shoulder stop enables more efficient assembly and manufacture of the inhaler article.

[0022] According to an aspect of the disclosure, adhesive may be used to seat the support member. Adhesive may be placed on the upstream end of the mouth plug. When the downstream end of the support member is pressed against the upstream end of the mouth plug containing adhesive, the support member may be adhered to the mouth plug. Or, alternatively, adhesive may be place on the internal front plug surface at the location of the support member. Examples of acceptable adhesives include PVA, gum Arabic, Pll, epoxy, cyanoacrylate and polychloroprene, while other adhesives may be used. Advantageously, with the use of adhesive, the inhaler article may be more stable and rigid.

[0023] The front plug has an upstream end and a downstream end. The support member has an upstream end and a downstream end. The mouth plug has an upstream end and a downstream end. When assembled, the downstream end of the front plug abuts the upstream end of the mouth plug. The support member is contained in the front plug. The upstream end of the support member may be in the front plug cavity. The support member may be at or near the downstream end of the front plug. The downstream end of the support member may abut the shoulder stop. Because the downstream end of the support member abuts the shoulder stop, the support member is blocked from moving in a downstream direction during use of the inhaler device. The presence of the shoulder stop lodges the support member in place in the interior of the inhaler article. The presence of the shoulder stop provides the advantage of ensuring that the support member is seated inside the inhaler article and does not move in response to longitudinal pressure such as, for example, pressure exerted against the support member by the capsule when the capsule is pierced. When the support member is placed at or near the downstream end of the front plug cavity, and the front plug is abutted against the mouth plug, the support member abuts the shoulder stop. Advantageously, the placement of the support member against, or abutting, the shoulder stop results in a more rigid and sturdy inhaler article. Advantageously, the presence of the shoulder stop allows for a manufacturing process that can accurately and reliably place the retention plug in the correct position.

[0024] According to an aspect of the disclosure, the support member is contained in the cavity of the front plug at or near the downstream end of the front plug cavity. Including the support member in the cavity of the front plug at or near the downstream end of the front plug cavity places the support member at or near the abutment between the front plug and the mouth plug. Including the support member in the cavity of the front plug at the downstream end of the front plug enables the support member to abut the shoulder stop. The presence of the support member reinforces that abutment at the region where the front plug abuts the mouth plug. Advantageously, the support member provides additional structural support in the region of the abutment between the front plug and the mouth plug. This additional structural support improves the rigidity and stability of the inhaler article at the region of the abutment between the front plug and the mouth plug, if the interface between the front plug and mouth plug were to become fragile or fail, it might allow relatively easily access to the nicotine-containing capsule which could potentially be ingested.

[0025] According to an aspect of the disclosure, the inhaler article further comprises a capsule containing dry powder. According to an aspect of the disclosure, the capsule is contained in the front plug cavity. According to an aspect of the disclosure, the capsule is contained in the front plug cavity upstream of the support member. Advantageously, placement of the capsule upstream of the support member allows for access to the capsule by a piercing element introduced into the inhaler article through the upstream end of the inhaler article. Alternatively, a piercing element may be introduced to the inhaler article to pierce the capsule from the side or from any other location. The front plug and the mouth plug are hollow tube-shaped elements. The front plug and the mouth plug are assembled along a longitudinal axis. To assemble the front plug, the support member and the mouth plug together along the longitudinal axis, a wrapping paper is wrapped around the front plug, the support member and the mouth plug, at least partially, to form a single tube-shaped article. According to an aspect of the invention, the mouth plug is made from a thicker material than the front plug. When the mouth plug is assembled against the front plug, a shoulder stop is formed where the front plug meets the mouth plug because the material of the mouth plug is thicker than the material of the front plug. In embodiments, the mouth plug and the front plug are made from the same material. In embodiments, the mouth plug is made from more layers of the material that forms the front plug. Advantageously, forming the mouth plug from a thicker material than the front plug provides the shoulder stop without requiring additional parts which makes manufacture more efficient.

[0026] According to an aspect of the disclosure, the presence of the shoulder stop holds the support member in place. The shoulder stop is provided by the mouth plug having an internal diameter that is less than the internal diameter of the front plug. For example, when a capsule is contained in the cavity of the front plug, and the capsule is pierced by inserting a needle into the capsule from the upstream end of the inhaler article, the pressure exerted against the upstream end of the capsule is translated to the support member. This pressure is in the longitudinal direction. When the piercing element pushes into the capsule, the capsule pushes against the support member. The support member is stopped from moving in a downstream direction inside the inhaler article because of the shoulder stop. The presence of the shoulder stop provides an inhaler article having increased rigidity and stability in the longitudinal direction as the inhaler article is activated. The presence of the shoulder stop provides an inhaler article having increased rigidity and stability in the longitudinal direction when the capsule is pierced. The article is activated when the capsule is pierced.

[0027] When the capsule is pierced and air passes the pierced capsule, the capsule is agitated. This agitation releases dry powder from the capsule. In embodiments, the dry powder comprises an active compound. Dry means that the powder is capable of being released from the capsule and entrained into airflow. In embodiments the dry powder may comprise a pharmaceutically active compound. In embodiments, the dry powder comprises nicotine. In embodiments, the active compound comprises nicotine. In embodiments, the dry powder comprises flavorants. In embodiments, the dry powder has a range of particle sizes of from 50 to 200 microns in average diameter. In embodiments the dry powder has a range of particle sizes of from 100 to 150 microns in average diameter.

[0028] The support member may be disk-shaped or tube-shaped. The support member may be cylindrical. The support member fits inside the front plug. The support member may have internal structure. The internal structure of the support member may provide structure to prevent the capsule from being pushed into the mouth plug when the capsule is pierced. The internal structure of the support member may also provide support member airways to allow air, including air mixed with dry particles released from a capsule, to flow through the support member toward the mouth end of the inhaler article. The support member internal structure may be in the form of a honeycomb. Advantageously, a support member having a honeycomb structure provides structure to block the capsule from moving downstream and also provides support member airways to allow air to flow through the support member. The support member internal structure may be triangular. Advantageously, a triangular internal structure provides a support member that is easy to assembly while still providing structure to block the capsule from moving downstream and providing support member airways to allow air to flow through the support member. The support member internal structure may be omega-shaped. Advantageously, an omega-shaped internal structure provides a support member that is easy to assembly while still providing structure to block the capsule from moving downstream and providing support member airways to allow air to flow through the support member. The support member internal structure may comprise an array of a plurality of inner hollow tubular elements. The inner hollow tubular elements may be parallelly arranged where a plane extending orthogonal to a longitudinal axis of the support member intersects each inner hollow tubular element. Advantageously, an array of tubular elements may be easy to assembly while still providing structure to block the capsule from moving downstream and providing support member airways to allow air to flow through the support member. The support member internal structure may be spoked. Advantageously, an spoked internal structure provides a support member that provides structure to block the capsule from moving downstream and providing support member airways to allow air to flow through the support member. The support member internal structure may be a damper. A damper is a structure that extends across the center of the support member. Where a damper is present, the support member airways are not in the center of the support member. Advantageously, an internal structure having a damper provides a support member that provides structure to block the capsule from moving downstream and also provides support member airways to allow air to flow through the support member. In addition, an internal support member structure that does not have a support member airway in the center may improve the agitation of the capsule after the capsule is pierced. When the capsule is pierced, it is pressed against the support member. When there is an opening in the center of the support member, the capsule, pressed against the support member, may not move as well as air flows past the capsule. That is, structure in the center of the support member may restrict the movement of the capsule during use, reducing the efficiency of the release of dry powder from the capsule. Advantageously, providing a support member having a damper, a flat structure in the center of the support member where the capsule contacts the support member may improve release of dry powder from the capsule during use. This damper may also be provided where an array of tubular elements is provided and the tubular element in the center of the support member is closed at the upstream end of the support member. In addition, the damper structure may block larger or unwanted dry particles from proceeding to the air outlet of the inhaler article while allowing smaller or more preferred particles to reach the user.

[0029] The support member, including the internal structure of the support member, may be made from biodegradable materials. The wrapping paper may be biodegradable. The front plug and the mouth plug may be made from biodegradable materials. The front plug, the mouth plug and the support member, including the internal structure of the support member, may be the same material. For example, the mouth plug may be made from more layers of material compared the number of layers of material used to produce the front plug, thus providing a mouth plug made from thicker material than the front plug. In providing an inhaler article made from multiple parts made from the same material, manufacture of the inhaler article is simplified. Reducing the number of materials may reduce the number of manufacturing steps to produce the inhaler article.

[0030] The wrapping paper material may be, for example, paper having a weight from 20 gsm to 200 gsm. The wrapping paper may have a weight of from 25 to 100 gsm. The wrapping paper may have a weight of from 30 to 100 gsm. The wrapping paper may have a weight of from 40 to 100 gsm. The wrapping paper may have a weight of from 50 to 100 gsm. The wrapping paper may have a weight of from 25 to 150 gsm. The wrapping paper may have a weight of from 30 to 150 gsm. The wrapping paper may have a weight of from 50 to 150 gsm.

[0031] The front plug material may be cardboard having a weight from 40 gsm to 600 gsm. The front plug may be cardboard having a weight from 50 gsm to 600 gsm. The front plug may be cardboard having a weight from 60 gsm to 600 gsm. The front plug may be cardboard having a weight from 40 gsm to 500 gsm. The front plug may be cardboard having a weight from 50 gsm to 600 gsm. The front plug may be cardboard having a weight from 60 gsm to 600 gsm. The front plug may be cardboard having a weight from 40 gsm to 400 gsm. The front plug may be cardboard having a weight from 50 gsm to 400 gsm. The front plug may be cardboard having a weight from 60 gsm to 600 gsm.

[0032] The mouth plug material may be, for example, cardboard having a weight from 40 gsm to 600 gsm. The front plug may be cardboard having a weight from 50 gsm to 600 gsm. The front plug may be cardboard having a weight from 60 gsm to 600 gsm. The front plug may be cardboard having a weight from 40 gsm to 500 gsm. The front plug may be cardboard having a weight from 50 gsm to 600 gsm. The front plug may be cardboard having a weight from 60 gsm to 600 gsm. The front plug may be cardboard having a weight from 40 gsm to 400 gsm. The front plug may be cardboard having a weight from 50 gsm to 400 gsm. The front plug may be cardboard having a weight from 60 gsm to 600 gsm. The mouth plug material may be two layers of material as described.

[0033] The support member material may be, for example, bioplastic or cardboard having a weight from 200 gsm to 700 gsm. The support member material may be, for example, bioplastic or cardboard having a weight from 250 gsm to 700 gsm. The support member material may be, for example, bioplastic or cardboard having a weight from 300 gsm to 700 gsm. The support member material may be, for example, bioplastic or cardboard having a weight from 400 gsm to 700 gsm.

[0034] The support member internal structure may have support member airways. The support member may have at least two support member airways. The support member airways may comprise screen material. Advantageously, the presence of screen material in the support member airways may prevent unwanted large dry powder particles from passing through the support member. The presence of screen material may prevent unwanted large dry powder particles from being inhaled by a user.

[0035] According to an aspect of the disclosure, the upstream end of the front plug inhaler article is flanged. This flange is a folded end. The flange is formed by bending the upstream end of the front plug of the inhaler article. This flanged end contains the capsule contained inside the front plug of the inhaler article. According to an aspect of the disclosure, the downstream end or mouth end of the mouth plug of the inhaler article is curved. The curved mouth-end provides an airflow exit so that the user can inhale dry powder released in the inhaler article while also controlling the pressure drop through the inhaler article and also preventing dry powder from leaking from the airflow exit.

[0036] According to an aspect of the disclosure, in use, air flows through the inhaler article via an airflow path. The airflow path through an inhaler article begins at an airflow inlet, travels through the inhaler article, past the capsule, through the support member, through the mouth plug and exits the inhaler article at a mouth end or downstream end where the air traveling in the airflow path is inhaled by a user. Air flows through the support member through the support member airways.

[0037] According to an aspect of the disclosure, activation of the inhaler article may occur by occur with a separate piercing element. The piercing element may be a needle, for example. The user may introduce a needle into the upstream end of the capsule to release dry powder prior to using the inhaler article. According to an aspect of the disclosure, the piercing element may be a component of a holder. The inhaler article may be inserted into a cavity of the holder, the piercing element may extend into the inhaler article to pierce the capsule, and the piercing element may withdraw from the inhaler article. The holder may have an air inlet aligned with the air inlet of the inhaler article. According to an aspect of the disclosure, the holder may have an airflow management system which provides spiral or angled airflow into the cavity of the inhaler article. This spiral or angled airflow may assist in moving the capsule inside the cavity of the inhaler article. The movement of the capsule in this spiral or angled airflow allows the dry powder contained in the capsule to shake loose. Advantageously, the presence of a spiral or angled airflow improves the emptying of dry powder from a capsule in an inhaler article.

[0038] For the purpose of the present disclosure, a longitudinal axis of a component may extend between the upstream end of the component and the downstream end of the component. A longitudinal axis of a component may extend between the distal end of the component and the proximal end of the component.

[0039] For the purpose of the present disclosure including the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term "about". Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A ± {10 %} of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.

[0040] All scientific and technical terms used herein have meanings commonly used in the art unless otherwise specified. The definitions provided herein are to facilitate understanding of certain terms used frequently herein.

[0041] As used herein, the singular forms “a”, “an”, and “the” encompass embodiments having plural referents, unless the content clearly dictates otherwise.

[0042] As used herein, “or” is generally employed in its sense including “and / or” unless the content clearly dictates otherwise. The term “and / or” means one or all of the listed elements or a combination of any two or more of the listed elements.

[0043] As used herein, “have”, “having”, “include”, “including”, “comprise”, “comprising” or the like are used in their open-ended sense, and generally mean “including, but not limited to”. It will be understood that “consisting essentially of”, “consisting of”, and the like are subsumed in “comprising,” and the like.

[0044] The words “preferred” and “preferably” refer to embodiments of the invention that may afford certain benefits, under certain circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful and is not intended to exclude other embodiments from the scope of the disclosure, including the claims. As used herein “plug” means an element of an inhaler article as described.

[0045] Any advantage described herein may result from or relate to any feature described herein. The invention is defined in the claims. However, below there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0046] Example Ex1 : An inhaler article comprising: a front plug comprising a front plug tube body comprising an upstream end and a downstream end, an external front plug surface and an internal front plug surface, the internal front plug surface defining a front plug cavity, the front plug having an internal diameter, a support member contained in the cavity of the front plug; a mouth plug comprising a mouth plug tube body comprising an upstream end and a downstream end, an external mouth plug surface and an internal mouth plug surface, the internal mouth plug surface defining a mouth plug cavity, the mouth plug having an internal diameter; wherein the internal diameter of the front plug is greater than the internal diameter of the mouth plug; wherein the inhaler article comprises the front plug containing the support member forming an upstream portion of the inhaler article and the mouth plug forming a downstream portion of the inhaler article; and wherein the lesser inner diameter of the mouth plug forms a shoulder stop to retain the support member in the inhaler article during use.

[0047] Example Ex2: An inhaler article according to Example 1 wherein the front plug comprises an external diameter and wherein the mouth plug comprises an external diameter, and wherein the front plug external diameter and the mouth plug external diameter are essentially equal.

[0048] Example Ex3: An inhaler article according to Examples 1 or 2, wherein the support member is contained in the cavity of the front plug at or near the downstream end of the front plug cavity.

[0049] Example Ex4: An inhaler article according to any one of the preceding Examples, wherein the support member has an upstream end and a downstream end and wherein the downstream end of the support member abuts the shoulder stop.

[0050] Example Ex5: An inhaler article according to any one of the preceding Examples, further comprising a capsule containing dry powder contained in the front plug cavity.

[0051] Example Ex6: An inhaler article according to Example 5 wherein the capsule is contained in the front plug cavity upstream of the support member.

[0052] Example Ex: An inhaler article according to Example 5 or 6 wherein the capsule comprises hydroxypropyl methylcellulose (HPMC).

[0053] Example Ex8: An inhaler article according to any one of Example 5 - 7 wherein the capsule contains nicotine powder.

[0054] Example Ex9: An inhaler article according to any one of the preceding Examples, wherein the front plug comprises front plug material, the front plug material having a thickness, wherein the mouth plug comprises mouth plug material, the mouth plug material having a thickness, and wherein the thickness of the front plug material is less than the thickness of the mouth plug material.

[0055] Example Ex10: An inhaler article according to any one of the preceding Examples, wherein the front plug material and the mouth plug material comprise cardboard.

[0056] Example Ex11: An inhaler article according to any one of the preceding Examples, further comprising a wrapping paper wrapped around the front plug and the mouth plug to form the inhaler article.

[0057] Example Ex1: An inhaler article according to any one of the preceding Examples, wherein the wrapping paper comprises paper from 20 gsm to 200 gsm. Example Ex13: An inhaler article according to any one of the preceding Examples, wherein the support member comprises internal support member structure.

[0058] Example Ex14: An inhaler article according to Example 13 wherein the internal support member structure comprises honeycomb structure, spoke structure, triangular structure, omega structure, a plurality of inner hollow tubular element, or a damper.

[0059] Example Ex15: An inhaler article according to Example 14 wherein the support member comprises at least 2 support member airways.

[0060] Example Ex16: An inhaler article according to Example 15, wherein at least one of the at least 2 support member airways comprise filter material.

[0061] Example Ex17: An inhaler article according to Example 16 wherein the filter material is mesh screen material.

[0062] Example Ex18: An inhaler article according any one of the preceding Example, wherein the upstream end of the front plug comprises a flanged end.

[0063] Example Ex19: An inhaler article according to any one of the preceding Examples, wherein the upstream end of the front plug comprises a folded closure comprising an airflow inlet.

[0064] Example Ex20: An inhaler article according to any one of the preceding Examples, wherein the downstream end of the mouth plug comprises a curved end.

[0065] Example Ex21 : An inhaler article according to any one of the preceding Examples, wherein the support member is affixed to the internal front plug surface by an adhesive.

[0066] Example Ex22: An inhaler article according to any one of the preceding Example, wherein the support member is affixed to the shoulder stop by an adhesive.

[0067] Examples will now be further described with reference to the figures in which:

[0068] Figure 1A shows a perspective view of an inhaler article according to the present disclosure. Figure 1 B shows a side perspective view of an inhaler article according to the present disclosure. Figure 1C shows a view of an embodiment of the upstream end of an inhaler article according to the present disclosure. Figure 1D shows a view of an embodiment of the downstream end of an inhaler article according to the present disclosure.

[0069] Figure 2 is an exploded view of the front plug, support member and mouth plug elements of the inhaler article of the present disclosure. Figure 3 is a transparent view of an assembled inhaler article according to the present disclosure.

[0070] Figure 4 is a cross-sectional view of an embodiment of the inhaler article according to the present disclosure.

[0071] Figure 5 is cross-sectional illustration of an embodiment of the inhaler article according to the present disclosure.

[0072] Figure 6A, Figure 6B, Figure 6C, Figure 6D, Figure 6E, Figure 6F and Figure 6G are illustrations of the embodiments of internal structure of a support member according to the present disclosure.

[0073] Figure 7 is an illustration of a holder with an inhaler article inserted into the holder according to the present disclosure.

[0074] Figure 8 is an illustration of an embodiment of a spiral air inlet according to the present disclosure.

[0075] Figure 1A shows a perspective view of an inhaler article 10 according to the present disclosure. As shown in Figure 1A, the assembled inhaler article 10 has a front plug 20, a mouth plug 30 wrapped with a wrapper 70. The front plug 20 has an upstream end 21 and a downstream end 22 (not shown in Figure 1A, but see Figure 2). The mouth plug 30 has an upstream end 31 (not shown in Figure 1, but see Figure 2) and a downstream end 32. Figure 1B shows a side perspective view of an inhaler article 10 according to the present disclosure. Figure 1 B illustrates the upstream end 21 , a front plug 20, a mouth plug 30, a wrapper 70, a downstream end 32 where the downstream end 32 is a curved downstream end 37. Figure 1C illustrates the upstream end 21 of the inhaler article 10 having an air inlet 28. In embodiments, the upstream end 21 of the inhaler article 10 has a flanged edge 27. The upstream end 21 of the inhaler article 10 may have an air inlet 28. Figure 1 D shows a view of an embodiment of the downstream end 32 of an inhaler article 22 having an air outlet 38 and a curved end 37.

[0076] Figure 2 is an exploded view of the inhaler article 10 showing a front plug 20, support member 50 and mouth plug 30 elements of the inhaler article 10 of the present disclosure. Figure 2 shows the front plug 20 having an upstream end 21 and a downstream end 22. The front plug 20 has an internal surface 23. The internal surface 23 of the front plug 20 defines a front plug cavity 24. The front plug 20 is made from front plug material 25 having a front plug material thickness 26. Figure 2 shows the support member 50. The support member 50 has an upstream end 51 and a support member downstream end 52. The mouth plug 30 has an upstream end 31 and a downstream end 32. The mouth plug has an internal surface 33 which defines a mouth plug cavity 34. The mouth plug 30 is made from mouth plug material 35 which has a mouth plug material thickness 36. The mouth plug material thickness 36 is greater than the front plug material thickness 26. When assembled, the support member 50 is placed inside the front plug 20 as shown by arrow 39. The downstream end 22 of the front plug 20 containing the support member 50 is abutted against upstream end 31 of the mouth plug 30. Because the thickness 36 of the material 35 of the mouth plug 30 is thicker than the thickness 26 of the material 25 of the front plug 20, when the mouth plug 30 abuts against the front plug 20, a shoulder stop 80 is formed. Or, in embodiments, the material 35 of the mouth plug may be the same thickness as the material 25 of the front plug, but multiple layers of material may be used to construct the mouth plug, so that the thickness of the mouth plug 36 is greater than the thickness of the front plug 26. This shoulder stop 80 prevents the support member 50 from moving into the mouth plug 30. Adhesive 57 may be used to affix the mouth plug 30 to the front plug 20, or adhesive 57 may be used to affix the support member 50 to the front plug 20. For example, adhesive 57 may be placed inside the front plug 20 (not shown) or on the shoulder stop 80 (shown in Fig. 2). When adhesive 57 is placed inside the front plug 20, the support member 50 may be affixed to the inside surface 23 of the front plug 20 when the support member 50 is inserted into the front plug 20. Or, adhesive 57 may be placed on the shoulder stop 80 so that when the front plug 20 abuts the mouth plug 30 when the inhaler article is assembled, the front plug 20 is affixed to the mouth plug 30. When the front plug 20 containing the support member 50 is abutted against the mouth plug 30, a wrapper 70 is wrapped around the front plug 20 and the mouth plug 30 to hold the front plug 20 and the mouth plug together to form the inhaler article 10.

[0077] Figure 3 is a transparent view of an assembled inhaler article according to the present disclosure. Figure 3 illustrates a front plug 20 containing a capsule 300 and a support member 50 abutted against a mouth plug 30 and wrapped by a wrapper 70. As shown in Figure 3, when the inhaler article 10 is assembled, the downstream end 52 of the support member 50 abuts the upstream end 31 of the mouth plug 30. The upstream end 31 of the mouth plug 30 is the shoulder stop 80. When assembled, the downstream end 52 of the support member 50 abuts the upstream end 31 of the mouth plug 30.

[0078] Figure 4 is a cross-sectional view of an embodiment of the inhaler article according to the present disclosure. Figure 4 illustrates the mouth plug 30 curved end 37 and the front plug flanged end 27. Air travels through the inhaler article from the air inlet 303, past the capsule 300 to the air outlet 304 via the airflow path 100 as shown by the arrows 100 of figure 4. When the capsule 300 is pierced, dry powder 301 released from the capsule 300 flows through the support element 50, through the mouth plug 30 and exits the inhaler article through the air outlet 304. Figure 4 also illustrates a dead end 451 which is formed by the internal curve of the curved downstream end 37 of the mouth plug 30. As dry powder 301 flows in the airflow path 100, it may become trapped in the dead end 451 . For example, if dry particles are large, gravity may cause the dry powder particles 301 to fall into the dead end 451 as air flows in the airflow path 100. Or, if dry powder 301 s released from the capsule 300 and the airflow ceases, dry powder 301 may fall into the dead end 451 . Advantageously, dry powder 301 may be captured in the dead end 451 instead of leaking out of the air outlet 304.

[0079] Figure 5 is a cross-sectional illustration of an embodiment of the inhaler article according to the present disclosure. The parameters shown in Figure 5 are defined below in Table 1. Figure 5 shows ranges of diameters and lengths of elements of the inhaler article. L1 is the length of the inhaler article 10 from the upstream end 21 to the downstream end 31. L2 is the length of the front plug 20. L3 is the length of the capsule 300. L4 is the length of the support member 50. L5 is the length of the mouth plug 30. L6 is the length of the wrapper 70. D1 is the diameter of the air inlet 28 or 303. D2 is the internal diameter of the front plug 20. D3 is the exterior diameter of the front plug 20. D4 is the diameter of the capsule. D5 is the external diameter of the support member 50. D6 is the internal diameter of the support member 50. D7 is the internal diameter of the mouth plug 30. D8 is the external diameter of the mouth plug. D9 is the diameter of the air outlet 38.

[0080] As described above, the internal diameter of the mouth plug 30 D7 is less than D5, the external diameter of the support member 50. The internal diameter D7 of the mouth plug 30 is less than D2, the internal diameter of the front plug 20. When the front plug 20 abuts against the mouth plug, the internal diameter D7 of the mouth plug 30 is less than the internal diameter D2 of the front plug 20. This reduction in the internal diameter forms the shoulder stop 80 which blocks the support member 50 from moving in the downstream direction. The support member 50 does not move in the downstream direction even when pressure is applied to the capsule 300 from the upstream direction, pressing the capsule 300 against the upstream end 51 of the support member 50. The internal diameter of the support member 50 D6 is less than the diameter of the capsule D4. This prevents the capsule from moving downstream past the support member 50.

[0081] Table 1

[0082] Parameter Range (mm) Preferable Most Preferable

[0083] L1 30 to 80 35 to 60 40 to 50

[0084] L2 15 to 40 18 to 35 20 to 30

[0085] L3 10 to 20 12 to 18 14 to 17

[0086] L4 3 to 10 5 to 9 6 to 8

[0087] L5 10 to 20 11 to 18 12 to 15 L6 15 to 45 25 to 44 35 to 42

[0088] L7 0 to 4 O to 3 O to 2

[0089] D1 0 to 5 O to 1 0

[0090] D2 4 to 12 5 to 10 6.5 to 7.5

[0091] D3 4 to 12 5 to 10 6.5 to 7.5

[0092] D4 3 to 10 4 to 8 5 to 7

[0093] D5 D1-1 D1-0.2 D1-0.025

[0094] D6 1 to 11 2 to 10 4 to 6

[0095] D7 D7 < D5 > D6 D6 + 1

[0096] D8 4 to 12 5 to 10 6.5 to 7.5

[0097] D9 0.5 to 6 1 to 5 1.5 to 3

[0098] Figure 6A, Figure 6B, Figure 6C, Figure 6D, Figure 6E, Figure 6F and Figure 6G are illustrations of the embodiments of internal structure of a support member 50 according to the present disclosure. Figure 6A illustrates a honeycomb structure 61. Figure 6A also illustrates, in cross-section, D6, the internal diameter of an embodiment of the support member 50 and D5, the external diameter of an embodiment of the support member 50. Support member airways 69 are also shown. Figure 6B illustrates a support member 50 having a spoke structure 62. Support member airways 69 are also shown. Figure 6C illustrates a support member 50 having a triangular structure 63. Support member airways 69 are also shown. Figure 6D illustrates a support member having an array of tubes structure 64. Support member airways 69 are also shown. Figure 6E illustrates a support member having a central aperture structure 65. Support member airways 69 are also shown. Figure 6F illustrates a support member 50 having an omega structure 66. Support member airways 69 are also shown. Figure 6G illustrates a support member 50 having a closed central area 690. The closed central area 690 is structure that prevents air from flowing through the center of the support member 50. The closed central area 690 may provide a flat area that reduces friction between the capsule 300 and the support member 50 to improve agitation of the capsule and improve release of dry powder 301 from the capsule 300 during use. Support member airways 69 are also shown. In each example, the support member has at least one support member airway 69. In embodiments, the support member airways 69 may have filter material 68. This filter material may prevent larger particles from entering the mouth of the user.

[0099] Figure 7 is an illustration of a holder 1200 with an inhaler article 10 according to the present disclosure inserted into the holder 1200. In use, the capsule 300 inside the inhaler article 10 is pierced. The capsule 300 may be pierced with a needle 101 introduced into the upstream end 21 of the inhaler article 10 by the user. Or, as shown in Figure 7, the inhaler article 10 may be inserted into a holder 1200 that has a piercing mechanism 109. This piercing mechanism 109 may include a needle 101 , that can be pushed into the capsule by a lever 127 activated by the user. The needle 101 may automatically retract from the capsule by a spring 102. The holder may have a case 111 that defines a cavity 112 into which the inhaler article 10 is inserted. The support member 50 is shown. The holder 1200 may also have a spiral air inlet 200 which introduces air into the front plug cavity 24 which contains the capsule 300. Air introduced into the front plug cavity 24, especially air that moves in a spiral fashion, causes the capsule 300 contained therein to be agitated. This agitation releases dry powder from the pierced capsule 300. LA is the longitudinal axis of the inhaler article 10.

[0100] Figure 8 is an illustration of an embodiment of a spiral air inlet 200 according to the present disclosure. The spiral air inlet 200 brings air into the holder 1200, spins the air in a spiral as shown by the arrow of Figure 8, and introduces this spirally flowing air into the front plug cavity 24 to agitate the capsule 300 and release dry powder 301 . The wrapper 70 is also shown.

Claims

1. An inhalation product for delivering dry powder to a user, comprising a front plug comprising a tubular body of the front plug comprising an upstream end and a downstream end, an outer surface of the front plug and an inner surface of the front plug, wherein the inner surface of the front plug forms a cavity of the front plug, wherein the front plug has an inner diameter, a support element contained in the cavity of the front plug; a mouthpiece plug comprising a tubular body of the mouthpiece plug comprising an upstream end and a downstream end, an outer surface of the mouthpiece plug and an inner surface of the mouthpiece plug, wherein the inner surface of the mouthpiece plug defines a cavity of the mouthpiece plug, wherein the mouthpiece plug has an inner diameter; and a capsule containing dry powder located in the cavity of the front plug upstream of the support element; in this case, the internal diameter of the front plug is larger than the internal diameter of the mouthpiece plug; wherein the inhalation product comprises said front plug containing a support element forming an upstream portion of the inhalation product and said mouthpiece plug forming a downstream portion of the inhalation product; and the smaller internal diameter of the mouthpiece plug forms a stopper to retain the support element in the inhalation product during use.

2. An inhalation product according to claim 1, characterized in that the support element has an end located upstream of the flow and an end located downstream of the flow, and the end of the support element located downstream of the flow is adjacent to the stop stop.

3. An inhalation product according to claim 1, characterized in that the capsule contains nicotine powder.

4. An inhalation product according to any of the preceding paragraphs, characterized in that the front plug comprises a front plug material that has a thickness, while the mouthpiece plug comprises a mouthpiece plug material that has a thickness, and while the thickness of the front plug material is less than the thickness of the mouthpiece plug material.

5. An inhalation product according to any of the preceding paragraphs, characterized in that the front plug and the mouthpiece plug contain cardboard.

6. An inhalation product according to any of the preceding claims, further comprising wrapping paper wrapped around the front plug and the mouthpiece plug to form the inhalation product.

7. An inhalation product according to any of the preceding paragraphs, characterized in that the support element comprises an internal support element structure.

8. The inhalation article according to claim 7, characterized in that the internal structure of the support element comprises a honeycomb structure, a spoke structure, a triangular structure, an omega-shaped structure, a plurality of internal hollow tubular elements, a closed central region, or a combination.

9. An inhalation product according to claim 7 or 8, characterized in that the support element contains at least 2 support element air ducts.

10. An inhalation product according to claim 9, characterized in that at least one of said at least 2 air ducts of the support element contains a filter material.

11. An inhalation product according to any of the preceding claims, characterized in that the upstream end of the front plug comprises a flanged end.

12. An inhalation product according to any of the preceding claims, characterized in that the downstream end of the mouthpiece plug comprises a curved end.

13. An inhalation product according to any of the preceding paragraphs, characterized in that the support element is attached to the inner surface of the front plug with glue.

14. An inhalation product according to any of the preceding paragraphs, characterized in that the support element is attached to the stop with glue.