Apparatus and method for manufacturing inhaler articles

Abstract

The present invention relates to a filling and closing rotating drum for an apparatus for manufacturing inhaler articles. The filling and closing rotating drum comprises a plurality of circumferentially arranged grooves. Adjacent grooves are separated by protruding edges. Each groove comprises a first round groove configured to receive an inhaler article precursor and a second round groove configured to receive an inhaler article precursor. The first and second round grooves are arranged between two adjacent protruding edges. The present invention further relates to an apparatus for manufacturing inhaler articles. The present invention further relates to a method for manufacturing inhaler articles.

Description

Technical Field

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

Background Art

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

[0003] It would be desirable to provide an apparatus and method for manufacturing an inhaler article with fewer space requirements for machinery. It would be desirable to provide a more compact apparatus for manufacturing an inhaler article. It would be desirable to provide an apparatus and method for manufacturing an inhaler article that avoids or reduces the risk of inadvertent migration of a capsule from a desired position within a paper tube during the process.

[0004] It would be desirable to provide an apparatus and method for manufacturing an inhaler article at a sufficiently high speed. It would be desirable to provide an apparatus and method for manufacturing an inhaler article that enables a simplified manufacturing process. It would be desirable to provide an apparatus and method for manufacturing an inhaler article that requires fewer process steps. It would be desirable to provide an apparatus and method for manufacturing an inhaler article that enables a simplified process for closing both ends of the inhaler article. It would be desirable to provide an apparatus and method for manufacturing an inhaler article that enables simultaneous filling and closing of both ends of a double-length article.

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

[0006] According to one embodiment of the present invention, a filling and closing rotating drum for an apparatus for manufacturing inhaler articles is provided. The filling and closing rotating drum comprises a plurality of circumferentially arranged grooves. Adjacent grooves are separated by protruding edges. Each groove comprises a first round groove configured to receive an inhaler article precursor. Each groove comprises a second round groove configured to receive an inhaler article precursor. The first and second round grooves of the grooves are arranged between two adjacent protruding edges. The filling and closing rotating drum may provide an apparatus for manufacturing inhaler articles that has fewer space requirements for machinery. A more compact apparatus for manufacturing inhaler articles may be provided by filling the filling and closing rotating drum. An apparatus for manufacturing inhaler articles that avoids or reduces the risk of inadvertent displacement of capsules from a desired position in the paper tube during the process may be provided by filling the filling and closing rotating drum. For example, because filling and closing occur on the same drum, there may generally be fewer opportunities for capsules to come out of the paper tube of the inhaler article precursor. The risk of capsules displacing from a desired position may also be reduced.

[0007] Apparatus may be provided for manufacturing inhaler articles at a sufficiently high speed by filling a filling and closing rotating drum. Apparatus may be provided for manufacturing inhaler articles that enable a simplified manufacturing process by filling a filling and closing rotating drum. Apparatus may be provided that requires fewer process steps by filling a filling and closing rotating drum. For example, if filling and closing are performed separately, a filling drum and a separate closing drum may be required. Apparatus may be provided for manufacturing inhaler articles that enable a simplified process of closing both ends of the inhaler article by filling a filling and closing rotating drum. Apparatus may be provided for manufacturing inhaler articles that enable simultaneous filling and closing of both ends of a double-length article by filling a filling and closing rotating drum.

[0008] Each groove may have a size and shape configured to have the ability to receive a single inhaler article precursor. Each groove may have a size and shape configured to have the ability to receive exactly one single inhaler article precursor. The size and shape of the grooves may be adapted to the size and shape of the inhaler article precursor. For example, the width of the grooves may be about 4 to 10 millimeters. The depth of the grooves may be 2 to 5 millimeters. The length of the grooves may be at least 4 centimeters.

[0009] Each rounded groove may be provided with a vacuum channel for holding an inhaler article precursor within the groove. The vacuum channel may be provided with a supply section. The supply section may be fluidly connected to a vacuum supply source.

[0010] The height difference between the bottom of the rounded groove and the top of the adjacent protruding edge may be 1 to 10 millimeters, preferably 2 to 8 millimeters, more preferably 3 to 7 millimeters, and more preferably 4 to 6 millimeters. The height difference may be measured along a direction perpendicular to the rotation axis of the filling and closing rotating drum. [Overview of the Initiative]

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

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

[0013] Apparatus may be provided for manufacturing inhaler articles that have fewer space requirements for machinery. More compact apparatus may be provided for manufacturing inhaler articles. Apparatus may be provided for manufacturing inhaler articles that avoid or reduce the risk of accidental displacement of the capsule from a desired position in the paper tube during the process. Apparatus may be provided for manufacturing inhaler articles at a sufficiently high speed. Apparatus may be provided for manufacturing inhaler articles that enable a simplified manufacturing process. Apparatus may be provided that requires fewer process steps. Apparatus may be provided for manufacturing inhaler articles that enable a simplified process of closing both ends of the inhaler article. Apparatus may be provided for manufacturing inhaler articles that enable simultaneous filling and closing of both ends of a double-length article.

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

[0015] The filling and closing rotating drum may be oriented within the apparatus such that its axis of rotation is oriented in the horizontal plane. As used herein, the term “horizontal plane” means a plane perpendicular to the vector pointing toward the center of gravity. As used herein, the term “horizontal” means a direction or plane substantially perpendicular to the center of gravity, for example, when the apparatus is set up in a manufacturing hall.

[0016] The device may include a fixed rolling handle.

[0017] As used herein, the term “fixed” refers to a component that is stationary relative to a moving component, such as a rotating drum or a movable conveying surface. For example, a fixed rolling hand does not follow the rotational movement of a filling and closing rotating drum. For example, a fixed sideways hand does not follow the movement of a movable conveying surface.

[0018] A fixed rolling hand may be positioned to push the inhaler article precursor from the first round groove to the adjacent second round groove by the relative movement of the filling and closing rotating drum with respect to the fixed rolling hand.

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

[0020] The filling rods and closing rods may be arranged in pairs. Each pair of filling rods and closing rods comprises one filling rod adjacent to one closing rod.

[0021] The rotating filling and closing unit may include a plurality of circumferentially arranged neutral rods. One neutral rod may be positioned between each pair of filling rods and closing rods.

[0022] Each filling rod may be equipped with a plunger cylinder. The plunger cylinder may be equipped with an opening for inserting an object.

[0023] Each closure rod may be configured to at least partially close the open tubular end of the inhaler article precursor by one or both of flaring, bending, and rounding. Each closure rod may be provided with a closure cap. The closure cap is configured to at least partially close the open end of the inhaler article by one or both of flaring, bending, and rounding. The closure caps may be positioned on both sides of the filling and closing rotating drum to close both ends of the inhaler article precursor.

[0024] The closing cap may include one or more bending heads for bending the open tubular end of the inhaler article inward. The bending heads may be configured to bend the deformable tubular element inward by at least 90 degrees. The closing cap may include a pre-bending head and a final bending head.

[0025] The pre-bending head may be concave in shape to bend the deformable tubular element inward by an angle less than 90 degrees. The final bending head may be a flat bending head to bend the deformable tubular element inward by an angle of approximately 90 degrees. The final bending head may also be convex in shape to bend the deformable tubular element inward by an angle greater than 90 degrees.

[0026] The closing cap may include one or more rounding heads for rounding the open tubular end of an inhaler article. The rounding heads may have a longitudinal central axis extending between the proximal and distal ends of the rounding head. The rounding heads may have a circular opening located in the center of the proximal end and defining a recess toward the distal end. The recess may be provided for insertion of the open tubular end of the inhaler article into the recess. At least a portion of the side wall of the recess may be provided as a rounding surface. The rounding surface may have a concave curvature. The rounding heads may include a rounding mechanism configured to advance the rounding heads linearly along the longitudinal central axis and, at the same time, rotate the rounding heads about the longitudinal central axis. The rounding mechanism may be driven by one or more motors. The rounding mechanism may include means for transmitting force from one or more motors to the rounding heads.

[0027] The rounding mechanism may be configured to process the open end of the article such that the rounded end includes a rounded edge surrounding the central opening. The rounded edge may be a rounded edge.

[0028] The filling and closing station may comprise one or more pretreatment means for pretreating the open end of the deformable tubular element of the inhaler article in order to obtain a pretreated portion with reduced structural stability. The pretreatment means may be arranged upstream of one or more closing caps. The pretreatment means may be configured to crimp the edge of the open end of the deformable tubular element. The pretreatment means may be configured to cut the edge of the open end of the deformable tubular element along one or more lines extending generally parallel to the axial direction of the inhaler article. The pretreatment means may be configured to score the edge of the open end of the deformable tubular element along one or more lines extending generally parallel to the axial direction of the inhaler article. Scoring may provide a discontinuous cut line in the deformable element. The pretreatment means may include a machining head for ribbing, cutting or scoring the open end of the deformable tubular element. The machining head of the pretreatment station may define a generally cylindrical recess having an internal dimension corresponding to the outer diameter of the open end of the deformable tubular element. The machining head of the pretreatment station may further comprise several treatment blades extending from the open side wall of the recess of the machining head towards the internal volume of the machining head. The treatment blades may extend in a funnel shape towards the internal volume of the machining head. The treatment blades may be equidistantly spaced around the recess.

[0029] Each treatment blade may have an engagement edge that contacts the open end of the deformable tubular element during the pretreatment process. The treatment blades may be formed to rib, cut or score the open end of the deformable tubular element during the pretreatment process. The number of treatment blades determines the number of ribbing lines, cutting lines or scoring lines provided to the open end of the deformable tubular element during the pretreatment process.

[0030] The pretreatment means may be provided upstream of the filling and closing station.

[0031] The filling and closing station may include a fixed rail unit. The fixed rail unit may include a first fixed rail for engaging with the filling rods. The first fixed rail may be configured to manipulate the longitudinal position of each filling rod depending on the angular position of each filling rod. The fixed rail unit may include a second fixed rail for engaging with the closing rods. The second fixed rail may be configured to manipulate the longitudinal position of each closing rod depending on the angular position of each closing rod. The term “angular position” refers to the angular displacement of the rotating filling and closing unit with respect to its axis of rotation. The term “longitudinal position” refers to the position along the direction parallel to the axis of rotation of the rotating filling and closing unit.

[0032] Each filling rod may include a first cam connected to a first fixed rail. Each closing rod may include a second cam connected to a second fixed rail.

[0033] The apparatus may be configured to process inhaler articles of a single length. The apparatus may include an additional closure station provided downstream of the filling and closing rotating drum. The additional closure station may be configured to close the open end on one side of each inhaler article. The apparatus may be configured to process inhaler articles of double length. Processing inhaler articles of double length may allow for an increase in production speed.

[0034] As used herein, the term “processing an article” refers to one or more steps in the manufacture of an inhaler article. The term “inhaler article” may refer to a finished article or an unfinished article. The term “inhaler article precursor” refers to an unfinished article. An unfinished inhaler article may comprise a deformable tubular element that forms an open end of the article. Generally, unfinished inhaler articles are supplied to the upstream end of the processing line. Inhaler articles received at the downstream end of the processing line may be finished inhaler articles or may require further processing to finally receive a finished article.

[0035] The terms “upstream” and “downstream” are used herein to refer to the processing direction of inhaler articles and inhaler article precursors. Generally, articles are processed or transported downstream from the upstream end to the downstream end of a processing line. The terms “processing direction” and “downstream direction” may be used interchangeably.

[0036] The filling and closing rotating drum may be configured to receive a plurality of double-length inhaler article precursors. Each double-length inhaler article precursor may have two open tubular ends. The filling and closing station may be configured to both fill and close each of the two open tubular ends of the inhaler article precursors while the inhaler article precursors are received by the filling and closing rotating drum. The filling and closing station may comprise a further rotating filling and closing unit. The filling and closing rotating drum may be positioned between the rotating filling and closing unit and the further rotating filling and closing unit. The rotating filling and closing unit, the further rotating filling and closing unit, and the filling and closing rotating drum may share a common axis of rotation. The rotating filling and closing unit, the further rotating filling and closing unit, and the filling and closing rotating drum may rotate at the same speed.

[0037] The apparatus may include a cutting station for cutting a twice-length inhaler article precursor in half. The cutting station may be located downstream of the filling and closing station. The apparatus may include a turning station for rotating all halved inhaler article precursors in the same direction so that all halved inhaler article precursors have the same orientation as the open ends created by the cutting. The apparatus may include a closing station for closing the open tubular ends of the halved inhaler article precursors. The closing station may be located downstream of the cutting station. The closing station may be located downstream of the turning station.

[0038] The filling and closing station may include a feeder unit for supplying material to the filling rod. The feeder unit may include a movable transport surface having a plurality of cavities. Each cavity may have an oval shape configured to receive capsule-shaped material.

[0039] The feeder unit may include a capsule supply unit for supplying capsules to the transport surface. The capsule supply unit may be arranged to insert the capsules into the cavity such that the longitudinal axis of the inserted capsule is parallel to the longitudinal axis of the oval cavity.

[0040] As used herein, the term “parallel” is not necessarily limited to an angle of exactly 0 degrees, but in some embodiments it may include angles that deviate to some extent from the strictly parallel direction. For example, deviations of about 15 degrees or less, or about 10 degrees or less, or about 5 degrees or less, or about 2 degrees or less, or about 1 degree or less may be acceptable. The term “parallel” may be limited to an angle of about 0 degrees. The term “parallel” may be limited to an angle of 0 degrees.

[0041] The feeder unit may include a capsule supply unit for supplying capsules to the transport surface. The capsule supply unit may be positioned to insert capsules into the cavity in an upright position such that the longitudinal axis of the inserted capsule is perpendicular to the longitudinal axis of the oval cavity.

[0042] The oval cavity may have a deeper recessed portion on one side to accommodate the capsule in an upright position.

[0043] The feeder unit may include a fixed tilting hand positioned downstream of the capsule supply section. The fixed tilting hand may be configured to rotate the capsules within each cavity by approximately 90 degrees, by the relative movement of a movable transport surface with respect to the fixed tilting hand, such that the longitudinal axis of the inserted capsule is parallel to the longitudinal axis of the oval cavity. The fixed tilting hand may be shaped as a triangular plate. The fixed tilting hand may be shaped as a curved plate. The fixed tilting hand may be shaped as a triangular curved plate.

[0044] The capsule supply unit may include a vibrating feeder bowl.

[0045] The movable conveying surface may form part of an endless belt or conveyor belt. The movable conveying surface may form part of a rotating drum. At least a portion of the movable conveying surface may be configured to vibrate. Vibration of the movable conveying surface may improve the proper insertion of objects into the cavity of the movable conveying surface.

[0046] The apparatus may be configured such that the inhaler article precursor is received on the filling and closing rotating drum for approximately two rotations of the drum before being discharged from the filling and closing rotating drum. "Rotating" means a full rotation of each drum.

[0047] The apparatus may include one or more additional rotating drums in addition to the filling and closing rotating drums. Each additional rotating drum may be located either upstream or downstream of the filling and closing rotating drums. At least one of the additional rotating drums may have a rounded groove for receiving the inhaler article precursor. At least one of the additional rotating drums may move at the same speed as the filling and closing rotating drums. At least one of the additional rotating drums may have half the number of rounded grooves as the filling and closing rotating drums. The additional rotating drums may move at the same speed as the filling and closing rotating drums, and the number of rounded grooves on the additional rotating drums may be half the number of rounded grooves on the filling and closing rotating drums.

[0048] Embodiments of the present invention provide a method for manufacturing an inhaler article. The method may include providing a filling and closing rotating drum. The filling and closing rotating drum may have a plurality of circumferentially arranged round grooves, each round groove configured to receive an inhaler article precursor. The method may include receiving a first inhaler article precursor that is at least partially filled, having an open tubular end into which an object is inserted. The method may include receiving a second empty inhaler article precursor that has an open tubular end into a second round groove. The method may include receiving a second inhaler article precursor that is at least partially filled by inserting an object into the open tubular end of the empty second inhaler article precursor article while the second inhaler article precursor is received in the second round groove. The method may include at least partially closing the open tubular end of the first inhaler article precursor that receives a first inhaler article precursor that is at least partially closed, having an object inserted into it, while the first inhaler article precursor is received in the first round groove.

[0049] Embodiments of the present invention provide a method for manufacturing an inhaler article. The method comprises providing a filling and closing rotating drum, the filling and closing rotating drum comprising a plurality of circumferentially arranged round grooves, each round groove configured to receive an inhaler article precursor. The method comprises receiving a first inhaler article precursor that is at least partially filled, having an open tubular end into which an object is inserted. The method comprises receiving a second empty inhaler article precursor that has an open tubular end into a second round groove. The method comprises receiving a second inhaler article precursor that is at least partially filled, by inserting an object into the open tubular end of the empty second inhaler article precursor article while the second inhaler article precursor is received in the second round groove. The method comprises at least partially closing the open tubular end of the first inhaler article precursor that receives a first inhaler article precursor that is at least partially closed, with an object inserted into it, while the first inhaler article precursor is received in the first round groove. The steps of the method may be carried out sequentially according to the arrangement described above.

[0050] Methods may be provided for manufacturing inhaler articles that have fewer space requirements for machinery. Methods may be provided for manufacturing inhaler articles that avoid or reduce the risk of accidental displacement of the capsule from a desired position in the paper tube during the process. Methods may be provided for manufacturing inhaler articles at a sufficiently high speed. Methods may be provided for manufacturing inhaler articles that enable a simplified manufacturing process. Methods may be provided that require fewer process steps. A simplified method for manufacturing inhaler articles may be provided, which includes closing both ends of the inhaler article. Methods may be provided for manufacturing inhaler articles that enable simultaneous filling and closing of both ends of a double-length article.

[0051] The first and second round grooves may be adjacent round grooves.

[0052] The method may include the step of removing the first inhaler article precursor, which is at least partially closed, from the filling and closing rotating drum to empty the first round groove again. The method may also include the step of moving the second inhaler article precursor, which is at least partially filled, from the second round groove into the first round groove, which has been emptied again.

[0053] The steps of inserting an object into the open tubular end of an empty second inhaler article precursor and at least partially closing the open tubular end of the first inhaler article precursor into which the object is inserted may be performed simultaneously.

[0054] The inhaler article precursor may remain on the filling and closing drum for approximately two rotations before being discharged from the drum. "Rotation" means a full rotation of each drum.

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

[0056] An inhaler article manufactured by the apparatus and method of the present invention may include a capsule. The capsule may contain one or more nicotine salts. The capsule may contain pharmaceutically active particles. For example, the pharmaceutically active particles may contain nicotine. The pharmaceutically active particles may have an aerodynamic median particle size 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. The capsule may contain one or more nicotine salts.

[0057] The capsule may contain nicotine particles (also called "nicotine powder" or "nicotine particles") containing nicotine, and optionally, flavor particles (also called "flavor particles"). The capsule may contain a predetermined amount of nicotine particles and optional flavor particles. The capsule may contain enough nicotine particles to provide at least two inhalations or "smokes," or at least about five inhalations or "smokes," or at least about ten inhalations or "smokes." The capsule may contain enough nicotine particles to provide about five to about fifty inhalations or "smokes," or about ten to about 30 inhalations or "smokes." Each inhalation or "smoke" 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.

[0058] Nicotine particles may have any useful concentration of nicotine, depending on the specific formulation used. Nicotine particles may have at least about 1 weight percent of nicotine to a maximum of about 30 weight percent of nicotine, or about 2 weight percent to about 25 weight percent of nicotine, or about 3 weight percent to about 20 weight percent of nicotine, or about 4 weight percent to about 15 weight percent of nicotine, or about 5 weight percent to about 13 weight percent of nicotine. Preferably, about 50 to about 150 micrograms of nicotine may be delivered to the user's lungs with each inhalation or "smoke-in".

[0059] The capsule may hold or contain at least about 5 milligrams of nicotine particles, or at least about 10 milligrams of nicotine particles. The capsule may hold or contain less than about 900 milligrams of nicotine particles, or less than about 300 milligrams of nicotine particles, or less than 150 milligrams of nicotine particles. The capsule may hold or contain between about 5 milligrams and about 300 milligrams of nicotine particles, or between about 10 milligrams and about 200 milligrams of nicotine particles.

[0060] When flavor particles are blended or combined with nicotine particles within a capsule, there may be an amount of flavor particles present that provides the desired flavor for each inhalation or "smoke" delivered to the user.

[0061] Nicotine particles may have any size distribution useful for preferential inhalation delivery into the user's lungs. The capsule may contain particles other than nicotine particles. Nicotine particles and other particles may form a powder system.

[0062] The capsule may hold or contain at least about 5 milligrams of dry powder (also called powdered powder) or at least about 10 milligrams of dry powder. The capsule may hold or contain less than about 900 milligrams of dry powder, or less than about 300 milligrams of dry powder, or less than about 150 milligrams of dry powder. The capsule may hold or contain about 5 milligrams to about 300 milligrams of dry powder, or about 10 milligrams to about 200 milligrams of dry powder, or about 25 milligrams to about 100 milligrams of dry powder.

[0063] The dry powder or powder system may consist of nicotine particles having a particle size of about 5 micrometers or less, or in the range of about 1 micrometer to about 5 micrometers, comprising at least about 40 weight percent, at least about 60 weight percent, or at least about 80 weight percent of the powder system.

[0064] Nicotine-containing particles may have an aerodynamic median particle size 5 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 aerodynamic median particle size is preferably measured using a cascade impactor.

[0065] The flavor particles may have an aerodynamic median particle size 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 aerodynamic median particle size is preferably measured using a cascade impactor.

[0066] The dried powder may have an average 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 average particle size refers to the average particle size per unit mass and is preferably measured by laser diffraction, laser diffusion, or electron microscopy.

[0067] The nicotine in the powder system or nicotine particles may be pharmaceutically acceptable free base nicotine, or a nicotine salt or nicotine salt hydrate. Examples of useful nicotine salts or nicotine salt hydrates include nicotine pyruvate, nicotine citrate, nicotine aspartate, nicotine lactate, nicotine tartarate, nicotine salicylate, nicotine fumarate, nicotine monopyruvate, nicotine glutamate, or nicotine hydrochloride. Compounds that combine with nicotine to form salts or salt hydrates may be selected based on their expected pharmacological effects.

[0068] Nicotine particles preferably contain an amino acid. Preferably, the amino acid may be leucine, such as L-leucine. Providing an amino acid such as L-leucine to nicotine-containing particles may reduce the adhesive force of the nicotine-containing particles and also reduce the attractive force between nicotine particles, and therefore may reduce the aggregation of nicotine particles.

[0069] Similarly, the adhesion to flavor particles may also be reduced, and therefore the aggregation of nicotine particles with flavor particles is also reduced. For this reason, the powder systems described herein may be free-flowing materials and maintain a stable relative particle size for each powder component, even when nicotine particles and flavor particles are combined.

[0070] Preferably, the nicotine may be a surface-modified nicotine salt, in which case the nicotine salt particles include coated particles or composite material particles. Preferably, the coating material or composite material may be L-leucine. One particularly useful nicotine particle may be nicotine 5-tartrate containing L-leucine.

[0071] The powder may contain a collection of flavor particles. The flavor particles may have any size distribution useful for selective inhalation delivery into the user's mouth or oral cavity.

[0072] The powder system may have a collection of powder flavor particles consisting of particles having a particle size of about 20 micrometers or larger, comprising at least about 40 weight percent, or at least about 60 weight percent, or at least about 80 weight percent. The powder system may have a collection of powder flavor particles consisting of particles having a particle size of about 50 micrometers or larger, comprising at least about 40 weight percent, or at least about 60 weight percent, or at least about 80 weight percent. The powder system may have a collection of powder flavor particles consisting of particles having a particle size in the range of about 50 micrometers to about 150 micrometers, comprising at least about 40 weight percent, or at least about 60 weight percent, or at least about 80 weight percent.

[0073] Flavor particles may contain compounds to reduce adhesion or surface energy and the resulting aggregation. Flavor particles may be surface-modified with adhesion-reducing compounds to form coated flavor particles. One preferred adhesion-reducing compound may be magnesium stearate. Providing, in particular coating, flavor particles with an adhesion-reducing compound such as magnesium stearate may reduce the adhesion of flavor particles, reduce the attractive forces between flavor particles, and thus reduce the aggregation of flavor particles. Therefore, aggregation of flavor particles containing nicotine particles may also be reduced. Thus, the powder systems described herein may have stable relative particle sizes between nicotine particles and flavor particles, even when nicotine particles and flavor particles are combined. The powder systems may preferably be free-flowing.

[0074] Conventional formulations for dry powder inhalation may contain carrier particles that function to increase the fluidity of the active particles, as the active particles may be too small to be affected by the simple airflow through the inhaler. The powder system may also contain carrier particles. These carrier particles may be saccharides such as lactose or mannitol, which may have a particle size greater than about 50 micrometers. The carrier particles may be used to improve dose uniformity by acting as a diluent or swelling agent in the formulation.

[0075] The powder systems used with the nicotine powder delivery systems described herein may be carrier-free or substantially carrier-free of saccharides such as lactose or mannitol. The absence of a carrier or substantially carrier-free saccharides such as lactose or mannitol may allow nicotine to be inhaled and delivered to the user's lungs at an inhalation volume or airflow similar to that of a typical smoking method.

[0076] Nicotine particles and flavors may be combined within a single capsule. As described above, the nicotine particles and flavors may each have reduced adhesion, and if the particle size of each component does not substantially change when combined, they result in a stable particle formulation. Alternatively, the powder system may include nicotine particles contained in a single capsule and flavor particles contained in a second capsule. The nicotine particles and flavor particles may be combined in any useful relative amounts such that the flavor particles are noticeable to the user when consumed together with the nicotine particles. Preferably, the nicotine particles and flavor particles form at least about 90 weight percent, or at least about 95 weight percent, or at least about 99 weight percent, or 100 weight percent of the total weight of the powder system.

[0077] The inhaler articles manufactured by the apparatus and method of the present invention may be similar in size and shape to smoking articles or cigarettes. The inhaler article may have an elongated body extending along the longitudinal axis of the inhaler article. The inhaler body may have a substantially uniform outer diameter along the length of the elongated body. The inhaler article may have a circular cross-section which may be uniform along the length of the elongated body. The inhaler body may have an outer diameter in 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 7.3 mm. The inhaler article may have a length (along the longitudinal axis) in the range of about 40 mm to about 80 mm, or about 40 mm to about 70 mm, or about 40 mm to about 50 mm, or about 48 mm.

[0078] The inhaler article may include a mouthpiece element. The mouthpiece element may be located proximal to the capsule cavity. The mouthpiece element may extend from the capsule cavity to the mouthpiece end of the inhaler article. The mouthpiece element may have a length in the range of about 10 mm to about 30 mm, preferably about 15 mm to about 25 mm, more preferably about 20 mm to about 22 mm. The mouthpiece element may have a diameter in 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 7.1 mm. The mouthpiece element may have a filtering function. The mouthpiece element may include a filter element. The filter element may extend substantially along the entire length of the mouthpiece element.

[0079] The inhaler article may comprise a deformable tubular element that is at least partially closed by the apparatus or method of the present invention. The deformable element may be formed of a cellulosic material. At least a portion of the deformable element may be formed of paper. The deformable element may provide a barrier to reduce or prevent contamination or foreign matter from entering the capsule cavity.

[0080] The inhaler article may comprise a body, a capsule cavity for holding a capsule, a mouthpiece element, and a deformable tubular element having at least a partially closed end.

[0081] The terms “proximal” and “distal” are used to describe the relative positions of components or parts of components of an inhaler article or system. The inhaler article according to the present invention has a proximal end. During use, nicotine particles exit the proximal end of the inhaler article for delivery to the user. The inhaler article has a distal end opposite the proximal end. The proximal end of the inhaler article may also be called the oral end.

[0082] The open tubular end of the inhaler article precursor processed by the apparatus and method of the present invention may contain or consist of a cellulose-based material, such as paper or cardboard. The open tubular end of the inhaler article may contain or consist of wrapping paper. [Brief explanation of the drawing]

[0083] [Figure 1] Figures 1a and 1b show the filling and closing rotating drum. [Figure 2] Figure 2 shows the filling and closing rotating drum. [Figure 3] Figures 3a to 3d show the filling and closing rotating drum. [Figure 4] Figures 4a and 4b show the apparatus for manufacturing inhaler articles. [Figure 5] Figures 5a and 5b show the filling and closing stations. [Figure 6] Figure 6a shows the filling rod. Figure 6b shows the closing rod. [Figure 7] Figure 7a shows the installation-removal system. Figure 7b shows the vibrating feeder bowl. [Figure 8] Figure 8 shows an apparatus for manufacturing inhaler articles. [Figure 9] Figure 9 shows an apparatus for manufacturing inhaler articles. [Figure 10] Figures 10a and 10b show a mechanism that utilizes a fixed, horizontally tilted hand. [Figure 11] Figure 11 shows a mechanism that utilizes a fixed, horizontally tilted hand. [Figure 12] Figure 12a shows a precursor for an inhaler article. Figure 12b shows an apparatus for manufacturing an inhaler article. [Figure 13] Figures 13a and 13b show the rounding tool. [Modes for carrying out the invention]

[0084] A non-exclusive list of non-limiting embodiments is provided below. One or more features of these embodiments may be combined with one or more features of any of the features described above, for example, one or more features of other embodiments, forms, or aspects described herein.

[0085] [Examples] Example E1: A filling and closing rotating drum for an apparatus for manufacturing inhaler articles, wherein the filling and closing rotating drum comprises a plurality of circumferentially arranged grooves, Adjacent grooves are separated by protruding edges, A filling and closing rotating drum, wherein each groove comprises a first round groove configured to receive an inhaler article precursor and a second round groove configured to receive an inhaler article precursor, the first and second round grooves being positioned between two adjacent protruding edges.

[0086] Example E2: A filling and closing rotating drum according to Example E1, wherein each round groove is provided with a vacuum channel for holding an inhaler article precursor within the round groove.

[0087] Example E3: A filling and closing rotating drum according to Example E1 or Example E2, wherein the height difference between the bottom of the round groove and the top of the adjacent protruding edge is 1 mm to 10 mm, preferably 2 mm to 8 mm, more preferably 3 mm to 7 mm, more preferably 4 mm to 6 mm, and the height difference is measured along a direction perpendicular to the rotation axis of the filling and closing rotating drum.

[0088] Example E4: Apparatus for manufacturing inhaler articles, wherein the apparatus comprises a filling and closing station, the filling and closing station comprises a filling and closing rotating drum configured to receive a plurality of inhaler article precursors, and each inhaler article precursor comprises at least one open tubular end, An apparatus comprising a filling and closing station configured to both fill and close at least one open tubular end of an inhaler article precursor while the inhaler article precursor is being received by a filling and closing rotating drum.

[0089] Example E5: Apparatus according to Example E4, wherein the filling and closing rotating drum is configured to receive inhaler article precursors such that the longitudinal axis of each inhaler article precursor is oriented parallel to the rotation axis of the filling and closing rotating drum.

[0090] Example E6: Apparatus according to Example E4 or Example E5, wherein the filling and closing rotating drum is positioned within the apparatus such that the axis of rotation of the filling and closing rotating drum is oriented in the horizontal plane.

[0091] Example E7: An apparatus according to any of Examples E4 to E6, wherein the filling and closing rotating drum is a filling and closing rotating drum according to any of Examples E1 to E3.

[0092] Example E8: Apparatus according to Example E7, comprising a fixed rolling hand, wherein the fixed rolling hand is positioned to push the inhaler article precursor from a first round groove to an adjacent second round groove by the relative movement of a filling and closing rotating drum with respect to the fixed rolling hand.

[0093] Example E9: A filling and closing station comprises a rotating filling and closing unit, the rotating filling and closing unit, A plurality of circumferentially arranged filling rods, each of which is configured to fill an object into the open tubular end of an inhaler article precursor, A plurality of circumferentially arranged closing rods, each closing rod configured to at least partially close the open tubular end of an inhaler article precursor, comprising: The filling rods and closing rods are arranged in an alternating pattern. An apparatus according to any of Embodiments E4 to E8, wherein the rotating filling and closing unit is disposed adjacent to the filling and closing rotating drum such that the axis of rotation of the rotating filling and closing unit coincides with the axis of rotation of the filling and closing rotating drum.

[0094] Example E10: The apparatus according to Example E9, wherein filling rods and closing rods are arranged in pairs, with each pair comprising one filling rod adjacent to one closing rod.

[0095] Example E11: Apparatus according to Example E10, wherein a rotating filling and closing unit comprises a plurality of circumferentially arranged neutral rods, and one neutral rod is positioned between each pair of filling and closing rods.

[0096] Example E12: An apparatus according to any of Examples E9 to E11, wherein each filling rod is equipped with a plunger cylinder.

[0097] Example E13: Apparatus according to Example E12, wherein the plunger cylinder has an opening for inserting an object.

[0098] Example E14: An apparatus according to any of Examples E9 to E13, wherein each closing rod is configured to at least partially close the open tubular end of the inhaler article precursor by either flaring or rounding or both.

[0099] Example E15: A filling and closing station comprises a fixed rail unit, the fixed rail unit comprising a first fixed rail for engaging with a filling rod and a second fixed rail for engaging with a closing rod, The first fixed rail is configured to manipulate the longitudinal axis position of each filling rod, depending on the angular position of each filling rod. A second fixed rail is configured to manipulate the longitudinal axis position of each closing rod, depending on the angular position of each closing rod. The angular position refers to the angular displacement of the rotating filling and closing unit with respect to its axis of rotation, and Apparatus according to Examples E9 to E14, wherein the longitudinal axis position refers to a position along the direction parallel to the rotation axis of the rotating filling and closing unit.

[0100] Example E16: The apparatus according to Example E15, wherein each filling rod is provided with a first cam connected to a first fixed rail, and each closing rod is provided with a second cam connected to a second fixed rail.

[0101] Example E17: A filling and closing rotating drum is configured to receive a plurality of double-length inhaler article precursors, each double-length inhaler article precursor having two open tubular ends, The filling and closing station is configured to both fill and close each of the two open tubular ends of the inhaler article precursor while the inhaler article precursor is being received by the filling and closing rotating drum. The filling and closing station is equipped with an additional rotating filling and closing unit. A filling and closing rotating drum is disposed between a rotating filling and closing unit and a further rotating filling and closing unit, and Apparatus according to Examples E4 to E16, wherein the rotating filling and closing unit and the filling and closing rotating drum share a common axis of rotation.

[0102] Example E18: Apparatus according to Example E17, comprising a cutting station for cutting an inhaler article precursor in half, wherein the cutting station is located downstream of the filling and closing station.

[0103] Example E19: Apparatus according to Example E18, comprising a closure station for closing the open tubular end of a halved inhaler article precursor, wherein the closure station is located downstream of the cutting station.

[0104] Example E20: An apparatus according to any of Examples E9 to E19, wherein the filling and closing station comprises a feeder unit for supplying material to a filling rod, the feeder unit having an oval shape with a movable transport surface having a plurality of cavities, each cavity configured to receive a capsule-shaped object.

[0105] Example E21: The apparatus according to Example E20, wherein the feeder unit includes a capsule supply unit for supplying capsules to a transport surface, and the capsule supply unit is arranged to insert capsules into the cavity such that the longitudinal axis of the inserted capsule is parallel to the longitudinal axis of the oval cavity.

[0106] Example E22: The apparatus according to Example E20, wherein the feeder unit includes a capsule supply unit for supplying capsules to a transport surface, and the capsule supply unit is positioned to insert the capsules into the cavity in an upright position such that the longitudinal axis of the inserted capsule is perpendicular to the longitudinal axis of the oval cavity.

[0107] Example E23: The apparatus according to Example E22, wherein the oval cavity has a deeper recessed portion on one side for receiving a capsule in an upright position.

[0108] Example E24: An apparatus according to Example E22 or Example E23, wherein the feeder unit comprises a fixed tilting hand disposed downstream of the capsule supply section, and the fixed tilting hand is configured to rotate the capsules by 90 degrees within each cavity by the relative movement of a movable transport surface with respect to the fixed tilting hand, such that the longitudinal axis of the inserted capsule is parallel to the longitudinal axis of the oval cavity.

[0109] Example E25: An apparatus according to any of Examples E21 to E24, wherein the capsule supply unit is equipped with a vibrating feeder bowl.

[0110] Example E26: An apparatus according to any of Examples E20 to E25, wherein a movable conveying surface forms part of an endless belt or a rotating drum.

[0111] Example E27: A method for manufacturing an inhaler article, To provide a filling and closing rotating drum having a plurality of circular grooves arranged in the circumferential direction, wherein each circular groove is configured to receive an inhaler article precursor, A first circular groove is used to receive a first inhaler article precursor that is at least partially filled and has an open tubular end into which an object is inserted; The second circular groove is used to receive an empty second inhaler article precursor having an open tubular end, While the second inhaler article precursor is received in the second circular groove, an object is inserted into the open tubular end of the empty second inhaler article precursor to receive the at least partially filled second inhaler article precursor, A method comprising: inserting an object into which a first inhaler article precursor is received in a first round groove, thereby at least partially closing the open tubular end of the first inhaler article precursor that receives the first inhaler article precursor which is at least partially closed.

[0112] Example E28: The method according to Example E27, wherein the first and second round grooves are adjacent round grooves.

[0113] Example E29: Removing the first inhaler article precursor, at least partially closed, from the filling and closing rotating drum, and emptying the first round groove again, A method according to Example E28, comprising moving a second inhaler article precursor, which is at least partially filled, from the second round groove into the first round groove, which has been emptied again.

[0114] Example E30: A method according to any of Examples E27 to E29, wherein the steps of inserting an object into the open tubular end of an empty second inhaler article precursor and at least partially closing the open tubular end of the first inhaler article precursor into which the object is inserted are performed simultaneously.

[0115] Example E31: The method according to any of Examples E27 to E30, wherein the object is a capsule, preferably a dry powder capsule.

[0116] Features described in relation to one embodiment may be equally applicable to other embodiments of the present invention.

[0117] The present invention will be further described with reference to the attached drawings, for illustrative purposes only.

[0118] Figure 1a shows a cross-sectional view of a portion of a filling and closing rotating drum for a device for manufacturing inhaler articles. The filling and closing rotating drum comprises a plurality of circumferentially arranged grooves 10. Adjacent grooves 10 are separated by protruding edges 12. Each groove 10 comprises a first round groove 14 and a second round groove 16. Each round groove 14, 16 is configured to receive an inhaler article precursor 18. The first round groove 14 and the second round groove 16 are positioned between two adjacent protruding edges 12.

[0119] Each of the circular grooves 14, 16 may be provided with a vacuum channel 20 for holding the inhaler article precursor 18 within the circular grooves 14, 16.

[0120] Figure 1b shows a portion of the filling and closing rotating drum from Figure 1a. In Figure 1b, the filling and closing rotating drum is shown linearly for clarity, but it is circular as shown in Figure 1a. The vacuum channel 20 is not shown in Figure 1b. The width of the protruding edges is the same as the distance "d" between adjacent circular grooves 14, 16.

[0121] The height difference "h" between the bottom of the round grooves 14, 16 and the top of the adjacent protruding edge 12 may be 1 mm to 10 mm, preferably 2 mm to 8 mm, more preferably 3 mm to 7 mm, and more preferably 4 mm to 6 mm. The height difference "h" is measured along a direction perpendicular to the rotation axis of the filling and closing rotating drum.

[0122] Advantageously, the filling and closing rotating drums are configured such that the height difference "h" is less than the height "x" of the inhaler article precursors 18 received in the round grooves 14, 16. This may achieve the optimized function of the voluntary rolling hand, as described below in conjunction with Figures 2 and 3.

[0123] Figure 2 is another illustration of the filling and closing rotating drum of Figures 1a and 1b together with a fixed rolling hand 22, illustrating how the inhaler article precursor is filled and closed. The direction of movement is indicated by arrows.

[0124] An incoming empty inhaler article precursor 18a is received in a previously empty groove 16. At that point, an adjacent groove 14 in the same groove 10 is occupied by a filled inhaler article precursor 18b. Then, as the filling and closing rotating drum rotates clockwise, within the filling and closing section 24 of the drum, the empty inhaler article precursor 18a in groove 16 is filled to become a filled inhaler article precursor 18b, and the filled inhaler article precursor 18b in groove 14 is closed to become a filled and closed inhaler article precursor 18c. Then, as the filling and closing rotating drum rotates further clockwise beyond the filling and closing section 24, the filled and closed inhaler article precursor 18c in groove 14 is removed from the drum, emptying groove 14. Then, as the filling and closing rotating drum rotates further clockwise, the groove 10, with the empty groove 14 and groove 16 occupied by the filled inhaler article precursor 18b, arrives at the fixed rolling hand 22. The fixed rolling hand 22 pushes the filled inhaler article precursor 18b from the round groove 16 into the adjacent round groove 14. As a result, as the filling and closing rotating drum rotates further, another incoming article precursor 18a can be received in the now empty round groove 16.

[0125] Figures 3a to 3d illustrate the operating principle of the fixed rolling hand 22 in more detail.

[0126] Figure 3a shows the filled inhaler article precursor 18b received in a round groove 16 that approaches the fixed rolling hand 22 as the filling and closing rotating drum rotates clockwise.

[0127] Figures 3b and 3c show how the fixed rolling hand 22 pushes the filled inhaler article precursor 18b from the round groove 16 into the adjacent round groove 14 as the filling and closing rotating drum rotates further. The frictional force between the fixed rolling hand 22 and the filled inhaler article precursor 18b is stronger than the suction force of the vacuum channel 20.

[0128] As shown in Figure 3d, the protruding edge 12 adjacent to the rounded groove 14, which receives the filled inhaler article precursor 18b, is prevented by the fixed rolling hand 22 from moving further as the filling and closing rotating drum rotates further. The distance between the top of the protruding edge 12 and the bottom of the fixed rolling hand 22 is smaller than the diameter of the filled inhaler article precursor 18b.

[0129] Figure 4a shows a perspective view of an apparatus for manufacturing inhaler articles. Figure 4b shows a side view of an apparatus for manufacturing inhaler articles. The apparatus in Figures 4a and 4b comprises a filling and closing station. The filling and closing station comprises a filling and closing rotating drum configured to receive a plurality of inhaler article precursors, for example, any of the filling and closing rotating drums in Figures 1 to 3. The filling and closing rotating drum has a circumferentially arranged protruding edge 12, only a portion of which is shown in Figure 4a. Adjacent round grooves 14, 16 (not shown in Figures 4a and 4b) receive inhaler article precursors 18a, 18b. Each inhaler article precursor initially has at least one open tubular end. The filling and closing station is configured to both fill and close at least one open tubular end of an inhaler article precursor while the inhaler article precursor is received by the filling and closing rotating drum.

[0130] The filling and closing rotating drum is configured to receive the inhaler article precursors 18a, 18b such that the longitudinal axis 26 of each inhaler article precursor is oriented parallel to the rotation axis 28 of the filling and closing rotating drum. The device may include a fixed rolling handle (not shown in Figures 4a and 4b).

[0131] The filling and closing station comprises a rotating filling and closing unit 30. The rotating filling and closing unit 30 comprises a plurality of circumferentially arranged filling rods 32. Each filling rod 32 is configured to fill the open tubular end of an unfilled inhaler article precursor 18a with material. The rotating filling and closing unit comprises a plurality of circumferentially arranged closing rods 34. Each closing rod 34 is configured to at least partially close the open tubular end of a filled inhaler article precursor 18b. The filling rods 32 and closing rods 34 are arranged in an alternating pattern. The rotating filling and closing unit 30 is positioned adjacent to the filling and closing rotating drum such that the axis of rotation 28 of the rotating filling and closing unit 30 coincides with the axis of rotation 28 of the filling and closing rotating drum. The rotating filling and closing unit 30 follows the rotational movement of the filling and closing rotating drum.

[0132] The filling rods 32 and closing rods 34 are arranged in pairs. Each pair of filling rods 32 and closing rods 34 comprises one filling rod 32 adjacent to one closing rod 34. The rotating filling and closing unit 30 includes a plurality of optional circumferentially arranged neutral rods 36. One neutral rod 36 is positioned between each pair of filling rods 32 and closing rods 34. The presence of the neutral rods 36 may simplify the stacking of rods on the station in addition to the filling rods 32 and closing rods 34. The presence of the neutral rods 36 may be particularly beneficial when all rods have the same diameter.

[0133] The filling and closing station comprises a fixed rail unit 38. The fixed rail unit 38 comprises a first fixed rail 40 for engaging with the filling rods 32. The first fixed rail 40 is configured to manipulate the longitudinal axial position of each filling rod 32, depending on the angular position of each filling rod 32, as the rotating filling and closing unit 30 rotates about the rotation axis 28.

[0134] The fixed rail unit 38 includes a second fixed rail 42 for engaging with the closing rods 34. The second fixed rail 42 is configured to manipulate the longitudinal axial position of each closing rod 34, depending on the angular position of each closing rod 34, as the rotating filling and closing unit 30 rotates about the pivot axis 28.

[0135] The filling and closing station may include an empty core 44 for the main drum motor shaft.

[0136] The filling and closing station in Figure 4a may further include a station rotating section 46. The filling and closing station in Figure 4a may further include a station fixing section 48. For example, the filling and closing rotating drum may be configured to receive a plurality of double-length inhaler article precursors, the station fixing section 46 may be a further rotating filling and closing unit, and the station fixing section 48 may be a further fixed rail unit. This is shown in the embodiment of Figure 4b.

[0137] Figure 4b shows a side view of an apparatus for manufacturing inhaler articles. A filling and closing rotating drum is configured to receive a plurality of double-length inhaler article precursors 18a, 18b. Each double-length inhaler article precursor initially has two open tubular ends.

[0138] A filling and closing station may be configured to both fill and close each of the two open tubular ends of the inhaler article precursors 18a and 18b while the inhaler article precursors 18a and 18b are received by a filling and closing rotating drum. The filling and closing station comprises two rotating filling and closing units, namely a rotating filling and closing unit 30 and a further rotating filling and closing unit 46. A filling and closing rotating drum is disposed between the rotating filling and closing unit 30 and the further rotating filling and closing unit 46. The rotating filling and closing unit 30, the further rotating filling and closing unit 46, and the filling and closing rotating drum share a common rotation axis 28.

[0139] An object 50, preferably a dry powder capsule, which is inserted into the empty inhaler article precursor 18a, is also shown in Figure 4b.

[0140] Figures 5a and 5b show an embodiment of a filling and closing station comprising a first fixed rail 40 and a second fixed rail 42.

[0141] Figure 5a shows a fixed rail unit 38 (or further fixed rail unit 48) along the rotation axis 28 in a front view. Each filling rod 32 includes a first cam 52 connected to a first fixed rail 40. Each closing rod 34 may include a second cam 54 connected to a second fixed rail 42.

[0142] Figure 5b shows the filling and closing station in three different configurations (from top to bottom), depending on the respective angular positions of the filling rod 32 and closing rod 34. The movement of the filling rod 32 and closing rod 34 may be individualized due to the individual first fixed rail 40 and second fixed rail 42. The left-right movement 56 of the filling rod 32 in the direction parallel to the rotation axis 28 is determined by the shape of the first fixed rail 40. The left-right movement 58 of the closing rod 32 in the direction parallel to the rotation axis 28 is determined by the shape of the second fixed rail 42.

[0143] Figure 6a shows an embodiment of the filling rod 32 in a cross-sectional view (top) and a perspective view (bottom). The filling rod 32 includes a plunger cylinder. The plunger cylinder includes a tubular element 60, a plunger element 62, and a cam follower 64.

[0144] The tubular element 60 is provided with an opening 66 for inserting an object. The object may then be inserted into the open end of an empty inhaler article precursor 18a. For example, the plunger element 62 moves along its longitudinal axis by a cam follower 64 connected to a first fixed rail 40 via a first cam 52, as shown in the embodiments of Figures 5a and 5b.

[0145] Figure 6b shows an embodiment of the closing cap for the closing rod 34 in a cross-sectional view (left) and perspective views (center and right). The closing cap is located at the end of the closing rod 34 in a direction toward the open end of the filled inhaler article precursor 18b. By the movement of the closing rod 34 and its closing cap toward and toward the object (along the axis of rotation 28 and the longitudinal axis 26 of the filled inhaler article precursor 18b), the closing cap comes into contact with the tubular wall of the open end of the inhaler article precursor 18b. Combined with the rotational movement of the closing cap about its central axis 68, the open end of the inhaler article precursor 18b is closed. Advantageously, the pressure applied is in the range of 1 to 10 Newtons.

[0146] Figure 7a shows a perspective view of an installation-removal system for an apparatus for manufacturing inhaler articles. A main drum 70, for example, a filling and closing rotating drum of any of the embodiments described above, is shown. A main drum motor shaft 72 is also shown. The installation-removal system comprises a station having a first station section 74 and a second station section 76. For example, the station may be a station rotating section 46 or a station fixed section 48, as described above. The installation-removal system may allow for easy and quick tool replacement by replacing a previous tool with a different tool.

[0147] Figure 7b shows a cross-sectional view of a vibrating feeder bowl for object feeding, preferably capsule feeding. The vibrating feeder bowl comprises a vibrating bowl 78, a ramp 80, and an outlet pipe 82 for objects 50, preferably capsules 50, to exit the vibrating feeder bowl. The objects 50 are placed into the vibrating feeder bowl as bulk and exit the vibrating feeder bowl aligned. In the shown embodiment, the pipe 82 allows the capsules 50 to exit longitudinally.

[0148] Figure 8 shows a perspective view of part of the apparatus for manufacturing inhaler articles. An empty inhaler article precursor 18a is received on the main drum 70 of the apparatus, for example, on a filling and closing rotating drum of any of the embodiments described above. The apparatus comprises a station rotating section 46, for example, a rotating filling and closing unit 30 as described above. The station rotating section 46, 30 comprises a plurality of filling rods 32, for example, the filling rods 32 of the embodiment in Figure 6a.

[0149] The apparatus includes a feeder unit for supplying the object 50 to a filling rod. The feeder unit includes a movable conveying surface 84 of an endless belt. The movable conveying surface 84 includes a plurality of cavities 86. Each cavity 86 has an oval shape configured to receive capsule-shaped objects 50, preferably dry powder capsules.

[0150] The feeder unit includes a capsule supply unit for supplying capsules 50 to a transport surface 84. The capsule supply unit includes an incoming pipe 88. Preferably, the incoming pipe feeds the capsules 50 to the transport surface 84 at an angle of less than 45 degrees relative to the transport surface 84, with respect to the long axis of the capsule 50. Such an angle may ensure that the capsules 50 fall properly along the incoming pipe 88, while an angle that is too small may clog the pipe. Such an angle may ensure that the capsules 50 fall properly into the cavity 86, while an angle that is too large may lead to vertical insertion.

[0151] The capsule supply unit is positioned to insert the capsule 50 into the oval cavity 86 such that the longitudinal axis of the inserted capsule 50 is parallel to the longitudinal axis of the oval cavity 86. The capsule 50 is inserted into the tubular element 60 of the filling rod 32 through the opening 66.

[0152] Figure 9 shows a perspective view of part of an apparatus for manufacturing inhaler articles. The apparatus includes a feeder unit having a capsule supply unit for supplying capsules 50 to a movable conveying surface 84 of a rotating drum. The capsule supply unit is positioned to insert the capsules 50 into the oval cavity 86 of the conveying surface 84, which is movable in an upright position, such that the longitudinal axis of the inserted capsule 50 is perpendicular to the longitudinal axis of the oval cavity.

[0153] The feeder unit includes a fixed tilting hand 90 located downstream of the capsule supply section. The fixed tilting hand 90 is shaped as a triangular, curved plate. The fixed tilting hand 90 is configured to rotate the capsules 50 in each cavity 86 by 90 degrees through the relative movement of a movable transport surface 84 with respect to the fixed tilting hand 90, so that the longitudinal axis of the inserted capsule 50 is parallel to the longitudinal axis of the oval cavity 86.

[0154] Figure 10a shows the mechanism of the fixed side-tilting hand 90 of the apparatus in Figure 9 in a cross-sectional view (left) and a front view (right). The fixed side-tilting hand 90 is shown transparently.

[0155] Figure 10b shows a preferred embodiment of the oval cavity 86 of the apparatus of Figures 9 and 10a. The oval cavity 86 of Figure 10b has a deeper recessed portion 87 on one side to facilitate receiving the capsule 50 in an upright position and rotating the capsule 50 by the lateral hand 90.

[0156] Figure 11 is another illustration showing the mechanism of the embodiment of Figure 10b in front view (left) and cross-sectional view (right). As shown on the left, the tip of the fixed lateral hand 90 is offset slightly relative to the cavity, i.e., to the left of the cavity 86. This may ensure that even the capsule 50, which is slightly bent out of the cavity 86, may be properly pushed into the cavity 86.

[0157] Figure 12a shows embodiments of a single-length inhaler article precursor 18 (left) and a double-length inhaler article precursor 18 (right). Each inhaler article precursor 18 comprises a paper tube or carton tube 92. Furthermore, the single-length inhaler article precursor 18 includes one retaining plug 94, while the double-length inhaler article precursor 18 includes two retaining plugs 94. The retaining plugs 94 provide internal end walls for the inserted object 50. The dotted line indicates the cutting line where the double-length inhaler article precursor 18 is cut in half 96.

[0158] Figure 12b is a perspective view of a part of an apparatus configured to process a double-length inhaler article precursor 18. The apparatus includes a cutting station 98 configured to cut the double-length inhaler article precursor 18 in half 96. The cutting station 98 includes a rotary cutter whose movement is indicated by a curved arrow. The cutting station 98 is provided downstream of a filling and closing rotary drum.

[0159] Figure 13a shows one embodiment of a rounding tool equipped with a rotating cap 100.

[0160] The contact tool 102 blocks one end of the filled inhaler article precursor 18b, while the cap 100 is applied to the open end of the filled inhaler article precursor 18b. The cap 100 is then rotated (indicated by arrow 104) while the tube (indicated by arrow 106) is pushed, as shown in the center of Figure 13a, to create an article with a rounded and at least partially closed end 19c, as shown on the right side of Figure 13a.

[0161] Figure 13b shows an alternative embodiment of the rounding tool equipped with a rotating cap 100. Inhaler article precursors 18b, 18c are not shown in Figure 13b. In the embodiment of Figure 13b, the rotating cap 100 is applied simultaneously to each end of the inhaler article precursor 18b, canceling the need for a contact tool 102 and achieving simultaneous closure of both ends. A fixed rail 42 may guide a cam follower 64 attached to a rod 108. The rotating wheel 110 may move within the chamber 112.

[0162] When inhaler article precursors of twice the length are processed, the inhaler article precursors may be cut in half and then optionally rotated, and fed into an additional drum where the remaining free end is rounded. The rounding process follows the same concept already described above.

Claims

1. A filling and closing rotating drum for an apparatus for manufacturing inhaler articles, wherein the filling and closing rotating drum comprises a plurality of circumferentially arranged grooves, Adjacent grooves are separated by protruding edges, A filling and closing rotating drum, wherein each groove comprises a first round groove configured to receive an inhaler article precursor and a second round groove configured to receive an inhaler article precursor, the first and second round grooves being positioned between two adjacent protruding edges.

2. The filling and closing rotating drum according to claim 1, wherein each round groove is provided with a vacuum channel for holding the inhaler article precursor within the round groove.

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

4. An apparatus for manufacturing inhaler articles, wherein the apparatus comprises a filling and closing station, the filling and closing station comprises a filling and closing rotating drum configured to receive a plurality of inhaler article precursors, and each inhaler article precursor comprises at least one open tubular end, Apparatus wherein the filling and closing station is configured to both fill and close the at least one open tubular end of the inhaler article precursor while the inhaler article precursor is being received by the filling and closing rotating drum.

5. The apparatus according to claim 4, wherein the filling and closing rotating drum is configured to receive the inhaler article precursors, so that the longitudinal axis of each inhaler article precursor is oriented parallel to the rotation axis of the filling and closing rotating drum, and preferably the filling and closing rotating drum is oriented within the apparatus such that the rotation axis of the filling and closing rotating drum is oriented in the horizontal plane.

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

7. The apparatus according to claim 6, comprising a fixed rolling hand, wherein the fixed rolling hand is arranged to push an inhaler article precursor from a first round groove to an adjacent second round groove by the relative movement of the filling and closing rotating drum with respect to the fixed rolling hand.

8. The filling and closing station comprises a rotating filling and closing unit, and the rotating filling and closing unit is A plurality of circumferentially arranged filling rods, each of which is configured to fill an object into the open tubular end of an inhaler article precursor, A plurality of circumferentially arranged closing rods, each closing rod configured to at least partially close the open tubular end of an inhaler article precursor, comprising: The filling rod and the closing rod are arranged in an alternating pattern. The apparatus according to any one of claims 4 to 7, wherein the rotating filling and closing unit is disposed adjacent to the filling and closing rotating drum such that the axis of rotation of the rotating filling and closing unit coincides with the axis of rotation of the filling and closing rotating drum.

9. The apparatus according to claim 8, wherein the filling rod and the closing rod are arranged in pairs, and each pair comprises one filling rod adjacent to one closing rod.

10. The filling and closing station comprises a fixed rail unit, the fixed rail unit comprising a first fixed rail for engaging with the filling rod and a second fixed rail for engaging with the closing rod, The first fixed rail is configured to manipulate the longitudinal axis position of each filling rod depending on the angular position of each filling rod, The second fixed rail is configured to manipulate the longitudinal axis position of each closing rod depending on the angular position of each closing rod, The aforementioned angular position refers to the angular displacement of the rotating filling and closing unit with respect to its axis of rotation, and The apparatus according to claim 8 or 9, wherein the longitudinal axis position refers to a position along a direction parallel to the rotation axis of the rotating filling and closing unit.

11. The filling and closing rotating drum is configured to receive a plurality of twice-length inhaler article precursors, each twice-length inhaler article precursor having two open tubular ends, The filling and closing station is configured to both fill and close each of the two open tubular ends of the inhaler article precursor while the inhaler article precursor is being received by the filling and closing rotating drum. The filling and closing station comprises a further rotating filling and closing unit, The filling and closing rotating drum is disposed between the rotating filling and closing unit and the further rotating filling and closing unit, and The apparatus according to any one of claims 4 to 10, wherein the rotating filling and closing unit and the filling and closing rotating drum share a common axis of rotation.

12. The apparatus according to any one of claims 8 to 11, wherein the filling and closing station comprises a feeder unit for supplying an object to the filling rod, and the feeder unit has an oval shape comprising a movable transport surface having a plurality of cavities, each cavity configured to receive a capsule-shaped object.

13. The apparatus according to claim 12, wherein the feeder unit comprises a capsule supply unit for supplying capsules to the transport surface, and the capsule supply unit is arranged to insert the capsules into the cavity such that the longitudinal axis of the inserted capsule is parallel to the longitudinal axis of the oval cavity.

14. The feeder unit includes a capsule supply unit for supplying capsules to the transport surface, and the capsule supply unit is preferably arranged to insert the capsules into the cavity in an upright position such that the longitudinal axis of the inserted capsule is perpendicular to the longitudinal axis of the oval cavity. The oval cavity has a deeper recessed portion on one side to receive the capsule in the upright position, and / or The apparatus according to claim 12, wherein the feeder unit comprises a fixed tilting hand disposed downstream of the capsule supply section, and the fixed tilting hand is configured to rotate the capsule by 90 degrees within each of the cavities by the relative movement of the movable transport surface with respect to the fixed tilting hand, such that the longitudinal axis of the inserted capsule becomes parallel to the longitudinal axis of the oval cavity.

15. A method for manufacturing an inhaler article, To provide a filling and closing rotating drum having a plurality of circular grooves arranged in the circumferential direction, wherein each circular groove is configured to receive an inhaler article precursor, A first circular groove is used to receive a first inhaler article precursor that is at least partially filled and has an open tubular end into which an object is inserted; The second circular groove is used to receive an empty second inhaler article precursor having an open tubular end, While the second inhaler article precursor is received in the second circular groove, an object is inserted into the open tubular end of the empty second inhaler article precursor to receive the at least partially filled second inhaler article precursor, A method comprising: inserting an object into the first inhaler article precursor and at least partially closing the open tubular end of the first inhaler article precursor that receives the first inhaler article precursor, while the first inhaler article precursor is received in the first round groove.

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