Apparatus and method for manufacturing inhaler articles

Abstract

The invention relates to a filling and closing rotary drum for an apparatus for manufacturing inhaler articles. The filling and closing rotary drum includes a plurality of circumferentially arranged grooves. Adjacent grooves are separated by protruding edges. Each groove includes a first channel configured to receive an inhaler article precursor and a second channel configured to receive an inhaler article precursor. The first channel and the second channel are arranged between two adjacent protruding edges. The invention also relates to an apparatus for manufacturing an inhaler article. The invention also relates to a method for manufacturing an inhaler article.

Description

TECHNICAL FIELD

[0001] The present invention relates to a filling and closing rotary drum. The present invention further relates to an apparatus for manufacturing inhaler articles. The present invention further relates to a method for manufacturing inhaler articles. BACKGROUND

[0002] Inhaler articles are known in the art, for example dry powder inhalers. In the field of manufacturing inhaler articles, it is known to provide a deformable tubular element and to close a distal end of the deformable tubular element, for example by folding the distal end of the tubular element inwards. Thereby, an object such as a powder capsule that has been previously inserted into the tubular element can be securely held within the article. SUMMARY

[0003] It is desirable to provide an apparatus and a method for manufacturing inhaler articles that have less machine space requirements. It is desirable to provide a more compact apparatus for manufacturing inhaler articles. It is desirable to provide an apparatus and a method for manufacturing inhaler articles that avoid or reduce the risk of a capsule being accidentally displaced from a desired position in the paper tube during the process.

[0004] It is desirable to provide an apparatus and a method for manufacturing inhaler articles at a sufficiently high speed. It is desirable to provide an apparatus and a method for manufacturing inhaler articles that allow for a simplified manufacturing process. It is desirable to provide an apparatus and a method for manufacturing inhaler articles that require less process steps. It is desirable to provide an apparatus and a method for manufacturing inhaler articles that allow for a simplified process of closing two opposite end portions of the inhaler articles. It is desirable to provide an apparatus and a method for manufacturing inhaler articles that allow for simultaneously filling and closing two end portions of a double length article.

[0005] According to an embodiment of the present invention, a filling and closing rotary drum of an apparatus for manufacturing inhaler articles is provided. The filling and closing rotary drum can comprise a plurality of circumferentially arranged grooves. Adjacent grooves can be separated by a protruding edge. Each groove can comprise a first channel configured for receiving an inhaler article precursor. Each groove can comprise a second channel configured for receiving an inhaler article precursor. The first channel and the second channel of a groove can be arranged between two adjacent protruding edges.

[0006] According to embodiments of the present invention, a filling and closing rotating drum for a device for manufacturing inhaler articles is provided. The filling and closing rotating drum comprises a plurality of circumferentially arranged recesses. Adjacent recesses are separated by a protruding edge. Each recess comprises a first channel configured for receiving an inhaler article precursor. Each recess comprises a second channel configured for receiving an inhaler article precursor. The first channel and the second channel of a recess are arranged between two adjacent protruding edges. With this filling and closing rotating drum, a device for manufacturing inhaler articles with less machine space requirements can be provided. With this filling and closing rotating drum, a more compact device for manufacturing inhaler articles can be provided. With this filling and closing rotating drum, a device for manufacturing inhaler articles can be provided which avoids or reduces the risk of a capsule being displaced from a desired position in the paper tube during the process. For example, since filling and closing occur on the same drum, the likelihood of a capsule being dislodged from a paper tube of an inhaler article precursor can be substantially smaller. In addition, the risk of a capsule being displaced from a desired position can be reduced.

[0007] With this filling and closing rotating drum, a device for manufacturing inhaler articles at a sufficiently high speed can be provided. With this filling and closing rotating drum, a device for manufacturing inhaler articles can be provided which allows for a simplified manufacturing process. With this filling and closing rotating drum, a device can be provided which requires less process steps. For example, if filling and closing are performed separately, a filling drum and a separate closing drum can be required. With this filling and closing rotating drum, a device for manufacturing inhaler articles can be provided which allows for a simplified process of closing both opposite ends of an inhaler article. With this filling and closing rotating drum, a device for manufacturing inhaler articles can be provided which allows for filling and closing of both ends of a double length article simultaneously.

[0008] Each channel can have a size and shape configured for being able to receive only one single inhaler article precursor. Each channel can have a size and shape configured for being able to receive exactly one inhaler article precursor. The size and shape of the channel can be adapted to the size and shape of the inhaler article precursor. For example, the width of the channel can be between about 4 mm to 10 mm. The depth of the channel can be between 2 mm to 5 mm. The length of the channel can be at least 4 cm.

[0009] Each channel can comprise a vacuum channel for holding an inhaler article precursor in the channel. The vacuum channel can comprise a supply portion. The supply portion can be fluidly connected to a vacuum supply.

[0010] The height difference between the bottom of the channel and the top of the adjacent protruding edge can be between 1 mm and 10 mm, preferably between 2 mm and 8 mm, more preferably between 3 mm and 7 mm, more preferably between 4 mm and 6 mm. The height difference can be measured in a direction perpendicular to the rotational axis of the filling and closing rotating drum.

[0011] According to embodiments of the present invention, there is provided an apparatus for manufacturing inhaler articles. The apparatus can comprise a filling and closing station. The filling and closing station can comprise a filling and closing rotating drum configured to receive a plurality of inhaler article precursors. Each inhaler article precursor can comprise at least one open tubular end. The filling and closing station can be configured to both fill and close the at least one open tubular end of the inhaler article precursor while the inhaler article precursor is being received by the filling and closing rotating drum. The filling and closing rotating drum of the apparatus can be a filling and closing rotating drum as described herein.

[0012] According to embodiments of the present invention, there is provided an apparatus for manufacturing inhaler articles. The apparatus comprises a filling and closing station. The filling and closing station comprises a filling and closing rotating drum configured to receive a plurality of inhaler article precursors. Each inhaler article precursor comprises at least one open tubular end. The filling and closing station is configured to both fill and close the at least one open tubular end of the inhaler article precursor while the inhaler article precursor is being received by the filling and closing rotating drum.

[0013] An apparatus for manufacturing inhaler articles with less machine space requirements can be provided. A more compact apparatus for manufacturing inhaler articles can be provided. An apparatus for manufacturing inhaler articles which avoids or reduces the risk of the capsule being accidentally displaced from the desired position in the paper tube during the process can be provided. An apparatus for manufacturing inhaler articles at a sufficiently high speed can be provided. An apparatus for manufacturing inhaler articles which allows for a simplified manufacturing process can be provided. An apparatus requiring less process steps can be provided. An apparatus for manufacturing inhaler articles which allows for a simplified process of closing both opposing ends of the inhaler article can be provided. An apparatus for manufacturing inhaler articles which allows for simultaneously filling and closing both ends of a double length article can be provided.

[0014] The filling and closing rotating drum can be configured to receive the inhaler article precursors such that the longitudinal axis of each inhaler article precursor is oriented parallel to the rotational axis of the filling and closing rotating drum.

[0015] The fill and close rotating drum can be oriented in the apparatus such that the rotational axis of the fill and close rotating drum is oriented in a horizontal plane. As used herein, the term "horizontal plane" refers to a plane that is perpendicular to a vector pointing to the center of gravity. As used herein, the term "horizontal" refers to a direction or plane that is substantially perpendicular to the center of gravity, for example when the apparatus is installed in a production hall.

[0016] The apparatus can comprise a stationary rolling hand.

[0017] As used herein, the term "stationary" refers to a part that is at rest relative to a moving part such as a rotating drum or a movable conveying surface. For example, a stationary rolling hand does not follow the rotational movement of the fill and close rotating drum. For example, a stationary laying hand does not follow the movement of the movable conveying surface.

[0018] The stationary rolling hand can be arranged for pushing the inhaler article precursor from a first channel to an adjacent second channel by means of the relative movement of the fill and close rotating drum relative to the stationary rolling hand.

[0019] The fill and close station can comprise a rotating fill and close unit. The rotating fill and close unit can comprise a plurality of circumferentially arranged fill rods. Each fill rod can be configured for filling an object into the open tubular end of an inhaler article precursor. The rotating fill and close unit can comprise a plurality of circumferentially arranged close rods. Each close rod can be configured for at least partially closing the open tubular end of an inhaler article precursor. The fill rods and the close rods can be arranged in an alternating sequence. The rotating fill and close unit can be arranged adjacent to the fill and close rotating drum such that the rotational axis of the rotating fill and close unit coincides with the rotational axis of the fill and close rotating drum. The rotating fill and close unit can follow the rotational movement of the fill and close rotating drum. Thus, the rotating fill and close unit can rotate at the same speed as the fill and close rotating drum.

[0020] The fill rods and the close rods can be arranged in pairs. Each pair of fill rod and close rod comprises one fill rod adjacent to one close rod.

[0021] The rotating fill and close unit can comprise a plurality of circumferentially arranged neutral rods. One neutral rod can be arranged between each pair of fill rod and close rod.

[0022] Each fill rod can comprise a plunger barrel. The plunger barrel can comprise an opening for inserting an object.

[0023] Each closure rod can be configured for at least partially closing an open tubular end of an inhaler article precursor by means of one or both of a turn-up, a fold, and a crimp. Each closure rod can include a closure cap. The closure cap is configured for at least partially closing an open end of an inhaler article by means of one or both of a turn-up, a fold, and a crimp. The closure cap can be arranged at both sides of the fill and closure rotary drum for closing two opposite ends of an inhaler article precursor.

[0024] The closure cap can include one or more fold heads for inwardly folding an open tubular end of an inhaler article. The fold heads can be configured for inwardly folding the deformable tubular element by at least 90 degrees. The closure cap can include a pre-fold head and an end fold head.

[0025] The pre-fold head can be concavely shaped for inwardly folding the deformable tubular element by an angle of less than 90 degrees. The end fold head can be a flat fold head for inwardly folding the deformable tubular element by an angle of about 90 degrees. The end fold head can also include a convexly shaped for inwardly folding the deformable tubular element by an angle of more than 90 degrees.

[0026] The closure cap can include one or more crimp heads for crimping an open tubular end of an inhaler article. The crimp head can include a longitudinal central axis extending between a proximal end and a distal end of the crimp head. The crimp head can include a circular opening centrally located at the proximal end and defining a recess towards the distal end. The recess can be arranged for inserting the open tubular end of the inhaler article into the recess. At least a portion of a sidewall of the recess can be arranged as a crimp surface. The crimp surface can include a concave curvature. The crimp head can include a crimp mechanism configured for linearly advancing the crimp head along the longitudinal central axis and simultaneously rotating the crimp head about the longitudinal central axis. The crimp mechanism can be driven by one or more motors. The crimp mechanism can include means for transmitting power from the one or more motors to the crimp head.

[0027] The crimp mechanism can be configured to process the open end of the article such that the crimped end includes a crimped edge defining a central orifice. The crimped edge can be a rounded edge.

[0028] The filling and closing station can comprise one or more pre-treatment devices for pre-treating the open end of the deformable tubular element of the inhaler article to obtain a pre-treated portion having a reduced structural stability. The pre-treatment devices can be arranged upstream of the one or more closing caps. The pre-treatment devices can be configured for crimping the edge of the open end of the deformable tubular element. The pre-treatment devices can be configured for cutting the edge of the open end of the deformable tubular element along one or more lines extending substantially parallel to the axial direction of the inhaler article. The pre-treatment devices can be configured for scoring the edge of the open end of the deformable tubular element along one or more lines extending substantially parallel to the axial direction of the inhaler article. Upon scoring, the deformable element can be provided with discontinuous cut lines. The pre-treatment devices can comprise a processing head for crimping, cutting or scoring the open end of the deformable tubular element. The processing head of the pre-treatment station can define a substantially cylindrical recess whose internal dimensions correspond to the outer diameter of the open end of the deformable tubular element. The processing head of the pre-treatment station can further comprise a number of processing blades extending from the open side wall of the recess of the processing head towards the internal volume of the processing head. The processing blades can extend funnel-shaped towards the internal volume of the processing head. The processing blades can be equally spaced on the circumference of the recess.

[0029] The processing blades can each have an engagement edge which contacts the open end of the deformable tubular element during the pre-treatment step. The processing blades can be formed so as to crimp, cut or score the open end of the deformable tubular element during the pre-treatment step. The number of processing blades determines the number of crimping, cutting or scoring lines provided to the open end of the deformable tubular element during the pre-treatment step.

[0030] The pre-treatment devices can be provided upstream of the filling and closing station.

[0031] The filling and closing station can comprise a fixed rail unit. The fixed rail unit can comprise a first fixed rail for engaging with the filling rods. The first fixed rail can be configured for manipulating the longitudinal position of the respective filling rod depending on the angular position of each filling rod. The fixed rail unit can comprise a second fixed rail for engaging with the closing rods. The second fixed rail can be configured for manipulating the longitudinal position of the respective closing rod depending on the angular position of each closing rod. The term "angular position" refers to an angular displacement with respect to the axis of rotation of the rotating filling and closing unit. The term "longitudinal position" refers to a position along a direction parallel to the axis of rotation of the rotating filling and closing unit.

[0032] Each filling rod can comprise a first cam connected to the first fixed rail. Each closing rod can comprise a second cam connected to the second fixed rail.

[0033] The apparatus can be configured for processing single length inhaler articles. The apparatus can include a further closing station disposed downstream of the filling and closing rotary drum. The further closing station can be configured for closing the open end on one side of each inhaler article. The apparatus can be configured for processing double length inhaler articles. Processing double length inhaler articles can allow for increased manufacturing speed.

[0034] As used herein, the term "processing articles" refers to one or more steps during the manufacture of inhaler articles. The term "inhaler articles" can refer to finished or unfinished articles. The term "inhaler article precursor" refers to unfinished articles. Unfinished inhaler articles can include deformable tubular elements that form open ends of the articles. Typically, unfinished inhaler articles are disposed at an upstream end of a processing line. Inhaler articles received at a downstream end of the processing line can be finished inhaler articles or can require further processing to ultimately receive finished articles.

[0035] The terms "upstream" or "downstream" refer herein to the processing direction of inhaler articles and inhaler article precursors. Typically, articles are processed or conveyed in a downstream direction from an upstream end of a processing line toward a downstream end. The terms "processing direction" and "downstream direction" can be used synonymously.

[0036] The filling and closing rotary drum can be configured for receiving a plurality of double length inhaler article precursors. Each double length inhaler article precursor can include two open tubular ends. The filling and closing station can be configured for both filling and closing each of the two open tubular ends of the inhaler article precursor while the inhaler article precursor is being received by the filling and closing rotary drum. The filling and closing station can include a further rotary filling and closing unit. The filling and closing rotary drum can be disposed between the rotary filling and closing unit and the further rotary filling and closing unit. The rotary filling and closing unit and the further rotary filling and closing unit and the filling and closing rotary drum can share a common rotational axis. The rotary filling and closing unit and the further rotary filling and closing unit and the filling and closing rotary drum can rotate at the same speed.

[0037] The apparatus can include a cutting station for cutting the double length inhaler article precursors into halves. The cutting station can be disposed downstream of the filling and closing station. The apparatus can include a turning station for turning all of the cut in half inhaler article precursors in the same direction such that they all have the same orientation of the open end resulting from the cutting. The apparatus can include a closing station for closing the open tubular ends of the cut in half inhaler article precursors. The closing station can be disposed downstream of the cutting station. The closing station can be disposed downstream of the turning station.

[0038] The filling and closing station can comprise a feeder unit for supplying objects to the filling rods. The feeder unit can comprise a movable conveying surface comprising a plurality of cavities. Each cavity can have an oblong shape configured for receiving a capsule object.

[0039] The feeder unit can comprise a capsule supply for supplying capsules to the conveying surface. The capsule supply can be arranged for inserting a capsule into a cavity such that the longitudinal axis of the inserted capsule is parallel to the longitudinal axis of the oblong cavity.

[0040] As used herein, the term "parallel" is not necessarily limited to an angle of exactly 0 degrees, but can in some embodiments include an angle that deviates somewhat from a strict parallel direction. For example, a deviation of about 15 degrees or less, or about 10 degrees or less, or about 5 degrees or less, or about 2 degrees or less, or about 1 degree or less can be permissible. The term "parallel" can be limited to an angle of about 0 degrees. The term "parallel" can be limited to an angle of 0 degrees.

[0041] The feeder unit can comprise a capsule supply for supplying capsules to the conveying surface. The capsule supply can be arranged for inserting a capsule into a cavity in an upright position such that the longitudinal axis of the inserted capsule is perpendicular to the longitudinal axis of the oblong cavity.

[0042] The oblong cavity can comprise a deeper recess at one side of the oblong cavity for receiving a capsule in an upright position.

[0043] The feeder unit can comprise a stationary laying hand arranged downstream of the capsule supply. The stationary laying hand can be configured to rotate a capsule in a respective cavity by about ninety degrees by means of a relative movement of the movable conveying surface with respect to the stationary laying hand such that the longitudinal axis of the inserted capsule is parallel to the longitudinal axis of the oblong cavity. The stationary laying hand can be shaped as a triangular plate. The stationary laying hand can be shaped as a curved plate. The stationary laying hand can be shaped as a triangular curved plate.

[0044] The capsule supply can comprise a vibrating feeder bowl.

[0045] The movable conveying surface can form part of an endless belt or conveyor belt. The movable conveying surface can form part of a rotating drum. At least a portion of the movable conveying surface can be configured to vibrate. The vibration of the movable conveying surface can improve the correct insertion of objects into the cavities of the movable conveying surface.

[0046] The apparatus can be configured such that the inhaler article precursor receives on the filling and closing rotating drum for about two revolutions of the filling and closing rotating drum before being ejected from the filling and closing rotating drum. "Revolution" means one full revolution of the respective drum.

[0047] In addition to the fill and close rotating drum, the apparatus can include one or more additional rotating drums. Each additional rotating drum can be located either upstream or downstream of the fill and close rotating drum. At least one of the additional rotating drums can include channels for receiving inhaler article precursors. At least one of the additional rotating drums can operate at the same speed as the fill and close rotating drum. At least one of the additional rotating drums can have half the number of channels as the fill and close rotating drum. At least one of the additional rotating drums can operate at the same speed as the fill and close rotating drum and have half the number of channels as the fill and close rotating drum.

[0048] According to embodiments of the present invention, a method for manufacturing inhaler articles is provided. The method can include providing a fill and close rotating drum. The fill and close rotating drum can include a plurality of circumferentially arranged channels, each channel configured to receive an inhaler article precursor. The method can include receiving, in a first channel, a first inhaler article precursor that is at least partially filled, the at least partially filled first inhaler article precursor including an open tubular end into which an object has been inserted. The method can include receiving, in a second channel, a second inhaler article precursor that is empty, the second inhaler article precursor including an open tubular end. The method can include inserting the object into the open tubular end of the empty second inhaler precursor article while the second inhaler article precursor is being received in the second channel to receive an at least partially filled second inhaler article precursor. The method can include at least partially closing the open tubular end of the first inhaler article precursor into which the object has been inserted while the first inhaler article precursor is being received in the first channel to receive an at least partially closed first inhaler article precursor.

[0049] According to embodiments of the present invention, a method for manufacturing inhaler articles is provided. The method includes providing a fill and close rotating drum. The fill and close rotating drum includes a plurality of circumferentially arranged channels, each channel configured to receive an inhaler article precursor. The method includes receiving, in a first channel, a first inhaler article precursor that is at least partially filled, the at least partially filled first inhaler article precursor including an open tubular end into which an object has been inserted. The method includes receiving, in a second channel, a second inhaler article precursor that is empty, the second inhaler article precursor including an open tubular end. The method includes inserting the object into the open tubular end of the empty second inhaler precursor article while the second inhaler article precursor is being received in the second channel to receive an at least partially filled second inhaler article precursor. The method includes at least partially closing the open tubular end of the first inhaler article precursor into which the object has been inserted while the first inhaler article precursor is being received in the first channel to receive an at least partially closed first inhaler article precursor. The method steps can be performed consecutively according to the order mentioned above.

[0050] A method for manufacturing inhaler articles with less machine space requirements can be provided. A method for manufacturing inhaler articles can be provided which avoids or reduces the risk of the capsules from being accidentally displaced from the desired position in the paper tube during the process. A method for manufacturing inhaler articles at a sufficiently high speed can be provided. A method for manufacturing inhaler articles which allows for a simplified manufacturing process can be provided. A method requiring less process steps can be provided. A simplified method for manufacturing inhaler articles can be provided, wherein both opposite ends of the inhaler articles are closed. A method for manufacturing inhaler articles which allows for simultaneously filling and closing both ends of a double length article can be provided.

[0051] The first and second channels can be adjacent channels.

[0052] The method can comprise the step of removing the at least partially closed first inhaler article precursor from the filling and closing rotating drum to re-empty the first channel. The method can comprise the step of moving the at least partially filled second inhaler article precursor from the second channel into the re-emptied first channel.

[0053] The step of inserting the object into the open tubular end of the empty second inhaler article precursor and the step of at least partially closing the open tubular end of the first inhaler article precursor into which the object has been inserted can be performed simultaneously.

[0054] The inhaler article precursor can remain positively received on the filling and closing drum for about two revolutions of the filling and closing drum before being ejected from the drum. A "revolution" means one full revolution of the respective drum.

[0055] The object can be a capsule, preferably a dry powder capsule.

[0056] The inhaler articles manufactured by the apparatus and method of the present invention can comprise a capsule. The capsule can comprise one or more nicotine salts. The capsule can comprise pharmaceutically active particles. For example, the pharmaceutically active particles can comprise nicotine. The mass median aerodynamic diameter of the pharmaceutically active particles can be about 5 microns or lower, or in the range of about 0.5 microns to about 4 microns, or in the range of about 1 micron to about 3 microns. The capsule can comprise one or more nicotine salts.

[0057] The capsule can contain nicotine particles (also referred to as "nicotine powder" or "nicotine granules") containing nicotine, and optionally flavor particles (also referred to as "flavor granules"). The capsule can contain a predetermined amount of nicotine particles and optional flavor particles. The capsule can 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." The capsule can contain sufficient nicotine particles to provide from about 5 to about 50 inhalations or "puffs," or from about 10 to about 30 inhalations or "puffs." Each inhalation or "puff" can deliver from about 0.1 mg to about 3 mg of nicotine particles to the lungs of a user, or from about 0.2 mg to about 2 mg of nicotine particles to the lungs of a user, or about 1 mg of nicotine particles to the lungs of a user.

[0058] The nicotine particles can have any useful concentration of nicotine, based on the particular formulation used. The nicotine particles can have at least about 1% by weight nicotine to about 30% by weight nicotine, or from about 2% to about 25% by weight nicotine, or from about 3% to about 20% by weight nicotine, or from about 4% to about 15% by weight nicotine, or from about 5% to about 13% by weight nicotine. Preferably, each inhalation or "puff" can deliver from about 50 to about 150 micrograms of nicotine to the lungs of a user.

[0059] The capsule can hold or contain at least about 5 mg of nicotine particles or at least about 10 mg of nicotine particles. The capsule can hold or 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. The capsule can hold or contain from about 5 mg to about 300 mg of nicotine particles or from about 10 mg to about 200 mg of nicotine particles.

[0060] When flavor particles are admixed or combined with nicotine particles within a capsule, the flavor particles can be present in an amount that provides a desired flavor for each inhalation or "puff" delivered to a user.

[0061] The nicotine particles can have any useful particle size distribution for preferential delivery to the lungs of a user upon inhalation. The capsule can include particles other than nicotine particles. The nicotine particles and other particles can form a powder system.

[0062] The capsule can hold or contain at least about 5 mg of dry powder (also referred to as a powder system) or at least about 10 mg of dry powder. The capsule can hold or 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. The capsule can hold or 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.

[0063] The dry powder or powder system can have at least about 40% by weight, or at least about 60% by weight, or at least about 80% by weight of the powder system comprised in nicotine particles having a particle size of about 5 microns or less or in the range of about 1 micron to about 5 microns.

[0064] The mass median 5 aerodynamic diameter of the particles comprising nicotine can be about 5 microns or less, or in the range of from about 0.5 microns to about 4 microns, or in the range of from about 1 micron to about 3 microns, or in the range of from about 1.5 microns to about 2.5 microns. Preferably, the mass median aerodynamic diameter is measured using a cascade impactor.

[0065] The mass median aerodynamic diameter of the particles comprising flavorant can be about 20 microns or greater, or about 50 microns or greater, or in the range of about 50 to about 200 microns, or in the range of about 50 to about 150 microns. Preferably, the mass median aerodynamic diameter is measured using a cascade impactor.

[0066] The dry powder can have an average diameter of about 60 microns or less, or in the range of about 1 micron to about 40 microns, or in the range of about 1.5 microns to about 25 microns. Average diameter refers to the average diameter per unit mass, and is preferably measured by laser diffraction, laser diffusivity, or electron microscopy.

[0067] The nicotine in the powder system or nicotine particles can be a pharmaceutically acceptable free base nicotine or a nicotine salt or a nicotine hydrate salt. Useful nicotine salts or nicotine salt 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 compound with which the nicotine is combined to form the salt or hydrate salt can be selected based on its expected pharmacological effect.

[0068] The nicotine particles preferably comprise an amino acid. Preferably, the amino acid can be leucine, such as L-leucine. Providing an amino acid such as L-leucine to the particles comprising nicotine can reduce the adhesion of the particles comprising nicotine, and can reduce the attractive forces between the nicotine particles and thus reduce agglomeration of the nicotine particles.

[0069] Similarly, the adhesion to the particles comprising flavorant can also be reduced, thus also reducing agglomeration of the nicotine particles with the flavorant particles. Thus, the powder system described herein can be a free-flowing material and each powder component has a stable relative particle size, even when the nicotine particles are combined with the flavorant particles.

[0070] Preferably, the nicotine can be a surface modified nicotine salt, wherein the nicotine salt particles comprise coated or composite particles. A preferred coating or composite material can be L-leucine. One particularly useful nicotine particle can be nicotine 5 bitartrate bound to L-leucine.

[0071] The powder system can comprise a population of flavor particles. The flavor particles can have any effective particle size distribution for selectively delivering inhalation into a user's mouth or buccal cavity.

[0072] The powder system can have at least about 40% by weight, or at least about 60% by weight, or at least about 80% by weight of the population of flavor particles of the powder system comprised in particles having a particle size of about 20 microns or greater. The powder system can have at least about 40% by weight, or at least about 60% by weight, or at least about 80% by weight of the population of flavor particles of the powder system comprised in particles having a particle size of about 50 microns or greater. The powder system can have at least about 40% by weight, or at least about 60% by weight, or at least about 80% by weight of the population of flavor particles of the powder system comprised in particles having a particle size in a range from about 50 microns to about 150 microns.

[0073] The flavor-containing particles can comprise a compound for reducing adhesion or surface energy and resulting agglomeration. The flavor particles can be surface modified with an adhesion-reducing compound to form coated flavor particles. One preferred adhesion-reducing compound can be magnesium stearate. Providing the flavor particles with an adhesion-reducing compound such as magnesium stearate, especially coating the flavor particles, can reduce the adhesion of the flavor-containing particles and can reduce the attractive forces between the flavor particles and thus reduce agglomeration of the flavor particles. Agglomeration of the flavor particles with the nicotine particles can also be reduced. Thus, the powder system described herein can have a stable relative particle size of the nicotine-containing particles to the flavor-containing particles even when the nicotine particles are combined with the flavor particles. The powder system can preferably be free-flowing.

[0074] Conventional formulations for dry powder inhalation comprise carrier particles to increase fluidization of the active particles, as the active particles can be too small to be affected by simple air flow through an inhaler. The powder system can include carrier particles. These carrier particles can be sugar such as lactose or mannitol, which can have a particle size greater than about 50 microns. By acting as a diluent or bulking agent in the formulation, the carrier particles can serve to improve dose uniformity.

[0075] The powder system used in conjunction with the nicotine powder delivery system described herein can be free of carriers or substantially free of sugar such as lactose or mannitol. Being free of carriers or substantially free of sugar such as lactose or mannitol can allow for inhalation of the nicotine and delivery into the lungs of a user at an inhalation rate or air flow rate similar to the inhalation rate or air flow rate of a typical smoking regime.

[0076] The nicotine particles and flavorant can be combined in a single capsule. As described above, the nicotine particles and flavorant can each have reduced adhesion, resulting in a stable particulate formulation in which the particle size of each component does not substantially change upon combination. Alternatively, the powder system includes nicotine particles contained within a single capsule and flavorant particles contained within a second capsule. The nicotine particles and flavorant particles can be combined in any useful relative amounts, such that the flavorant particles are perceptible to a user when consumed with the nicotine particles. Preferably, the nicotine particles and flavorant particles form at least about 90% by weight, or at least about 95% by weight, or at least about 99% by weight, or 100% by weight of the total weight of the powder system.

[0077] The inhaler article manufactured by the apparatus and method of the present application can be similar in size and shape to a smoking article or cigarette. The inhaler article can have an elongated body extending along a longitudinal axis of the inhaler article. The inhaler body can have a substantially uniform outer diameter along the length of the elongated body. The inhaler article can have a circular cross-section that can be uniform along the length of the elongated body. The inhaler body can have an outer diameter in a range from about 6 millimeters to about 10 millimeters, or from about 7 millimeters to about 10 millimeters, or from about 7 millimeters to about 9 millimeters, or from about 7 millimeters to about 8 millimeters, or about 7.3 millimeters. The inhaler article can have a length (along the longitudinal axis) in a range from about 40 millimeters to about 80 millimeters, or from about 40 millimeters to about 70 millimeters, or from about 40 millimeters to about 50 millimeters, or about 48 millimeters.

[0078] The inhaler article can include a mouthpiece element. The mouthpiece element can be located proximal to the capsule cavity. The mouthpiece element can extend from the capsule cavity to a mouthpiece end of the inhaler article. The mouthpiece element can have a length in a range from about 10 millimeters to about 30 millimeters, preferably from about 15 millimeters to about 25 millimeters, and more preferably from about 20 millimeters to about 22 millimeters. The mouthpiece element can have a diameter in a range from about 6 millimeters to about 10 millimeters, or from about 7 millimeters to about 10 millimeters, or from about 7 millimeters to about 9 millimeters, or from about 7 millimeters to about 8 millimeters, or about 7.1 millimeters. The mouthpiece element can have a filtration function. The mouthpiece element can include a filter element. The filter element can extend substantially the full length of the mouthpiece element.

[0079] The inhaler article can include a deformable tubular element that has been at least partially enclosed by the apparatus or method of the present application. The deformable element can be formed of a cellulosic material. At least a portion of the deformable element can be formed of paper. The deformable element can provide a barrier to reduce or prevent the ingress of contaminants or foreign matter into the capsule cavity.

[0080] The inhaler article can include a body, a capsule cavity holding a capsule, a mouthpiece element, and a deformable tubular element having at least partially enclosed ends.

[0081] The terms "proximal" and "distal" are used to describe the relative position of components or parts of components of an inhaler article or system. An inhaler article according to the present application has a proximal end. In use, nicotine granules exit the proximal end of the inhaler article for delivery to a user. The inhaler article has a distal end opposite the proximal end. The proximal end of the inhaler article can also be referred to as the mouth end.

[0082] The open tubular end of an inhaler article precursor processed by the apparatus and method of the present application can comprise or can consist of a cellulose-based material, such as paper or cardboard. The open tubular end of the inhaler article can comprise or can consist of a wrapping paper.

[0083] A non-exhaustive list of non-limiting examples is provided below. Any one or more features of these examples can be combined with any one or more features of another example, embodiment or aspect described herein.

[0084] Example El : A fill and close rotary drum of an apparatus for manufacturing an inhaler article, the fill and close rotary drum comprising a plurality of circumferentially arranged grooves,

[0085] wherein adjacent grooves are separated by a protruding edge, and

[0086] wherein each groove comprises a first channel configured for receiving an inhaler article precursor and a second channel configured for receiving an inhaler article precursor, the first channel and the second channel being arranged between two adjacent protruding edges.

[0087] Example E2: The fill and close rotary drum according to Example El, wherein each channel comprises a vacuum channel for holding an inhaler article precursor in the channel.

[0088] Example E3: The fill and close rotary drum according to Example El or Example E2, wherein the height difference between the bottom of a channel and the top of an adjacent protruding edge is between 1 mm and 10 mm, preferably between 2 mm and 8 mm, more preferably between 3 mm and 7 mm, more preferably between 4 mm and 6 mm, the height difference being measured in a direction perpendicular to the rotational axis of the fill and close rotary drum.

[0089] Example E4: An apparatus for manufacturing an inhaler article, the apparatus comprising a fill and close station, the fill and close station comprising a fill and close rotary drum configured for receiving a plurality of inhaler article precursors, each inhaler article precursor comprising at least one open tubular end,

[0090] wherein the fill and close station is configured for both filling and closing the at least one open tubular end of the inhaler article precursor while the inhaler article precursor is being received by the fill and close rotary drum.

[0091] Example E5: The apparatus according to Example E4, wherein the fill and closure rotating drum is configured to receive the inhaler article precursors such that a longitudinal axis of each inhaler article precursor is oriented parallel to an axis of rotation of the fill and closure rotating drum.

[0092] Example E6: The apparatus according to Example E4 or Example E5, wherein the fill and closure rotating drum is oriented in the apparatus such that an axis of rotation of the fill and closure rotating drum is oriented in a horizontal plane.

[0093] Example E7: The apparatus according to any one of Examples E4 to E6, wherein the fill and closure rotating drum is a fill and closure rotating drum according to any one of Examples E1 to E3.

[0094] Example E8: The apparatus according to Example E7, comprising a stationary rolling hand arranged for pushing an inhaler article precursor from a first channel to an adjacent second channel by means of relative movement of the fill and closure rotating drum with respect to the stationary rolling hand.

[0095] Example E9: The apparatus according to any one of Examples E4 to E8, wherein the fill and closure station comprises a rotating fill and closure unit, the rotating fill and closure unit comprising

[0096] a plurality of circumferentially arranged fill bars, each fill bar being configured for filling an object into an open tubular end of an inhaler article precursor; and

[0097] a plurality of circumferentially arranged closure bars, each closure bar being configured for at least partially closing an open tubular end of an inhaler article precursor;

[0098] wherein the fill bars and the closure bars are arranged in an alternating order, and

[0099] wherein the rotating fill and closure unit is arranged adjacent to the fill and closure rotating drum such that an axis of rotation of the rotating fill and closure unit coincides with an axis of rotation of the fill and closure rotating drum.

[0100] Example E10: The apparatus according to Example E9, wherein the fill bars and the closure bars are arranged in pairs, each pair comprising one fill bar adjacent to one closure bar.

[0101] Example E11 : The apparatus according to Example E10, wherein the rotating fill and closure unit comprises a plurality of circumferentially arranged neutral bars, and wherein one neutral bar is arranged between each pair of fill bar and closure bar.

[0102] Example E12: The apparatus according to any one of Examples E9 to E11, wherein each fill bar comprises a plunger barrel.

[0103] Example E13: The apparatus according to Example E12, wherein the plunger barrel comprises an opening for object insertion.

[0104] Example E14: The apparatus according to any one of Examples E9 to E13, wherein each closing rod is configured for at least partially closing an open tubular end of an inhaler article precursor by means of one or both of a flanging and a crimping.

[0105] Example E15: The apparatus according to any one of Examples E9 to E14, wherein the filling and closing station comprises a stationary track unit comprising a first stationary track for engaging with the filling rods and a second stationary track for engaging with the closing rods,

[0106] wherein the first stationary track is configured for manipulating a longitudinal position of a respective filling rod depending on an angular position of each filling rod,

[0107] wherein the second stationary track is configured for manipulating a longitudinal position of a respective closing rod depending on an angular position of each closing rod,

[0108] wherein the angular position refers to an angular displacement relative to an axis of rotation of the rotating filling and closing unit, and

[0109] wherein the longitudinal position refers to a position along a direction parallel to an axis of rotation of the rotating filling and closing unit.

[0110] Example E16: The apparatus according to Example E15, wherein each filling rod comprises a first cam connected to the first stationary track, and wherein each closing rod comprises a second cam connected to the second stationary track.

[0111] Example E17: The apparatus according to any one of Examples E4 to E16, wherein the filling and closing rotating drum is configured for receiving a plurality of double-length inhaler article precursors, each double-length inhaler article precursor comprising two open tubular ends;

[0112] wherein the filling and closing station is configured for filling and closing each of the two open tubular ends of the inhaler article precursor at the same time as the inhaler article precursor is being received by the filling and closing rotating drum,

[0113] wherein the filling and closing station comprises a further rotating filling and closing unit,

[0114] wherein the filling and closing rotating drum is arranged between the rotating filling and closing unit and the further rotating filling and closing unit, and

[0115] wherein the rotating filling and closing unit and the filling and closing rotating drum share a common rotation axis.

[0116] Example E18: The apparatus according to Example E17, comprising a cutting station for cutting the inhaler article precursor into halves, the cutting station being arranged downstream of the filling and closing station.

[0117] Example E19: The apparatus according to Example E18, comprising a closing station for closing the open tubular end of the split in half inhaler article precursor, the closing station being arranged downstream of the cutting station.

[0118] Example E20: The apparatus according to any one of Examples E9 to E19, wherein the filling and closing station comprises a feeder unit for supplying objects to the filling rod, the feeder unit comprising a movable conveying surface comprising a plurality of cavities, each cavity having an oblong shape configured for receiving a capsule object.

[0119] Example E21 : The apparatus according to Example E20, wherein the feeder unit comprises a capsule supply source for supplying capsules to the conveying surface, the capsule supply source being arranged to insert the capsules into the cavities such that the longitudinal axis of the inserted capsules is parallel to the longitudinal axis of the oblong cavities.

[0120] Example E22: The apparatus according to Example E20, wherein the feeder unit comprises a capsule supply source for supplying capsules to the conveying surface, the capsule supply source being arranged to insert the capsules into the cavities in an upright position such that the longitudinal axis of the inserted capsules is perpendicular to the longitudinal axis of the oblong cavities.

[0121] Example E23: The apparatus according to Example E22, wherein the oblong cavities comprise a deeper recess at one side of the oblong cavities for receiving the capsules in the upright position.

[0122] Example E24: The apparatus according to Example E22 or Example E23, wherein the feeder unit comprises a stationary laying hand arranged downstream of the capsule supply source and configured to rotate the capsules in the respective cavities ninety degrees by means of relative movement of the movable conveying surface with respect to the stationary laying hand such that the longitudinal axis of the inserted capsules is parallel to the longitudinal axis of the oblong cavities.

[0123] Example E25: The apparatus according to any one of Examples E21 to E24, wherein the capsule supply source comprises a vibrating feeder bowl.

[0124] Example E26: The apparatus according to any one of Examples E20 to E25, wherein the movable conveying surface forms part of an endless belt or a rotating drum.

[0125] Example E27: A method for manufacturing inhaler articles, the method comprising

[0126] providing a filling and closing rotating drum comprising a plurality of circumferentially arranged channels, each channel being configured for receiving an inhaler article precursor;

[0127] receiving in a first channel a first inhaler article precursor that is at least partially filled, the at least partially filled first inhaler article precursor comprising an open tubular end into which an object has been inserted;

[0128] receiving in a second channel a second inhaler article precursor that is empty comprising an open tubular end;

[0129] inserting an object into the open tubular end of the empty second inhaler article precursor while the second inhaler article precursor is being received in the second channel to receive an at least partially filled second inhaler article precursor; and

[0130] at least partially closing the open tubular end of the first inhaler article precursor into which the object has been inserted while the first inhaler article precursor is being received in the first channel to receive an at least partially closed first inhaler article precursor.

[0131] Example E28: The method according to Example E27, wherein the first channel and the second channel are adjacent channels.

[0132] Example E29: The method according to Example E28, comprising

[0133] removing the at least partially closed first inhaler article precursor from the filling and closing rotating drum to re-empty the first channel; and

[0134] moving the at least partially filled second inhaler article precursor from the second channel into the re-emptied first channel.

[0135] Example E30: The method according to any one of Examples E27 to E29, wherein the step of inserting the object into the open tubular end of the empty second inhaler article precursor and the step of at least partially closing the open tubular end of the first inhaler article precursor into which the object has been inserted are performed simultaneously.

[0136] Example E31 : The method according to any one of Examples E27 to E30, wherein the object is a capsule, preferably a dry powder capsule.

[0137] Features described in relation to one embodiment can equally apply to other embodiments of the application.

[0138] The present application will be further described by way of example only with reference to the accompanying drawings in which: BRIEF DESCRIPTION OF DRAWINGS

[0139] Figure 1 a and 1 b show a filling and closing rotating drum;

[0140] Figure 2 a and 1 b show a filling and closing rotating drum;

[0141] Figure 3 a and 1 b show a filling and closing rotating drum;

[0142] Figure 4 a and 4b show an apparatus for manufacturing inhaler articles;

[0143] Figure 5 a and 4b show an apparatus for manufacturing inhaler articles;

[0144] Figure 6 a and 4b show an apparatus for manufacturing inhaler articles;

[0145] Figure 6 a and 4b show an apparatus for manufacturing inhaler articles;

[0146] Figure 7 a and 4b show an apparatus for manufacturing inhaler articles;

[0147] Figure 7 a and 4b show an apparatus for manufacturing inhaler articles;

[0148] Figure 8 a and 4b show an apparatus for manufacturing inhaler articles;

[0149] Figure 9 a and 4b show an apparatus for manufacturing inhaler articles;

[0150] Figure 10 a and 4b show an apparatus for manufacturing inhaler articles;

[0151] Figure 11 a and 4b show an apparatus for manufacturing inhaler articles;

[0152] Figure 12 a and 4b show an apparatus for manufacturing inhaler articles;

[0153] Figure 12 a and 4b show an apparatus for manufacturing inhaler articles;

[0154] Figure 13 a and 4b show an apparatus for manufacturing inhaler articles; DETAILED DESCRIPTION

[0155] Figure 1a shows a portion of a filling and closing rotating drum of an apparatus for manufacturing inhaler articles in a cross-sectional view. The filling and closing rotating drum comprises a plurality of circumferentially arranged grooves 10. Adjacent grooves 10 are separated by a protruding edge 12. Each groove 10 comprises a first channel 14 and a second channel 16. Each channel 14, 16 is configured for receiving an inhaler article precursor 18. The first channel 14 and the second channel 16 are arranged between two adjacent protruding edges 12.

[0156] Each channel 14, 16 can comprise a vacuum channel 20 for holding the inhaler article precursor 18 in the channel 14, 16.

[0157] Figure 1 b shows Figure 1 a portion of the filling and closing rotating drum of a. In Figure 1 b, the filling and closing rotating drum is shown linear for the sake of clarity, but it is circular in Figure 1 a. The vacuum channels 20 are not shown in Figure 1 b. The distance "d" between adjacent channels 14, 16 as well as the width of the protruding edges is the same.

[0158] The height difference "h" between the bottom of the channels 14, 16 and the top of the adjacent protruding edges 12 can be between 1 mm and 10 mm, preferably between 2 mm and 8 mm, more preferably between 3 mm and 7 mm, more preferably between 4 mm and 6 mm. The height difference "h" is measured along a direction perpendicular to the rotation axis of the filling and closing rotating drum.

[0159] Advantageously, the filling and closing rotating drum is configured such that the height difference "h" is smaller than the height "x" of the inhaler article precursor 18 received in the channels 14, 16. Thereby, the optimization function of the optional rolling hand as explained in Figure 2 and 3 below can be achieved.

[0160] Figure 2 is Figure 1 a and lb of the filling and closing rotating drum together with a further depiction of the stationary rolling hand 22, which indicates a method of filling and closing the inhaler article precursors. The direction of movement is indicated by the arrow.

[0161] An empty inhaler article precursor 18a is received in a previously empty channel 16. At this time, the adjacent channel 14 of the same groove 10 is occupied by a filled inhaler article precursor 18b. Then, as the filling and closing rotary roller rotates clockwise, the empty inhaler article precursor 18a in the channel 16 is filled to become a filled inhaler article precursor 18b in the filling and closing section 24 of the roller, and the filled inhaler article precursor 18b in the channel 14 is closed to become a filled and closed inhaler article precursor 18c. Then, as the filling and closing rotary roller rotates further clockwise beyond the filling and closing section 24, the filled and closed inhaler article precursor 18c is removed from the channel 14, leaving the channel 14 empty. Then, as the filling and closing rotary roller rotates further clockwise, the groove 10 with the empty channel 14 and the channel 16 occupied by the filled inhaler article precursor 18b reaches the fixed roller hand 22. The fixed roller 22 pushes the filled inhaler article precursor 18b from the channel 16 into the adjacent channel 14. Thus, as the filling and closing rotary rollers rotate further, another introduced article precursor 18a can be received at the now-emptied channel 16.

[0162] Figure 3 The working principle of the fixed roller 22 is shown in more detail from a to 3d.

[0163] Figure 3 a shows an inhaler article precursor 18b receiving filling in channel 16 as the filling and closing rotary rollers approach the stationary roller 22.

[0164] Figure 3 Figures b and 3c illustrate how the stationary roller 22 pushes the filled inhaler article precursor 18b from channel 16 into the adjacent channel 14 as the filling and closing rotary rollers rotate further. The friction between the stationary roller 22 and the filled inhaler article precursor 18b is stronger than the suction force of the vacuum channel 20.

[0165] As in Figure 3 As shown in Figure d, as the filling and closing rotary rollers rotate further, the protruding edge 12 of the channel 14 near the now-filled inhaler article precursor 18b inhibits further movement of the filled inhaler article precursor 18b by the retaining roller 22. The distance between the top of the protruding edge 12 and the bottom of the retaining roller 22 is less than the diameter of the filled inhaler article precursor 18b.

[0166] Figure 4 A perspective view shows the equipment used to manufacture inhaler products. Figure 4 b shows a side view of the equipment used to manufacture inhaler articles. Figure 4The equipment in a and 4b includes a filling and sealing station. The filling and sealing station includes a filling and sealing rotary drum configured to receive multiple inhaler article precursors, for example... Figures 1 to 3 The filling and closing rotary drum as described in any one of the following. The filling and closing rotary drum includes circumferentially arranged projecting edges 12, some of which are located in... Figure 4 As shown in section a. Adjacent channels 14 and 16 (in Figure 4 (not shown in 4a and 4b) Inhaler article precursors 18a and 18b have been received. Each inhaler article precursor initially includes at least one open tubular end. The filling and sealing station is configured to both fill and seal at least one open tubular end of the inhaler article precursor while it is being received by the filling and sealing rotary drum.

[0167] The filling and sealing rotary rollers are configured to receive inhaler article precursors 18a, 18b such that the longitudinal axis 26 of each inhaler article precursor is oriented parallel to the axis of rotation 28 of the filling and sealing rotary rollers. The apparatus may include a fixed roller hand (in... Figure 4 (not shown in a and 4b).

[0168] The filling and sealing station includes a rotary filling and sealing unit 30. The rotary filling and sealing unit 30 includes a plurality of circumferentially arranged filling rods 32. Each filling rod 32 is configured to fill an object into the open tubular end of an unfilled inhaler article precursor 18a. The rotary filling and sealing unit includes a plurality of circumferentially arranged sealing rods 34. Each sealing rod 34 is configured to at least partially seal the open tubular end of the filled inhaler article precursor 18b. The filling rods 32 and sealing rods 34 are arranged in an alternating sequence. The rotary filling and sealing unit 30 is arranged adjacent to the filling and sealing rotary drum such that the axis of rotation 28 of the rotary filling and sealing unit 30 coincides with the axis of rotation 28 of the filling and sealing rotary drum. The rotary filling and sealing unit 30 moves in tandem with the rotation of the filling and sealing rotary drum.

[0169] Filling rods 32 and closing rods 34 are arranged in pairs. Each pair of filling rods 32 and closing rods 34 includes a filling rod 32 adjacent to a closing rod 34. The rotary filling and closing unit 30 includes a plurality of optionally circumferentially arranged neutral rods 36. A neutral rod 36 is arranged between each pair of filling rods 32 and closing rods 34. In addition to the filling rods 32 and closing rods 34, the presence of the neutral rod 36 facilitates the stacking of rods on the station. The presence of the neutral rod 36 may be particularly advantageous when all rods have the same diameter.

[0170] The filling and closing station comprises a stationary track unit 38. The stationary track unit 38 comprises a first stationary track 40 for engaging with the filling rods 32. The first stationary track 40 is configured for manipulating the longitudinal position of the respective filling rod 32 depending on the angular position of each filling rod 32 when the rotating filling and closing unit 30 is rotated around the rotation axis 28.

[0171] The stationary track unit 38 comprises a second stationary track 42 for engaging with the closing rods 34. The second stationary track 42 is configured for manipulating the longitudinal position of the respective closing rod 34 depending on the angular position of each closing rod 34 when the rotating filling and closing unit 30 is rotated around the rotation axis 28.

[0172] The filling and closing station can comprise an empty core 44 for the main drum motor shaft.

[0173] Figure 4 The filling and closing station of a can further comprise a station rotating part 46. Figure 4 The filling and closing station of a can further comprise a station stationary part 48. For example, the filling and closing rotating drum can be configured for receiving a plurality of double length inhaler article precursors, and the station rotating part 46 can be a further rotating filling and closing unit, and the station stationary part 48 can be a further stationary track unit. This is shown in Figure 4 b.

[0174] Figure 4 b shows in a side view an apparatus for manufacturing inhaler articles. The filling and closing rotating drum is configured for receiving a plurality of double length inhaler article precursors 18a, 18b. Each double length inhaler article precursor initially comprises two open tubular ends.

[0175] The filling and closing station can be configured for filling and closing each of the two open tubular ends of the inhaler article precursors 18, 18b at the same time while the inhaler article precursors 18a, 18b are being received by the filling and closing rotating drum. The filling and closing station comprises two rotating filling and closing units, namely the rotating filling and closing unit 30 and a further rotating filling and closing unit 46. The filling and closing rotating drum is arranged between the rotating filling and closing unit 30 and the further rotating filling and closing unit 46. The rotating filling and closing unit 30 and the further rotating filling and closing unit 46 and the filling and closing rotating drum share a common rotation axis 28.

[0176] The object 50, preferably a dry powder capsule, inserted into the empty inhaler article precursor 18a is also shown in Figure 4 b.

[0177] Figure 5Figures 4a and 4b show embodiments of a filling and closing station comprising a first fixed track 40 and a second fixed track 42.

[0178] Figure 5 Figure 4a shows a fixed track unit 38 (or a further fixed track unit 48) in a front view along the rotation axis 28. Each filling rod 32 comprises a first cam 52 connected to the first fixed track 40. Each closing rod 34 can comprise a second cam 54 connected to the second fixed track 42.

[0179] Figure 5 Figure 4b shows the filling and closing station in three different configurations (from top to bottom) depending on the angular position of the respective filling rods 32 and closing rods 34. Due to the separate first fixed track 40 and second fixed track 42, the movement of the filling rods 32 and closing rods 34 can be individualized. The left and right movement 56 of the filling rods 32 in a direction parallel to the rotation axis 28 is determined by the shape of the first fixed track 40. The left and right movement 58 of the closing rods 32 in a direction parallel to the rotation axis 28 is determined by the shape of the second fixed track 42.

[0180] Figure 6 Figure 4a shows a fixed track unit 38 (or a further fixed track unit 48) in a front view along the rotation axis 28. Each filling rod 32 comprises a first cam 52 connected to the first fixed track 40. Each closing rod 34 can comprise a second cam 54 connected to the second fixed track 42.

[0181] The tubular element 60 comprises an opening 66 for object insertion. The object can then be inserted into the open end of the empty inhaler article precursor 18a. For example, the plunger element 62 is moved along the longitudinal direction by means of the cam follower 64 as in Figure 5 In the embodiments of figures 4a and 4b, the cam follower is connected to the first fixed track 40 via the first cam 52.

[0182] Figure 6 Figure 4b shows the filling and closing station in three different configurations (from top to bottom) depending on the angular position of the respective filling rods 32 and closing rods 34. Due to the separate first fixed track 40 and second fixed track 42, the movement of the filling rods 32 and closing rods 34 can be individualized. The left and right movement 56 of the filling rods 32 in a direction parallel to the rotation axis 28 is determined by the shape of the first fixed track 40. The left and right movement 58 of the closing rods 32 in a direction parallel to the rotation axis 28 is determined by the shape of the second fixed track 42.

[0183] Figure 7a A pick-and-place system for an apparatus for manufacturing inhaler articles is shown in perspective view. A main drum 70 is shown, for example a fill and close rotating drum of any of the above-described embodiments. A main drum motor shaft 72 is also shown. The pick-and-place system comprises a station having a station first portion 74 and a station second portion 76. For example, the station can be the station rotating portion 46 or the station fixed portion 48 as described above. The pick-and-place system can allow easy and quick change of tools by replacing a previous tool with a different tool.

[0184] Figure 7 b A vibratory feeder bowl for a supply of objects, preferably capsules, is shown in cross-sectional view. The vibratory feeder bowl comprises a vibrating bowl 78, a ramp 80 and an outlet tube 82 for objects 50, preferably capsules 50, to exit the vibratory feeder bowl. The objects 50 are put into the vibratory feeder bowl as bulk material and exit the vibratory feeder bowl in alignment. In the shown embodiment, the tube 82 causes the capsules 50 to exit in vertical orientation.

[0185] Figure 8 A portion of an apparatus for manufacturing inhaler articles is shown in perspective view. Empty inhaler article precursors 18a are received on a main drum 70 of the apparatus, for example a fill and close rotating drum of any of the above-described embodiments. The apparatus comprises a station rotating portion 46, for example a rotating fill and close unit 30 as described above. The station rotating portion 46, 30 comprises a plurality of fill rods 32, for example Figure 6 a Fill rods 32 of an embodiment of the fill and close unit 30.

[0186] The apparatus comprises a feeder unit for supplying objects 50 to the fill rods. The feeder unit comprises a movable conveying surface 84 of an endless belt. The movable conveying surface 84 comprises a plurality of cavities 86. Each cavity 86 has an oblong shape configured for receiving a capsule object 50, preferably a dry powder capsule.

[0187] The feeder unit comprises a supply of capsules 50 for supplying the capsules 50 to the conveying surface 84. The supply of capsules 50 comprises an introduction tube 88. Preferably, the introduction tube feeds the capsules 50 to the movable conveying surface 84 at an angle of less than 45 degrees of the longitudinal axis of the capsules 50 relative to the movable conveying surface 84. Such an angle can ensure that the capsules 50 drop down the introduction tube 88 properly, while too small an angle can clog the tube. Such an angle can ensure that the capsules 50 drop into the cavities 86 properly, while too large an angle can result in vertical insertion.

[0188] The supply of capsules 50 is arranged for inserting the capsules 50 into the cavities 86 such that the longitudinal axis of the inserted capsules 50 is parallel to the longitudinal axis of the oblong cavities 86. The capsules 50 are inserted into the tubular elements 60 of the fill rods 32 via the openings 66.

[0189] Figure 9A portion of an apparatus for manufacturing inhaler articles is shown in perspective view. The apparatus comprises a feeder unit with a capsule supply for supplying capsules 50 to a movable conveying surface 84 of a rotating drum. The capsule supply is arranged to insert capsules 50 in an upright position into oblong cavities 86 of the movable conveying surface 84, such that the longitudinal axis of the inserted capsules 50 is perpendicular to the longitudinal axis of the oblong cavities.

[0190] The feeder unit comprises a stationary laying hand 90 arranged downstream of the capsule supply. The stationary laying hand 90 is shaped as a triangular curved plate. The stationary laying hand 90 is configured to rotate the capsules 50 in the respective cavities 86 ninety degrees by means of relative movement of the movable conveying surface 84 with respect to the stationary laying hand 90, such that the longitudinal axis of the inserted capsules 50 is parallel to the longitudinal axis of the oblong cavities 86.

[0191] Figure 10 a The mechanism of the stationary laying hand 90 of the apparatus of Figure 9 is shown in cross-sectional view (left-hand side) and front view (right-hand side). The stationary laying hand 90 is shown transparently.

[0192] Figure 10 b shows Figure 9 and 10 a preferred embodiment of the oblong cavities 86 of the apparatus. Figure 10 The oblong cavities 86 of b comprise a deeper recessed portion 87 at one side of the oblong cavities, in order to facilitate receiving capsules 50 in an upright position and turning the capsules 50 by the laying hand 90.

[0193] Figure 11 is another depiction of the mechanism of the embodiment of Figure 10 b. As shown at the left-hand side, the tip of the stationary laying hand 90 is slightly offset to the cavities, i.e. to the left side of the cavities 86. This can ensure that capsules 50 which are slightly curved out of the cavities 86 can be properly pushed into the cavities 86.

[0194] Figure 12 a shows an embodiment of a single length inhaler article precursor 18 (left-hand side) and an embodiment of a double length inhaler article precursor 18 (right-hand side). The inhaler article precursors 18 each comprise a paper tube or carton tube 92. Furthermore, the single length inhaler article precursor 18 comprises one holding plug 94 and the double length inhaler article precursor 18 comprises two holding plugs 94. The holding plugs 94 provide an inner end wall for the inserted objects 50. The dashed line indicates a cutting line of the double length inhaler article precursor 18 to be cut into halves 96.

[0195] Figure 12b shows a part of an apparatus configured for processing double length inhaler article precursors 18 in perspective view. The apparatus comprises a cutting station 98 configured for cutting double length inhaler article precursors 18 into halves 96. The cutting station 98 comprises a rotating cutter, the movement of which is indicated by the curved arrow. The cutting station 98 is disposed downstream of the filling and closing rotating drum.

[0196] Figure 13 a shows an embodiment of a crimping tool comprising a rotating cap 100.

[0197] The cap 100 is applied to the open end of the filled inhaler article precursor 18b while the latter is blocked against the tool 102 at its other end. Then as in Figure 13 a, the cap 100 is rotated (indicated by arrow 104) while pressing the tube (indicated by arrow 106), resulting in an article with a crimped and at least partially closed end 19c as shown in Figure 13 a on the right hand side.

[0198] Figure 13 b shows an alternative embodiment of a crimping tool comprising a rotating cap 100. The inhaler article precursors 18b, 18c are shown in Figure 13 b. In the embodiment of Figure 13 b, the rotating cap 100 is applied at each end of the inhaler article precursor 18b simultaneously, eliminating the need for a blocking tool 102 and simultaneously achieving closure of both ends. The fixed track 42 can guide the cam follower 64 attached to the lever 108. The rotating wheel 110 can move within the chamber 112.

[0199] In the case of processing double length inhaler article precursors, once the inhaler article precursors have been cut into halves and optionally diverted, they can be fed to a further drum in which crimping of the remaining free edges takes place. The crimping process follows the same concept already described above.

Claims

1. A filling and sealing rotary drum for an apparatus for manufacturing inhaler articles, the filling and sealing rotary drum comprising a plurality of circumferentially arranged grooves, The adjacent grooves are separated by a protruding edge, and Each groove includes a first channel configured to receive an inhaler article precursor and a second channel configured to receive an inhaler article precursor, the first channel and the second channel being arranged between two adjacent protruding edges.

2. The filling and sealing rotary drum of claim 1, wherein each channel includes a vacuum channel for holding the inhaler article precursor in the channel.

3. The filling and closing rotary drum according to claim 1 or claim 2, wherein the height difference between the bottom of the channel and the top of the adjacent protruding edge is between 1 mm and 10 mm, preferably between 2 mm and 8 mm, more preferably between 3 mm and 7 mm, and even more preferably between 4 mm and 6 mm, said height difference being measured along a direction perpendicular to the rotation axis of the filling and closing rotary drum.

4. An apparatus for manufacturing inhaler articles, the apparatus comprising a filling and sealing station, the filling and sealing station including filling and sealing rotary drums configured to receive a plurality of inhaler article precursors, each inhaler article precursor including at least one open tubular end. The filling and sealing station is configured to both fill and seal at least one open tubular end of the inhaler article precursor while it is being received by the filling and sealing rotary roller.

5. The device of claim 4, wherein the filling and sealing rotary roller is configured to receive the inhaler article precursor such that the longitudinal axis of each inhaler article precursor is oriented parallel to the rotation axis of the filling and sealing rotary roller, preferably wherein the filling and sealing rotary roller is oriented in the device such that the rotation axis of the filling and sealing rotary roller is oriented in a horizontal plane.

6. The device according to claim 4 or claim 5, wherein the filling and closing rotary drum is the filling and closing rotary drum according to any one of claims 1 to 3.

7. The apparatus of claim 6, further comprising a fixed roller arranged for pushing an inhaler article precursor from a first channel to an adjacent second channel by means of relative movement of the filling and closing rotating rollers relative to the fixed roller.

8. The apparatus according to any one of claims 4 to 7, wherein the filling and sealing station comprises a rotary filling and sealing unit, the rotary filling and sealing unit comprising... Multiple circumferentially arranged filling rods, each configured to fill an object into an open tubular end of an inhaler article precursor; and Multiple circumferentially arranged closure bars, each closure bar configured to at least partially close the open tubular end of the inhaler article precursor; The filling rod and the closing rod are arranged in an alternating sequence, and The rotary filling and sealing unit is arranged adjacent to the rotary filling and sealing drum such that the axis of rotation of the rotary filling and sealing unit coincides with the axis of rotation of the rotary filling and sealing drum.

9. The device of claim 8, wherein the filling rod and the closing rod are arranged in pairs, each pair including a filling rod adjacent to a closing rod.

10. The device according to claim 8 or claim 9, wherein the filling and sealing station includes a fixed track unit, the fixed track unit including a first fixed track for engaging with the filling rod and a second fixed track for engaging with the sealing rod. The first fixed track is configured to manipulate the longitudinal position of the corresponding filler rod depending on the angular position of each filler rod. The second fixed track is configured to manipulate the longitudinal position of the corresponding closing bar depending on the angular position of each closing bar. The angular position refers to the angular displacement relative to the rotation axis of the rotary filling and closing unit, and The longitudinal position refers to the position along the direction parallel to the rotation axis of the rotary filling and closing unit.

11. The device according to any one of claims 4 to 10, wherein the filling and closing rotary drum is configured to receive a plurality of double-length inhaler article precursors, each double-length inhaler article precursor comprising two open tubular ends; The filling and sealing station is configured to both fill and seal each of the two open tubular ends of the inhaler article precursor while it is being received by the filling and sealing rotary roller. The filling and sealing station includes additional rotary filling and sealing units. The filling and sealing rotary drum is arranged between the rotary filling and sealing unit and the additional rotary filling and sealing unit, and The rotary filling and sealing unit and the rotary filling and sealing drum share a common axis of rotation.

12. The device according to any one of claims 8 to 11, wherein the filling and sealing station includes a feeder unit for supplying an object to the filling rod, the feeder unit including a movable conveying surface including a plurality of cavities, each cavity having an elongated oval shape configured to receive a bladder-shaped object.

13. The device of claim 12, wherein the feeder unit includes a bladder supply source for supplying a bladder to the conveying surface, the bladder supply source being arranged to insert the bladder into the cavity such that the longitudinal axis of the inserted bladder is parallel to the longitudinal axis of the elongated cavity.

14. The device of claim 12, wherein the feeder unit includes a bladder supply source for supplying a bladder to the conveying surface, the bladder supply source being arranged to insert the bladder into the cavity in an upright position such that the longitudinal axis of the inserted bladder is perpendicular to the longitudinal axis of the elongated cavity, preferably. The elongated cavity includes a deeper recess on one side for receiving the sac in the upright position, and / or The feeder unit includes a fixed flat handle disposed downstream of the bladder supply source and configured to rotate the bladder in the corresponding cavity by ninety degrees by means of relative movement of the movable conveying surface relative to the fixed flat handle, such that the longitudinal axis of the inserted bladder is parallel to the longitudinal axis of the elongated cavity.

15. A method for manufacturing an inhaler article, the method comprising: A filling and closing rotary drum is provided, comprising multiple circumferentially arranged channels, each channel configured to receive an inhaler article precursor; A first inhaler article precursor, at least partially filled, is received in a first channel, the at least partially filled first inhaler article precursor including an open tubular end into which an object has been inserted; A hollow second inhaler article precursor, including an open tubular end, is received in the second channel; When the second inhaler article precursor is being received in the second channel, an object is inserted into the open tubular end of the empty second inhaler article precursor to receive at least partially filled second inhaler article precursor. as well as When the first inhaler article precursor is being received in the first channel, the open tubular end of the first inhaler article precursor into which the object has been inserted is at least partially closed to receive the at least partially closed first inhaler article precursor.

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