Inhalation device

Abstract

A passive inhalation device 100 for introducing at least one ingredient into an airflow for inhalation by a user without requiring a source of electrical energy comprises first 120 and second 118 port

Description

The present invention relates to an inhalation device and associated method for manufacturing the inhalation device. The present invention has particular, but not exclusive, relevance to single-use, or limited-use, passive inhalation devices that do not use a source of electrical power to provide heat for releasing compounds such as nicotine, and / or other active pharmaceutical ingredients (APIs), as part of an aerosol or vapour for inhalation by a user. Inhalation devices, such as electronic cigarettes (‘e-cigarettes’), vaporisers (‘vapes’), and the like are well known, smokeless, alternatives to more traditional tobacco based products such as traditional cigarettes, cigars, and pipes. Typically, these inhalation devices comprise an electronic nicotine delivery system (ENDS) for delivering a dose of vaporised nicotine solution for inhalation. An ENDS generally uses a heating element (referred to as an ‘atomiser’) to heat a nicotine containing liquid (or ‘e-liquid’) together with flavourings, propylene glycol, vegetable glycerine, and other ingredients to create an aerosol that can be inhaled. Similar electronic delivery systems are also often used for other APIs such as cannabis, tetrahydrocannabinol (THC), cannabidiol (CBD), and / or the like. Whilst many ENDS products have reusable parts, there is an increasing prevalence of devices that are designed to be disposed of after a single use. This has the potential to result in large amounts of associated waste hence causing a significant negative environmental impact, not least due to presence of the electronic parts and, in particular, the presence of a (typically lithium-ion) battery. For example, in addition to the CO2 emissions related to the disposal of such large quantities of ENDS products, there is a corresponding loss of precious materials (e.g., lithium), and an associated increased risk of environmental leeching of toxic chemicals, and / or fires in landfill / recycling centres. Although a number of unpowered (‘passive’) inhalation devices exist, either for delivery of nicotine based compounds or for non-nicotine based compounds, these can provide a relatively poor user experience. Moreover, existing unpowered devices often require assembly of a plurality of components that are made and packaged separately, thus increasing the complexity of the product, and the amount of (often non-biodegradable) material required to manufacture and package them. In one available unpowered nicotine API based inhalation device, for example, a separate tubular cartridge containing a nicotine based solution contained in a preinfused porous plug has to be assembled with a plastic mouthpiece, in a manner that breaks a seal on the cartridge, to allow release of gaseous nicotine when air is drawn through the plug. Whilst this device provides nicotine and can thus be used as part of a nicotine replacement therapy, it does not include any additional flavour of the type that users of modern vaporiser devices have become used to. Accordingly, the inhalation device provides a somewhat tasteless experience. In contrast, another available unpowered ‘vapourless’ inhalation device, is designed for the delivery of non-nicotine based flavoured inhalants. In this inhalation device, a tubular fibrous insert that carries a volatile compound for delivery by inhalation (e.g., a flavoured or scented inhalant such as an essential oil or the like) has to be inserted into a separate reusable delivery device. This inhalation device is designed to provide a pleasant, and psychologically similar, experience to that of smoking by allowing use with a range of inserts with different flavours, and mimicking the hand-to-mouth actions typically associated with smoking and vaping. However, as the inhalation device does not provide any nicotine (or other API with a similar effect) the device provides little more than a placebo effect to those seeking to use it to reduce or stop smoking or vaping. Moreover, the device is an expensive, reusable item which makes it less attractive to new or occasional users. The invention aims to provide an inhalation device and associated method of manufacture that overcomes or at least partially ameliorates one or more of the above issues. In one example disclosed herein there is described, an inhalation device for introducing at least one ingredient into an airflow for inhalation by a user without requiring a source of electrical energy, the inhalation device comprising: a first portion comprising at least one ingredient reservoir, each ingredient reservoir respectively holding a corresponding ingredient for subsequent introduction, during operation, into the airflow for inhalation by the user; and a second portion comprising at least one porous reservoir for receiving, from at least one said ingredient reservoir, the ingredient stored in that at least one said ingredient reservoir, for subsequent introduction into the airflow for inhalation by the user; wherein the second portion is configured to define at least one fluidic path through the inhalation device for respectively guiding the airflow, during inhalation by the user, from at least one air inlet, via each porous reservoir, for delivery to the user, wherein each ingredient reservoir comprises a respective seal for respectively sealing the corresponding ingredient held by that ingredient reservoir within that ingredient reservoir, and for separating the corresponding ingredient held by that ingredient reservoir from a corresponding porous reservoir, and wherein the inhalation device further comprises at least one ingredient release mechanism for facilitating the respective piercing, breaking or removal of each seal, by a user during operation, to respectively allow the ingredient held by each ingredient reservoir to pass into the corresponding porous reservoir. The at least one ingredient release mechanism may comprise at least one seal breaking element, each seal breaking element being configured for piercing or breaking a corresponding seal of a respective ingredient reservoir when a user applies a force for pushing that seal breaking element through that seal. The at least one seal breaking element may comprise at least one seal breaking element that is provided within at least one ingredient reservoir and that is configured to be pushed, into a corresponding cavity holding a corresponding porous reservoir, through the corresponding seal when the user applies the force. The at least one seal breaking element may comprise at least one seal breaking element that is provided as part of at least one porous reservoir and that is configured to be pushed into a corresponding ingredient reservoir through the corresponding seal when the user applies the force. The at least one seal breaking element may comprise at least one seal breaking element that is provided on the inhalation device externally to the at least one ingredient reservoir. The at least one ingredient release mechanism may comprise at least one frangible line provided in at least one corresponding seal, each frangible line being configured to respectively break when a user performs a corresponding seal breaking action. The at least one ingredient release mechanism may comprise at least one seal pulling feature configured for breaking or removal of at least one corresponding seal when a user pulls the seal pulling feature. The at least one seal pulling feature may be configured to peel back at least a portion of at least one corresponding seal when a user pulls the seal pulling feature. The at least one seal pulling feature may comprise a pull tab. The at least one ingredient release mechanism may be configured to break the seal when a user performs at least one of: an action to twist the inhalation device; and / or an action to bend the inhalation device. The first portion may comprise at least one ingredient reservoir holding an ingredient comprising at least one active pharmaceutical ingredient (API). The first portion may comprise at least one ingredient reservoir holding an ingredient comprising at least one flavouring. The first portion may comprise a plurality of the ingredient reservoirs. Each ingredient reservoir of at least a subset of two or more of the plurality of ingredient reservoirs may respectively hold the same ingredient. Each ingredient reservoir of at least a subset of two or more of the plurality of ingredient reservoirs, may respectively hold a different ingredient. The second portion may comprise a plurality of the porous reservoirs, each porous reservoir being configured for receiving the ingredient held in a different respective ingredient reservoir of the plurality of the porous reservoirs when a corresponding seal is broken. A first porous reservoir of the plurality of the porous reservoirs may configured for introducing a first ingredient into the airflow by generating an aerosol containing the first ingredient, a second porous reservoir of the plurality of the porous reservoirs may be configured for introducing a second ingredient into the airflow by a mechanism other than by generating an aerosol, and the first porous reservoir may be located downstream of the second porous reservoir within the airflow. At least one porous reservoir may have a location, size, and / or pore structure that is configured for introducing a corresponding ingredient into the airflow by generating an aerosol. At least one porous reservoir may have a location, size, and / or pore structure that is configured for introducing a corresponding ingredient into the airflow by evaporation into a gas-phase vapour. The second portion may include an inhalation piece for insertion into a mouth or nostril(s) of a user. The inhalation piece may include at least one feature for facilitating the mixing of air into which a plurality of different ingredients has been introduced, as that air is drawn into the mouthpiece, via the at least one fluidic path, during inhalation by the user. The second portion may be configured to define a plurality of fluidic paths through the inhalation device, each fluidic path being respectively configured to guide the airflow, during inhalation by the user, from the at least one air inlet, via a different respective porous reservoir, into a mouth of the user. The inhalation device may be configured for the sealing, unsealing, and resealing of at least one fluidic path. The inhalation device may be at least partially formed of at least one of a cardboard, a compressed pulp, and / or another biodegradable material. In one example disclosed herein there is described, a method of manufacturing an inhalation device as summarised above, the method comprising: forming the first part and the second part, and securing the first part to the second part to form the inhalation device. The forming of the first part and the second part, and the securing the first part to the second part to form the inhalation device, may be performed as part of a reel-to-reel or roll-to-roll manufacturing process for bulk production of such inhalation devices. Embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings in which: Figures 1(a) and 1(b) are each a simplified three-dimensional illustration of an inhalation device as respectively viewed from a different perspective; Figure 2 is a simplified exploded illustrative view showing the main components of the inhalation device 100 of Figures 1(a) and 1(b) in simplified cross-section; Figure 3 is a simplified cross-sectional illustrative view showing the inhalation device 100 of Figures 1 (a) and 1 (b) when assembled; Figure 4 is a simplified cross-sectional illustrative view showing a partially used inhalation device of the type shown in Figures 1(a) and 1(b); and Figures 5(a) and 5(b) are each a simplified three-dimensional illustration of the inhalation device with a different sealing mechanism. Overview An example inhalation device will now be described in overview with reference to Figures 1(a) and 1(b) each of which is simplified three-dimensional illustration of an inhalation device 100 as respectively viewed from a different perspective. It will be appreciated that the illustrated example represents just one way in which the inhalation device may be implemented to provide a number of corresponding technical contributions. Accordingly, following a detailed description of the illustrated inhalation device provided below, a number of possible modifications and alternatives to the illustrated inhalation device will be described. The illustrated inhalation device 100 is a single-use (or limited-use) unpowered (or passive) inhalation device that is designed both to minimise the negative environmental impacts associated with disposable devices, and to improve the user experience associated with using passive devices. The inhalation device 100 comprises a layered structure including: an airflow layer 110, an inhalation compound containment layer 112, and a membrane layer 114. The airflow layer 110 comprises a mouthpiece 116, and a plurality of wick chambers / cavities 118-1, 118-2 (118) that are arranged, in fluidic communication with the mouthpiece 116, to provide one or more fluidic paths that extend through the inhalation device 100 from one or more air inlets (not visible in Figures 1 (a) and 1 (b)), via the wick chambers 118, to the mouthpiece 116. As described in more detail later, each of the wick chambers 118 includes a porous reservoir or ‘wick’ (not visible in Figures 1(a) and 1(b)) for receiving, during use, one or more liquid ingredients for introduction to a flow of air for inhalation. The inhalation compound containment layer 112 is provided with, in the illustrated example, a plurality of ingredient reservoirs 120-1, 120-2 (120). Each ingredient reservoir is respectively configured for separate storage of one or more liquid ingredients for introduction to the flow of air through the device for inhalation during use (e.g., as a vapour / aerosol). The ingredients may comprise, for example, one or more active pharmaceutical ingredients (such as a nicotine based API or the like) and / or one or more flavourings. It will be appreciated that when the inhalation device 100 is assembled, the ingredient reservoirs 120 may hold the same or different ingredients and may hold the same or different quantities of those ingredients. In the illustrated example, each of the ingredient reservoirs 120 is in the form of a respective deformable blister (e.g., similar to the blisters of a blister pack for packaging pharmaceutical products). The membrane layer 114 comprises a pierceable membrane that extends between the airflow layer 110 and the inhalation compound containment layer 112 to provide, for each ingredient reservoir 120, a respective breakable seal that separates that ingredient reservoir 120, from the interior of a corresponding wick chamber 118. As described in more detail later, the inhalation device 100 is provided with a number of ingredient release features 122-1, 122-2 (122). Each ingredient release feature 122 is configured to facilitate the breaking, by a user during use, of the respective breakable seal that separates the corresponding ingredient reservoir 120 from the interior of the associated wick chamber 118. The breaking, by a user during use, of a breakable seal thus allows the ingredient stored in the corresponding ingredient reservoir 120 to flow into the corresponding wick chamber 118 and hence the porous wick provided in that wick chamber 118. In the illustrated example, the ingredient release features 122 are provided as part of the blister like ingredient reservoirs 120 such that a user pressing, during use, on a given ingredient reservoir 120 with sufficient force will deform that ingredient reservoir 120 and pierce the corresponding breakable seal. Beneficially, therefore, this deformation not only causes the breakable seal to be broken, but also provides a force that urges the ingredient stored in the corresponding ingredient reservoir 120 to enter into the corresponding wick chamber 118 under pressure, thus enhancing the flow of the ingredient into (and hence saturation of) the associated wick. In typical operation, when a user is ready to use the inhalation device 100, the user can prepare the inhalation device 100 by applying the ingredient release feature(s) 122, in respect of the ingredient(s) that the user wishes to use, to cause the corresponding ingredient(s) to flow into the corresponding wick chamber(s) and hence load the associated porous reservoir(s) / wick(s) with the corresponding ingredient(s). The user can then place the mouthpiece 116 in their mouth and draw air from the air inlet(s), via the fluidic path(s), through the wick chambers 118, and the mouthpiece 116, into their mouth as they inhale. As the air passes through I over the porous reservoirs / wicks in the wick chambers 118, any ingredient(s) loaded into those reservoirs / wicks may passively release some of the ingredient into the passing airflow to form a vapour / aerosol. In summary, therefore, the inhalation device 100 beneficially provides for the potential introduction of both an API and a flavour (or either an API or a flavour), into the flow of air through the inhalation device, for inhalation during use (e.g., by generation of a vapour / aerosol) without requiring a source of power to provide electrical heating. The simplicity of the inhalation device 100 allows the possibility that a relatively high proportion of the device can be manufactured from biodegradable or recyclable materials. By avoiding any requirement for a battery and associated electronics, therefore, the inhalation device 100 can be manufactured entirely from materials that are less harmful to (or do not harm) the environment following disposal. The potential environmental harm caused by disposal is therefore minimised. The storage of each (potentially different) ingredient in a separate respective sealed ingredient reservoir (blister) for release by piercing the membrane at the time of use inhibits the potential for adverse interaction between ingredients before use, and can thus beneficially help to prolong the shelf-life of the inhalation device 100 (compared, for example, to storage within a pre-infused porous element, wick, or the like). Moreover, by integrating, within the same single component, the sealed ingredient reservoirs for storing the flavour and / or API ingredient(s), and the associated ingredient release feature(s) for releasing those ingredient(s), the requirement for associated assembly by a user is beneficially avoided. This also has the potential to provide distribution benefits by consolidating the various elements in a single device. The ability to respectively release each ingredient into a different porous reservoir (wick) after an associated seal has been broken beneficially allows for the fluidic flow path(s) I release mechanism(s) to be respectively tailored to the release of an associated ingredient (e.g., by appropriate configuration of the pore size, pore shape, volume, surface area (and / or the like) of the wick and / or the cross-sectional area of the corresponding fluidic path(s), or appropriate portions of those fluidic path(s), through which air is drawn). The configuration of the inhalation device 100, especially the ability to deliver API and a flavour together, aligns with the typical behavioural patterns of people that use disposable vaporiser devices whilst, at the same time, providing a potentially improved user experience compared, for example, with at least some existing passive (unpowered) devices. Accordingly, the inhalation device 100 provides a single-use (or limited-use) disposable device that has the potential to appeal to the user behaviours that have caused disposable, powered, vaporiser devices to become popular. The inhalation device 100 introduced above, will now be described in more detail with reference to Figures 2 to 4. Inhalation Device Components, Assembly, and Use Figure 2 is a simplified exploded view showing the main components of the inhalation device 100 of Figures 1(a) and 1(b). Figure 3 is a simplified cross-sectional view showing the inhalation device 100 of Figures 1(a) and 1(b) in an assembled form. Figure 4 is a simplified cross-sectional view showing a partially used inhalation device 100 of the type shown in Figures 1 (a) and 1 (b). In Figures 2 and 3, the airflow layer 110, inhalation compound containment layer 112, and membrane layer 114, are shown in simplified cross-section for illustrative purposes. The mouthpiece 116 is formed at a first distal end of the airflow layer 110 and comprises one or more air outlets for air drawn through the wick chambers 118, via the fluidic path(s) defined by the airflow layer 110. It will be appreciated that the airflow layer 110 may be configured to define an entire internal boundary of the mouthpiece 116 ( / .e., one or more air cavities within the mouthpiece) and associated air outlet(s). Nevertheless, the airflow layer 110 may be configured to define only a part of the internal boundary of the mouthpiece 116 and associated airoutlet(s). In this case, the membrane layer 114 and / or a surface of the inhalation compound containment layer 112, at an interface between the airflow layer 110 and the membrane layer 114 / inhalation compound containment layer 112, may complete the internal boundary of the mouthpiece 116 ( / .e., by covering the air cavity / cavities formed within the mouthpiece) and the associated air outlet(s). The mouthpiece 116 is fluidically connected to a first of the wick chambers 118-1 by a first fluidic flow restrictor 124-1 provided at a downstream end of the first of the wick chambers 118-1. The first fluidic flow restrictor 124-1 may comprise a single narrower section of the fluidic path or may comprise a plurality of holes or pores of appropriate dimensions. The first of the wick chambers 118-1 is fluidically connected to a second of the wick chambers 118-2 by a second fluidic flow restrictor 124-2 provided at a downstream end of the second of the wick chambers 118-2. The second fluidic flow restrictor 124-1 may comprise a single narrower section of the fluidic path or may comprise a plurality of holes or pores of appropriate dimensions. The first of the wick chambers 118-1 is fluidically connected to one or more air inlet(s) 126 provided, for example, at a second distal end of the airflow layer 110 opposite the mouthpiece 116 via which air can be drawn into the device during inhalation be a user. Hence, air drawn through the inhalation device 100 in operation follows a general path illustrated by arrow F albeit potentially subject to turbulent flow as it passes through the wick chambers 118 and via the fluidic flow restrictors 124-1, 124-2 (124). The fluidic flow restrictors 124 and air inlet(s) 126 are mutually configured to provide, in operation, the necessary airflow (including droplets of API / flavouring or the like), and airflow resistance, to require an inhalation pressure that is similar to that of a conventional vape or e-cigarette. It will be appreciated that each fluidic flow restrictor 124 may have a different respective configuration (e.g., size, shape, number, and size of holes / pores, and / or the like). Moreover, the respective fluidic flow restrictor 124, at the downstream end of each wick chamber 118, may be configured in dependence on the characteristics of the ingredient 130-1, 130-2 (130) that is released into that wick chamber 118 during use. Each wick chamber 118 is configured to receive a respective porous reservoir / wick 128-1, 128-2 (128) when the inhalation device 100 is assembled (as seen in Figure 3). It will be appreciated that the airflow layer 110 may be configured to respectively define only a part of the internal boundary of each wick chamber 118 ( / .e., part of the cavity into which the wick is received during assembly). In this case, the membrane layer 114, at an interface between the airflow layer 110 and the membrane layer 114, may complete the internal boundary of the wick chambers 118 ( / .e., by covering the cavities into which the wicks are received during assembly) to form corresponding sealed chambers when the inhalation device 100 is assembled (as seen in Figure 3). Nevertheless, the airflow layer 110 may be configured to respectively define an entire internal boundary of each wick chamber 118 to form a corresponding sealed chamber. In this case a portion of the airflow layer 110 forming an interface between each wick chamber 118 and the membrane layer 114 / ingredient reservoirs 120 of the inhalation compound containment layer 112 may be breakable (e.g., pierceable) to allow the ingredient stored in the corresponding ingredient reservoir 120 to flow, during use, into the corresponding wick chamber 118, and hence the porous wick 128 provided in that wick chamber 118. It will be appreciated that each porous reservoir / wick 128 may have a different respective configuration (e.g., number, size, and structure of the pores, and / or shape of the wick and / or the like), and hence the configuration of the corresponding wick chambers 118 may also be different. Moreover, the respective porous reservoir / wick 128 (e.g., number, size, and structure of the pores, and / or shape of the wick and / or the like) may be configured in dependence on the characteristics of the ingredient 130 that is released into that porous reservoir / wick 128 during use. For example, when the inhalation device 100 is assembled, one or both of the porous reservoirs / wicks 128 may be held / positioned in the fluidic path(s) such that air passes over the surface of the porous reservoir(s) / wick(s) 128 and / or is pulled through the porous reservoir(s) / wick(s). Further, the size, shape, and location of each porous reservoir / wick 128 (and / or the size, shape, and pore structure of that porous reservoir / wick 128) may be respectively configured such that the interaction between that porous reservoir / wick 128 and the fluidic path(s) is the same as, or different from, that of the other porous reservoir / wick 128. The size, shape, and location of each porous reservoir / wick 128 may, for example, vary depending on the required surface area for evaporation, mode of aerosol generation, and / or the required resistance to drawing air through the inhalation device 100 forthat porous reservoir / wick 128 and associated ingredient 130. It will be appreciated that the ingredients 130 that may be used in the inhalation device 100 may not, necessarily, need to be formed into an aerosol during use. For example, ingredients may be introduced to the airflow by evaporation into a gas-phase vapour. Accordingly, where aerosol generation is not required for a particular ingredient then the porous reservoir / wick 128 need not be configured for the purposes of generating an aerosol. Beneficially, where the inhalation device 100 is to be used with both an ingredient that is to be introduced to the airflow by generation of an aerosol and an ingredient that is introduced to the airflow by a mechanism other than generation of an aerosol, the aerosol generating porous reservoir / wick 128 may, beneficially, be located downstream of the non-aerosol generating porous reservoir / wick 128 thereby inhibiting / minimising loss of the aerosol. Similarly, where the inhalation device 100 is to be used with ingredients that are to be introduced to the airflow by generation of aerosol with particles of different sizes, the porous reservoir / wick for generating an aerosol with smaller particles may be positioned upstream of a porous reservoir / wick for generating an aerosol with larger particles. Conversely if an ingredient is particularly prone to deposition, then this may be introduced to the airflow further downstream than another ingredient that is not (or is less) prone to deposition. As mentioned above, to help improve shelf life prior to use, the inhalation compound containment layer 112 has a plurality of ingredient reservoirs 120 (e.g., in the form of deformable blisters) that are each respectively configured for separate storage of one or more ingredients 130 (flavour and / or API) for introduction to a flow of air for inhalation during use. When the inhalation device 100 is assembled, each ingredient reservoir 120 is respectively aligned with the corresponding wick chamber 118 (and associated porous reservoir / wick 128) for receiving the liquid ingredient 130 held by that ingredient reservoir 120. Beneficially, as only a relatively small quantity of the ingredients 130 need to be held in the ingredient reservoirs 120, separate from porous reservoirs / wicks 128, the need to use high barrier materials (that are typically less sustainable) is minimised. The membrane layer 114, in this example, is formed of a pierceable material that is provided between each ingredient reservoir 120 and the corresponding wick chamber 118 to seal the ingredient 130 held in that ingredient reservoir 120. The membrane layer 114 may, for example, comprise a protective film (e.g., a foil film or the like) and, where appropriate, an adhesive for adhering the protective film to the inhalation compound containment layer 112 and (if necessary) the airflow layer 110. The membrane layer 114, in the illustrated example, extends the full extent of the interface between the airflow layer 110 and the inhalation compound containment layer 112. This can be beneficial for simplifying the process for manufacturing the inhalation device 100. Nevertheless, the membrane layer 114 may, instead, comprise a respective discrete membrane cover for each ingredient reservoir 120 (e.g., that is adhered to the inhalation compound containment layer 112 around the boundary of that ingredient reservoir 120). In this case the airflow layer 110 and the inhalation compound containment layer 112 may be adhered to one another at their interface (where the membrane layer 114 is not located). As mentioned above, the inhalation device 100 is provided with an ingredient release mechanism comprising a number of ingredient release features 122. As seen in Figures 2 and 3, in this example the ingredient release features 122 comprise sharp pointed (e.g., conical) protrusion that respectively extend from an interior surface of each ingredient reservoir 120 (in this example a surface that is furthest from the membrane layer 114). Each protrusion 122 extends, within the ingredient reservoir 120, towards the membrane layer 114, and the corresponding wick chamber 118 (in this example in a direction that is substantially orthogonal to the membrane layer). In the illustrated example, each protrusion 122 is formed form the same material as (and is integrated with) the ingredient reservoir 120 thereby simplifying manufacture. It will, nevertheless, be appreciated that the protrusion 122 may be formed of another material (and / or a separate element may be provided within the ingredient reservoir 120 for facilitating piercing / breaking of the seal). Each protrusion 122 is configured for piercing part of the membrane layer 114 that seals the ingredient reservoir 120 within which that protrusion 122 is located. Specifically, as seen for one of the ingredient reservoirs 120-1 in Figure 4, each protrusion 122 is configured to be pushed through the corresponding part of the membrane layer 114 that seals the corresponding ingredient reservoir 120 when a user presses on and deforms that ingredient reservoir 120. Hence, the ingredient stored in the corresponding ingredient reservoir 120 is urged, under the pressure induced by the user pressing on that ingredient reservoir 120, to enter into the corresponding wick chamber 118 and hence into the associated porous reservoir / wick 128. Thus, to activate / prime the inhalation device, a user need only crush one or more ingredient reservoirs 120, piercing the foil with the corresponding sharp feature(s) 122, and collapsing the ingredient reservoir(s) 120 to force ingredient(s) into the porous reservoir(s) / wick(s). The liquid ingredient 130 stored in a particular ingredient reservoir 120 pressed by the user is thus released from that ingredient reservoir 120 into the associated porous reservoir / wick 128 in a controlled manner. The controlled piercing is beneficial as it helps to inhibit uncontrolled leaking of the ingredient 130, for example out of the sides of the inhalation device 100. It will be appreciated that the use of integral protrusions 122 of the type described above represent only one of a number of ways in which the inhalation device 100 may be primed for use by unsealing I breaking the seal of one or more ingredient reservoirs 120 in accordance with a user’s preference. A number of other possible methods are summarised later, by way of example only, in the sub-section titled Modifications and Alternatives. Inhalation device Manufacture The simple layered structure of the inhalation device 100 allows the inhalation device 100 to be manufactured using a reel-to-reel (or roll-to-roll) manufacturing process thereby increasing the scalability of manufacture compared to more complex existing inhalation devices (both powered and unpowered). For example, in the specific example described above, the inhalation compound containment layer 112 (including the ingredient reservoirs 120 / blisters) and airflow layer 110 (including the mouthpiece 116 and wick chambers 118 defining the fluidic path(s)) may, beneficially, be fabricated by thermoforming the layers from a continuous sheet of polyethylene terephthalate (PET) or the like. Each ingredient reservoir 120 / blister can then be filled with the corresponding ingredient and capped with the membrane layer 114 (e.g., comprising a layer of adhesive and foil, film, or other membrane material). An appropriate porous reservoir / wick 128 may then be respectively introduced to each wick chamber 118 of the airflow layer 110. The wick chambers 118 may then be similarly capped with an appropriate material, further membrane layer, or the like (if necessary). Nevertheless, the wick chambers 118 may be left open for effective capping by the inhalation compound containment layer 112 (and associated membrane layer 114) in the next stage of fabrication. The inhalation compound containment layer 112 and the airflow layer 110 may then be joined to one another using any appropriate technique (e.g., by heat sealing, or using an appropriate adhesive). It will be appreciated that, where a reel-to-reel (or roll-to-roll) manufacturing process is used, multiple inhalation devices may be supplied to vendors in a reel / roll format, rather than individually, and may then be removed from that reel / roll at the point of sale. Nevertheless, whilst supplying in a reel / roll format has the environmental benefit that packaging may be reduced, this does not preclude the possibility that the inhalation devices are supplied in an individually packaged form. Whilst PET is not biodegradable, it will be appreciated that the configuration of the inhalation device 100 is more conducive to the recycling of any parts made from PET. Moreover, to further reduce their environmental impact (e.g., arising from disposal in landfill or the like), at least some of the parts of the inhalation device 100 may be manufactured using biodegradable materials such as biodegradable films (e.g., for the membrane layer(s)), cardboard, formed pulp, or other biodegradable or compostable materials. These materials are particularly applicable for components where high barrier properties are not needed. For example, the relatively small ingredient reservoirs and the membrane layer (or the part of the membrane layer that seals the ingredient reservoirs) may be formed of materials with higher barrier properties whereas the rest of the device may be made of materials with lower barrier properties. It will be appreciated that the need for materials with higher barrier properties will also depend on the intended use life of the inhalation device 100 and nature of the ingredients used. Where only a short use life is needed materials with lower barrier properties can be used. Similarly, for powdered ingredients, it may be possible to use materials with lower barrier properties for the ingredient reservoirs. Modifications and Alternatives A detailed example of an inhalation device has been described above. As those skilled in the art will appreciate, a number of modifications and alternatives can be made to the above inhalation device whilst still benefiting from one or more of the technical contributions that the concepts embodied in that inhalation device provide, and / or providing one or more additional technical contributions. For example, whilst, in the illustrated example described above, liquid ingredients were described, the inhalation device could be adapted for use with non-liquid (e.g., powdered) ingredients. Moreover, it will be appreciated that whilst, in the illustrated example described above, two ingredient reservoirs, associated wick chambers and porous reservoirs / wicks are provided, a similar inhalation device could be configured with a single ingredient reservoir containing an API, a flavouring, and / or the like, together with a single associated wick chamber and porous reservoir / wick. Alternatively, a similar inhalation device could be configured with more than two ingredient reservoirs (e.g., multiple blisters of flavour / API ingredient containing liquids / powders). For example, in addition to the first two ingredient reservoirs described in respect of the illustrated example, a similar inhalation device could have one or more further ingredient reservoirs, each further ingredient reservoir holding the same ingredient (e.g., API, a flavouring, and / or the like), as a respective one of the first two ingredient reservoirs. The provision of one or more further ingredient reservoirs in this manner allows for a more prolonged usage (and / or some limited reuse) of the inhalation device as one of the ingredient reservoirs holding the same ingredient can be used when another has been exhausted, thereby, extending the use life of the device (with relatively minimal additional material compared, for example, to a disposable electronic vaporiser). Moreover, a different number of the ingredient reservoirs holding the same ingredient may be used at the same time to increase the amount of vapour / aerosol released to suit the preference of a user. Alternatively, or additionally, in addition to the first two ingredient reservoirs described in respect of the illustrated example (and possibly one or more further ingredient reservoirs holding the same ingredient), a similar inhalation device could have one or more extra ‘selection’ ingredient reservoirs, each further ingredient reservoir holding a different respective ingredient (e.g., a different flavouring, and / or the like). The provision of one or more extra ingredient reservoirs in this manner allows the user to select which ingredient (or combination of ingredients) to release (e.g., a preferred flavouring or combination of flavourings) to suit the preference of a user at a particular time. It will be appreciated that where one or more further / selection ingredient reservoirs are provided, each ingredient reservoir may be associated with a different respective (fresh) wick, which can contribute to maintaining the experience of the user. Nevertheless, a plurality of ingredient reservoirs may be associated with the same wick (e.g., a plurality of ingredient reservoirs holding the same ingredient or a plurality of ingredient reservoirs holding different ingredients of a particular flavour combination), which can decrease the complexity of the product and simplify manufacture. It will be appreciated that whilst, in the illustrated example described above, the wick chambers and associated wicks are provided in the same fluidic paths, this need not be the case. The inhalation device could be configured with a plurality of independent fluidic paths with at least one respective independent fluidic path passing through each wick chamber. In this case, the mouthpiece could be configured to receive air drawn through the independent fluidic paths passing through the different wick chambers and to promote the mixing of the air drawn via the different independent fluidic paths before it enters the mouth of the user (e.g., by including one or more features for introducing turbulence to the airflows and / or the like). It will be appreciated that in scenarios in which the inhalation device is to be used with both an ingredient that is to be formed into an aerosol and an ingredient that is not to be formed into an aerosol, this may beneficially avoid the need to locate an aerosol generating porous reservoir / wick downstream of a non-aerosol generating porous reservoir / wick. It will be further appreciated that even where a plurality of independent fluidic paths is not provided, the mouthpiece could be configured to promote further mixing of the air drawn into the mouthpiece. It will be appreciated whilst, in the illustrated example described above, a single membrane layer is provided that seals the ingredient reservoir(s) (and possibly the wick chambers also), a plurality of membrane layers may be provided. For example, one membrane layer could be provided that covers the ingredient reservoir(s) (e.g., extending the across part(s) or all of the inhalation compound containment layerwhere it interfaces with the airflow layer), and one membrane layer could be provided that covers the wick chamber(s) (e.g., extending the across part(s) or all of the airflow layer where it interfaces with the inhalation compound containment layer). It will be appreciated whilst, in the illustrated example described above, an ingredient release mechanism is used that comprises integral protrusions that are used for piercing the membrane layer and releasing the ingredient(s), other techniques may be used to facilitate unsealing I breaking I removal of the seal of the ingredient reservoir(s) possibly in addition to, or as an alternative to, the use of an integral protrusion. For example, the membrane layer(s) may be respectively provided with one or more frangible (e.g., pre-perforated I partially perforated) lines that extend at least partially across the part of the membrane layer(s) that seals each ingredient reservoir where the membrane layer(s) is to be preferentially broken. Each frangible line may be configured to respectively break when a user presses on and deforms the corresponding ingredient reservoir. The frangible line(s) may be configured to break simply as a result of the pressing action of the user (without any other ingredient release features), or may be assisted by a seal breaking element (which may be sharp or blunt) provided in the corresponding ingredient reservoir or elsewhere in the inhalation device (e.g., on a corresponding wick, in a corresponding wick chamber, and or the like). In another example the porous reservoir / wick may be rigid and may have a shape that is configured to be pushed through the membrane layer(s) into the ingredient reservoir, thus piercing / splitting the membrane layer(s) at a preferred location in the process, in a controlled manner (possibly facilitated by one or more frangible lines as described above). In yet another example, a feature elsewhere on the inhalation device, external to the ingredient reservoir(s) (e.g., forming part of the corresponding wick chamber or the like), may be configured to pierce / split the membrane layer(s) in a controlled manner (possibly facilitated by one or more frangible lines as described above). In another example, the membrane layer(s) may be configured to allow a user to peel at least the part of a membrane layer(s) sealing an ingredient reservoir off, or to allow at least the part of a membrane layer(s) adjacent an ingredient reservoir to be directly broken by the user. For example, the respective part of the membrane layer(s) adjacent each ingredient reservoir may be provided with a pull tab that is fixed to (or an integral part of) the corresponding part of the membrane layer(s), extends out of the inhalation device (e.g., from between the airflow layer and the inhalation compound containment layer), and is configured to allow the user to pull the tab and hence rip / split / remove that part of the membrane layer(s) in a controlled manner (possibly facilitated by one or more frangible lines as described above). In another example, the inhalation device may be configured in a manner that allows it to be twisted (e.g., relative to its longitudinal axis) or bent (e.g. relative to a lateral axis) to create strain in the membrane layer(s) to break the membrane layer(s) at one or more preferential locations in a controlled manner (possibly facilitated by one or more frangible lines as described above). The inhalation device may also be configured for unsealing the inhalation device prior to use to allow fluidic communication between the internal fluidic path(s) and the ambient environment external to the inhalation device and thus allow air to flow through the device. The inhalation device may also be configured to allow resealing of the inhalation device after a use to inhibit fluidic communication between the internal fluidic path(s) and the ambient environment external to the inhalation device and thus inhibit air to flow through the device, thereby prolonging the use life of the product. Referring to Figure 5a, for example, the inhalation device may be provided with one or more removable and replaceable caps 140 which may be coupled to the device by a flexible connector or the like to reduce the possibility of loss. Alternatively, the inhalation device may be provided other closures that are configured for (re)sealing the mouthpiece outlet and / or air inlet while the inhalation device is not in use. Referring to Figure 5b, for example, these closures may be integrated with the device, for example in the form of flaps 150, slidable tabs, or the like, that may be opened and closed when needed. Whilst the inhalation device described above is configured for inhalation via a mouth of the user, the inhalation device could be adapted for inhalation via the nose. For example, rather than provision of inhalation mouthpiece, the inhalation device could be provided with an inhalation nosepiece for inserting into a user’s nostril(s). Various other modifications will be apparent to those skilled in the art and will not be described in further detail here.

Claims

1. An inhalation device for introducing at least one ingredient into an airflow for inhalation by a user without requiring a source of electrical energy, the inhalation device comprising:a first portion comprising at least one ingredient reservoir, each ingredient reservoir respectively holding a corresponding ingredient for subsequent introduction, during operation, into the airflow for inhalation by the user; anda second portion comprising at least one porous reservoir for receiving, from at least one said ingredient reservoir, the ingredient stored in that at least one said ingredient reservoir, for subsequent introduction into the airflow for inhalation by the user;wherein the second portion is configured to define at least one fluidic path through the inhalation device for respectively guiding the airflow, during inhalation by the user, from at least one air inlet, via each porous reservoir, for delivery to the user,wherein each ingredient reservoir comprises a respective seal for respectively sealing the corresponding ingredient held by that ingredient reservoir within that ingredient reservoir, and for separating the corresponding ingredient held by that ingredient reservoir from a corresponding porous reservoir, andwherein the inhalation device further comprises at least one ingredient release mechanism for facilitating the respective piercing, breaking or removal of each seal, by a user during operation, to respectively allow the ingredient held by each ingredient reservoir to pass into the corresponding porous reservoir.

2. An inhalation device according to claim 1, wherein the at least one ingredient release mechanism comprises at least one seal breaking element, each seal breaking element being configured for piercing or breaking a corresponding seal of a respective ingredient reservoir when a user applies a force for pushing that seal breaking element through that seal.

3. An inhalation device according to claim 2, wherein the at least one seal breaking element comprises at least one seal breaking element that is provided within at least one ingredient reservoir and that is configured to be pushed, into a corresponding cavity holding a corresponding porous reservoir, through the corresponding seal when the user applies the force.

4. An inhalation device according to claim 2 or 3, wherein the at least one seal breaking element comprises at least one seal breaking element that is provided as part of at least one porous reservoir and that is configured to be pushed into a corresponding ingredient reservoir through the corresponding seal when the user applies the force.

5. An inhalation device according to claim 2, 3, or 4 wherein the at least one seal breaking element comprises at least one seal breaking element that is provided on the inhalation device externally to the at least one ingredient reservoir.

6. An inhalation device according to any preceding claim, wherein the at least one ingredient release mechanism comprises at least one frangible line provided in at least one corresponding seal, each frangible line being configured to respectively break when a user performs a corresponding seal breaking action.

7. An inhalation device according to any preceding claim, wherein the at least one ingredient release mechanism comprises at least one seal pulling feature configured for breaking or removal of at least one corresponding seal when a user pulls the seal pulling feature.

8. An inhalation device according to claim 7, wherein the at least one seal pulling feature is configured to peel back at least a portion of at least one corresponding seal when a user pulls the seal pulling feature.

9. An inhalation device according to claim 7 or 8, wherein the at least one seal pulling feature comprises a pull tab.

10. An inhalation device according to any preceding claim, wherein the at least one ingredient release mechanism is configured to break the seal when a user performsat least one of: an action to twist the inhalation device; and / or an action to bend the inhalation device.

11. An inhalation device according to any preceding claim, wherein the first portion comprises at least one ingredient reservoir holding an ingredient comprising at least one active pharmaceutical ingredient (API).

12. An inhalation device according to any preceding claim, wherein the first portion comprises at least one ingredient reservoir holding an ingredient comprising at least one flavouring.

13. An inhalation device according to any preceding claim, wherein the first portion comprises a plurality of the ingredient reservoirs.

14. An inhalation device according to claim 13, wherein each ingredient reservoir of at least a subset of two or more of the plurality of ingredient reservoirs, respectively holds the same ingredient.

15. An inhalation device according to claim 13 or 14, wherein each ingredient reservoir of at least a subset of two or more of the plurality of ingredient reservoirs, respectively holds a different ingredient.

16. An inhalation device according to claim 13, 14, or 15, wherein the second portion comprises a plurality of the porous reservoirs, each porous reservoir being configured for receiving the ingredient held in a different respective ingredient reservoir of the plurality of the porous reservoirs when a corresponding seal is broken.

17. An inhalation device according to claim 16, wherein a first porous reservoir of the plurality of the porous reservoirs is configured for introducing a first ingredient into the airflow by generating an aerosol containing the first ingredient, a second porous reservoir of the plurality of the porous reservoirs is configured for introducing a second ingredient into the airflow by a mechanism other than by generating an aerosol, and the first porous reservoir is located downstream of the second porous reservoir within the airflow.

18. An inhalation device according to any preceding claim, wherein at least one porous reservoir has a location, size, and / or pore structure that is configured for introducing a corresponding ingredient into the airflow by generating an aerosol.

19. An inhalation device according to any preceding claim, wherein at least one porous reservoir has a location, size, and / or pore structure that is configured for introducing a corresponding ingredient into the airflow by evaporation into a gas-phase vapour.

20. An inhalation device according to any preceding claim, wherein the second portion includes an inhalation piece for insertion into a mouth or nostril(s) of a user.

21. An inhalation device according to claim 20, wherein the inhalation piece includes at least one feature for facilitating the mixing of air into which a plurality of different ingredients has been introduced, as that air is drawn into the mouthpiece, via the at least one fluidic path, during inhalation by the user.

22. An inhalation device according to any preceding claim, wherein the second portion is configured to define a plurality of fluidic paths through the inhalation device, each fluidic path being respectively configured to guide the airflow, during inhalation by the user, from the at least one air inlet, via a different respective porous reservoir, into a mouth of the user.

23. An inhalation device according to any preceding claim, wherein the inhalation device is configured for the sealing, unsealing, and resealing of at least one fluidic path.

24. An inhalation device according to any preceding claim, wherein the inhalation device is at least partially formed of at least one of a cardboard, a compressed pulp, and / or another biodegradable material.

25. A method of manufacturing an inhalation device according to any preceding claim, the method comprising:forming the first part and the second part, and securing the first part to the second part to form the inhalation device.

26. A method as claimed in claim 25, wherein the forming of the first part and the second part, and the securing the first part to the second part to form the inhalation device, are performed as part of a reel-to-reel or roll-to-roll manufacturing process for bulk production of such inhalation devices.Application No: GB2414869.4Examiner: Mr Mike LeaningClaims searched: 1-26Date of search: 9 April 2025Patents Act 1977: Search Report under Section 17Documents considered to be relevant:Category Relevant to claims Identity of document and passage or figure of particular relevance X 1, 2, 4, 5, 19, 20 and 23. WO2010 / 017586 Al (KELLY) Please see the whole document. A - WO00 / 66205 Al (HAW PAR HEALTHCARE LTD.) Please see the figures, noting reservoir 11 closed by a seal 21 that in use is pierced by a spike 29, releasing a medical ingredient into a porous sponge 14. A - US2023 / 232899 Al (ZOMINY) Please see paragraph 0027. A - US2021 / 290866 Al (MINSKOFF) Please see paragraphs 0028 and 0166-0168).Categories:X Document indicating lack of novelty or inventive step A Document indicating technological background and / or of the art. state Y Document indicating lack of inventive step if P Document published on or after the declared priority date but combined with one or more other documents of before the filing date of this invention. same category. & Member of the same patent family E Patent document published on or after, but with priority date earlier than, the filing date of this application.Field of Search:Search of GB, EP, WO &US patent documents classified in the following areas of the UKCX :International Classification:Subclass Subgroup Valid From A24F 0042 / 20 01 / 01 / 2020 A61M 0015 / 00 01 / 01 / 2006 A24F 0042 / 00 01 / 01 / 2020 A24F 0042 / 60 01 / 01 / 2020 A61M 0015 / 00 01 / 01 / 2006 A61M 0015 / 06 01 / 01 / 200628

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