High-barrier powder capsule

Abstract

A capsule article (100) comprises a polymeric body (110) extending along a longitudinal axis from a first end to a second end and defining a capsule cavity (105) containing a powder, and a metal foil (120) and a sealant layer (130) covering an outer surface of the polymeric body. A method of forming a sealed capsule comprises the steps of wrapping a capsule with a metal foil; and encasing the capsule with a sealant layer to form a sealed barrier encasing the capsule.

Description

Technical Field

[0001] This disclosure relates to high-barrier capsules containing powder. The high-barrier capsule is covered by a metal foil and a sealant layer. The metal foil and sealant layer work together to inhibit the transfer of water or moisture into the contents of the high-barrier capsule. Background Technology

[0002] Capsules typically have poor water resistance. Therapeutic dry powders are usually made of hygroscopic materials that degrade upon contact with water or moisture. These capsules are usually sealed in non-biodegradable packaging. This non-biodegradable packaging can increase the manufacturing cost and complexity of these capsules and related inhaler systems.

[0003] There is a need to provide capsules that inhibit or prevent the transfer of water or moisture into the capsule cavity. It is desirable to provide biodegradable, high-barrier capsules. It is desirable that the high-barrier capsule maintains the aerodynamics of the capsule and allows it to rotate or spin during consumption within the inhaler device. It is desirable that the high-barrier capsule is cost-effective, simple, and easy to apply to capsules for inhalable dry powders. It is desirable that the high-barrier capsule is formed from food-safe materials. Summary of the Invention

[0004] According to one aspect of the invention, a capsule article is provided, comprising a polymer body extending along a longitudinal axis from a first end to a second end and defining a capsule cavity containing powder. A metal foil and a sealant layer cover the outer surface of the polymer body.

[0005] Advantageously, the metal foil and sealant layer work together to form a protective barrier for the encapsulated capsule. The metal foil and sealant layer form a low-profile protective barrier for the encapsulated capsule, which can maintain the shape of the capsule and maintain its aerodynamic properties.

[0006] Capsule articles may include a sealant layer that contacts a metal foil, which separates the sealant layer from the polymer body. Coating the metal foil with a sealant layer may be advantageous for filling pores or cracks formed in or during the metal foil wrapping process.

[0007] The capsule article may include a sealant layer that contacts a metal foil, separating the metal foil from the polymer body. The sealant layer facilitates adhesion of the metal foil to the polymer body. The sealant layer advantageously fills the pores in the metal foil layer. Forming the metal foil as the outer layer of the capsule article further stabilizes the capsule article during storage or transport at higher temperatures. Forming the metal foil as the outer layer of the capsule article prevents the capsule article from becoming sticky and increasing surface friction during storage or transport at higher temperatures.

[0008] Capsule articles may include a sealant layer that contacts and separates the metal foil from the polymer body, and a second sealant layer that contacts the metal foil, with the metal foil separating the sealant layer from the second sealant layer. Encasing the metal foil between the two sealant layers can improve barrier properties while advantageously filling pores or cracks formed during the metal foil wrapping process using the second sealant layer.

[0009] The polymer body of the capsule article can be defined in an oblong shape, and the metal foil and sealant layer further define the oblong shape. The metal foil and sealant layer, which mimic the external shape of the capsule, can advantageously maintain the capsule's aerodynamics and allow the high-barrier capsule to spin or rotate during consumption.

[0010] The sealing layer of the capsule product may have a melting temperature of about 100 degrees Celsius or less, or in the range of about 40 degrees Celsius to about 80 degrees Celsius. The powder contained in the capsule cavity can degrade at temperatures above 100 degrees Celsius or above 80 degrees Celsius, therefore the application of liquid or flowable sealing agents to the capsule or metal foil is advantageously carried out at temperatures of about 100 degrees Celsius or less.

[0011] The sealant layer of capsule products can have a thickness of about 2 micrometers to about 15 micrometers or about 3 micrometers to about 10 micrometers. A sealant thickness of less than 15 micrometers or less than 10 micrometers can maintain capsule aerodynamics and allow high-barrier capsules to spin or rotate during consumption, while still cooperating with the metal foil to form a sealing barrier around the capsule cavity.

[0012] The sealing layer of capsule products may include wax materials. The sealing layer of capsule products may include microcrystalline wax. The wax material may be a food-safe material and may also be a biodegradable material.

[0013] The metal foil in capsule products can have a thickness ranging from about 2 micrometers to about 10 micrometers, or from about 4 micrometers to about 8 micrometers. A metal foil thickness of less than 10 micrometers or less than 8 micrometers can maintain capsule aerodynamics and allow high-barrier capsules to spin or rotate during consumption, while still cooperating with the metal foil to form a sealing barrier around the capsule cavity.

[0014] Metal foil used in capsule products may include aluminum foil. Aluminum foil can be a food-safe material and can also be a biodegradable material.

[0015] The metal foil and sealant layer, along with an optional second sealant layer, can be combined to form a sealing barrier encapsulating the polymer body or capsule cavity. It has been found that combining the metal foil with the sealant layer advantageously forms a sealing barrier with reduced thickness and maintained capsule aerodynamics, allowing high-barrier capsules to spin or rotate during consumption while still engaging with the metal foil to form a sealing barrier around the capsule cavity.

[0016] According to another aspect of the present invention, a method for forming a sealed capsule is provided, comprising the steps of: wrapping the capsule with a metal foil; and encapsulating the capsule with a sealing layer to form a sealing barrier for encapsulating the capsule.

[0017] Advantageously, wrapping articles with metal foil can be performed at high speeds with high resolution or accuracy. The metal foil and sealant layer work together to form a protective barrier for the encapsulated capsule. The metal foil and sealant layer form a low-profile protective barrier for the encapsulated capsule, which can maintain the shape of the capsule and maintain its aerodynamic properties. The metal foil and sealant layer can work together to provide a stronger moisture barrier than each layer alone can provide.

[0018] The method may include encapsulating the metal foil with a sealant layer. Encapsulating or coating the metal foil with a sealant layer may be advantageous for filling holes or cracks formed during the metal foil wrapping process.

[0019] The method may include encapsulating the capsule with a sealant layer and then wrapping the sealant layer with metal foil.

[0020] The method may include encapsulating a capsule with a sealant layer, then wrapping the sealant layer with a metal foil, and then encapsulating the metal foil with a second sealant layer. Encasing the metal foil between the two sealant layers can improve barrier properties while advantageously filling any holes or cracks formed during the metal foil wrapping process using the second sealant layer.

[0021] The method may include encapsulating capsules with a sealant layer at a temperature of about 100 degrees Celsius or less, or at a temperature in the range of about 40 degrees Celsius to about 80 degrees Celsius. The powder contained within the capsule cavity can degrade at temperatures above 100 degrees Celsius or above 80 degrees Celsius, therefore applying a liquid or flowable sealant to the capsule or foil is advantageously carried out at a temperature of about 100 degrees Celsius or less.

[0022] The method may include applying a sealant or sealant layer to the metal foil before wrapping the metal foil onto the polymer body of the capsule. The sealant or sealant layer may be applied to the metal foil prior to the wrapping step of forming the encapsulated capsule. The metal foil and sealant layer may form a laminate that can be wrapped onto the capsule. This sealant-metal foil laminate may have a thickness or uniform thickness in the range of about 5 micrometers to about 25 micrometers, or about 10 micrometers to about 20 micrometers.

[0023] The encapsulated capsule can then be heated to a temperature above the melting temperature of the sealant layer to form a sealing barrier for the encapsulated capsule. When the sealant is pre-applied to the surface of the foil, the encapsulated capsule can advantageously be brought into contact with a hot surface, hot air, or the sealing process can be performed by induction heating.

[0024] High-barrier capsules can be used in inhaler devices having a capsule cavity. Airflow management through the capsule cavity of the inhaler device allows the high-barrier capsule contained therein to rotate during inhalation and consumption. The high-barrier capsule may contain particles including nicotine (also referred to as "nicotine powder" or "nicotine particles"), and optionally particles including flavoring (also referred to as "flavoring particles"). If moisture comes into contact with these particles, they can become hygroscopic and harmfully clump together. Rotation of the punctured high-barrier capsule can be paused, and the nicotine particles released from the punctured high-barrier capsule can be atomized into the inhaled air moving through the inhaler device. Optional flavoring particles may be larger than nicotine particles and may aid in the delivery of nicotine particles to the user's lungs, while the flavoring particles are preferentially retained in the user's oral cavity or buccal space. Nicotine particles and optional flavoring particles can be delivered using the inhaler device at an inhalation rate or airflow rate within the range of conventional smoking inhalation rates or airflow rates.

[0025] The term "melting temperature" refers to the temperature at which a material begins to flow under one atmosphere or standard pressure without any external force other than gravity and air pressure.

[0026] The term "wax material" refers to a low molecular weight moldable substance that may be of natural or synthetic origin. Within the framework of this application, wax is a substance or mixture of substances with a molecular weight of less than about 7,000 Daltons. Examples are natural paraffin wax, synthetic paraffin wax, microcrystalline wax, low molecular weight polymers of ethylene, propylene or copolymers of propylene and acrylic acid monomers, such as acrylic acid or methacrylic acid and their esters. Various copolymers of ethylene, propylene, and vinyl acetate are also known.

[0027] Other waxes from natural sources include cannabi wax, candelilla wax, damask / wax, sugarcane wax, palm oil, hard wax, etc.

[0028] Referring to the above applications, the wax can be a formulation of several components, such as those listed, and may also contain a small amount of high molecular weight polymers to adjust the rheological and mechanical properties of the composition.

[0029] All scientific and technical terms used in this article have their common meanings in the field, unless otherwise specified. The definitions provided are for ease of understanding of certain terms used frequently in this article.

[0030] As used herein, unless the content explicitly indicates otherwise, the singular forms “a” and “the” cover embodiments having plural referents.

[0031] As used herein, unless otherwise expressly indicated by the content, "or" is generally used in the sense of including "and / or". The term "and / or" means one or all of the listed elements or any combination of two or more of the listed elements.

[0032] As used in this text, "having," "containing," "including," etc., are used in their open sense and generally mean "including (but not limited to)." It should be understood that phrases such as "basically composed of," "composed of," etc., fall under the category of "including."

[0033] The terms "preferred" and "preferred" refer to embodiments of the invention that provide certain benefits in certain circumstances. However, other embodiments may also be preferred in the same or other circumstances. Furthermore, the description of one or more preferred embodiments does not imply that other embodiments are useless, and is not intended to exclude other embodiments from the scope of this disclosure, including the claims.

[0034] This disclosure relates to high-barrier capsules containing powder. The high-barrier capsule is covered by a metal foil and a sealant layer. The metal foil and sealant layer work together to inhibit the transfer of water or moisture into the contents of the high-barrier capsule.

[0035] The high-barrier capsule article includes a polymer body extending along a longitudinal axis from a first end to a second end and defining a capsule cavity containing powder. A metal foil and a sealant layer cover the outer surface of the polymer body.

[0036] The capsule body may be formed from a polymeric material. The polymeric material may be hydroxypropyl methylcellulose (HPMC). The capsule may be a size 1 to 4 capsule, or a size 3 capsule. The polymeric body may be defined as an oblong shape. The polymeric body may have a single-wall thickness ranging from about 75 micrometers to about 120 micrometers, or from about 85 micrometers to about 110 micrometers. The polymeric body may have a longitudinal length from one end to the other end ranging from about 14 millimeters to about 22 millimeters, or from about 15 millimeters to about 20 millimeters. The polymeric body may have an outer diameter ranging from about 4.5 millimeters to about 10 millimeters, or from about 5.5 millimeters to about 6.5 millimeters.

[0037] High-barrier capsule articles may include a sealant layer in contact with a metal foil that separates the sealant layer from the polymer body. The metal foil may completely cover the polymer body. The sealant layer may completely cover the metal foil. The metal foil may be wrapped around a first end and a second end of the polymer body. The first end may form a hemispherical surface, and the second end may also form a hemispherical surface. Wrapping the metal foil around the first and second hemispherical ends creates a curved air passage that interacts with intake air to improve the aerodynamics and rotational or spin characteristics of the high-barrier capsule during consumption.

[0038] The capsule article may include a sealant layer that contacts a metal foil, separating the metal foil from the polymer body. The sealant layer may completely cover the polymer body. The metal foil may completely cover the sealant layer. The metal foil may be wrapped around a first end and a second end of the polymer body. The first end may form a hemispherical surface, and the second end may also form a hemispherical surface. Wrapping the metal foil around the first and second hemispherical ends creates a curved air passage that interacts with intake air to improve the aerodynamics and rotational or spin properties of the high-barrier capsule during consumption. The sealant layer provides adhesion of the metal foil to the polymer body.

[0039] The capsule article may include a sealant layer that contacts and separates the metal foil from the polymer body, and a second sealant layer that contacts the metal foil, separating the sealant layer from the second sealant layer. The sealant layer may completely cover the polymer body. The metal foil may completely cover the sealant layer. The metal foil may be wrapped around a first end and a second end of the polymer body. The first end may form a hemispherical surface, and the second end may form a hemispherical surface. Wrapping the metal foil around the first and second hemispherical ends may form a curved air channel that cooperates with the intake air to improve the aerodynamics and rotational or spin properties of the high-barrier capsule during consumption. The sealant layer provides adhesion of the metal foil to the polymer body.

[0040] The polymer body of the capsule article can be defined in an oblong shape, and the metal foil and sealant layer further define the oblong shape. The metal foil and sealant layer, which mimic the external shape of the capsule, can advantageously maintain the capsule's aerodynamics and allow the high-barrier capsule to spin or rotate during consumption.

[0041] The sealing layer of the capsule product may have a melting temperature of about 100 degrees Celsius or less, or in the range of about 40 degrees Celsius to about 80 degrees Celsius. The powder contained in the capsule cavity can degrade at temperatures above 100 degrees Celsius or above 80 degrees Celsius, therefore the application of liquid or flowable sealing agents to the capsule or metal foil is advantageously carried out at temperatures of about 100 degrees Celsius or less.

[0042] The sealant layer of capsule products can have a thickness of about 2 micrometers to about 15 micrometers or about 3 micrometers to about 10 micrometers. A sealant thickness of less than 15 micrometers or less than 10 micrometers can maintain capsule aerodynamics and allow high-barrier capsules to spin or rotate during consumption, while still cooperating with the metal foil to form a sealing barrier around the capsule cavity.

[0043] The sealing layer of a capsule product may comprise a mixture of wax materials, aliphatic polyesters, and paraffin wax, preferably applied from an aqueous dispersion. The sealing layer may comprise a mixture of cellulose esters and paraffin wax, preferably applied from an aqueous or alcoholic dispersion. The sealing layer may be prepared from an organic solvent dispersion of cellulose derivatives (esters, ethers, or nitrates) and paraffin wax. The sealing layer may comprise a plant wax-based formulation (e.g., cannabidiol wax, candelilla wax, damask / wax, sugarcane wax, palmitic acid, hard wax, etc.). This sealing layer may be prepared by a dispersion coating applied by solution, hot-melt coating, or extrusion coating.

[0044] The sealing layer of capsule products may include adhesion promoters, such as polymers or materials having carboxylic acid functional groups, or other substances, such as anti-blocking agents and anti-slip agents.

[0045] The sealing layer formulation of capsule products can be adapted by technicians to improve adhesion to the polymer matrix or metal foil, adjust its melting point, and ensure its biodegradability or compostability.

[0046] The sealing layer of capsule products may include wax materials. The sealing layer of capsule products may include microcrystalline wax. The wax material may be a food-safe material and may also be a biodegradable material.

[0047] It can also oxidize substances such as microcrystalline wax to enhance adhesion to polar substrates.

[0048] The metal foil used in capsule manufacturing can have a thickness ranging from about 2 micrometers to about 10 micrometers, or from about 4 micrometers to about 8 micrometers. A metal foil thickness of less than 10 micrometers or less than 8 micrometers maintains capsule aerodynamics and allows the high-barrier capsule to spin or rotate during consumption while still engaging with the metal foil to form a sealing barrier around the capsule cavity. Pores or pinholes may be present in this metal foil due to manufacturing or assembly processes.

[0049] Metal foil used in capsule products may include aluminum foil. Aluminum foil can be a food-safe material and can also be a biodegradable material.

[0050] The metal foil and sealant layer, along with an optional second sealant layer, can be combined to form a moisture-proof or sealing barrier encapsulating the polymer body or capsule cavity. It has been found that combining the metal foil with the sealant layer advantageously forms a moisture-proof or sealing barrier that can individually exceed the barrier effect of each layer added together, while reducing thickness and maintaining capsule aerodynamics, and allowing high-barrier capsules to spin or rotate during consumption, while still cooperating with the metal foil to form a synergistic moisture-proof and sealing barrier around the capsule cavity.

[0051] The metal foil and sealant layer of the capsule product may have a total thickness ranging from about 4 micrometers to about 15 micrometers, or from about 8 micrometers to about 12 micrometers, or about 10 micrometers.

[0052] The metal foil and sealant layer and the second sealant layer of the capsule product may have a total thickness ranging from about 6 micrometers to about 25 micrometers, or from about 10 micrometers to about 20 micrometers, or about 15 micrometers.

[0053] This disclosure relates to a method for forming a sealed capsule, comprising the steps of: wrapping the capsule with metal foil; and encapsulating the capsule with a sealing agent layer to form a sealing barrier for encapsulating the capsule. The high-barrier powder capsule may have a strength of 0.02 g / (m³) measured at 38°C and 90% relative humidity. 2 (x days) or less permeability.

[0054] The method may include encapsulating the metal foil with a sealant layer. Encapsulating or coating the metal foil with a sealant layer may be advantageous for filling holes or cracks formed during the metal foil wrapping process.

[0055] This method may include encapsulating a capsule with a sealant layer, and then wrapping the sealant layer with a metal foil. The outer metal foil layer or surface can ensure a low-friction outer surface even under elevated ambient temperatures. The sealant layer can adhere the metal foil to the capsule polymer layer while filling any pores or pinholes present in the metal foil.

[0056] The method may include encapsulating a capsule with a sealant layer, then wrapping the sealant layer with a metal foil, and then encapsulating the metal foil with a second sealant layer. Encasing the metal foil between the two sealant layers can improve barrier properties while advantageously filling any holes or cracks formed during the metal foil wrapping process using the second sealant layer.

[0057] The method may include encapsulating capsules with a sealant layer at a temperature of about 100 degrees Celsius or less, or in the range of about 40 degrees Celsius to about 80 degrees Celsius. The powder contained within the capsule cavity can degrade at temperatures above 100 degrees Celsius or above 80 degrees Celsius, therefore applying a liquid or flowable sealant to the capsule or foil is advantageously carried out at a temperature of about 100 degrees Celsius or less.

[0058] High-barrier capsules may contain pharmaceutically active particles. For example, pharmaceutically active particles may include nicotine. The median aerodynamic diameter of the pharmaceutically active particles may be about 5 micrometers or less, or in the range of about 0.5 micrometers to about 4 micrometers, or in the range of about 1 micrometer to about 3 micrometers.

[0059] High-barrier capsules may contain nicotine particles (also known as "nicotine powder" or "nicotine particles") including nicotine, and optionally contain particles including flavoring (also known as "flavoring particles"). High-barrier capsules may contain a predetermined amount of nicotine particles and optional flavoring particles. High-barrier capsules may contain sufficient nicotine particles to provide at least 2 inhalations or "puffs," or at least about 5 inhalations or "puffs," or at least about 10 inhalations or "puffs." High-barrier capsules may contain sufficient nicotine particles to provide about 5 to about 50 inhalations or "puffs," or about 10 to about 30 inhalations or "puffs." Each inhalation or "puff" delivers about 0.1 mg to about 3 mg of nicotine particles to the user's lungs, or about 0.2 mg to about 2 mg of nicotine particles to the user's lungs, or about 1 mg of nicotine particles to the user's lungs.

[0060] Depending on the specific formulation used, nicotine particles may have any applicable nicotine concentration. Nicotine particles may contain at least about 1% wt of nicotine up to about 30% wt, or about 2% wt to about 25% wt, or about 3% wt to about 20% wt, or about 4% wt to about 15% wt, or about 5% wt to about 13% wt of nicotine. Preferably, each inhalation or "inhalation" delivers about 50 to about 150 micrograms of nicotine to the user's lungs.

[0061] High-barrier capsules may contain at least about 5 mg of nicotine particles or at least about 10 mg of nicotine particles. Capsules may contain less than about 900 mg of nicotine particles, or less than about 300 mg of nicotine particles, or less than 150 mg of nicotine particles. Capsules may contain from about 5 mg to about 300 mg of nicotine particles or from about 10 mg to about 200 mg of nicotine particles.

[0062] When flavor particles are mixed or combined with nicotine particles within a capsule, the flavor particles can provide the desired amount of flavor to the user with each inhalation or "vape".

[0063] Nicotine particles may have any useful particle size distribution for preferably inhaled delivery to the user's lungs. Capsules may include particles other than nicotine particles. Nicotine particles and other particles may form a powder system.

[0064] High-barrier capsules may contain at least about 5 mg of dry powder (also known as a powder system) or at least about 10 mg of dry powder. High-barrier capsules may contain less than about 900 mg of dry powder, or less than about 300 mg of dry powder, or less than about 150 mg of dry powder. High-barrier capsules may contain from about 5 mg to about 300 mg of dry powder, or from about 10 mg to about 200 mg of dry powder, or from about 25 mg to about 100 mg of dry powder.

[0065] The dry powder or powder system may include at least about 40% by weight, or at least about 60% by weight, or at least about 80% by weight of the powder system in nicotine particles having a particle size of about 5 micrometers or less, or in the range of about 1 micrometer to about 5 micrometers.

[0066] The mass median aerodynamic diameter of particles including nicotine can be about 5 micrometers or less, or in the range of about 0.5 micrometers to about 4 micrometers, or in the range of about 1 micrometer to about 3 micrometers, or in the range of about 1.5 micrometers to about 2.5 micrometers. Preferably, the mass median aerodynamic diameter is measured using a cascaded impactor.

[0067] The mass median aerodynamic diameter of the particles, including the fragrance, can be about 20 micrometers or greater, or about 50 micrometers or greater, or in the range of about 50 to about 200 micrometers, or in the range of about 50 to about 150 micrometers. Preferably, the mass median aerodynamic diameter is measured using a cascaded impactor.

[0068] Nicotine in powder systems or nicotine granules can be pharmaceutically acceptable free nicotine, nicotine salts, or nicotine hydrates. Suitable nicotine salts or nicotine hydrates include, for example, nicotine pyruvate, nicotine citrate, nicotine aspartate, nicotine lactate, nicotine bitartrate, nicotine salicylate, nicotine fumarate, nicotine monopyruvate, nicotine glutamate, or nicotine hydrochloride. The compounds that combine with nicotine to form salts or hydrates can be selected based on their expected pharmacological effects.

[0069] Preferably, the nicotine particles contain amino acids. Preferably, the amino acid can be leucine, such as L-leucine. Providing the nicotine-containing particles with an amino acid such as L-leucine reduces the adhesive force of the nicotine-containing particles and reduces the attraction between nicotine particles, thus reducing particle agglomeration. Similarly, the adhesive force with fragrance-containing particles can be reduced, thereby also reducing the agglomeration of nicotine and fragrance particles. Therefore, even when nicotine and fragrance particles are combined, the powder system described herein can be a free-flowing material with each powder component having a stable relative particle size.

[0070] Preferably, the nicotine can be a surface-modified nicotine salt, wherein the nicotine salt particles include coated or composite particles. A preferred coating or composite material is L-leucine. A particularly suitable nicotine particle can be a nicotine tartrate bound with L-leucine.

[0071] The powder system may contain a group of flavor particles. The flavor particles may have any particle size distribution suitable for selective delivery into the user's mouth or buccal cavity during inhalation.

[0072] The particles containing fragrance may include compounds for reducing adhesion or surface energy and the resulting agglomeration. The fragrance particles may be surface-modified using these adhesion-reducing compounds to form coated fragrance particles. A preferred adhesion-reducing compound may be magnesium stearate. Providing the fragrance particles with adhesion-reducing compounds such as magnesium stearate, especially coating the fragrance particles, reduces the adhesive force of the fragrance-containing particles and the attraction between the particles, thus reducing agglomeration of the fragrance particles. Therefore, agglomeration of the fragrance particles with nicotine particles is also reduced. Thus, even when nicotine particles and fragrance particles are combined, the powder system described herein can have a stable relative particle size between the nicotine-containing particles and the fragrance-containing particles. Preferably, the powder system is free-flowing.

[0073] The nicotine particles and flavor particles can be combined in any useful relative amount such that the flavor particles are noticeable to the user when consumed together with the nicotine particles. Preferably, the nicotine particles and flavor particles form at least about 90% wt, or at least about 95% wt, or at least about 99% wt, or 100% wt of the total weight of the powder system. Detailed Implementation

[0074] The invention is defined in the claims. However, a non-exhaustive list of non-limiting examples is provided below. Any one or more features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0075] Example Ex1: A capsule article comprising: a polymer body extending along a longitudinal axis from a first end to a second end and defining a capsule cavity containing powder; and a metal foil and a sealant layer covering the outer surface of the polymer body.

[0076] Example Ex2. The capsule article of Example Ex1, wherein the sealant layer contacts the metal foil, and the metal foil separates the sealant layer from the polymer body.

[0077] Example Ex3. The capsule article of Example Ex1, wherein the sealant layer contacts the metal foil and the sealant layer separates the metal foil from the polymer body.

[0078] Example Ex4. The capsule article of Example Ex1, wherein the sealant layer contacts the metal foil and the sealant layer separates the metal foil from the polymer body, and a second sealant layer contacts the metal foil and the metal foil separates the sealant layer from the second sealant layer.

[0079] Example Ex5. A capsule article of any of the preceding examples, wherein the polymer body defines an oblong shape, and the metal foil and the sealant layer define an oblong shape.

[0080] Example Ex6. A capsule article of any of the foregoing examples, wherein the sealant layer has a melting temperature of about 100 degrees Celsius or less, or in the range of about 40 degrees Celsius to about 80 degrees Celsius.

[0081] Example Ex7. A capsule article of any of the preceding examples, wherein the sealant layer has a thickness of about 2 micrometers to about 15 micrometers, or about 3 micrometers to about 10 micrometers.

[0082] Example Ex8. A capsule article of any of the preceding examples, wherein the sealant layer comprises a wax material.

[0083] Example Ex9. A capsule product of any of the preceding examples, wherein the sealing layer comprises microcrystalline wax.

[0084] Example Ex10. A capsule article of any of the foregoing examples, wherein the metal foil has a thickness ranging from about 2 micrometers to about 10 micrometers or from about 4 micrometers to about 8 micrometers.

[0085] Example Ex11. A capsule article of any of the preceding examples, wherein the metal foil includes aluminum foil.

[0086] Example Ex12. A capsule article of any of the foregoing examples, wherein the sealant layer and the metal foil cooperate to form a sealing barrier encapsulating the polymer body or capsule cavity.

[0087] Example Ex13. A method of forming a sealed capsule, comprising the steps of: wrapping the capsule with a metal foil; and encapsulating the capsule with a sealant layer to form a sealing barrier encapsulating the capsule.

[0088] Example Ex14. According to the method of Example Ex13, wherein the encapsulation step includes encapsulating the metal foil with the sealant layer.

[0089] Example Ex15. According to the method of Example Ex13, wherein the encapsulation step includes encapsulating the capsule with the sealant layer and then wrapping the sealant layer with the metal foil.

[0090] Example Ex16. According to the method of Example Ex15, the encapsulation step includes encapsulating the metal foil with a second sealant layer.

[0091] Example Ex17. The method according to Examples Ex13 to Ex16 further includes setting the sealant layer onto the metal foil prior to the wrapping step of forming the encapsulation capsule.

[0092] Example Ex18. The method according to Example Ex17 further includes heating the encapsulated capsule to a temperature above the melting temperature of the sealant layer to form a sealing barrier encapsulating the capsule. Attached Figure Description

[0093] Several examples will now be described further with reference to the accompanying drawings, in which:

[0094] Figure 1 This is a perspective view of an exemplary high-barrier capsule;

[0095] Figure 2 It is along Figure 1 A schematic cross-sectional view of an exemplary high-barrier capsule taken from line 2-2;

[0096] Figure 3 It is along Figure 1 A schematic cross-sectional view of another exemplary high-barrier capsule taken from line 2-2; and

[0097] Figure 4 It is along Figure 1 A schematic cross-sectional view of another exemplary high-barrier capsule taken from line 2-2.

[0098] The illustrations are not necessarily to scale and are presented for illustrative rather than limiting purposes. The accompanying drawings depict one or more aspects described in this disclosure. However, it should be understood that other aspects not depicted in the drawings fall within the scope and spirit of this disclosure.

[0099] Figure 1 This is a perspective view of an exemplary high-barrier capsule 100. Figures 2 to 4 This is an alternative construction to the high-barrier capsule 100. The high-barrier capsule 100 includes a polymer body 110, which extends along the longitudinal axis L. A Extending from the first end 101 to the second end 102, a capsule cavity 105 containing powder 150 is defined. A metal foil 120 and a sealant layer 130 cover the outer surface of the polymer body 110.

[0100] Figure 2 This is a schematic cross-sectional view of an exemplary high-barrier capsule 100. The sealant layer 130 contacts the metal foil 120, and the metal foil 120 separates the sealant layer 130 from the polymer body 110.

[0101] Figure 3 This is a schematic cross-sectional view of another exemplary high-barrier capsule 100. The sealant layer 130 contacts the metal foil 120 and separates the metal foil 120 from the polymer body 110.

[0102] Figure 4 This is a cross-sectional schematic diagram of another exemplary high-barrier capsule 100. A sealant layer 130 contacts a metal foil 120 and separates the metal foil 120 from the polymer body 110, and a second sealant layer 135 contacts the metal foil 120 and separates the sealant layer 130 from the second sealant layer 135.

[0103] For the purposes of this specification and the appended claims, unless otherwise stated, all figures representing quantities, quantities, percentages, etc., shall be understood to be modified by the term "about" in all cases. Furthermore, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges that may be specifically listed or not listed herein. Thus, in this context, the numeral A is understood as A ± 2%A. Within this context, the numeral A can be considered as a value within the general standard error for the measurement of the attribute modified by the numeral A. In certain instances used in the appended claims, the numeral A may deviate from the percentages listed above, provided that the amount of deviation from A does not materially affect the essential and novel features of the claimed invention. Furthermore, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges that may be specifically listed or not listed herein.

Claims

1. A capsule product comprising: A polymer body extending along a longitudinal axis from a first end to a second end and defining a capsule cavity containing powder; as well as The metal foil and sealant layer covering the outer surface of the polymer body The sealant layer and the metal foil work together to form a sealing barrier that encapsulates the polymer body or capsule cavity.

2. The capsule article of claim 1, wherein the sealant layer contacts the metal foil, and the metal foil separates the sealant layer from the polymer body.

3. The capsule article of claim 1, wherein the sealant layer contacts the metal foil, and the sealant layer separates the metal foil from the polymer body.

4. The capsule article of claim 1, wherein the sealant layer contacts the metal foil and the sealant layer separates the metal foil from the polymer body, and a second sealant layer contacts the metal foil and the metal foil separates the sealant layer from the second sealant layer.

5. The capsule article of claim 1, wherein the polymer body defines an oblong shape, and the metal foil and sealant layer define an oblong shape.

6. The capsule article according to claim 1, wherein the sealant layer has a melting temperature of 100 degrees Celsius or less.

7. The capsule article according to claim 6, wherein the sealant layer has a melting temperature in the range of 40 degrees Celsius to 80 degrees Celsius.

8. The capsule article according to claim 1, wherein the sealant layer has a thickness of 2 micrometers to 15 micrometers.

9. The capsule article according to claim 8, wherein the sealant layer has a thickness of 3 micrometers to 10 micrometers.

10. The capsule article of claim 1, wherein the sealing layer comprises a wax material.

11. The capsule article according to claim 1, wherein the sealing layer comprises microcrystalline wax.

12. The capsule article of claim 1, wherein the metal foil has a thickness ranging from 2 micrometers to 10 micrometers.

13. The capsule article of claim 12, wherein the metal foil has a thickness ranging from 4 micrometers to 8 micrometers.

14. The capsule article according to claim 1, wherein the metal foil comprises aluminum foil.

15. A method for forming a sealed capsule, comprising the following steps: a. Wrap the capsule in metal foil; as well as b. Encapsulate the capsule with a sealant layer to form a sealing barrier encapsulating the capsule.

16. The method of claim 15, wherein step b comprises encapsulating the metal foil with the sealant layer.

17. The method of claim 15, wherein step b comprises encapsulating the capsule with the sealant layer and then wrapping the sealant layer with the metal foil.

18. The method of claim 17, wherein step b comprises encapsulating the metal foil with a second sealant layer.

Images