Inhaler article having a triangular support

Abstract

An inhaler article (10) comprising a base portion (3) and a retaining portion (4), wherein the base portion comprises a substrate (29), the retaining portion comprising a hollow tubular element (110) having a radius and an interior surface (112) and defining an interior cavity (120), and a support (130) within the interior cavity of the retaining portion, a portion of the support contacting the interior surface of the retaining portion and a portion of the support forming a triangular shape extending within the interior cavity of the retaining portion, the length of at least one side of the triangular shape being longer than the radius of the retaining portion.

Description

[Technical Field]

[0001] The present disclosure relates to an inhaler article comprising a retention portion having a triangular support within an interior cavity of the retention portion. [Background technology]

[0002] Inhaler articles, such as dry powder inhalers, are often manipulated before and during use. For example, inhaler articles may be subjected to longitudinal and transverse pressures during manufacturing, packaging, opening, insertion into a holder, activation, use, and disposal. Inhaler articles are not always well-suited to withstand such handling, nor are they always well-suited to reliably deliver dry powder particles to a user's lungs without leakage at inhalation volumes or airflow rates within the range of inhalation volumes or airflow rates of traditional smoking methods. Dry powder inhalers can be complex to operate or involve moving parts. Dry powder inhalers often attempt to provide an adequate dry powder dose or capsule load in a single draw.

[0003] Some dry powder inhalers have a component for storing dry powder, such as a capsule. The capsule may be located within the base portion of the inhaler article. The capsule can be activated by being pierced by a separate piercing element. The separate piercing element may be provided by a holder into which the inhaler article is inserted prior to piercing and use. Once the capsule is activated or pierced, the consumer may use the inhaler article by sucking on the mouth end (downstream end or proximal end) of the inhaler, generating airflow through the inhaler. As air flows through the inhaler article, the capsule rotates about itself within the base portion of the inhaler article. The agitation of the capsule within the base portion of the inhaler article and the airflow pressure release the dry powder from the pierced capsule. The powder does not shake the capsule when agitated. The released dry powder is carried to the user's mouth by the airflow. For the inhaler article to operate properly and release the powder from the capsule so that it can be delivered to the user's mouth, the capsule should remain in the base portion of the inhaler article during operation.

[0004] Some inhaler articles include a retention segment located downstream of the retention portion. The retention portion may have a support within the retention portion. Advantageously, a retention portion having a support is provided to retain the capsule in the base portion of the inhaler before, during, and after piercing, and during use. The support of the retention portion is provided to prevent the capsule from leaving the base portion before, during, and after piercing, and during use of the inhaler article. The support of the retention portion also provides structural strength to the inhaler article. For example, the support of the retention portion may be strong in the direction of the longitudinal axis of the inhaler article, preventing the capsule from leaving the base portion of the inhaler article before, during, and after piercing, and during use of the inhaler article. The support of the retention portion may be strong enough to prevent deformation of the support of the retention portion in the direction of the longitudinal axis of the inhaler article when the capsule is pressed against the retention portion when penetrated by the piercing element. The support of the retention portion may be strong enough in the direction of the longitudinal axis of the inhaler article to prevent the capsule from being pushed out of the base portion during piercing. For example, the support of the retention portion may be sufficiently strong in the direction of the longitudinal axis of the inhaler article to prevent the inhaler article from shattering during normal use, including manufacturing, packaging, opening, inserting into a holder, using the inhaler article, and disposing of the inhaler article. For example, the retention portion may be sufficiently strong in a direction perpendicular to the longitudinal axis of the inhaler article to prevent the inhaler article from shattering during normal use, including manufacturing, packaging, opening, inserting into a holder, using the inhaler article, and disposing of the inhaler article. The retention portion may be hollow or porous to allow dry powder to pass through. Summary of the Invention [Problem to be solved by the invention]

[0005] The upstream end (distal end) of the retaining portion of a capsule-containing inhaler article is subjected to a substantial longitudinal force during the activation process of the capsule. During this activation process, a piercing element extends into the upstream end of the inhaler article to contact and penetrate the capsule located within the article. Upon first contact, the piercing element presses the capsule against the upstream end of the retaining portion to successfully penetrate the capsule. As the piercing element penetrates the capsule, the capsule is pressed against the upstream end of the retaining portion. Therefore, downstream components of the inhaler article, particularly the retaining portion, should be relatively resistant to deformation in the longitudinal direction, particularly under compression.

[0006] Furthermore, a consumer may hold the inhaler article within the area of ​​the retention portion. To facilitate activation of the capsule, the consumer may apply a significant transverse force to the inhaler article in the area of ​​the retention portion. Therefore, the retention portion should also be relatively resistant to deformation in the transverse direction, especially under compression.

[0007] Some inhaler articles are useful for providing a user with an aerosol from heated (but not burned) tobacco located within the inhaler article. Sometimes, the inhaler article includes a capsule containing a flavor. The user may hold the inhaler article within the region of the capsule. To facilitate activation of the capsule, the consumer may apply a significant transverse force to the inhaler article in the region of the capsule to crush the capsule to release the flavor. The region of the capsule may be adjacent to the retention portion. Therefore, for heat-non-burn inhaler articles, the region of the retention portion of the inhaler article should also be relatively resistant to deformation in the transverse direction, particularly under compression.

[0008] A retention portion having a relatively low porosity may have sufficient strength to facilitate capsule activation. However, when a consumer inhales an inhaler article having such a retention portion, the inhaler article may have a relatively high resistance to withdrawal. Particles from the capsule may be trapped by the structure of the inhaler article downstream of the capsule. As a result, the consumer may not be able to properly deplete the capsule, and the dose withdrawn by the consumer may be relatively small.

[0009] It is desirable to provide an inhaler article having a retention portion with a withdrawal resistance that allows the user adequate access to the contents of the base portion of the inhaler article.

[0010] To provide a satisfying experience for consumers of inhaler articles, it is desirable to provide inhaler articles that are cost-effective, quick to manufacture, and operate effectively. Cost-effectiveness means that the article can be produced with a minimum of manufacturing steps, using inexpensive materials, resulting in a high performance article at a minimum cost.

[0011] It is further desirable to provide an inhaler article that is sufficiently rigid to resist longitudinal forces. Longitudinal forces are applied when a capsule contained in the base portion of the inhaler article is pierced, forcing the capsule longitudinally against the support of the retaining portion of the inhaler article. It is also desirable to provide an inhaler article that is sufficiently rigid to resist transverse forces. Transverse forces, forces perpendicular to the longitudinal axis of the inhaler article, are applied when the inhaler article is operated, including manufacturing, packaging, opening, inserting into a holder, using the inhaler article, and disposing of the inhaler article.

[0012] It is desirable to allow penetration of a capsule located inside an inhaler article and prevent the capsule from being pushed out of the base portion of the inhaler article when the capsule is pierced. That is, it is desirable to provide an inhaler article having a retaining portion structured to retain the capsule within the inhaler article when a piercing element presses the capsule against the retaining portion. It is desirable to provide an inhaler article that is rigid enough to resist deformation or crushing when the capsule is pierced. It is desirable to provide an inhaler article that is rigid enough to resist deformation or crushing during operation of the inhaler article. It is desirable to provide an inhaler article having a retaining portion that has sufficient rigidity or strength in the longitudinal direction to resist deformation or crushing when the capsule is pierced. It is desirable to provide an inhaler article having a support within the retaining portion that has sufficient rigidity or strength to resist deformation or crushing when the capsule is pierced. It is desirable to provide an inhaler article having a support within the retaining portion that has sufficient rigidity or strength to prevent or obstruct the capsule from exiting the base portion or being pushed out of the base portion of the inhaler article when the capsule is pierced. It would be desirable to provide an inhaler article that is simple and cost-effective to manufacture, while still providing the necessary stiffness and low resistance to withdrawal.It would be desirable to provide an inhaler article made from biodegradable materials. [Brief explanation of the drawings]

[0013] [Figure 1] FIG. 1 shows a schematic diagram of an inhaler article according to an embodiment of the present invention. [Figure 2A] FIG. 2A shows a partially transparent perspective view of the inhaler article of FIG. [Figure 2B] FIG. 2B shows a partially transparent perspective view of another embodiment of an inhaler article. [Figure 3] FIG. 3 shows a schematic diagram of the inhaler article of FIG. [Figure 4] FIG. 4 is a schematic diagram of an inhaler article inserted into a holder. [Figure 5] FIG. 5 shows a schematic cross-sectional view of the inhaler article of FIG. 1 in a holder, with a piercing element. [Figure 6A] FIG. 6A shows a cross-sectional view of the upstream end of the retaining portion of the inhaler article of FIG. [Figure 6B] FIG. 6B shows a perspective view of the upstream end of the retaining portion of the inhaler article of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0014] The inventors have found that the geometric shape of the support within the retention portion contributes to the strength of the retention portion in the longitudinal direction of the inhaler article and in directions perpendicular to the longitudinal axis. The inventors have found that the claimed geometric shape of the support within the retention portion contributes to the ability of the retention portion to prevent a capsule contained within the base portion from exiting the base portion of the inhaler article during penetration. The inventors have found that the triangular support claimed herein contributes to the strength of the retention portion in the longitudinal direction of the inhaler article and in directions perpendicular to the longitudinal axis, preventing a capsule from being extruded from the base portion of the inhaler article during penetration, while still providing low resistance to withdrawal through the inhaler article. The inventors have found that a support having an angular rather than curved tip contributes to the strength of the retention portion in the longitudinal direction of the inhaler article and in directions perpendicular to the longitudinal axis, preventing the capsule from being extruded from the base portion of the inhaler article during penetration, while still providing low resistance to withdrawal through the inhaler article. The inventors have found that a support having at least one of the first leg and the second leg longer than the radius of the retention portion contributes to the strength of the retention portion in the longitudinal direction of the inhaler article and in directions perpendicular to the longitudinal axis, preventing the capsule from being extruded from the base portion of the inhaler article during penetration, while still providing low resistance to withdrawal through the inhaler article. The inventors have found that a support in which both the first leg and the second leg are longer than the radius of the retention portion contributes to the strength of the retention portion in the longitudinal direction of the inhaler article and in directions perpendicular to the longitudinal axis, preventing the capsule from being extruded from the base portion of the inhaler article during penetration, while still providing low resistance to withdrawal through the inhaler article. The inventors have found that a support in which the first bend and the second bend are angular (and not curved) contributes to the strength of the retention portion in the longitudinal direction of the inhaler article and in directions perpendicular to the longitudinal axis, preventing the capsule from being extruded from the base portion of the inhaler article during penetration, while still providing low resistance to withdrawal through the inhaler article.The inventors have found that having the flap and second flap shorter than the radius of the retainer contributes to the strength of the retainer portion in the longitudinal direction of the inhaler article and in directions perpendicular to the longitudinal axis, prevents the capsule from being extruded from the base portion of the inhaler article during penetration, and provides low resistance to withdrawal through the inhaler article while maintaining the roundness of the retainer portion. The inventors have found that the triangular support by which the first flap and second flap are attached to the inner surface of the retainer portion with an adhesive contributes to the strength of the retainer portion in the longitudinal direction of the inhaler article and in directions perpendicular to the longitudinal axis, prevents the capsule from being extruded from the base portion of the inhaler article during penetration, while still providing low resistance to withdrawal through the inhaler article. The inventors have found that when the geometry of the support has the described characteristics, a thin or thinner material can be used for the support, providing sufficient strength along the longitudinal axis of the retention portion and perpendicular to the longitudinal axis of the inhaler article to prevent the capsule from being pushed out of the base portion of the inhaler product during penetration, while providing low resistance to withdrawal through the inhaler article. The inventors have also found that the claimed retention portion is efficient to manufacture.

[0015] The present disclosure relates to an inhaler article having a longitudinal axis between an upstream end and a downstream end. The inhaler article may include a base portion and a retention portion. The inhaler, and the base portion and retention portion each have a length "l", a radius "r", and a central axis. The base portion includes a substrate. The substrate may be a plant material such as tobacco. The substrate may be tobacco. The substrate may be a capsule. The capsule may be located within a cavity of the base portion. The capsule may contain a dry powder. The retention portion may include a hollow tubular element having an interior surface defining an interior cavity. The retention portion may include a support within the interior cavity of the retention portion. The support may be formed from a sheet of material. The support may include a first flap, a first bend, a first leg, a second bend, a second leg, a third bend, and a second flap. The first flap of the support contacts the interior surface of the hollow tubular element of the retention portion along the length of the first flap. The first leg of the support includes a length between the first bend and the second bend. The second bend has a tip. The tip is angular, not curved or arced. The second leg of the support includes a length between the second bend and the third bend. The first leg, the second bend, and the second leg form two legs of a triangle extending into the internal cavity of the retainer when the retainer is viewed from the upstream end of the retainer. The second flap contacts the internal surface of the hollow tubular element of the retainer portion. In an embodiment, the length of at least one of the first leg and the second leg is greater than the radius of the retainer. In an embodiment, the lengths of the first leg and the second leg are equal. In an embodiment, the first leg and the second leg are straight. The lengths of the first flap and the second flap of the support may be less than the radius of the retainer.

[0016] The inventors surprisingly found that the specific geometric shape of the support contributes to the performance of the retention portion. Furthermore, when the first leg, the second bend, and the second leg form two legs of a triangle extending into the internal cavity of the retention portion, the retention portion functions very well to prevent the capsule from being pushed out of the base portion when the capsule is pierced. In particular, when the capsule is pressed against the support when pierced by the piercing element, if the capsule is rounded on the edge that contacts the support, the triangular support prevents the capsule from being pushed into the retention portion. Furthermore, the triangular support maintains the roundness of the retention portion in a direction transverse to the longitudinal axis of the inhaler article.

[0017] The inventors surprisingly found that a support having at least one of the first and second legs longer than the radius of the retaining portion contributes to the performance of the retaining portion. The inventors found that this geometric shape is more effective in providing a retaining portion with longitudinal rigidity compared to a triangular support having first and second legs shorter than the radius of the retaining portion. The inventors found that this geometric shape is more effective in providing a retaining portion with transverse rigidity compared to a triangular support having first and second legs shorter than the radius of the retaining portion. The inventors found that when the length of the first or second leg, or both the first and second legs, is longer than the radius of the retaining portion, the support is more rigid and resistant to longitudinal and / or transverse deformation. The first or second leg may be longer than the radius of the retaining portion to hold the oval capsule on the base portion. The inventors have surprisingly found that when both the first leg and the second leg are longer than the radius of the retaining portion, the retaining portion is effective in retaining an oval capsule on the base portion even when the capsule is pierced. Furthermore, the inventors have found that a retaining portion having a support with first or second legs of approximately equal length is more cost-effective to manufacture than a support that is triangular in shape but has first and second legs that are shorter than the radius of the retaining portion.

[0018] The inventors surprisingly found that when the length of at least one of the first leg and the second leg is greater than the radius of the retainer, the capsule is better held when the capsule is pressed longitudinally against the support. This is particularly true when the support is made of a thinner material. When the length of at least one of the first leg and the second leg is greater than the radius of the retainer, the support may be made of a thinner material.

[0019] The inventors surprisingly found that when the length of both the first leg and the second leg is greater than the radius of the retainer, the capsule is better held when pressed longitudinally against the support. This is particularly true when the support is made of a thin or thinner material. When the length of at least one of the first leg and the second leg is greater than the radius of the retainer, the support may be made of a thin or thinner material. When the length of both the first leg and the second leg is greater than the radius of the retainer, the support may be made of a thin or thinner material.

[0020] The material of the retention portion may be, for example, paper, cardboard, polymer, plastic, bioplastic, extruded bioplastic, metal, foil, or any suitable material. The material of the retention portion may be the same as the material of the inhaler article. The material of the retention portion may be different from the material of the inhaler article.

[0021] The support material may be a flexible material that can be shaped as desired. The support material may be, for example, paper, cardboard, paperboard, polymer, plastic, bioplastic, extruded bioplastic, metal, foil, or any suitable material. The support material may be a sheet of material. As used herein, the term "sheet" refers to a material having a width and length that is substantially greater than its thickness.

[0022] The sheet of material may be paper or cardboard. The sheet of material may be paper. The support may be made from a sheet of material having a thickness of 250 microns or less. The support may be made from a sheet of material having a thickness of 200 microns or less. Support materials having a thickness of 250 microns or less are considered thin. Similarly, support materials having a thickness of 200 microns or less are considered even thinner.

[0023] For support geometries in which at least one of the first leg and the second leg is longer than the radius of the retention portion, the support may be made from thinner material while maintaining sufficient rigidity in the longitudinal and / or transverse directions. For support geometries in which the second bend, the tip is angled, and the support is not curved, the support may be made from thinner material while maintaining sufficient rigidity in the longitudinal and / or transverse directions. For support geometries in which the first bend and the third bend are angled (not curved), the support may be made from thinner material while maintaining sufficient rigidity in the longitudinal and / or transverse directions. For purposes of this disclosure, "angled" refers to a sharp angle or fold in the material, as distinguished from an arc or curve without a sharp fold in the material.

[0024] For example, if the support geometry is such that at least one of the first and second legs is longer than the radius of the retaining portion, or has an angled tip, or the first and third bends are angled, or the first and second flaps are shorter than the radius of the retaining portion, or the first and second flaps are attached to the inner surface of the retaining portion with adhesive, or a combination of these geometries, the support may be made from thin or thinner paper. For example, the support may be made from paper having a thickness of 124 microns and a basis weight of 170 gsm. If the support geometry is such that at least one of the first and second legs is longer than the radius of the retaining portion, the support may be made from paper having a thickness of 124 microns and a basis weight of 100 gsm. If the support geometry is such that at least one of the first and second legs is longer than the radius of the retaining portion, the support may be made from paper having a thickness of 10 microns and a basis weight of 78 gsm.

[0025] For support geometries in which the first and second legs are longer than the radius of the retaining portion, the support may be made from a thinner material. For example, for support geometries in which the first and second legs are longer than the radius of the retaining portion, the support may be made from a thinner or thinner paper. For support geometries in which the first and second legs are longer than the radius of the retaining portion, the support may be made from a material. For example, for support geometries in which the first and second legs are longer than the radius of the retaining portion, the support may be made from paper having a thickness of 124 microns and a basis weight of 170 gsm. For support geometries in which the first and second legs are longer than the radius of the retaining portion, the support may be made from paper having a thickness of 125 microns and a basis weight of 100 gsm. For support geometries in which the first and second legs are longer than the radius of the retaining portion, the support may be made from paper having a thickness of 100 microns and a weight of 78 gsm. Using thinner or thinner materials reduces manufacturing complexity and costs. Using thinner or thinner materials allows for more efficient manufacturing.

[0026] The inventors surprisingly found that a second bend with an angled (e.g., non-rounded) tip contributes to the performance of the retention portion. The tip may be a fold in the material of the support. The inventors found that this geometric shape is more effective at providing a retention portion with longitudinal rigidity compared to supports with rounded contours (e.g., an "omega" shape). The inventors found that this geometric shape is more effective at providing a retention portion with transverse rigidity compared to supports with rounded contours. The inventors found that when the tip (second bend) is angled, the support is more rigid and more resistant to longitudinal and / or transverse deformation. Furthermore, the inventors found that a retention portion with an angled tip is more cost-effective to manufacture compared to a support with a rounded shape. In addition, due to the geometry of the support with an angled second bend and a non-rounded tip, the support may be made from a thinner material.

[0027] The inventors surprisingly found that it is more efficient to manufacture a retaining portion having a support when the first bend and the third bend are angled (e.g., not rounded). Another way to say that the first bend and the third bend are angled is that the first bend and the third bend are folded within the material of the support. In an embodiment, the first bend and the third bend are not arcs.

[0028] The inventors surprisingly found that having the first and second legs straight (e.g., not curved) contributes to the performance of the support portion. The inventors found that this geometry is more effective at providing a support portion with longitudinal rigidity compared to supports with non-straight first and second legs. The inventors found that this geometry is more effective at providing a support portion with transverse rigidity compared to supports with curved first or second legs. The inventors found that when the first and second legs are straight, the support is more rigid and more resistant to longitudinal and / or transverse deformation. Due to the geometry of the support with straight (not curved) first and second legs, the support can be made from thinner material while retaining its rigidity in the longitudinal and / or transverse planes. The inventors found that a support portion with straight first and second legs is more cost-effective to manufacture compared to supports with curved legs.

[0029] The inventors surprisingly found that having first and second flaps shorter than the radius of the retention portion contributes to the performance of the retention portion. The inventors found that this geometry is more effective in providing a retention portion that does not deform when the first and second flaps are shorter than the radius of the retention portion. That is, with longer flaps, the retention portion may deform. With longer flaps, the retention portion may become less circular. The inventors found that this geometry, in which the first and second flaps are shorter than the radius of the retention portion, results in a retention portion that is stiffer, more circular, and more resistant to longitudinal and / or transverse deformation. The inventors also found that retention portions are more cost-effective to manufacture when the first and second flaps are shorter than the radius of the retention portion compared to retention portions having longer first and second flaps.

[0030] The length of the support, where the first and second flaps are shorter than the radius of the support portion, is greater than 2d, where d is the diameter of the support portion, when at least one of the first and second legs is longer than the radius of the support portion, and when the first, second, and third bends are angled. For example, if the inner diameter of the support portion is 7 mm, the length of the support (when extended) will be greater than 14 mm. If the inner diameter of the support portion is 6.55 mm and each of the first and second flaps is, for example, 2.7 mm, the length of the support (when extended) may be 14.3 mm or more.

[0031] An inhaler article having a retaining portion with a support having first and second legs longer than the radius of the retaining portion, with an angled, non-rounded second bend (tip), the first and second legs being straight (not curved), the first and third bends being angled (not curved), and the first and second flaps being shorter than the radius of the retaining portion, is effective in retaining a capsule within the inhaler article and preventing deformation of the inhaler article in the longitudinal direction and transverse to the longitudinal direction when the capsule is penetrated. The following features contribute to the strength of the triangular insert shape: paper thickness / basis weight, the acute angle of the triangle at the second bend between the first and second legs, and the area of ​​adhesive applied to the side of the flap that contacts the retaining portion inner surface.

[0032] The length of the retention portion may be relatively small. For example, for an inhaler article having a length of 45 mm, the retention portion may be 5 to 9 mm. The inventors surprisingly found that by incorporating a retention portion geometry, it is possible to keep the length of the retention portion relatively small relative to the length of the inhaler article. The inventors surprisingly found that a retention portion having a geometry and characteristics such as a support having an angled tip, first and third bends having angles, a first leg and a second leg being straight, a length of at least one of the first leg and the second leg being greater than the radius of the retention portion, and a length of the first flap and the second flap being shorter than the radius of the retention portion allows the length of the retention portion to be relatively small relative to the overall length of the inhaler article while still maintaining sufficient rigidity to withstand longitudinal and / or transverse deformation. Manufacturing an inhaler article with a shorter retention portion is more cost-effective.

[0033] When the inhaler article contains a capsule containing a dry powder active ingredient, the upstream end of the inhaler article may have a folded edge that functions to retain the capsule within the cavity at the upstream end.

[0034] The retention portion of the inhaler article may comprise two parts: a hollow tubular element and a support made from a separate sheet of material disposed inside the hollow tubular element. The retention portion may be disposed downstream of the capsule. The retention portion may comprise a hollow tubular element. The hollow tubular element may define a hollow interior region or internal cavity of the retention portion. The retention portion may comprise a support element within the internal cavity of the retention portion.

[0035] The support may include a first flap that contacts the inner surface of the hollow tubular element of the retention portion. At the first bend, the support extends from the inner surface of the hollow tubular element of the retention portion and extends into the internal cavity of the retention portion, forming a first leg of a triangle within the internal cavity of the retention portion when viewed from the upstream end of the retention portion. A second bend in the material of the support forms the tip of the triangle. The second leg forms a second leg of the triangular shape within the internal cavity of the retention portion when viewed from the upstream end of the retention portion. The support then contacts the inner surface of the hollow tubular element of the retention portion and extends along the inner surface of the hollow tubular element of the retention portion. That is, the support has a first flap, a first bend, a first leg, a second bend, a second leg, a third bend, and a second flap, and this entire structure forms a triangular shape extending into the internal cavity of the retention portion with its two ends attached to the internal surface of the retention portion. The two ends, the first and second flaps, may be attached to the internal surface. The two ends, the first and second flaps, may be attached to the inner surface of the retaining portion by adhesive.

[0036] The support element may hold the capsule within the cavity between the retaining portion and the upstream end. The support may be formed from a sheet. The support may extend from a first point on the interior surface of the hollow tubular element. The support element may extend into the interior cavity of the retaining portion. The support element may form a triangular shape extending within the interior cavity of the retaining portion from a first point to a second point on the interior surface of the hollow tubular element of the retaining portion.

[0037] According to the present invention, there is provided an inhaler article. When the inhaler article contains a capsule containing a dry powder active ingredient, the inhaler article comprises a substrate portion that is a capsule cavity containing the capsule. The capsule contains a dry powder. The dry powder is the active ingredient. A retaining portion is disposed downstream of the capsule-containing substrate portion.

[0038] In contrast to prior art inhaler articles, the inhaler article of the present invention comprises a retaining portion having a hollow tubular element and a support. The support is attached to the inner surface of the hollow tubular element of the retaining portion and extends from first and second points on the inner surface of the hollow tubular element into its internal cavity, forming a triangular support within the internal cavity of the retaining portion. The support acts to provide a support barrier for one or more components disposed upstream of the retaining portion. For example, the support may act to provide a barrier for a capsule located within the cavity. This may help prevent or limit downstream movement of one or more components, such as a capsule, disposed upstream of the retaining portion. This may be particularly beneficial when a piercing element is used to pierce a capsule from the upstream end of the inhaler article. The support may prevent the capsule from being extruded from the capsule cavity when the capsule is pierced from the upstream end of the inhaler article. When the substrate within the base portion is tobacco, the retaining portion functions to provide rigidity in the longitudinal and / or transverse directions within the inhaler article.

[0039] Furthermore, because the support is formed from a sheet and extends from first and second points on the inner surface of the hollow tubular element into the inner cavity, forming a triangular shape, the retention portion can still retain an opening of an appropriate size for one or both of air and dry powder to flow through the retention portion, for example, from a capsule. This means that the retention portion can have an appropriately low resistance to withdrawal. This also means that the retention portion can have an appropriately low filtration effect and an appropriately low resistance to withdrawal.

[0040] Furthermore, forming the support element from a sheet can allow for efficient design of the support element, since the flexibility of the sheet can allow the sheet to be easily formed into the shape most suitable for providing support for one or more components, such as a capsule, located upstream of the retention portion. In addition, optimized design of the support can provide longitudinal and transverse rigidity. This is particularly important for inhaler articles with dry powder-containing capsules, which can be provided in a range of shapes, sizes, or both shapes and sizes. Thus, the design of the support element, and where the support element provides its support barrier, can mean that the support element can be designed to provide effective support for the inhaler article in which the support element is provided. Furthermore, the support element can be provided in a form that can be efficiently manufactured.

[0041] As used herein, the term "retention portion" is used to mean a generally cylindrical element that defines a lumen or airflow passage along its longitudinal axis. In particular, the term "retention section" is used hereinafter in reference to a hollow tubular body having a substantially cylindrical cross-section and a hollow tubular element that defines at least one airflow conduit that establishes uninterrupted fluid communication between an upstream end of the retention portion and a downstream end of the retention portion. However, it will be understood that alternative geometries (e.g., alternative cross-sectional shapes) of the retention element may be possible.

[0042] As used herein, the term "longitudinal" refers to a direction corresponding to the major longitudinal axis of the inhaler article, extending between the upstream and downstream ends of the inhaler article.

[0043] The terms "upstream" and "downstream" refer to the relative locations of the holder, inhaler article, and inhaler system elements described in relation to the direction of inhalation airflow as it is drawn through the inhaler article, holder, and inhaler system. "Downstream" is the oral end. "Upstream" is distal to the oral end.

[0044] During use, air is drawn longitudinally through the inhaler article from the upstream end to the downstream end. The term "transverse" refers to a direction perpendicular to the longitudinal axis. Any reference to a "cross section" of the inhaler article or a component thereof refers to a transverse cross section, unless otherwise specified.

[0045] The term "length" refers to the dimension of a component of an inhaler article in the longitudinal direction. For example, it may be used to refer to the dimension of a capsule or a holding portion in the longitudinal direction. The term "tangential" refers to a direction at an angle from a referenced direction. For example, a tangential angle is non-parallel to a referenced direction.

[0046] The terms "proximal" and "distal" are used to describe the relative positions of components or portions of components of an inhaler article, holder, or inhaler system. According to the present disclosure, the holder or an element forming the holder (such as a sleeve) has a proximal end that receives the inhaler article during use and an opposing distal end that may be closed or have an end closer to the proximal end of the holder. According to the present disclosure, the inhaler article has a proximal end. During use, powder particles exit the proximal end of the inhaler article for delivery to the user. The inhaler has a distal end opposite the proximal end. The proximal end of the inhaler article may also be referred to as the oral end or downstream end. The distal end of a component may correspond to the upstream end of such component. The proximal end of a component may also correspond to the downstream end of such component.

[0047] For purposes of this disclosure, "tip" means the shape formed by the intersection of two legs that share a common endpoint. The "tip" can also be referred to as the angle at the intersection of the two legs, or the apex of the angle. The "tip" is not rounded.

[0048] Unless otherwise specified, the resistance to draw (RTD) of a component or inhaler article is measured in accordance with ISO 6565-2015. RTD refers to the pressure required to force air through the entire length of the component. The terms "pressure drop" or "draw resistance" of a component or article may also refer to "resistance to draw." These terms generally refer to measurements in accordance with ISO 6565-2015 being performed successfully under test at a temperature of about 22 degrees Celsius, a pressure of about 101 kPa (about 760 Torr), and a relative humidity of about 60%, with a volumetric flow rate of about 17.5 milliliters per second at the output or downstream end of the component being measured.

[0049] The inhaler article may comprise an upstream section. The upstream section may include a folded end. The upstream section may be a base portion. The inhaler article may comprise a downstream section located downstream of the upstream section. The retention portion may be downstream from the upstream section. The downstream section may be spaced apart from the upstream section. The downstream section may comprise a retention portion. Furthermore, there may be multiple sections. For example, there may be an upstream section, which may be a base portion. There may be a retention portion downstream of the base portion. Optionally, there may be a mouthpiece portion downstream of the retention portion.

[0050] The inhaler article may include a cavity defined between the upstream section and the downstream section. The cavity may be configured to accommodate a capsule containing an inhalable material. The inhalable material may be a dry powder. The dry powder may be an active ingredient. The active ingredient may be nicotine. The cavity may be configured to be in fluid communication with the exterior of the inhaler article. The cavity may include a capsule cavity, an internal cavity of the retaining portion, and an optional mouthpiece having an internal cavity. The capsule cavity of the base portion, the internal cavity of the retaining portion, and the optional mouthpiece having an internal cavity may abut against each other to form one continuous cavity.

[0051] The Young's modulus (or elastic modulus) of the material of the filter segment may be greater than about 10 MPa. Unless otherwise specified, the Young's modulus of the material of the filter segment is measured according to ASTM E111-17. The Young's modulus (or elastic modulus) of the material of the filter segment may be greater than about 20 MPa. The Young's modulus (or elastic modulus) of the material of the filter segment may be greater than about 30 MPa. Young's modulus (or elastic modulus) preferably refers to the Young's modulus of the material of the component along the longitudinal axis or direction of the component.

[0052] A capsule can be defined by having a specific puncture strength (in Newtons). The puncture strength of a capsule refers to the specific penetration or puncture force (in Newtons) that a piercing element or needle must exert on the capsule to penetrate or activate the capsule. Methods for measuring the puncture strength of a capsule are known to those skilled in the art. For example, the puncture strength of a capsule may be measured according to ASTM F1306-16. For example, the puncture strength of a sample capsule may be measured using a 3.2 mm (8 gauge) diameter piercing element or hemispherical probe.

[0053] The capsule may be pierced by inserting a piercing element into the capsule through the upstream end of the inhaler article. The piercing element may be solid. The piercing element may be hollow. The piercing element may be a needle. The piercing element may be a 27 gauge (outer diameter = 0.42 mm) to 4 gauge (outer diameter = 5 mm) needle. The piercing element may have a diameter in the range of about 0.42 mm to about 0.9 mm. The piercing element may have a diameter in the range of about 0.6 mm to about 0.9 mm. The piercing element may have a diameter that may be in the range of about 0.6 mm to about 0.9 mm. The piercing element may have a diameter in the range of about 0.7 mm to about 0.9 mm. The piercing element may have a diameter in the range of about 0.75 mm to about 0.85 mm. The piercing element may have a diameter of about 0.8 mm. The piercing element may have a chamfered piercing end. For example, the piercing element may have a single cutting surface or a chamfered edge that defines the cutting surface. The piercing element may have a cutting plane angle between the longitudinal axis of the piercing element and a single cutting plane. The cutting plane angle may be in the range of about 25 degrees to about 35 degrees. Preferably, the cutting plane angle is in the range of about 28 degrees to about 32 degrees. Preferably, the cutting plane angle is about 30 degrees. It has been found that piercing elements having these diameters and these cutting plane angles require a force of about 5 Newtons or less to actuate or pierce a capsule contained within the inhaler article described herein.

[0054] The force applied by the piercing element to the upstream end of the capsule when piercing the capsule is transmitted to the retaining portion. When the piercing element is pressed against the capsule, this force is transmitted to the hollow retaining portion. Therefore, the retaining portion should be strong enough not to be damaged when this longitudinal force is applied. Furthermore, the retaining portion should allow particles to be transmitted to the mouthpiece of the inhaler article so that they can be released from the capsule after piercing, entrained in the airflow through the inhaler article, and delivered to the user. Alternatively, the retaining portion should allow aerosol released from the base portion to be delivered to the user.

[0055] The support-containing retaining portion may be configured to withstand, without substantial deformation, a longitudinal force of at least about 50% of the capsule's puncture strength applied to the upstream end of the retaining portion. The retaining portion may be configured to substantially retain its structure when a longitudinal force of at least about 200% of the capsule's puncture strength is applied to the upstream end of the retaining portion. The retaining portion may be configured to withstand, without substantial deformation, a longitudinal force of up to about 200% of the capsule's puncture strength applied to the upstream end of the retaining portion. The retaining portion may be configured to withstand, without substantial deformation, a force of up to about 100% of the capsule's puncture strength applied to the upstream end of the retaining portion. The retaining portion may be configured to withstand, without substantial deformation, a force of up to about 200% of the capsule's puncture strength applied to the upstream end of the retaining portion. The retaining portion may be configured to withstand, without substantial deformation, a force of at least 50% to about 100% of the capsule's puncture strength applied to the upstream end of the retaining portion. The retaining portion may be configured to withstand a force of at least 50% to about 200% of the puncture strength of the capsule applied to the upstream end of the retaining portion without substantial deformation. The retaining portion may be configured to withstand a force of 50% to 200% of the force required to puncture the capsule with the piercing element. The retaining portion may be configured to withstand a force of about 3 Newtons to about 10 Newtons.

[0056] The retention portion may extend from the capsule cavity or base portion to the downstream end of the inhaler article. In other words, the length of the downstream section of the inhaler article may be the same as the length of the retention portion. Alternatively, the retention portion may be separate from the downstream section of the inhaler article. That is, there may be a mouthpiece portion between the retention portion and the mouth end of the inhaler article.

[0057] The length of the inhaler article may be 35 to 55 mm. The length of the inhaler article may be 40 to 50 mm. The length of the inhaler article may be about 45 mm. The length of the retention portion may be less than about 10 mm. The length of the retention portion may be less than 9 mm. The length of the retention portion may be 4 to 10 mm. The length of the retention portion may be 4 to 9 mm. The length of the retention portion may be 5 to 9 mm. The length of the retention portion may be 5 to 8 mm. The length of the retention portion may be 10% to 40% of the length of the inhaler article. The length of the retention portion may be 10% to 30% of the length of the inhaler article. The length of the retention portion may be 10% to 25% of the length of the inhaler article. The length of the retention portion may be 10% to 20% of the length of the inhaler article. The length of the retention portion may be 20% to 40% of the length of the inhaler article. The length of the retention portion may be 20% to 35% of the length of the inhaler article. The length of the retention portion may be 20% to 30% of the length of the inhaler article. The length of the retention portion may be 15% of the length of the inhaler article. Retention portion.

[0058] The length of the holding portion is preferably about 5mm to 10mm. The length of the holding portion is preferably 5mm to 9mm. The length of the holding portion is preferably 6 to 9mm. The length of the holding portion is preferably 6 to 8mm. The holding portion may be 7mm. The specific geometric shape of the support, i.e., the support is formed from a sheet of material and includes a first flap, a first bend, a first leg, a second bend, a second leg, a third bend, and a second flap, the first flap of the support having a length, the first flap of the support contacting the inner surface of the retention portion, the first leg of the support having a length between the first bend and the second bend, the second bend having a tip, the second leg of the support having a length between the second bend and the third bend, the first leg, the second bend, and the second leg forming two legs of a triangle extending into the inner cavity of the retention portion when viewed from the upstream end of the retention portion, the support forming a second flap, the second flap of the support having a length that contacts the inner surface of the retention portion, and the length of at least one of the first leg and the second leg being greater than the radius of the retention portion, provides sufficient rigidity to maintain the length of the retention portion as described above. That is, the specific geometric shape of the support allows the retention portion to be shortened. A shorter retaining portion reduces the cost of the assembled inhaler article.

[0059] The inhaler article may have an outer diameter within the range of about 6 mm to about 10 mm, or about 7 mm to about 10 mm, or about 7 mm to about 9 mm, or about 7 mm to about 8 mm, or about 7.2 mm. The inhaler article may have a length (along the longitudinal axis) within the range of about 30 mm to about 100 mm, or about 40 mm to about 100 mm, or about 40 mm to about 80 mm, or about 40 mm to about 60 mm. Preferably, the length of the inhaler article is about 45 mm. The length of the inhaler article is preferably selected so that the mouthpiece end of the inhaler article protrudes from the holder of the inhaler system, which is described in more detail below.

[0060] The (distal, forward, or upstream) end of the inhaler article may have a folded end that may be folded back to expose a capsule contained within the cavity prior to penetrating the capsule. The folded end may be folded back when the inhaler article is inserted into a holder having complementary features to allow folding of the distal end of the inhaler article.

[0061] The mouth end (downstream, proximal, or mouthpiece end) of the inhaler article may have a rounded end. The rounded end is toroidal in shape. The toroidal shape is divided into two rounded halves, like cutting a bagel in half. The rounded sides of the toroidal shape may form the mouth end of the inhaler article. The rounded end has a central opening. The rounded end captures particles that do not flow through the central opening when the inhaler article is used. The rounded end prevents particles from leaking out of the mouth end of the inhaler article.

[0062] The inhaler article may be fitted into the holder. A piercing element may be provided by the holder. The piercing element may be inserted into the capsule and removed from the capsule by the action of a spring in the holder. The piercing element provided by the holder may then be inserted into the inhaler article and pierce the capsule. The piercing element may then be retracted from the inhaler article, leaving the pierced capsule within the inhaler article.

[0063] The inhaler article may be placed in a holder. The inhaler article may be removed from the holder. The inhaler article may remain in the holder. Powder may be removed from a capsule located within the inhaler article by drawing air from an air inlet located at the upstream end of the inhaler article through the inhaler article to the mouthpiece or downstream end of the inhaler article. As air is drawn through the inhaler article from the upstream end of the inhaler article to the downstream end of the inhaler article and passes through the pierced capsule, particles are released from the capsule and entrained in the airflow passing through the inhaler article, and the particles are delivered to the mouthpiece or downstream end of the inhaler article and to the user. The holder may provide a swirling airflow at the downstream end of the inhaler article to induce a rotational airflow around the capsule, allowing the capsule to rotate and improving the release of particles from the capsule into the capsule cavity. The holder may provide a swirling airflow at the downstream end of the inhaler article to induce a rotational airflow around the capsule, agitating the capsule and improving the release of particles from the capsule into the capsule cavity. The inhaler article may have end plugs to induce a rotational airflow around the capsule, causing it to agitate and improve the release of particles from the capsule into the capsule cavity.The inhaler article may have end plugs to induce a rotational airflow around the capsule, causing it to rotate and improve the release of particles from the capsule into the capsule cavity.

[0064] The body of the inhaler article, or "inhaler article", may have any suitable shape. The body of the inhaler article, or "inhaler article", may resemble a smoking article or a conventional cigarette in size and shape. The inhaler article may have a substantially uniform outer diameter along the length of the inhaler article. The inhaler article may have a substantially uniform inner diameter along the length of the inhaler article. The inhaler article may have any suitable transverse cross-sectional shape. For example, the transverse cross-section may be circular, oval, square, or rectangular. The inhaler article preferably has a circular cross-section, which may be uniform along the length of the inhaler article, forming an elongated cylindrical body.

[0065] The inhaler article may have an end plug. The end plug may be located at the upstream end of the inhaler article. The end plug may provide an air intake that creates a swirling airflow through a channel in the inhaler article extending from the upstream end of the inhaler article through the retention portion to the mouthpiece end of the inhaler article. The end plug and capsule may be located within a hollow tube. The channel may be formed by the capsule cavity in the base portion, the internal cavity of the retention portion, and the internal cavity of a further downstream portion, such as the mouthpiece portion. The internal cavities of these portions may abut each other, creating a channel extending from the capsule cavity to the downstream end of the inhaler article. The downstream end of the capsule cavity may abut the upstream end of the retention portion. The material of the capsule cavity, the hollow tubular element of the retention portion, and the optional downstream mouthpiece portion may be formed of a polymeric or cellulosic material, or any other suitable material.

[0066] The retention portion of the inhaler article may be formed from a biodegradable material. Preferably, the retention portion is formed from paperboard or cardboard. Preferably, the retention portion is formed from paperboard or cardboard. The retention portion may have a uniform thickness along its length. The hollow tubular element of the retention portion may have a thickness in the range of about 1 mm to about 2 mm.

[0067] The inhaler article may include a filter wrapper surrounding the substrate portion, the retention portion, and the optional mouthpiece portion. The packaging material may be formed from a biodegradable material. The packaging material may be formed from a paper wrapper.

[0068] The inhaler article may include an upstream section including a folded end. The folded end may define a central channel. The central channel may include a first end defining an upstream boundary of the base portion having the capsule cavity and a second opposite end defining the distal end of the inhaler article body. The second opposite end may define the open distal end of the inhaler article body. When the folded end is open, the second opposite end may define the open distal end of the inhaler article body. The central channel may extend along the longitudinal axis of the inhaler article between the upstream end and the downstream end and may include a base portion and a retaining portion. The central channel may extend along the longitudinal axis of the inhaler article and may include a base portion, a retaining portion, and a mouthpiece portion. The longitudinal axis may define an opening at the distal end of the inhaler article coaxial with the longitudinal axis of the inhaler article.

[0069] Advantageously, the inhaler article may include an open opening along the longitudinal axis and may have no element blocking or obstructing the open distal end of the inhaler article to reduce the complexity of the inhaler article: after the capsule has been pierced, the consumer may simply block or obstruct the open distal end with the holder or the consumer's finger to direct the inhalation airflow substantially through the air inlet on the inhaler article.

[0070] Airflow through the inhaler article preferably enters the inhaler article through the upstream end of the inhaler article via an airflow inlet channel or through the open distal end of the inhaler article, and then travels along the longitudinal axis of the inhaler article, through the capsule cavity in the base portion, through the retaining portion, and out the mouthpiece or downstream end of the inhaler article.

[0071] The central channel may have a uniform inner or open diameter extending from the capsule cavity to the open distal or most upstream end of the inhaler article. The central channel may have a diameter that is at least about 50%, or at least about 70%, or at least about 75% of the diameter of the inhaler article. The central channel of the inhaler article may have a diameter within a range of about 50% to about 90% of the diameter of the capsule held within the capsule cavity. The central channel may have a diameter within a range of about 3 mm to about 6.5 mm, or about 4 mm to about 6 mm, or about 5 mm to about 6 mm, or about 5.5 mm. Alternatively, the central channel may have a diameter within a range of about 0.5 mm to about 2 mm. This sizing of the central channel ensures that the capsule does not become detached from the inhaler article through the central channel.

[0072] As discussed above, the end plug or holder may induce a rotating or swirling airflow as air flows through the airflow inlet channel of the end plug or holder and through the capsule cavity. Advantageously, this swirling airflow generated by the airflow inlet channel of the end plug or holder is useful for efficient depletion of the capsule during consumption after it has been pierced. Advantageously, this "swirling" effect may cause agitation or rotation of the capsule to provide uniform entrainment of a portion or fraction of the nicotine particles from the capsule over two or more, five or more, or ten or more inhalations or "puffs" by the user.

[0073] The inhalable material may include nicotine. Preferably, the capsule contains pharmaceutically active particles. The pharmaceutically active particles may include nicotine. The pharmaceutically active particles may have a mass median aerodynamic diameter of about 5 micrometers or less, or in the range of about 0.5 micrometers to about 4 micrometers, or in the range of about 1 micrometer to about 3 micrometers.

[0074] Advantageously, the inhaler article efficiently delivers nicotine particles, either in the form of pharmacologically active particles or aerosol, to the lungs at inhalation doses or airflow rates that are within the range of inhalation doses or airflow rates of conventional smoking methods.

[0075] The inhaler article or system described herein may provide dry powder to the lungs at an inhalation volume or airflow rate that is within the range of that of traditional smoking. The consumer may take multiple inhalations or "puffs," with each "puff" delivering a portion of the dry powder contained within the capsule contained within the capsule cavity. The inhaler article may have a form similar to a traditional cigarette and may mimic the traditional smoking technique. The inhaler article may be simple to manufacture and convenient for the consumer to use.

[0076] Airflow management through the capsule cavity of the inhaler article may cause the capsule contained therein to rotate during inhalation and consumption. The capsule may contain nicotine-containing particles (also referred to as "nicotine powder" or "nicotine particles") and, optionally, flavor-containing particles (also referred to as "flavor particles"). Rotation of the pierced capsule may suspend and aerosolize the nicotine particles released from the pierced capsule into the inhaled air traveling through the inhaler article. The flavor particles may be larger than the nicotine particles and help deliver the nicotine particles to the user's lungs, while the flavor particles preferentially remain in the user's mouth or oral cavity. The nicotine particles and optional flavor particles may be delivered by the inhaler article at an inhalation volume or airflow rate within the range of that of conventional smoking.

[0077] The term "nicotine" refers to nicotine and nicotine derivatives (eg, free base nicotine, nicotine salts, and the like).

[0078] The term "flavorant" or "flavor" refers to an organoleptic compound, composition, or material that alters, or is intended to alter, the taste or aroma characteristics of nicotine during its consumption or inhalation.

[0079] Alternatively, the substrate portion comprises tobacco. The substrate portion may also include a heater. The heater may heat the tobacco, which also includes an aerosolizing agent, to release a nicotine-containing aerosol into the airflow from the substrate portion through the retention portion to the mouthpiece end of the inhaler article for delivery to the user. When the substrate portion comprises tobacco, the support functions to prevent longitudinal movement of the tobacco plug in response to forces such as airflow moving longitudinally from the upstream end to the downstream end of the inhaler article.

[0080] According to one aspect of the present disclosure, there is provided an inhaler system comprising an inhaler article as described herein and a holder for receiving the inhaler article, the holder including a housing defining a housing cavity configured to receive the inhaler article, the holder including a piercing element extending into the housing cavity and configured to pierce a capsule of the inhaler article.

[0081] The holder may include a piercing element extending into the housing cavity configured to pierce the capsule of the inhaler article.

[0082] A holder for an inhaler article may be combined with an inhaler article (described herein) containing a capsule. The inhaler article may be activated or primed by piercing the capsule. Piercing the capsule reliably activates the capsule within the inhaler article (by piercing the capsule with the holder's piercing element), releasing particles contained within the capsule and allowing them to be entrained in the airflow through the inhaler article and delivered to the consumer. While the holder is separate from the inhaler article, a consumer may utilize both the inhaler article and the holder while consuming particles released within the inhaler article. Multiple of these inhaler articles may be combined with a holder to form a system or kit. A single holder may be utilized with 10 or more, 25 or more, 50 or more, or 100 or more inhaler articles to activate (pierce or pierce) the capsule contained within each inhaler article and provide reliable activation. Optionally, a visual indication (marking) may be provided on each inhaler article to indicate that the capsule of the inhaler article has been pierced. Such marking may indicate that the inhaler article has been used.

[0083] The inhaler article holder includes a housing having a housing cavity for receiving the inhaler article and a sleeve configured to hold the inhaler article within the housing cavity. The sleeve has a sleeve cavity and is movable within the housing cavity along the longitudinal axis of the housing. The sleeve has a first open end and a second opposite end. The first open end is configured to receive the distal end of the inhaler article. The second opposite end of the sleeve is configured to contact the distal end of the inhaler article. The second opposite end of the sleeve is configured to direct substantially all inhaled air to flow through the inhaler article via at least one air inlet extending in a direction non-parallel to the central channel.

[0084] The holder may include an opening structure for receiving the folded distal end of the inhaler article and for folding back the folded end such that a folded flap at the distal end of the inhaler article folds back into the inhaler article to expose the capsule within the capsule cavity to the interior of the holder.

[0085] The piercing element is preferably fixed to and extends from the inner surface of the housing. The piercing element may be configured to extend through the second, opposite end of the sleeve and into the capsule cavity to penetrate the capsule along the longitudinal axis of the housing. The piercing element may be a metal or rigid needle. The piercing element may form a single opening through the capsule received in the capsule cavity. The piercing element may be configured to pass through an end plug or hollow tube of the inhaler article, specifically through their central through-channel, and into the capsule cavity.

[0086] The holder may further include a spring element configured to bias the sleeve toward the open proximal end of the housing and between a relaxed position and a compressed position. The spring element may be contained within the housing cavity (also referred to as the inhaler article cavity) of the holder and may be compressed as the movable sleeve and inhaler article move toward the piercing element. The spring element may be located between the sleeve and the distal end of the housing, or may contact the sleeve and the distal end of the housing. The spring element may be between the distal end of the sleeve and the distal end of the housing. The spring element may contact the distal end of the sleeve and the distal end of the housing. The spring element may be disposed around the piercing element. The spring element may be coaxial with the piercing element. The spring element may be a conical spring.

[0087] The spring element biases the inhaler article away from the piercing element. During use, a user may insert the inhaler article into the inhaler article cavity of the holder. By doing so, the spring may be compressed, allowing the inhaler article to move toward the distal end of the inhaler article cavity. Eventually, the piercing element may penetrate a capsule disposed within the inhaler article. Once penetration occurs, the user may release the inhaler article, allowing the spring to bias the inhaler article toward the proximal end of the inhaler article cavity and away from the piercing element. The user may then inhale the proximal end of the inhaler article.

[0088] The sleeve may define a first air inlet zone comprising at least one air opening through the sleeve. The first air inlet zone is proximate the proximal end of the sleeve. The first air inlet zone is configured to allow air to flow from an interior of the sleeve to an airflow channel formed between the sleeve and the housing inner surface. The sleeve may include a second air inlet zone comprising at least one air opening through the sleeve. The second air inlet zone is proximate the distal end of the sleeve. The second air inlet zone is configured to allow air to flow from the airflow channel to an interior of the sleeve.

[0089] The holder may include a marking element extending into the housing (or inhaler article) cavity. The marking element may be configured to mark the surface of the inhaler article. The marking element may extend perpendicular to the longitudinal axis of the holder and the inhaler article. The marking element may be configured to mechanically mark the outer surface of the inhaler article. For example, the marking element may be configured to scrape, cut, abrade, imprint, fold, or curve the outer surface of the inhaler article. The marking element may have a sharp edge configured to scratch the outer surface of the inhaler article when received within the housing cavity. The marking element may color the outer surface of the inhaler article when received within the housing cavity. The marking element may mark the outer surface of the inhaler article when the piercing element penetrates a capsule disposed within the inhaler article, thus indicating that the inhaler article has been activated and can be consumed by the user. Advantageously, this may also prevent a user from attempting to reuse a previously activated inhaler article.

[0090] The marking element may extend perpendicular to the longitudinal axis of the holder and the inhaler article. The marking element may be formed from a rigid material configured to provide a visual indication that the marking element has contacted the outer surface of the inhaler. The marking element may be fixed to the holder housing. The marking element may form an alignment pin, as described above.

[0091] The marking element may extend through at least a portion of the thickness of the holder. The marking element may extend through the sleeve. The marking element may extend into the housing cavity and into the sleeve. The marking element may extend at least a marking distance beyond the sleeve such that the marking element contacts the inhaler outer surface when the inhaler article is received within the housing cavity. The marking element may be aligned with and mate with an elongated slot in the sleeve.

[0092] The inhaler articles described herein may be combined with a piercing element or a holder containing a piercing element to deliver nicotine particles from the capsule to the user. The piercing element or piercing device (or holder) may be separate from or not form part of the inhaler article. Multiple inhaler articles may be combined with piercing elements or piercing devices (or holders) to form a kit.

[0093] The method includes inserting an inhaler article into a sleeve of a holder for the inhaler article, as described herein, until the distal end of the inhaler article contacts a second, opposite end of the sleeve. The method includes inserting an inhaler article into a sleeve of a holder for the inhaler article, as described herein, until the folded distal end of the inhaler article contacts complementary features of the holder, folding the folded end flaps into the distal end of the inhaler article and into the interior of the distal end of the inhaler article. The inhaler article includes a body (the body extending along the inhaler longitudinal axis from the mouthpiece end to the distal end), a length of the body, and a capsule disposed within the inhaler article body. The inhaler article and sleeve are then moved toward a piercing element until the piercing element penetrates the capsule. The sleeve is then moved away from the piercing element until the piercing element is detached from the pierced capsule. Air is then drawn into the second, opposite end of the holder sleeve, directing the inhalation airflow toward the air inlet of the holder and creating a rotating or vortex airflow through the cavity of the inhaler article. This swirling inhalation airflow is directed into the capsule cavity while the inhaler article is placed in an inhaler article holder. The swirling inhalation airflow rotates or agitates the capsule, releasing the particles contained therein. The particles are entrained in the airflow. The consumer inhales the particles. This can be repeated several times until the particles contained in the capsule are depleted. For example, the user can take several "puffs" to inhale the particles contained in the capsule. The consumed inhaler article can then be removed from the holder and disposed of. An unused inhaler article can then be inserted into the holder, and the method can be repeated.

[0094] The capsule may be sealed within the inhaler article prior to consumption. For transport and storage, the inhaler article may be contained in a sealed or airtight container or bag. The inhaler article may include one or more peelable sealing layers for covering one or more air inlet channels at the distal end of the inhaler article or the air outlet at the mouthpiece end of the inhaler article. This may ensure that the inhaler article maintains proper hygiene and freshness, or may prevent the capsule from drying out, becoming hard, and becoming brittle. The retaining portion may increase the rigidity of the inhaler article during manufacture, packaging, transport, storage, opening, insertion into a holder, use, and disposal.

[0095] The capsule may rotate about its longitudinal or central axis as air is drawn through the inhaler article. The capsule may be formed of an airtight material that substantially contains the particles within the capsule interior. The capsule may be configured to be pierced or perforated by a piercing element when within the capsule cavity. The piercing element may be separate from the inhaler article or may be combined with the inhaler article. The capsule may be formed of any suitable material. The capsule may be formed of a metallic or polymeric material that functions to keep contaminants out of the capsule but can be pierced or perforated by a piercing element prior to consumption to allow release of nicotine particles from within the capsule. The capsule may be formed of a polymeric material. The polymeric material may be hydroxypropyl methylcellulose (HPMC). The capsule may be any suitable size. The capsule may be a size 1 to size 4 capsule, or a size 3 capsule, or a size 3 capsule.

[0096] The capsule may contain nicotine (also referred to as "nicotine powder" or "nicotine particles") and, optionally, pharmaceutically active particles, including flavor-containing particles (also referred to as "flavor particles"). The capsule may contain a predetermined amount of nicotine particles and, optionally, flavor particles. The capsule may contain sufficient nicotine particles to provide at least two inhalations or "puffs," or at least about five inhalations or "puffs," or at least about 10 inhalations or "puffs." The capsule may contain sufficient nicotine particles to provide about 5-50 inhalations or "puffs," or about 10-30 inhalations or "puffs." Each inhalation or "puff" may deliver about 0.1 mg to about 3 mg of nicotine particles to the user's lungs, or about 0.2 mg to about 2 mg of nicotine particles to the user's lungs, or about 1 mg of nicotine particles to the user's lungs.

[0097] The nicotine particles may have any useful concentration of nicotine based on the particular formulation employed. The nicotine particles may have at least about 1% up to about 30% by weight nicotine, or about 2% to about 25% by weight nicotine, or about 3% to about 20% by weight nicotine, or about 4% to about 15% by weight nicotine, or about 5% to about 13% by weight nicotine. Preferably, with each inhalation or "puff," about 50 to about 150 micrograms of nicotine may be delivered to the user's lungs.

[0098] The capsule may hold or contain at least about 5 mg of nicotine particles, or at least about 10 mg of nicotine particles. The capsule may 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 may hold or contain between about 5 mg and about 300 mg of nicotine particles, or between about 10 mg and about 200 mg of nicotine particles.

[0099] When flavor particles are blended or combined with nicotine particles in a capsule, the flavor particles may be present in an amount that provides the desired flavor with each inhalation or "puff" delivered to the user.

[0100] The nicotine particles may have any useful size distribution for preferential inhalation delivery to the user's lungs. The capsule may contain particles other than nicotine particles. The nicotine particles and other particles may form a powder system.

[0101] A capsule may hold or contain at least about 5 mg of dry powder (also called a powder system), or at least about 10 mg of dry powder. A capsule may 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. A capsule may hold or contain between about 5 mg and about 300 mg of dry powder, or between about 10 mg and about 200 mg of dry powder, or between about 25 mg and about 100 mg of dry powder.

[0102] The dry powder or powder system may 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 comprising nicotine particles having a particle size of about 5 micrometers or less, or within the range of about 1 micrometer to about 5 micrometers.

[0103] The nicotine-containing particles may have a mass median aerodynamic diameter of about 5 micrometers or less, or in the range of about 0.5 micrometers to about 4 micrometers, or in the range of about 1 micrometer to about 3 micrometers, or in the range of about 1.5 micrometers to about 2.5 micrometers. The mass median aerodynamic diameter is preferably measured using a cascade impactor.

[0104] The flavor-containing particles may have a mass median aerodynamic diameter of about 20 micrometers or more, or about 50 micrometers or more, or in the range of about 50 to about 200 micrometers, or in the range of about 50 to about 150 micrometers. The mass median aerodynamic diameter is preferably measured using a cascade impactor.

[0105] The dry powder may have a median particle size of about 60 micrometers or less, or in the range of about 1 micrometer to about 40 micrometers, or in the range of about 1.5 micrometers to about 25 micrometers. The mean particle size refers to the average particle size per mass, and is preferably measured by laser diffraction, laser diffusion, or electron microscopy.

[0106] The nicotine in powder system or nicotine particles can be pharmaceutically acceptable free base nicotine, or nicotine salt or nicotine salt hydrate.Useful nicotine salt or nicotine salt hydrate includes, for example, nicotine pyruvate, nicotine citrate, nicotine aspartate, nicotine lactate, nicotine bitartrate, nicotine salicylate, nicotine fumarate, nicotine mono-pyruvate, nicotine glutamate or nicotine hydrochloride.The compound that combines with nicotine to form a salt or salt hydrate can be selected based on its expected pharmacological effect.

[0107] Preferably, the nicotine particles comprise an amino acid. Preferably, the amino acid may be leucine, such as L-leucine. Providing nicotine-containing particles with an amino acid, such as L-leucine, may reduce the adhesive force of the nicotine-containing particles, and may also reduce the attractive force between the nicotine particles, thereby reducing the aggregation of the nicotine particles. Similarly, the adhesive force to flavor-containing particles may also be reduced, thereby reducing the aggregation of nicotine particles with flavor particles. Therefore, the powder system described herein may be a free-flowing material, and may have a stable relative particle size of each powder component even when nicotine particles and flavor particles are combined.

[0108] Preferably, the nicotine is a surface-modified nicotine salt, in which case the nicotine salt particles include coated particles or composite particles. A preferred coating or composite material may be L-leucine. One particularly useful nicotine particle may be nicotine bitartrate with L-leucine.

[0109] The powder system may comprise a population of flavor particles, which may have any useful size distribution, selectively for inhalation delivery to the user's mouth or oral cavity.

[0110] The powder system may 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 in the powder system comprise particles having a particle size of about 20 micrometers or greater. The powder system may 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 in the powder system comprise particles having a particle size of about 50 micrometers or greater. The powder system may 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 in the powder system comprise particles having a particle size in the range of about 50 micrometers to about 150 micrometers.

[0111] The flavor-containing particles may contain a compound to reduce adhesion or surface energy and the resulting aggregation. The flavor particles may be surface-modified with an adhesion-reducing compound to form coated flavor particles. One preferred adhesion-reducing compound may be magnesium stearate. Providing flavor particles, particularly coating them, with an adhesion-reducing compound such as magnesium stearate may reduce the adhesion of the flavor-containing particles, reduce the attractive forces between flavor particles, and therefore reduce aggregation of the flavor particles. Therefore, aggregation of flavor particles with nicotine particles may also be reduced. Therefore, the powder system described herein may have a stable relative particle size of the nicotine-containing particles and the flavor-containing particles, even when nicotine particles and flavor particles are combined. Preferably, the powder system may be free-flowing.

[0112] Conventional formulations for dry powder inhalation contain carrier particles that function to increase the fluidization of active particles, because active particles may be too small to be affected by simple airflow through the inhaler.Powder system may also contain carrier particles.These carrier particles may be saccharides such as lactose or mannitol, which may have a particle size of more than about 50 micrometers.Carrier particles can be used in formulations to improve dose uniformity by acting as a diluent or bulking agent.

[0113] Powder systems utilized with the nicotine powder delivery systems described herein may be carrier-free or substantially free of saccharides such as lactose or mannitol, which may allow the nicotine to be inhaled and delivered to the user's lungs at an inhalation volume or airflow rate similar to that of a typical smoking session.

[0114] The nicotine particles and flavors can be combined in a single capsule. As mentioned above, the nicotine particles and flavors can each have reduced adhesive strength, which results in a stable particle formulation, and when the nicotine particles and flavors are combined, the particle size of each component does not change substantially. Alternatively, the powder system includes nicotine particles contained in a single capsule and flavor particles contained in a second capsule.

[0115] The nicotine particles and flavor particles can be combined in any useful relative amounts such that the flavor particles are detectable by the user when consumed together with the nicotine particles. Preferably, the nicotine particles and flavor 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.

[0116] The inhaler and inhaler system are less complex and have a simplified airflow path compared to conventional dry powder inhalers. Advantageously, the rotation of the capsule within the inhaler article may aerosolize the nicotine particles or powder system and help maintain a free-flowing powder. Therefore, the inhaler article may not require the high inhalation dose typically utilized by conventional inhalers to deliver the nicotine particles deep into the lungs.

[0117] The inhaler article may use a flow rate of less than about 5 L / min, or less than about 3 L / min, or less than about 2 L / min, or less than about 1.6 L / min. Preferably, the flow rate may be in the range of about 1 L / min to about 3 L / min, or about 1.5 L / min to about 2.5 L / min. Preferably, the inhalation volume or flow rate may be similar to the Health Canada smoking method flow rate, i.e., about 1.6 L / min.

[0118] The inhaler system may be used by a consumer similar to smoking a traditional cigarette or vaping an e-cigarette. Such smoking or vaping may be characterized by two steps: during the first step, a small volume containing the total amount of nicotine desired by the consumer is drawn into the oral cavity, followed by a second step, in which this small volume containing an aerosol containing the desired amount of nicotine is further diluted with fresh air and drawn deeper into the lungs. Both steps are controlled by the consumer. During the first inhalation step, the consumer may determine the amount of nicotine to be inhaled. During the second step, the consumer may determine the amount to be diluted from the first volume and drawn deeper into the lungs to maximize the concentration of active agent delivered to the epithelial surface of the airways. This smoking mechanism is sometimes referred to as "puff-inhale-exhale."

[0119] The dry powder utilized in the dry powder inhalers of the present disclosure may eliminate or substantially reduce any exhalation of pharmaceutically active particles during the "exhalation" phase. Preferably, substantially all, or at least about 99%, or at least about 95%, or at least 90% of the pharmaceutically active particles have a particle size that is delivered to the lungs but is not small enough to be exhaled normally by breathing. The pharmaceutically active particle size may be in the range of about 0.75 micrometers to about 5 micrometers, or 0.8 micrometers to about 3 micrometers, or 0.8 micrometers to about 2 micrometers.

[0120] As described above, the inhaler article comprises a hollow tubular element having a length "l", a radius "r", a central axis, and an interior surface defining an interior cavity, and a support formed from a sheet and extending from first and second points on the interior surface into the interior cavity of the retention portion to form a triangular support within the interior cavity of the retention portion.

[0121] The hollow tubular element of the retention portion may be formed from a sheet of material.The hollow tubular element of the retention portion and the support may be formed from separate sheets of material.

[0122] The retaining portion may comprise a hollow tubular element or tube. The tube may be separate from the sheet forming the support. The tube may be formed from a sheet of the same material as the sheet of material forming the support or a different material. For example, the tube of the retaining portion may comprise a tube separate from the sheet forming the support element. The support is a structure within the internal cavity of the retaining portion. The support is formed from a sheet of material and includes a first flap, a first bend, a first leg, a second bend, a second leg, a third bend, and a second flap, wherein the first flap of the support has a length, the first flap of the support contacts an interior surface of the retention portion, the first leg of the support includes a length between the first bend and the second bend, the second bend includes a tip, the second leg of the support includes a length between the second bend and the third bend, the first leg, the second bend, and the second leg form two legs of a triangle extending into the interior cavity of the retention portion when the retention portion is viewed from the upstream end of the retention portion, the support forms a second flap, and the second flap of the support includes a length that contacts the interior surface of the retention portion, and the length of at least one of the first leg and the second leg is greater than the radius of the retention portion.

[0123] The retaining portion may comprise a hollow tubular element or tube. The tube may be separate from the sheet forming the support. The tube may be formed from a sheet of the same material as the sheet of material forming the support or a different material. For example, the tube of the retaining portion may comprise a tube separate from the sheet forming the support element. The support is a structure within the internal cavity of the retaining portion. The support is formed from a sheet of material and includes a first flap, a first bend, a first leg, a second bend, a second leg, a third bend, and a second flap, wherein the first flap of the support has a length, the first flap of the support contacts an interior surface of the retention portion, the first leg of the support includes a length between the first bend and the second bend, the second bend includes a tip, the second leg of the support includes a length between the second bend and the third bend, the first leg, the second bend, and the second leg form two legs of a triangle extending into the interior cavity of the retention portion when the retention portion is viewed from the upstream end of the retention portion, the support forms a second flap, and the second flap of the support includes a length that contacts the interior surface of the retention portion, and the lengths of the first leg and the second leg are both greater than the radius of the retention portion.

[0124] The first leg and the second leg may be equal to one another within manufacturing tolerances. For example, the tip of the support may be spaced ±0.5 mm from the central axis of the retaining portion. The tip of the support may be spaced ±0.5 mm to the left or right of the central axis, and the first leg and the second leg may still be considered equal within manufacturing tolerances.

[0125] The first and second flaps of the support may be attached to the hollow tubular element of the retaining portion by adhesive, with the first and second flaps of the support contacting the tube of the retaining portion.

[0126] The hollow tubular element may form the outer surface of the retention portion. Substantially the entire portion of the sheet forming the hollow tubular element may form the outer surface of the retention portion. The outer surface of the retention portion may be curved. The retention portion may be cylindrical.

[0127] The support element may extend along a portion of the length of the retention portion. Preferably, the support is flush with the upstream end of the retention portion. This means that the support may be at the end of the retention portion closest to the capsule. Thus, the support element may be able to better prevent or limit capsule movement, for example, when the capsule is pierced. Preferably, the support element extends to the downstream end of the retention portion. The support element may extend along about 10 to about 100 percent of the length of the retention portion, preferably about 25 to about 100 percent of the length of the retention portion, and more preferably about 50 to about 100 percent of the length of the retention portion. Most preferably, the support element extends along substantially the entire length of the retention portion. Thus, the support element may have a length equal to the length of the retention portion. This may provide the retention portion with additional mechanical strength and rigidity along the entire length of the retention portion.

[0128] The first and second flaps of the support may be attached to an interior surface of the retaining portion. At the first and third bends, the support extends into the interior cavity of the retaining portion when the retaining portion is viewed from the upstream end of the retaining portion. Advantageously, this can simplify manufacture of the retaining portion and can provide a suitable support barrier for one or more substrate components, such as a capsule, located upstream of the retaining portion.

[0129] The first and second flaps of the support may be attached to the inner surface of the retention portion by adhesive. The use of adhesive can help improve the mechanical strength of the retention portion in one or both of the longitudinal and transverse directions. This can help improve the retention portion's ability to provide a support barrier and its resistance to collapse or deformation.

[0130] The sheet of material of the support extends from the interior surface of the retention portion at a first bend and a third bend. The first leg and the second leg form two sides of a triangle that extends into the interior cavity of the retention portion. The first leg and the second leg form an angle at the second bend. The second bend forms a tip. The tip may have an angle of less than 90 degrees. The tip may have an angle of less than 70 degrees. The tip may have an angle of less than 67.5 degrees. The tip may have an angle of less than 45 degrees. The tip may have an angle of less than 40 degrees. The tip may have an angle of 22 degrees to 68 degrees. The tip may have an angle of 22.5 degrees to 67.5 degrees. The tip may have an angle of 30 degrees to 45 degrees. The tip may have an angle of 30 degrees to 44 degrees. The tip may have an angle of 32.5 degrees to 43.5 degrees. The tip may have an angle of 37.5 degrees ±5 degrees. The tip may include a 37.5 degree angle.

[0131] The retention portion is structured and arranged to provide the retention portion with sufficient mechanical strength and rigidity in one or both of the longitudinal and transverse directions to prevent or limit movement of one or more components, such as a capsule, disposed upstream of the retention portion without significant deformation of the retention portion during use of the inhaler article. This mechanical strength and rigidity, or rigidity, of the retention portion also supports the inhaler article as it is manufactured, packaged, shipped, opened, inserted into a holder, used, and discarded.

[0132] The first flap and the second flap each have a length. Preferably, the first flap and the second flap have approximately equal lengths. Advantageously, the first and second flaps having approximately equal lengths provide approximately equal reinforcement to the retention portion along the length of the first flap and along the length of the second flap. The length of the first and second flaps may be approximately equal to the radius of the retention portion. The length of the first and second flaps may be less than the radius of the retention portion. Preferably, the length of the first and second flaps is less than the radius of the retention portion. For example, when the diameter of the inhaler article is approximately 7 mm, the length of the first and second flaps may be less than 4.5 mm. The length of the first and second flaps may be 2 mm to 4.5 mm. The length of the first and second flaps may be 2 mm to 4 mm. The length of the first and second flaps may be 2.3 mm to 3.5 mm. The length of the first and second flaps may be 2.5 mm to 3.3 mm. The first and second flaps may have a length of 2.7 mm±1 mm. The first and second flaps may have a length of 2.7 mm. The inventors have found that when the length of the first and second flaps is shorter than the radius of the retention portion, the retention portion retains its round shape or is less likely to deform from its round shape.

[0133] The first bend of the support and the third bend of the support may be spaced apart from each other. The first bend and the second bend may be spaced apart by less than 4 mm. The first bend and the second bend may be spaced apart by less than 3 mm. The first bend and the second bend may be spaced apart by 2 mm to 4 mm. The first bend and the second bend may be spaced apart by 2.25 mm to 2 mm. The first bend and the second bend may be spaced apart by 2.5 mm to 3 mm. The first bend and the second bend may be spaced apart by 2.7 mm ± 1 mm. The first bend and the second bend may be spaced apart by 2.7 mm.

[0134] The first bend and the second bend may be spaced apart by less than 30% of the circumference of the retention portion. The first bend and the second bend may be spaced apart by less than 25% of the circumference of the retention portion. The first bend and the second bend may be spaced apart by less than 20% of the circumference of the retention portion. The first bend and the second bend may be spaced apart by 10% to 30% of the circumference of the retention portion. The first bend and the second bend may be spaced apart by 15% to 30% of the circumference of the retention portion. The first bend and the second bend may be spaced apart by 20% to 30% of the circumference of the retention portion.

[0135] The first bend in the inner surface of the retention portion and the third bend in the inner surface of the hollow tubular element of the retention portion can be spaced apart from each other around the retention portion by about 5 percent to about 50 percent of the circumference of the retention portion, preferably about 10 percent to about 40 percent of the circumference of the retention portion, and more preferably about 15 percent to about 30 percent of the circumference of the retention portion.

[0136] The first and second flaps may be attached to the inner surface of the retention portion. The first and second flaps may be attached to the inner surface of the hollow tubular element of the retention portion by adhesive. The use of adhesive may help improve the mechanical strength of the retention portion in one or both of the longitudinal and transverse directions. This may therefore help improve the retention portion's resistance to collapse or deformation. This may help improve the retention portion's rigidity.

[0137] The support may have a tip, the tip being positioned within the internal cavity of the retaining portion. The tip is at a second bend. The second bend is at a tip. The tip may extend into the internal cavity of the retaining portion by the length of the first leg and the second leg. The tip is at an angle formed by the intersection of the first leg and the second leg. The tip may be spaced apart from the internal surface of the retaining portion at the first bend by the length of the first leg. The tip may be spaced apart from the internal surface of the retaining portion at the second bend by the length of the second leg. At least one of the first leg or the second leg is longer than the radius of the retaining portion.

[0138] The first leg or the second leg, or both the first leg and the second leg, may be longer than the radius of the retaining portion by about 0.2 millimeters or more. The first leg or the second leg, or both the first leg and the second leg, may be longer than the radius of the retaining portion by about 0.5 millimeters or more. The first leg or the second leg, or both the first leg and the second leg, may be longer than the radius of the retaining portion by about 1 millimeter or more.

[0139] The first leg or the second leg, or both the first leg and the second leg, may be no more than about 3 millimeters longer than the radius of the retaining portion. The first leg or the second leg, or both the first leg and the second leg, may be no more than about 2.5 millimeters longer than the radius of the retaining portion. The first leg or the second leg, or both the first leg and the second leg, may be no more than about 2 millimeters longer than the radius of the retaining portion.

[0140] The first leg or the second leg, or both the first and second legs, may be about 0.2 millimeters to about 3 millimeters longer than the radius of the retention portion. The first leg or the second leg, or both the first and second legs, may be about 0.5 millimeters to about 2.5 millimeters longer than the radius of the retention portion. The first leg or the second leg, or both the first and second legs, may be about 1 millimeter to about 2 millimeters longer than the radius of the retention portion. The first leg or the second leg, or both the first and second legs, may be about 1.5 millimeters longer than the radius of the retention portion. The tip may be located at a point adjacent to a point on the inner surface of the hollow tubular element of the retention portion. The tip may contact the inner surface of the hollow tubular element of the retention portion. The tip may be positioned approximately equidistant from the first bend and the third bend.

[0141] As used herein, the term "radial center" is used to refer to the center of a cross-section of the retention portion, which is the same as the central axis. The tip may be pointed. For example, the support element may have a substantially triangular cross-section, with the tip being the apex of a triangle that extends into the interior cavity of the retention portion.

[0142] The term "substantially triangular" is used to describe the shape of the first leg, second bend (or tip), and second leg, which form a shape that can be described as two sides of a triangle extending within the internal cavity of the hollow tubular portion. The first leg of the support includes a length between the first bend and the second bend. The second bend includes the tip. The second leg of the support includes a length between the second bend and the third bend. The first leg, second bend, and second leg form the two legs of the triangle extending within the internal cavity of the retention portion when the retention portion is viewed from the upstream end of the retention portion.

[0143] The term "substantially triangular" is used to describe the support.

[0144] When describing the "substantially triangular" shape of the support, the third side of the triangle may not be present. Alternatively, the third side of the "substantially triangular" shape may be an imaginary line between the first bend and the third bend. Alternatively, the third side of the "substantially triangular" shape may be formed by the interior surface of a hollow tubular element, which curves the third side of the triangle. However, the shape of the support extending into the interior cavity of the retention portion is best described as two sides of a triangle. However, the support may not form a three-sided triangle, but the first leg, second bend (or tip), and second leg form two sides of a triangular-shaped protrusion extending into the interior cavity of the retention portion.

[0145] Because the support does not connect the first bend and the second bend to form a third side of the triangle, the support does not form an actual triangle (defined as a closed two-dimensional shape with three sides, three angles, and three vertices). Instead, the support extends along the interior surface of the hollow tubular portion at the first bend and the third bend, forming a first flap and a second flap. However, while the support does not necessarily form a three-sided triangle, the first leg, the second bend (or tip), and the second leg form two sides of a triangular protrusion that extends into the interior cavity of the retention portion. That is, the first leg, the second bend, and the second leg form two legs of a triangle that extends into the interior cavity of the retention portion when the retention portion is viewed from the upstream end of the retention portion.

[0146] The support element may include three bends. That is, the sheet forming the support element may include a first bend at the inner surface of the hollow tubular element of the retention portion, a second bend at the tip, and a third bend at a second point on the inner surface of the hollow tubular element of the retention portion. This may further strengthen the retention portion in one or both of the longitudinal and transverse directions and enable the retention portion to withstand large forces applied in one or both of the longitudinal and transverse directions before substantially deforming. This may therefore improve the ability of the retention portion to prevent or restrict movement of one or more components, such as a capsule, located upstream of the retention portion.

[0147] The tip of the support may be positioned approximately equidistant from the first bend and the third bend. The tip may be positioned closer to the first bend than to the third bend. That is, the first leg and the second leg may be different lengths. Preferably, the first leg and the second leg have the same or essentially the same length. The first leg and the second leg may be substantially planar. That is, the first leg and the second leg may not be curved.

[0148] In this manner, the cross section of the retention portion may exhibit a triangular shape that extends into the interior cavity of the retention portion when the retention portion is viewed from the upstream end of the retention portion.

[0149] The support may be completely surrounded by the hollow tubular element of the holding part and therefore does not form an outer surface of the holding part.

[0150] The angle defined by the intersection of the first leg and the second leg (second bend or tip) may be about 50 degrees or less. The angle defined by the intersection of the first leg and the second leg (second bend or tip) may be about 45 degrees or less. The angle defined by the intersection of the first leg and the second leg (second bend or tip) may be about 35 degrees or less. The angle defined by the intersection of the first leg and the second leg (second bend or tip) may be about 5 degrees to about 50 degrees. The angle defined by the intersection of the first leg and the second leg (second bend or tip) may be about 10 degrees to about 45 degrees. The angle defined by the intersection of the first leg and the second leg (second bend or tip) may be about 15 degrees to about 40 degrees. The angle defined by the intersection of the first leg and the second leg (second bend or tip) may be about 20 degrees to about 40 degrees. The angle defined by the intersection of the first leg and the second leg (second bend or tip) may be about 25 degrees to about 40 degrees. The angle defined by the intersection of the first leg and the second leg (second bend or tip) may be about 35 degrees to about 42 degrees. The angle defined by the intersection of the first leg and the second leg (second bend or tip) may be about 32.5 degrees to 43.5 degrees. The angle defined by the intersection of the first leg and the second leg (second bend or tip) may be 37.5 degrees ± 5 degrees.

[0151] The first flap of the support has a length that contacts the inner surface of the retention portion. The second flap of the support has a length that contacts the inner surface of the retention portion. The first and second flaps of the support contact the inner surface of the retention portion. The first flap of the support may be attached to the inner surface of the retention portion by an adhesive. The second flap of the support may be attached to the inner surface of the retention portion by an adhesive. The first and second flaps of the support may be attached to the inner surface of the retention portion by an adhesive. The use of an adhesive may help improve the mechanical strength of the retention portion in one or both of the longitudinal and transverse directions. This may therefore help improve the retention portion's resistance to collapse or deformation and the retention portion's ability to prevent or limit the movement of one or more components, such as a capsule, disposed upstream of the retention portion. Furthermore, the triangular shape formed by the first leg, the second bend, and the third leg may help improve the mechanical strength of the retention portion in one or both of the longitudinal and transverse directions. This may therefore help to improve the resistance of the retention portion to collapse or deformation, and the ability of the retention portion to prevent or restrict movement of one or more components, such as a capsule, positioned upstream of the retention portion.

[0152] The retention portion may include at least one longitudinal plane of symmetry. The retention portion may also be radially symmetric. This may simplify assembly of the inhaler article, as the orientation in which the retention portion is placed within the inhaler article is less critical. Furthermore, this may also mean that the retention portion is able to distribute loads more evenly and can withstand increased applied forces.

[0153] The cross-sectional area of ​​the retention portion is preferably substantially constant along the entire length of the retention portion, such that the resistance to withdrawal of the inhaler article may also be constant along the entire length of the retention portion.

[0154] Preferably, the retention portion has a substantially constant cross-section along the entire length of the retention portion. That is, the cross-section of the retention portion does not vary substantially along the entire length of the retention portion. This may simplify manufacturing of the retention portion. Alternatively, the cross-section of the retention portion may vary along the length of the retention portion. For example, the support may have a cross-section that varies along the length of the retention portion. For example, the support may not extend along the entire length of the retention portion.

[0155] The support may divide the hollow interior region of the retention portion into multiple channels. The number of channels may be selected based on the desired nucleation of aerosol particles and the desired withdrawal resistance of the inhaler article. The support element may divide the cavity of the retention portion into two channels. When the tip does not contact the inner surface of the retention portion, the support element divides the cavity of the retention portion into two channels. The support element may divide the cavity of the retention portion into three channels. When the tip of the support contacts the inner surface of the retention portion, the cavity may be divided into three channels.

[0156] The tip of the support element may be spaced from the radial center of the retention portion by a distance of at least about 5 percent of the radius of the retention portion. The tip of the support element may be spaced from the radial center of the retention portion by a distance of at least about 5 percent of the radius of the retention portion, or by a distance of at least about 10 percent of the radius of the retention portion. The tip of the support element may be spaced from the radial center of the retention portion by a distance of at least about 5 percent of the radius of the retention portion, or by a distance of at least about 15 percent of the radius of the retention portion.

[0157] The tip of the support may be spaced from the radial center of the retention portion by a distance greater than or equal to about 5 percent of the radius of the retention portion and less than or equal to about 90 percent of the radius of the retention portion. The tip of the support may be spaced from the radial center of the retention portion by a distance greater than or equal to about 5 percent of the radius of the retention portion and less than or equal to about 80 percent of the radius of the retention portion. The tip of the support may be spaced from the radial center of the retention portion by a distance greater than or equal to about 5 percent of the radius of the retention portion and less than or equal to about 70 percent of the radius of the retention portion.

[0158] The tip of the support may be spaced from the radial center of the retention portion by a distance of about 5 percent to about 90 percent of the radius of the retention portion. The tip of the support may be spaced from the radial center of the retention portion by the distance of the tip of the support, or may be spaced from the radial center of the retention portion by a distance of about 10 percent to about 80 percent of the radius of the retention portion. The tip of the support may be spaced from the radial center of the retention portion by a distance of about 15 percent to about 70 percent of the radius of the retention portion.

[0159] The tip of the support may be spaced apart from the radial center of the retention portion by a distance of about 0.2 millimeters or more. The tip of the support may be spaced apart from the radial center of the retention portion by a distance of about 0.5 millimeters or more. The tip of the support may be spaced apart from the radial center of the retention portion by a distance of about 1 millimeter or more. The tip of the support may be spaced apart from the radial center of the retention portion by a distance of about 1.2 millimeters ±0.5 millimeters.

[0160] The tip of the support may be spaced apart from the radial center of the retention portion by a distance of about 3 millimeters or less. The tip of the support may be spaced apart from the radial center of the retention portion by a distance of about 2.5 millimeters or less. The tip of the support may be spaced apart from the radial center of the retention portion by a distance of about 2 millimeters or less. The tip of the support may be spaced apart from the radial center of the retention portion by a distance of about 1.5 millimeters or less.

[0161] The tip of the support may be spaced from the radial center of the retention portion by a distance of about 0.2 mm to about 3 mm. The tip of the support may be spaced from the radial center of the retention portion by a distance of about 0.5 mm to about 2.5 mm. The tip of the support may be spaced from the radial center of the retention portion by a distance of about 1 mm. The tip of the support may be spaced from the radial center of the retention portion by a distance of about 2 mm. The tip of the support may be spaced from the radial center of the retention portion by a distance of about 0.5 mm to about 1 mm.

[0162] The support element may have a depth approximately equal to the inner radius of the retaining portion. That is, at least one of the first leg and the second leg may have a length greater than the radius of the retaining portion. The first leg and the second leg may have a length greater than the radius of the retaining portion.

[0163] As used herein, the term "depth" refers to the distance between the first bend on the inner surface of the holding portion and the tip (second bend) of the support. This is the length of the first leg. Alternatively, "depth" refers to the distance between the tip (second bend) and the third bend. This is the length of the second leg. Thus, the term "depth" refers to the length of either the first or second leg. The first and second legs may have essentially equal lengths.

[0164] The support element may be the only support element of the holding portion, i.e. the holding portion may comprise a single support element.

[0165] The retention portion preferably has an outer diameter approximately equal to the outer diameter of the inhaler article.

[0166] The retention portion may have an outer diameter of about 5 millimeters or more. The retention portion may have an outer diameter of about 6 millimeters or more. The retention portion may have an outer diameter of about 7 millimeters or more. The retention portion may have an outer diameter of about 12 millimeters or less. The retention portion may have an outer diameter of about 10 millimeters or less. The retention portion may have an outer diameter of about 8 millimeters or less.

[0167] The retention portion may have an outer diameter of about 5 mm to about 12 mm. The retention portion may have an outer diameter of about 6 mm to about 10 mm. The retention portion may have an outer diameter of about 7 mm to about 8 mm. The retention portion may have an outer diameter of about 7.2 mm.

[0168] The hollow tubular element of the retention portion has a thickness. Accordingly, the inner diameter of the retention portion may be smaller than the outer diameter of the retention portion. The retention portion may have an inner diameter of about 4.5 millimeters or more. The retention portion may have an inner diameter of about 5.5 millimeters or more. The retention portion may have an inner diameter of about 6.5 millimeters or more. The retention portion may have an inner diameter of about 11.5 millimeters or less. The retention portion may have an inner diameter of about 9.5 millimeters or less. The retention portion may have an inner diameter of about 7.5 millimeters or less. The retention portion may have an inner diameter of about 4.5 millimeters to about 11.5 millimeters. The retention portion may have an inner diameter of about 5.5 millimeters to about 9.5 millimeters. The retention portion may have an inner diameter of about 6.5 millimeters to about 7.5 millimeters.

[0169] The hollow tubular element of the retention portion may have a total internal surface area of ​​about 25 square millimeters per millimeter of length or more, preferably about 28 square millimeters per millimeter of length or more, more preferably about 30 square millimeters per millimeter of length or more, or about 35 square millimeters per millimeter of length or more.

[0170] The hollow tubular element of the retention portion may have a total internal surface area of ​​about 70 square millimeters per millimeter of length or less, preferably about 60 square millimeters per millimeter of length or less, more preferably about 50 square millimeters per millimeter of length or less, or about 40 square millimeters per millimeter of length or less.

[0171] The hollow tubular element of the retention portion may have a total internal surface area of ​​about 25 square millimeters per length millimeter to about 70 square millimeters per length millimeter, preferably about 28 square millimeters per length millimeter to about 60 square millimeters per length millimeter, more preferably about 30 square millimeters per length millimeter to about 50 square millimeters per length millimeter, or about 30 square millimeters per length millimeter to about 40 square millimeters per length millimeter. The hollow tubular element of the retention portion may have a total internal surface area of ​​about 35 square millimeters per length millimeter to about 70 square millimeters per length millimeter, preferably about 40 square millimeters per length millimeter to about 70 square millimeters per length millimeter, more preferably about 50 square millimeters per length millimeter to about 70 square millimeters per length millimeter, or about 60 square millimeters per length millimeter to about 70 square millimeters per length millimeter.

[0172] The retention portion can provide an unrestricted flow channel. This means that the hollow tubular segment preferably provides a negligible resistance to withdrawal (RTD). The term "negligible RTD" is used to describe an RTD of less than 1 mmH2O per 10 millimeters of retention portion length, preferably less than 0.4 mmH2O per 10 millimeters of retention portion length, and more preferably less than 0.1 mmH2O per 10 millimeters of retention portion length. When viewing the retention portion from the upstream end of the retention portion, the triangular support profile extending into the retention portion's internal cavity provides little obstruction to the flow of air and particles through the retention portion. Thus, the flow channel is essentially free of components that obstruct longitudinal air flow. Preferably, the flow channel is substantially empty.

[0173] The retention portion may have a longitudinal porosity of about 90 percent or greater.

[0174] As used herein, the longitudinal porosity of the retention portion is defined by the ratio of the cross-sectional area of ​​the material forming the retention portion to the internal cross-sectional area of ​​the inhaler article at the location of the retention portion.

[0175] The longitudinal porosity of the retention portion may be advantageously selected to provide a desired overall withdrawal resistance of the inhaler article.

[0176] The longitudinal porosity of the retention portion may be substantially constant along the entire length of the retention portion. For example, the cross-sectional area of ​​the material forming the retention portion may be substantially constant along the entire length of the retention portion, and the inhaler article may also have a substantially constant internal cross-sectional area along the entire length of the retention portion. The retention portion may have a substantially constant cross-section along the entire length of the retention portion, such that the cross-sectional area of ​​the material forming the retention portion is substantially constant along the entire length of the retention portion. The retention portion may also have a cross-section that varies along the length of the retention portion, and a substantially constant cross-sectional area of ​​the material forming the retention portion along the entire length of the retention portion.

[0177] The longitudinal porosity of the retention portion may vary along the length of the retention portion, for example, this may be the case when the retention portion does not have a constant cross-section along its entire length, such that the cross-sectional area of ​​the material forming the retention portion varies along the length of the retention portion.

[0178] The materials forming one or both of the support of the retaining portion and the hollow tubular element may be the same or different materials. Each of the retaining portion and the support may be formed from paper, any other paper-based material, any other cellulosic material, a bioplastic-based material, or metal. For example, the retaining portion and the support may be formed from one or more of paper, paperboard, cardboard, reconstituted tobacco paper, cellophane, and aluminum.

[0179] The support is formed from a sheet of material. The retention portion may also be formed from a sheet of material. The sheet forming the support may be the same as or different from the sheet forming the retention portion. Preferably, the sheet is formed from a biodegradable material.

[0180] The sheet may be formed from a paper-based material, such as paper, paperboard, or cardboard. The paper-based material may be bleached or unbleached. The paper-based material may be one or more of lightweight, inexpensive, and biodegradable. When one or both of the support element and the hollow tubular element are formed from a paper sheet, the retaining portion exhibits sufficient mechanical strength and rigidity to withstand significant deformation during interaction with a holder for receiving an inhaler article, while being able to prevent or limit movement of one or more components, such as a capsule, disposed upstream of the retaining portion.

[0181] The sheet forming one or both of the retaining portion and the support may have a basis weight (grams per square meter, gsm) of about 15 gsm or more, preferably about 25 gsm or more, more preferably about 35 gsm or more, or about 45 gsm or more. A sheet having such a basis weight can avoid crack formation and / or breakage during bending and / or folding of the sheet. Thus, the sheet can maintain its structural integrity when bent or folded to form the support element. This can improve the retaining portion's resistance to collapse or deformation and its ability to prevent or limit movement of at least a portion of the aerosol-forming substrate and / or at least a portion of the susceptor element.

[0182] The sheet forming one or both of the retention portion and the support may have a basis weight of about 150 gsm or less, preferably about 130 gsm or less, more preferably about 110 gsm or less, or about 80 gsm or less, or about 50 gsm or less. Providing a sheet with such a basis weight can advantageously ensure that the retention portion has a desired porosity along its longitudinal axis. This may be such that the retention portion has a desired resistance to pulling. Furthermore, providing a sheet with such a basis weight can advantageously facilitate manufacturing of the retention portion, for example, by making the sheet easier to roll, bend, and / or fold.

[0183] The sheet forming one or both of the holding portion and the support may have a basis weight of about 15 gsm to about 150 gsm, about 20 gsm to about 130 gsm, about 60 gsm to about 100 gsm, about 70 gsm to about 80 gsm.

[0184] The support may be made from a sheet of material having a thickness of 250 to 200 microns. The support may be made from a sheet of material having a thickness of less than 250 microns. The support may be made from a sheet of material having a thickness of less than 125 microns. The support may be made from a sheet of material having a thickness of 250 to 125 microns. The support may be made from a sheet of material having a thickness of 250 to 100 microns. The support may be made from a sheet of material having a thickness of 200 to 100 microns. The support may be made from a sheet of material having a thickness of less than 150 microns. The support may be made from a sheet of material having a thickness of about 100 microns. The support may be made from a sheet of material having a thickness of less than 125 microns. The support may be made from a sheet of material having a thickness of 150 to 100 microns. The support may be made from a sheet of material having a thickness of 140 to 100 microns. The support may be made from a sheet of material having a thickness of 125 to 100 microns. The support may be made from a sheet of material having a thickness of 120 microns to 130 microns. The support may be made from a sheet of material having a thickness of 75 to 125 microns. The support may be made from a sheet of material having a thickness of 75 to 140 microns. The support may be made from a sheet of material having a thickness of 75 to 150 microns.

[0185] Support materials having a thickness of 250 microns or less are considered thin. Similarly, support materials having a thickness of 200 microns or less are considered even thinner.

[0186] The support may be made from a sheet of material having a basis weight (or weight) of 250 gsm (grams per square meter) or less. The support may be made from a sheet of material weighing 200 gsm or less. The support may be made from a sheet of material weighing 175 gsm or less. The support may be made from a sheet of material weighing 170 gsm or less. The support may be made from a sheet of material weighing 150 gsm or less. The support may be made from a sheet of material weighing 140 gsm or less. The support may be made from a sheet of material weighing 130 gsm or less. The support may be made from a sheet of material weighing 125 gsm or less. The support may be made from a sheet of material weighing 100 gsm or less. The support may be made from a sheet of material weighing between 50 gsm and 250 gsm. The support may be made from a sheet of material weighing between 50 gsm and 200 gsm. The support may be made from a sheet of material weighing between 50 gsm and 200 gsm. The support may be made from a sheet of material weighing between 50 gsm and 175 gsm. The support may be made from a sheet of material weighing between 50 gsm and 175 gsm. The support may be made from a sheet of material weighing between 75 and 200 gsm. The support may be made from a sheet of material weighing between 160 gsm and 180 gsm. The support may be made from a sheet of material weighing about 170 gsm. The support may be made from a sheet of material weighing less than 170 gsm. The support may be made from a sheet of material weighing between 90 gsm and 110 gsm. The support may be made from a sheet of material weighing about 100 gsm. The support may be made from a sheet of material weighing between 68 gsm and 88 gsm. The support may be made from a sheet of material weighing about 78 gsm. The support may be made from a sheet of material weighing about 80 gsm.

[0187] The support may be made of paper having a thickness of 124 microns and a basis weight of 170 gsm. The support may be made of paper having a thickness of 125 microns and a basis weight of 100 gsm. The support may be made of paper having a thickness of 100 microns and a weight of 78 gsm.

[0188] The sheet forming the support may have a basis weight of about 70 grams per square meter (gsm) to 200 gsm. The sheet forming the support may have a basis weight of 75 to 200 gsm. The sheet forming the support may have a basis weight of 75 to 125 gsm. The sheet forming the support may have a basis weight of 90 to 180 gsm. The sheet forming the support may have a basis weight of 90 to 120 gsm. The sheet forming the support may have a basis weight of 70 to 90 gsm. The sheet forming the support may have a basis weight of about 45 gsm to about 110 gsm. The sheet forming the support may have a basis weight of about 45 gsm. The sheet forming the support may have a basis weight of about 60 gsm. The sheet forming the support may have a basis weight of about 78 gsm. The sheet forming the support may have a basis weight of 100 gsm. The sheet forming the support may have a basis weight of 110 gsm. The sheet forming the support may have a basis weight of 170 gsm. Providing a sheet having such a basis weight may advantageously facilitate manufacturing of the retaining portion, for example, by making the sheet easier to roll, bend, and / or fold.

[0189] The sheet forming one or both of the retaining portion and the support may have a thickness of about 15 micrometers or more, about 30 micrometers or more, or about 45 micrometers or more. The sheet forming one or both of the retaining portion and the support may have a thickness of about 100 micrometers or more. The sheet forming one or both of the retaining portion and the support may have a thickness of 100 micrometers to 130 micrometers. The sheet forming one or both of the retaining portion and the support may have a thickness of about 124 micrometers. The sheet forming one or both of the retaining portion and the support may have a thickness of about 125 micrometers. A sheet having such a thickness may avoid crack formation and / or breakage during bending and / or folding of the sheet. Thus, the sheet may maintain its structural integrity when bent or folded to form the support element. This may improve the retaining portion's resistance to collapse or deformation and its ability to prevent or limit movement of at least a portion of the aerosol-forming substrate and / or at least a portion of the susceptor element.

[0190] The sheet forming one or both of the support and the retaining portion may have a thickness of about 150 micrometers or less, preferably about 140 micrometers or less, and more preferably about 130 micrometers or less. Providing a sheet having such a thickness can advantageously ensure that the retaining portion has a desired porosity along its longitudinal axis. This may be such that the retaining portion has a desired resistance to withdrawal. Furthermore, providing a sheet having such a basis weight can advantageously facilitate manufacturing of the retaining portion, for example, by making the sheet easier to roll, bend, and / or fold.

[0191] The sheet forming the retaining portion and / or the support may have a thickness of about 15 micrometers to about 150 micrometers, preferably about 30 micrometers to about 140 micrometers, and more preferably about 90 micrometers to about 130 micrometers.

[0192] The sheet forming the support may have a thickness of about 15 micrometers to about 150 micrometers, preferably about 30 micrometers to about 140 micrometers, and more preferably about 90 micrometers to about 130 micrometers.

[0193] Providing a sheet having such a basis weight may advantageously facilitate manufacturing of the retaining portion, for example, by making the sheet easier to roll, bend, and / or fold.

[0194] When the sheet forming one or both of the retaining portion and the support is an aluminum sheet, the sheet may have a thickness of about 10 micrometers to about 20 micrometers. Aluminum sheets having such thicknesses can advantageously facilitate the manufacture of the retaining portion, for example, by making the sheet easy to roll, bend, and / or fold. Furthermore, aluminum sheets having such thicknesses can provide the retaining portion with sufficient strength and rigidity to prevent or resist movement of one or more components, such as a capsule, disposed upstream of the retaining portion, while preventing deformation of the retaining portion. Furthermore, aluminum sheets having such basis weights can advantageously ensure that the retaining portion has a desired porosity along its longitudinal axis.

[0195] The hollow tubular element of the retaining portion may have a thickness of about 15 micrometers or more, about 45 micrometers or more, or about 100 micrometers or more. Providing the retaining portion with such a thickness may prevent deformation of the retaining portion while providing the retaining portion with sufficient strength and rigidity to prevent or limit movement of one or both of the first element and the susceptor element.

[0196] The hollow tubular element of the retention portion may have a thickness of about 600 micrometers or less, about 500 micrometers or less, or about 400 micrometers or less. Providing the hollow tubular element of the retention portion with such a thickness may advantageously ensure that the retention portion has a desired longitudinal porosity, which may be such that the retention portion has a desired resistance to withdrawal. Furthermore, providing the retention portion with such a thickness may mean that individual retention portions can be easily cut from a continuous rod of retention portion, which may simplify the manufacture of the retention portion.

[0197] The hollow tubular element of the retaining portion may have a thickness of about 15 micrometers to about 600 micrometers, about 50 micrometers to about 500 micrometers, or about 100 micrometers to about 400 micrometers. Preferably, the hollow tubular element of the retaining portion has a thickness of about 100 micrometers to about 130 micrometers.

[0198] The inventors of the present invention have found that a retaining portion having a hardness of at least about 90 percent can enable the retaining portion to prevent or limit movement of one or more components, such as a capsule, positioned upstream of the retaining portion while avoiding significant deformation during interaction between the inhaler article and the holder.

[0199] The term "hardness" as used herein refers to resistance to deformation. Hardness is typically expressed as a percentage. FIG. 21 shows a retaining portion 50 before the application of load F and the same retaining portion 52 during the application of load F. Before the application of load F, the retaining portion 50 has an outer diameter D S After the setting load is applied during setting, the retaining portion 52 (still under load) has a (reduced) outer diameter D d The depression is d=D S -D d Referring to FIG. 21, the hardness is given by the following formula: [Number 1] JPEG2026505675000002.jpg1454

[0200] D in the formula S is the outer diameter of the original (unpressed) retaining part, and D d is the depressed outer diameter after applying a constant load for a certain duration. The harder the holding part, the closer the hardness will be to 100%.

[0201] As explained in more detail below, determining the hardness of a retaining portion requires aligning the retaining portion parallel to a plane and subjecting the same portion of each retaining portion being tested to a constant load for a fixed duration. This test is a DD60A test and is performed using a known DD60A Densimeter instrument (manufactured and sold by Heinr. Borgwaldt GmbH, Germany), which includes a measuring head and a retaining portion receiver for the retaining portion.

[0202] Loads are applied using two load-application cylindrical rods that extend across the diameter of all of the retention segments at once. Standard test methods for this device require testing to produce 20 contact points between the retention segments and the load-application cylindrical rods. In some cases, the retention segments being tested may be long enough that only 10 retention segments are needed to form 20 contact points, each contacting both load-application rods (because they are long enough to extend between both rods). In other cases, if the retention segments are too short to achieve this, 20 retention segments should be used to form 20 contact points, with each retention segment contacting only one of the load-application rods, as discussed further below.

[0203] Two further fixed cylindrical rods are positioned below the retaining portion to support the retaining portion and to counter the loads exerted by each of the load-applying cylindrical rods, such an arrangement being described in more detail below.

[0204] The standard operating procedure for such devices is to apply a total load of 2 kg for 20 seconds. After 20 seconds have elapsed (and with the load still applied to the retaining portion), the depression on the load-applying cylindrical rod is measured and then used to calculate the hardness using the above equation. The temperature is kept within the range of 22°C ± 2°C. The above test is referred to as the DD60A test. The hardness of the retaining portion of an inhaler article may not differ significantly between the retaining portion of a consumed inhaler article and the retaining portion of an unused inhaler article. However, the standard method for measuring the hardness of the retaining portion is when the retaining portion is not part of the consumed inhaler article.

[0205] The hardness of the retention portion may be at least about 90%. Preferably, the hardness of the retention portion is at least about 92%. This provides better resistance to movement of one or more components, such as a capsule, located upstream of the retention portion. This also provides better resistance to deformation of the retention portion during interaction between the inhaler article and the holder.

[0206] Retaining portions having low total weights have the advantage that they can be assembled into inhaler articles using high-speed machines and processes. In particular, the present inventors have found that retaining portions having total weights of about 150 milligrams or less can be advantageously assembled into inhaler articles using existing high-speed inhaler article assembly machines.

[0207] The retention portion may have a total weight of about 150 milligrams or less, preferably about 100 milligrams or less, and more preferably about 70 milligrams or less. The retention portion may have a total weight of about 15 milligrams to about 150 milligrams, preferably about 20 milligrams to about 100 milligrams, or about 25 milligrams to about 70 milligrams. The retention portion may have a total weight of about 34 milligrams. The retention portion may have a total weight of about 76 milligrams. The retention portion may have an average weight of about 10 milligrams or less per millimeter of retention portion length, preferably about 8 milligrams or less per millimeter of retention portion length, and more preferably about 6 milligrams or less per millimeter of retention portion length. Providing a retention portion with such an average weight may advantageously enable the retention portion to be assembled into an inhaler article using existing high-speed inhaler article assembly machinery. The retention portion may have an average weight of about 1 to about 10 milligrams per millimeter of retention portion length, preferably about 1.5 to about 8 milligrams per millimeter of retention portion length, and more preferably about 2 to about 6 milligrams per millimeter of retention portion length.

[0208] The retention portion may have an average weight of about 4.25 milligrams per millimeter of retention portion length. As used herein, the average weight of the retention portion is measured by dividing the total weight of the retention portion by the length of the retention portion.

[0209] A portion of the retaining portion may be surrounded by the wrapper. The entire retaining portion may be surrounded by the wrapper. The wrapper may be a paper wrapper.

[0210] The retaining portion is preferably connected to one or more of the adjacent components of the inhaler article by a wrapper, which may be a paper wrapper.

[0211] The retaining portion may comprise an adhesive. For example, if the retaining portion comprises a tube, the sheet forming the support may be attached to the tube by an adhesive at the point where the sheet contacts the tube. That is, the first and second flaps of the support may be attached to the interior surface of the hollow tubular element of the retaining portion by an adhesive.

[0212] The adhesive may include at least one of PVA, PVOH, and hot melt glue. The adhesive may also include a binder. Suitable binders include, but are not limited to, gums such as guar gum, xanthan gum, gum arabic, and locust bean gum; cellulose binders such as hydroxypropyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, methyl cellulose, and ethyl cellulose; polysaccharides such as starch, organic acids such as alginic acid, conjugate base salts of organic acids such as sodium alginate, agar, and pectin; and combinations thereof. Preferably, the binder includes guar gum.

[0213] The present disclosure also relates to a method for forming a retention portion for an inhaler article. The method may include providing a device for forming the retention portion. The device may include the device. The device may have an inner surface. The inner surface may define a channel in the device. The channel may have a substantially constant cross-section along the entire length of the first section of the device. For example, a portion of the channel extending through the first section of the device may be substantially cylindrical. The channel may extend from an upstream opening of the device. The channel may extend to a downstream opening of the device. The method may also include providing a hollow tube. The method may further include passing a sheet of material through the upstream opening of the device and into the channel. The method may further include gluing the sheet of material to form a hollow tubular element. Forming the hollow tubular element from the sheet may include forming a seam by overlapping a portion of the sheet at a first end with a portion of the sheet at an opposing second end of the sheet. Forming the seam may include attaching a portion of the sheet at the first end to a portion of the sheet at the second end with adhesive. The seam may extend along the length of the hollow tube.

[0214] The diameter of the channel of the device may be approximately the same as the diameter of the hollow tube of the retaining portion. The diameter of the channel may be selected so that the outer surface of the hollow tube of the retaining portion remains in contact with the inner surface of the device during the step of passing the hollow tube through the first section of the device to assist in shaping the hollow tube into the retaining portion.

[0215] The method may include attaching a first flap of the support and a second flap of the support to an inner surface of a hollow tubular element of the retaining portion. The attaching step may be performed before the retaining portion exits the device. In this case, the attaching step may be performed while the hollow tubular element of the retaining portion passes through the channel. The attaching step may be performed after the retaining portion exits the device.

[0216] The method may include enclosing a wrapper around the retaining portion. The enclosing step may be performed before the retaining portion exits the device. The enclosing step may be performed after the retaining portion exits the device.

[0217] The method may include attaching a wrapper to the retaining portion, for example, by adhesive. The step of attaching the wrapper to the retaining portion may be performed before the retaining portion exits the device. The step of attaching the wrapper to the retaining portion may be performed after the retaining portion exits the device.

[0218] Features described with respect to one example or one embodiment may also be applicable to other examples and embodiments. [Example]

[0219] Below is provided a non-exhaustive list of non-limiting examples, any one or more of the features of these examples may be combined with any one or more features of another example or embodiment described herein.

[0220] Example 1: an inhaler article extending between an upstream end and a downstream end, the inhaler article comprising at least a base portion and a retaining portion, the inhaler article and the base portion and the retaining portion each comprising a length "l", a radius "r", and a central axis, the base portion comprising a base, the retaining portion comprising a hollow tubular element having an interior surface and defining an interior cavity, and a support within the interior cavity of the retaining portion, the support formed from a sheet of material and comprising a first flap, a first bend, a first leg, a second bend, a second leg, a third bend, and a second flap, the first flap of the support comprising a length, the first flap of the support comprising a length, the first flap of the support comprising a length, the second flap of the support comprising a length, the second flap of the support comprising a length, the second flap of the support comprising a length, the third flap of the support comprising a length, the third flap of the support comprising a length, the fourth flap of the support comprising a length, the fourth flap of the support comprising a length, the fifth flap of the support comprising a length, the fifth flap of the support comprising a length, the sixth flap of the support comprising a length, the sixth flap of the support comprising a length, the sixth flap of the support comprising a length, the sixth flap of the support comprising a length, the sixth flap of the support comprising a length, the sixth flap of the support comprising a length, the eighth ... an inhaler article comprising: a support having a length that contacts the inner surface of the retainer; a first leg of the support including a length between a first bend and a second bend, the second bend including a tip; a second leg of the support including a length between the second bend and a third bend; the first leg, the second bend and the second leg forming two legs of a triangle that extends into an internal cavity of the retainer when the retainer is viewed from the upstream end of the retainer; the support forming a second flap; the second flap of the support having a length that contacts the inner surface of the retainer; and a length of at least one of the first leg and the second leg being greater than a radius "r" of the retainer. Example 2: The inhaler article of example 1, wherein the retention portion is downstream of the substrate portion. Example 3: The inhaler article of example 2, wherein the inhaler article further comprises a mouthpiece. Example 4: The inhaler article of example 3, wherein the inhaler article comprises a base portion, a retention portion downstream of the base portion, and a mouthpiece downstream of the retention portion, the mouthpiece forming a downstream end of the inhaler article. Example 5: The inhaler article of any one of Examples 1-4, wherein the inhaler article comprises a cylinder. Example 6: The inhaler article of any one of Examples 1-5, wherein the first leg and the second leg are straight. Example 7: The inhaler article of any one of Examples 1-6, wherein a length of at least one of the first flap and the second flap is less than a radius of the retention portion. Example 8: The inhaler article of any one of Examples 1-7, wherein at least one of the first flap and the second flap is attached to an inner surface of the retention portion. Example 9: A first flap and a second flap are attached to the inner surface of the retaining portion with an adhesive. Example 10: The inhaler article of any one of Examples 1-9, wherein the substrate comprises paper or cardboard. Example 11: The inhaler article of any one of Examples 1 to 10, wherein the substrate comprises a powder. Example 12: The inhaler article of Example 11, wherein the powder is contained within a capsule. Example 13: The inhaler article of any one of Examples 1-10, wherein the substrate comprises tobacco. Example 14: The inhaler article of any one of Examples 1-13, further comprising a wrapper surrounding the substrate portion and at least a portion of the retention portion. Example 15: The inhaler article of any one of Examples 1 to 14, wherein the length of the inhaler article is 40 to 50 mm. Example 16: The inhaler article of example 15, wherein the length of the retention portion is 5 to 9 mm. Example 17: The inhaler article of Example 15, wherein the length of the retention portion is 6 to 8 mm. Example 18: The inhaler article of any one of Examples 1 to 17, wherein the length of the retention portion is 10-20% of the length of the inhaler article. Example 19: The inhaler article of example 18, wherein the support is formed from a sheet of material that is different from the material of the retainer. Example 20: The inhaler article of any one of Examples 1-19, wherein the support comprises a sheet of material having a thickness of 100-125 μm. Example 21: The inhaler article of any one of Examples 1 to 20, wherein the support comprises a 75 to 200 gsm material. Example 22: The inhaler article of any one of Examples 1 to 21, wherein the radius of the retention portion, measured from the inner surface of the retention portion to the central axis of the retention portion, is 3 to 4 mm. Example 23: The inhaler article of any one of Examples 1 to 22, wherein the radius of the retention portion, measured from the inner surface of the retention portion to the central axis of the retention portion, is 3.2 to 3.75 mm. Example 24: The inhaler article of any one of Examples 1-23, wherein the length of the first leg and the length of the second leg are greater than the length of the radius of the retention portion. Example 25: The inhaler article of any one of Examples 1-24, wherein the first bend and the third bend are angles rather than curves. Example 26: The inhaler article of any one of Examples 1 to 25, wherein the tip is angled at between 32.5 degrees and 43.5 degrees. Example 27: An inhaler system comprising the inhaler article of any one of Examples 1 to 26 and a holder for receiving the inhaler article, wherein the holder: a housing defining a housing cavity configured to receive an inhaler article; a piercing element extending into the housing cavity and configured to pierce the capsule of the inhaler article.

[0221] Embodiments of the invention will now be described in detail, by way of example only, with reference to the accompanying drawings, in which:

[0222] 1, 2A, and 2B show an inhaler article 10 according to the present disclosure. The inhaler article 10 extends between its upstream end 1 and downstream (or mouth) end 2. The inhaler article 10 comprises a base portion 3, a retention portion 4, and a mouthpiece 6 located downstream of the base portion 3 and the retention portion 4. The mouthpiece 6 is spaced from the base portion 3 by the retention portion 4. The inhaler article 10 comprises the base portion 3, the retention portion 4, and the mouthpiece 6, arranged in a linear fashion from the upstream end 1 to the downstream end 2. In an embodiment, the retention portion 4 may be the mouthpiece 6.

[0223] As shown in FIG. 2A , the substrate portion 3 includes a cavity 7 that accommodates a substrate 29. As shown in FIG. 2A , the substrate 29 is housed within a capsule 9 that is housed within the cavity 7. The cavity 7 is configured to house the capsule 9. The capsule 9 within the cavity 7 houses the substrate 29. The substrate portion 3 houses the substrate 29. The substrate portion 3 houses the capsule 9, which houses the substrate material 29. The capsule 9 is located between the upstream end 1 and the retention portion 4 of the inhaler article 10. The inhalable material 29 within the capsule 9 includes nicotine. According to the embodiment shown in FIG. 2A , the substrate material 29 is a dry powder 299 contained within the capsule 9. As shown in FIG. 2A , the substrate portion 3 includes a folded upstream end 5 and a hollow tube 12 that defines the cavity 7. The retention portion 4 may extend from the cavity 7, or a downstream portion thereof, to the downstream end 2 of the inhaler article 10. Alternatively, as shown in Figures 1, 2A, and 2B, the retaining portion 4 may be a portion of the inhaler article 10 between the base portion 3 that houses the substrate 29 and the mouthpiece 6 that forms the downstream end 2 of the inhaler article 10.

[0224] The inhaler article 10 further comprises a wrapper 8. The wrapper 8 may encase the base portion 3. The wrapper 8 may encase the base portion 3 and the retention portion 4. The wrapper may wrap the base portion 3, the retention portion 4, and the mouthpiece 6. The wrapper may encase the hollow tube 12 and the retention portion 4. The hollow tube 12 defines a cavity 7. The upstream ends of the hollow tube 12 and the retention portion 4 define the cavity 7. The downstream end of the hollow tube 12 abuts the upstream end of the retention portion 4. The retention portion 4 may form the downstream end 2 of the inhaler article 10. Alternatively, there is a mouthpiece 6 that forms the downstream end 2 of the inhaler article 10. As shown in FIGS. 2A and 2B , the wrapper 8 surrounds the hollow tube 12, the retention portion 4, and the mouthpiece 6 of the base portion 3. In an embodiment, the wrapper 8 secures the retention portion 4 in axial alignment with the hollow tube 12. In an embodiment, when the wrapper 8 surrounds the base portion 3, the retaining portion 4, and the mouthpiece 6, the wrapper 8 secures the mouthpiece 6 and the retaining portion 4 in linear axial alignment with the hollow tube 12 of the base portion 3.

[0225] In the embodiment shown in FIG. 2B, the substrate portion 3 includes a substrate 29, which is tobacco 298. In the embodiment shown in FIG. 2B, the substrate portion 3, the retention portion 4, and the mouthpiece portion 6 are shown linearly aligned. Additionally, as shown in FIG. 2B, an optional upstream element 11 is shown at the upstream end 1 of the inhaler article 10. In the embodiment shown in FIG. 2B, the substrate 29, which is tobacco 298, may be wrapped by a hollow tubular element 12. In this embodiment, the hollow tubular element 12 may be plug wrap. In the embodiment shown in FIG. 2B, the inhaler article 10 is shown having the substrate portion 3, the retention portion 4, and the mouthpiece linearly axially aligned from the upstream end 1 to the downstream end 2. The substrate portion 3 and the retention portion 4 may be surrounded by a wrapper 8. The wrapper 8 secures the retention portion 4 in axial alignment with the hollow tube 12 of the substrate portion 3. In embodiments, when wrapper 8 surrounds base portion 3, retention portion 4, and mouthpiece 6, wrapper 8 secures mouthpiece 6 and retention portion 4 in linear axial alignment with hollow tube 12 of base portion 3. Additionally, when optional upstream element 11 is present, wrapper 8 secures upstream element 11, base portion 3, retention portion 4, and mouthpiece 6 in axial alignment with hollow tube 12.

[0226] As shown in FIG. 2A and in cross section in FIG. 4, the folded end 5 of the hollow tube 12 defines a central channel or passageway 55 extending from the upstream end of the folded end 5 through the center of the folded end 5. The central channel 55 of the folded end 5 is arranged to provide access to the capsule cavity 7 for a piercing element 101, such as the piercing element 101 of the holder 1210 for the inhaler article 10. Such a piercing element is configured to pierce or perforate the capsule 9 to activate it for consumption. Piercing the capsule allows the powder contained within the capsule to be released by the airflow through the inhaler article, delivering the powder to the user. The diameter of the central channel 55 is less than approximately 6 mm. The central channel is structured to accommodate a piercing element or needle between 27 gauge (outer diameter = 0.42 mm) and 4 gauge (outer diameter = 5 mm). As shown in FIG. 3, the central channel 55 is 1 mm.

[0227] As shown in FIG. 3, the total length of the inhaler article 10 is approximately 45 mm. The length of the capsule cavity 7 is approximately 25 mm, and the length of the retaining portion 4 is approximately 7 mm. The length of the hollow tube 12 surrounding the capsule cavity 7 is approximately 25 mm to approximately 28 mm. The inner diameter of the hollow tube 12 surrounding the capsule cavity 7 is approximately 6.47 mm to approximately 6.63 mm, depending on the thickness of the hollow tube 12 material. The outer diameter of the hollow tube 12 is approximately 7.1 mm to approximately 7.5 mm. As shown in FIG. 3, the outer diameter of the hollow tube 12 is 7.3 mm. The length of the packaging material 8 is approximately 45 mm. The diameter of the inhaler article 10 is approximately 7.1 to 7.5 mm. The relative RTD, or RTD per unit length, of the retaining portion 4 is approximately 0.02 mm of water column per mm. The RTD of the retaining portion 100 is approximately 0.34 mm of water column. The diameter of the capsule 9 is about 6 mm, and the length of the capsule 9 is about 16 mm.

[0228] FIG. 4 shows an inhaler system 1200. The inhaler system 1200 includes an inhaler article 10 and a separate holder 1210. The inhaler article 10 may be received within the holder 1210 to activate or pierce a capsule 9 (not shown in FIG. 4, but see FIGS. 1 and 2A and 2B) disposed within the inhaler article 10. The inhaler article 10 remains within the holder 1210 during use by a consumer. The holder 1210 is configured to induce a swirling inhalation airflow that enters the received inhaler article 10. The holder 1210 is configured to fold or break the folded end 5 of the inhaler article 10.

[0229] The inhaler system 1200 includes an inhaler article 10 and a holder 1210. The inhaler article 10 extends along an inhaler longitudinal axis LA. The holder 1210 includes a movable sleeve 1220 that holds the inhaler article 10 received within the sleeve cavity 122.

[0230] The holder 1210 for the inhaler article 10 includes a housing 111 including a housing cavity 112 for receiving the inhaler article 1050, and a sleeve 1220 configured to hold the inhaler article 1050 within the housing cavity 112. The sleeve 1220 defines a sleeve cavity 122 and is movable within the housing cavity 112 along the longitudinal axis LA of the housing 111. The sleeve 1220 includes a first open end 124 and a second opposite end 1226. The second opposite end 1226 of the sleeve 1220 is configured to allow air to enter the sleeve cavity 122. Air may enter the sleeve cavity through an air inlet 127. The second opposite end 1226 of the sleeve 1220 is configured to induce swirl in the air entering the sleeve cavity 122.

[0231] The holder 1210 may include a penetrating element 101 secured to and extending from the inner surface 109 of the housing. The penetrating element 101 may be configured to extend through a second, opposite end 1226 of the sleeve 1220 and into the sleeve cavity 122 along the longitudinal axis LA of the housing 111. The holder 1210 may include a spring element 102 configured to bias the sleeve 1220 away from the penetrating element 101.

[0232] Figure 5 shows a schematic cross-sectional view of the inhaler article 10 of Figure 1 in a holder 1210 (as shown in Figure 4), with the piercing element 101 entering the upstream end 1 of the inhaler article 10 and about to pierce the capsule 9. As shown in Figure 5, the retaining portion 4 extends to the mouth end 2 of the inhaler article.

[0233] As best seen in Figures 6A and 6B, the retention portion 4 of the inhaler article 10 has a length "l" 113, a radius "r" 114 (shown in Figure 6B), and a central axis 115 (shown in cross section in Figure 6B). The length 113 of the retention portion 4 shown in Figures 6A and 6B is 7 mm. The diameter of the retention portion 4 may be 7.5 to 6.4 mm. The diameter of the retention portion 4 shown in Figures 6A and 6B is 6.55 mm ± 0.08 mm. The radius 114 of the retention portion 4 may be 3.75 mm to 3.2 mm. The radius 114 of the retention portion 4 shown in Figures 6A and 6B is 3.2 to 3.3 mm. The central axis 115 is shown as a dot in Figure 6B because Figure 6B is a cross section. The retention portion 4 comprises a hollow tubular element 110 of material that defines an interior cavity 120 of the retention portion 4. The hollow tubular element 110 has an interior surface 103. The retaining portion 4 also includes a support 130 within the inner cavity 120 of the retaining portion 4 formed from the sheet.

[0234] The support 130 has a first flap 131, a first bend 132, a first leg 133, a second bend 134, a second leg 135, a third bend 136, and a second flap 137. The first flap 131 of the support 130 has a length. The first flap 131 of the support contacts the inner surface 103 of the hollow tubular element 110 of the holding portion 4. The first flap 131 of the support may be attached to the inner surface 103 of the hollow tubular element 110 of the holding portion 4. The first flap 131 of the support may be attached to the inner surface 103 of the hollow tubular element 110 of the holding portion 4 by an adhesive.

[0235] As shown in FIG. 6B, the length of the first flap 131 is shorter than the radius of the hollow tubular element 110 of the holding portion 4. As shown in FIG. 6B, the inner radius of the hollow tubular element of the holding portion is 3.2 to 3.3 mm, and the length of the first flap 131 is less than 3.2 mm or less than 3.3 mm. The length of the first flap 131 may be, for example, less than 3 mm. The length of the first flap 131 may be, for example, 2.5 mm to 3.2 mm. The length of the first flap 131 may be, for example, 2.7 mm. The length of the first flap 131 may be shorter than the radius 114 of the hollow tubular element of the holding portion 4.

[0236] At first bend 132, support 130 rotates to extend into internal cavity 120 of retaining portion 4. First bend 132 is a fold in the sheet material of support 130. As shown in FIG. 6B, first bend 132 extends into internal cavity 120 of retaining portion 4 at an angle. To the extent that an angle can be defined between the straight leg and the arc, the angle can be, for example, 65 degrees to 75 degrees. When viewed from the upstream end of retaining portion 4 and as shown in FIG. 6B, first leg 133, second bend 134, and second leg 135 form two sides of a triangle that extends into internal cavity 120 of retaining portion 4. Second bend 134 defines angle 138. Angle 138 can be 32.5 degrees to 43.5 degrees.

[0237] The second leg 135 extends on the inner surface of the hollow tubular element 110 of the retaining portion 4 between the second bend or tip 134 and the third bend 136. The second leg 135 has a length. The length of at least one of the first leg 133 and the second leg 135 is greater than the radius of the hollow tubular element 110 of the retaining portion 4. As shown in Figures 6A and 6B, the length of the second leg 135 is greater than the radius 114 of the retaining portion 4. As shown in Figures 6A and 6B, the lengths of both the first leg 133 and the second leg 135 are each greater than the radius 114 of the retaining portion.

[0238] At the third bend 136, the support 130 contacts the inner surface 103 of the hollow tubular element of the retaining portion 4. At the third bend 136, the support 130 rotates to form a second flap 137. The third bend 136 may be a fold in the sheet material of the support 130. As shown in FIG. 6B, the third bend 132 forms an angle between the third bend 132 and the inner surface 103 of the hollow tubular element 110 of the retaining portion 4. To the extent that an angle can be defined between the straight leg and the arc, the angle can be, for example, between 65 degrees and 75 degrees.

[0239] The second flap 137 of the support 130 may be attached to the inner surface 103 of the hollow tubular element 110 of the holding portion 4. The second flap 137 of the support may be attached to the inner surface 103 of the hollow tubular element 110 of the holding portion 4 by adhesive. As shown in FIG. 6B , the second flap 137 has a length. The length of the second flap 137 may be, for example, less than 3.2 mm or less than 3.3 mm. The length of the second flap 137 may be, for example, less than 3 mm. The length of the second flap 137 may be, for example, 2.5 mm to 3.2 mm. The length of the second flap 137 may be, for example, 2.7 mm. The length of the second flap 137 may be less than the radius 114 of the hollow tubular element of the holding portion 4.

[0240] The support 130 is formed from a paper sheet. The paper sheet has a basis weight of approximately 78 gsm. The support 130 is formed from a paper sheet scored with a first bend 132, a second bend 134, and a third bend 136. This scored sheet facilitates creating a bend when manufacturing the support 130 and inserting it into the hollow tubular element 110 of the retention portion 4. The length of the support 130, measured when the support 130 is unbent and measured from the end of the first flap 131 to the end of the second flap 137, is approximately 14.3 mm. The width of the support 130 is equivalent to the length of the retention portion 4, which is approximately 7 mm. That is, the support 130 extends along substantially the entire length of the retention portion 4, from the upstream surface of the retention portion to the downstream surface of the retention portion. In practice, the support 130 has substantially the same width as the retention portion 4.

[0241] The retention portion 4 has a total weight of about 72 milligrams. Therefore, the retention portion has an average weight of about 4.2 milligrams per millimeter. The retention portion 4 has a constant cross-section along the entire length of the retention portion 4.

[0242] The first bend 132, the second bend 134, and the third bend 136 of the support 130 are parallel to the longitudinal axis of the retention portion 4. As such, the first bend 132, the second bend 134, and the third bend 136 are parallel to one another. The first bend 132 and the third bend 136 are spaced apart from one another by a distance of approximately 2.68 mm along the inner surface 103 of the retention portion hollow tubular element 110.

[0243] The first leg 133 and the second leg 135 define an angle 138 of 37.5 degrees ±5 degrees at the second bend, or tip. The second bend, or tip 134, of the support 130 is spaced from the radial center 115 of the retaining portion 4 by a distance of approximately 1.2 mm.

[0244] The retention portion is manufactured by first forming the hollow tubular element 110 of the retention portion 4. A sheet of support 130 is folded at a first bend 132, a second bend 134, and a third bend 136 to form the triangular shape of the support 130. Adhesive is then applied to the sides of the first flap 131 and the second flap 137 intended to contact the inner surface 103 of the hollow tubular element 110 of the retention portion 4. The support 130 is then inserted into the hollow tubular element 110 of the retention portion 4 so that the first flap 131 and the second flap 137 contact the inner surface 103 of the hollow tubular element 110 of the retention portion 4 and the first leg 133, the second bend or tip 134, and the second leg 135 extend into the internal cavity of the retention portion to form the triangular shape. The adhesive may be heated, cured, or set in a further step. The retention portion 4 containing the support 130 may then be cut to the desired length.

[0245] For purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, and the like are to be understood in all instances as modified by the term "about." Also, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein. Thus, in this context, the number A is understood as A ± 10% of A. Within this context, the number A can be considered to include values ​​that are within the general standard error for measurement of the property that the number A modifies. In some instances, as used in the appended claims, the number A may deviate by the percentages recited above, so long as the amount by which A deviates does not materially affect the basic and novel characteristics of the claimed invention. Also, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein.

Claims

1. an inhaler article extending between an upstream end and a downstream end comprising a base portion and a retention portion, said inhaler article, and said base portion and said retention portion each comprising a length "l", a radius "r", and a central axis; the substrate portion comprises a substrate; the retaining portion being a hollow tubular element having an interior surface and defining an interior cavity; a support within the internal cavity of the retaining portion; the support is formed from a sheet of material and includes a first flap, a first bend, a first leg, a second bend, a second leg, a third bend, and a second flap; the first flap of the support has a length, the first flap of the support contacts the inner surface of the retaining portion; the first leg of the support has a length between the first bend and the second bend; the second bend includes a tip; the second leg of the support has a length between the second bend and the third bend; the first leg, the second bend, and the second leg form two legs of a triangle extending into the internal cavity of the retaining portion when the retaining portion is viewed from the upstream end of the retaining portion; the support defines the second flap, the second flap of the support having a length that contacts the inner surface of the retaining portion; The inhaler article, wherein the length of at least one of the first leg and the second leg is greater than the radius of the retaining portion.

2. 2. The inhaler article of claim 1, wherein the radius of the retention portion is 3 to 4 mm.

3. The inhaler article of claim 1 or claim 2, wherein the length of the first leg and the length of the second leg are greater than the radius of the retaining portion.

4. The inhaler article according to any one of claims 1 to 3, wherein a length of at least one of the first flap and the second flap is shorter than the radius of the retention portion.

5. The inhaler article of any one of claims 1 to 4, wherein the first flap and the second flap are attached to the inner surface of the retaining portion with an adhesive.

6. The inhaler article of any one of claims 1 to 5, wherein the first bend and the third bend are angled.

7. The inhaler article according to any one of claims 1 to 6, wherein the support is formed from a sheet of material different from the material of the retaining portion.

8. The inhaler article of any one of claims 1 to 7, wherein the support comprises paper or cardboard.

9. The inhaler article of any one of claims 1 to 8, wherein the support comprises a sheet of material having a thickness of 100 to 125 μm.

10. An inhaler article according to any one of the preceding claims, wherein the support comprises 75 to 200 gsm of material.

11. The inhaler article of any one of claims 1 to 10, wherein the substrate comprises a powder.

12. 12. The inhaler article of claim 11, wherein the powder is contained within a capsule.

13. The inhaler article of any one of claims 1 to 10, wherein the substrate comprises tobacco.

14. The inhaler article of any one of claims 1 to 13, wherein the length of the inhaler article is 40 to 50 mm and the length of the retaining portion is 5 to 9 mm.

15. An inhaler system comprising an inhaler article according to any one of claims 1 to 14 and a holder for receiving the inhaler article, wherein the holder: a housing defining a housing cavity configured to receive the inhaler article; a piercing element extending into the housing cavity and configured to pierce a capsule of the inhaler article.

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