Inhaler with a vortex tunnel

Abstract

Inhaler with vortex tunnel The inhaler article includes a body extending along a longitudinal axis from a mouthpiece end to a distal end, and has an end-piece element at the distal end. A capsule cavity is defined within the body and extends along the longitudinal axis. A mouthpiece air channel extends from the capsule cavity to the mouthpiece end. A vortex tunnel is located between the end-piece element and the capsule cavity. The vortex tunnel has an air inlet and an air passage extending from the air inlet to the capsule cavity. The end-piece element is configured to restrict or prevent airflow into the capsule cavity through the distal end, and the air inlet and air passage of the vortex tunnel are configured to allow air to be drawn into the capsule cavity, creating a vortex of inhaled air through the capsule cavity. [Selected Figure] Figure 2

Description

[Technical field]

[0001] The present disclosure relates to an inhaler article that includes a vortex tunnel upstream of a capsule cavity. [Background technology]

[0002] Dry powder inhalers are not always fully suitable for delivering dry powder particles to the lungs at inhalation volumes or airflow rates within the range of traditional smoking methods. Dry powder inhalers can be complex to operate or involve moving parts. Dry powder inhalers often attempt to deliver the entire dry powder dose in one breath. In addition, these complex dry powder inhalers are difficult to manufacture at high speeds.

[0003] It would be desirable to provide an inhaler article that is formed from materials that form the makeup of current cigarettes. It would be desirable to provide an inhaler article that can be assembled at high speed. It would also be desirable to provide an inhaler article that has a configuration similar to that of a conventional cigarette that is easy to hold and familiar to users. It would also be desirable to provide an inhaler article that is convenient to use by consumers. Summary of the Invention

[0004] Various aspects of the present disclosure relate to an inhaler article having a vortex tunnel upstream or distal to a capsule cavity. The vortex tunnel is configured to induce or induce a swirl of the inhalation airflow through the capsule cavity of the inhaler. The swirl or vortex of the inhalation airflow induces a rotation of the capsule present in the capsule cavity. Inhalation air enters the vortex tunnel through the body of the inhaler article.

[0005] In one aspect of the disclosure, an inhaler article includes a body extending along a longitudinal axis from a mouthpiece end to a distal end, with an endpiece element at the distal end. A capsule cavity is defined within the body and extends along the longitudinal axis. A mouthpiece air channel extends from the capsule cavity to the mouthpiece end. A vortex tunnel is between the endpiece element and the capsule cavity. The vortex tunnel has an air inlet and an air passage extending from the air inlet to the capsule cavity. The endpiece element is configured to restrict or prevent airflow into the capsule cavity through the distal end, and the air inlet and air passage of the vortex tunnel are configured to allow air to be drawn into the capsule cavity to form a vortex of inhaled air through the capsule cavity.

[0006] In another embodiment of the present disclosure, an inhaler system includes an inhaler article as described herein and a capsule disposed within a capsule cavity of the inhaler article, the capsule containing particles having a mass median aerodynamic diameter of about 15 micrometers or less, or a mass median aerodynamic diameter of 10 micrometers or less, or a mass median aerodynamic diameter of 5 micrometers or less, or a mass median aerodynamic diameter in the range of about 0.5 micrometers to about 15 micrometers, or in the range of about 1 micrometer to about 10 micrometers, or in the range of about 5 micrometers to about 10 micrometers.

[0007] In one or more embodiments, the air passage of the vortex tunnel may be defined by an inner diameter of the vortex tunnel, which may be smaller than an inner diameter of the body of the inhaler article.

[0008] In one or more embodiments, a porous element may be provided between the capsule cavity and the mouthpiece air channel.

[0009] The end piece element may substantially prevent or inhibit air from entering the inhaler article through the distal end. In some embodiments, the end piece element may prevent air from entering the inhaler article through the distal end. In one or more embodiments, the end piece element may have a resistance to withdrawal (RTD) of greater than about 30 mm water column, or greater than about 50 mm water column, or greater than about 75 mm water column, or greater than 100 mm water column, or greater than 200 mm water column, or in the range of 30 mm water column to 100 mm water column.

[0010] The end piece elements may be formed of any suitable material. In one or more embodiments, the end piece elements may be formed of at least one of cellulose or acetate, fiber or tow, or viscose paper. In one or more embodiments, the end piece elements may be formed of a cellulosic material, such as cellulose or cellulose acetate. Such end piece elements may have a resistance to withdrawal (RTD) of greater than about 30 mm water column, or greater than about 50 mm water column, or greater than about 75 mm water column, or greater than 100 mm water column, or greater than about 200 mm water column, or in the range of 30 mm water column to 100 mm water column.

[0011] In one or more embodiments, the vortex tunnel has an outer diameter that contacts the inner diameter of the body of the inhaler article. The inner diameter of the vortex tunnel may be in a range of about 60% to about 25% of the outer diameter of the vortex tunnel or the inner diameter of the body of the inhaler article, or the inner diameter may be in a range of about 50% to about 35% of the outer diameter of the vortex tunnel or the inner diameter of the body of the inhaler article. The vortex tunnel may have a length that is greater than the inner diameter of the vortex tunnel.

[0012] The vortex tunnel may include any suitable number of air inlets in communication with the air passage. For example, the vortex tunnel may include one, two, three, or four air inlets. In one or more embodiments, the vortex tunnel may include two air inlets in communication with the air passage.

[0013] In one or more embodiments, the vortex tunnel defines an open cylinder. The air passage may extend substantially coaxially along the axis of the open cylinder. In some of these embodiments, the vortex tunnel includes two opposing air inlets that enter the open cylinder at a tangent to the inner diameter of the open cylinder. The air inlets may be disposed on opposite sides of the inhaler article. The air inlets may also extend substantially along an axis that is disposed on opposite sides of a central longitudinal axis of at least one of the vortex tunnel and the inhaler article.

[0014] In one or more embodiments, the mouthpiece air channel and porous element may be contained within a first body portion of the inhaler article, and the capsule cavity, vortex tunnel and end piece may be contained within a second body portion of the inhaler article. The first body portion may be axially aligned in series with the second body portion. A wrapper may cover the first body portion and be joined to the second body portion.

[0015] In one or more embodiments, the body of the inhaler article has an outer diameter that can be substantially constant from the distal end to the mouthpiece end. The outer diameter of the body can range from about 6 mm to about 10 mm, or from about 7 mm to about 8 mm.

[0016] In one or more embodiments, the end piece may extend longitudinally along the longitudinal axis of the body of the inhaler article. The end piece may have a length in the range of about 5 mm to about 10 mm, and the vortex tunnel may extend longitudinally along the longitudinal axis of the body a length in the range of about 5 mm to about 10 mm.

[0017] In one or more embodiments, the system may include a capsule containing particles that include nicotine.

[0018] In one or more embodiments, the system may include a capsule further containing a second population of flavor particles.

[0019] In one or more embodiments, the system may further include a piercing element removably engageable with the inhaler article to activate the capsule. As used herein, the term "activating" the capsule refers to opening the capsule, such as by piercing, to allow particles contained within the capsule to be released. The end piece element may be configured to be pierced by the piercing element when activating the capsule.

[0020] Advantageously, the inhaler article may be formed of materials used to assemble conventional cigarettes. In addition, the inhaler article defines a form similar to that of conventional cigarettes. This may allow for rapid assembly or manufacturing of the inhaler article. Advantageously, rotation of the capsule may provide uniform mixing of a portion or fraction of nicotine particles from the capsule over two or more, or five or more, or ten or more inhalations or "puffs" by the consumer. Advantageously, the inhaler article may be formed of biodegradable materials.

[0021] The inhaler article described herein may provide dry powder to the lungs at an inhalation volume or airflow rate within the range of that of traditional smoking methods. The consumer may take multiple inhalations or "puffs", with each "puff" delivering a partial amount of the dry powder contained in the capsule contained within the capsule cavity. The inhaler article may have a form similar to a traditional cigarette and may mimic the routine of traditional smoking. The inhaler may be simple to manufacture and convenient for the consumer to use.

[0022] Airflow management through the capsule cavity may rotate the capsule during inhalation and consumption. The capsule contains nicotine particles containing nicotine (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 moving 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 within the range of inhalation volumes or airflows of conventional smoking methods.

[0023] The term "resistance to draw" or "RTD" refers to the static pressure difference between the two ends of a sample when crossed by a stream of air under steady conditions with a volumetric flow rate of 17.5 milliliters per second at the output end. The RTD of a sample can be measured using the method described in ISO standard 6565:2002.

[0024] The term "nicotine" refers to nicotine and nicotine derivatives, such as free base nicotine, nicotine salts, and the like.

[0025] The term "flavoring agent" or "flavor" refers to an organoleptic compound, composition, or material that alters, and is intended to alter, the taste or aroma characteristics of nicotine during its consumption or inhalation. The term "flavoring agent" or "flavor" preferably refers to the compounds disclosed in the Flavor Extracts Manufacturers Association (FEMA) Flavor Ingredients Library, and in particular in publications 3-27 on GRAS flavoring substances (e.g., Hall, RL & Oser, BL, Food Technology, February 1965 pg 151-197), GRAS flavoring substances 27 (SM Cohen et al., Food Technology Aug. 2015 pg. 40-59), and publications 4-26 on intermediate GRAS flavoring substances. For the purposes of this disclosure, nicotine is not considered a flavoring agent or flavor.

[0026] The inhaler articles described herein may be combined with a piercing element or device to deliver nicotine particles to a consumer. The piercing element or device may be separate from or may not form part of the inhaler article. A number of these inhaler articles may be combined with a piercing element or device to form a kit.

[0027] An inhaler article according to the present disclosure includes a body extending along a longitudinal axis from a mouthpiece end to a distal end. An endpiece element is located at the distal end. A capsule cavity is defined within the body and extends along the longitudinal axis. A mouthpiece air channel extends from the capsule cavity to the mouthpiece end. A vortex tunnel is between the endpiece element and the capsule cavity. The vortex tunnel has an air inlet and an air passage extending from the air inlet to the capsule cavity. The endpiece element is configured to restrict or prevent airflow into the capsule cavity through the distal end, and the air inlet and air passage of the vortex tunnel are configured to allow air to be drawn into the capsule cavity to form a vortex of inhaled air through the capsule cavity.

[0028] The body of the inhaler article, or "inhaler body", may have any suitable shape. The inhaler body may be elongated. In other words, the inhaler body may have a length that is substantially greater than other dimensions of the inhaler body. The inhaler body may have a substantially uniform outer diameter along its length. The inhaler body may have any suitable cross-sectional shape. For example, the cross-section may be circular, oval, square, or rectangular. The inhaler body may have a circular cross-section that may be uniform along the length of the inhaler body forming an elongated cylindrical body.

[0029] The body of the inhaler article, or "inhaler body", may resemble a smoking article or a conventional cigarette in size and shape. The inhaler body may have an elongated cylindrical 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 cylindrical body. The inhaler body may have a circular cross-section that may be uniform along the length of the elongated cylindrical body.

[0030] 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 8 mm. The inhaler body may have a length (along the longitudinal axis) in the range of about 40 mm to about 100 mm, or about 50 mm to about 80 mm, or about 60 mm to about 80 mm, or 65 mm.

[0031] The inhaler body may be formed of a polymeric or cellulosic material, or any other suitable material. The inhaler body may be formed of a biodegradable material. The inhaler body may be formed of paperboard or cardboard. The inhaler body may have a uniform thickness along its length. The inhaler body may have a thickness in the range of about 1 mm to about 2 mm.

[0032] The inhaler body may form a unitary structure, with the body extending continuously from the endpiece element to the mouthpiece end. The endpiece element, the vortex tunnel, the capsule cavity (and capsule, if present), the porous element and the mouthpiece air channel may be arranged in series within the inhaler body. In other words, the endpiece element, the vortex tunnel, the capsule cavity (and capsule, if present), the porous element and the mouthpiece air channel may be disposed end-to-end along the longitudinal axis of the inhaler body.

[0033] The inhaler body may be formed in two parts, a first part and a second part. The first part and the second part may be axially aligned in serial adjacent relationship and assembled together to form the inhaler body. A wrapper may be utilized to assembly the first part and the second part. The wrapper may be a biodegradable material. The wrapper may be a paper wrapper.

[0034] The first portion may include the mouthpiece or mouthpiece air channel, and porous elements, if present. The second portion may include the capsule cavity (and capsule, if present), the vortex tunnel, and the endpiece elements.

[0035] In some embodiments, the inhaler body may be formed of three sections, or four or more sections. The three sections, or four or more sections may be axially aligned in serial adjacent relationship and grouped together to form the inhaler body. A wrapper may be utilized to group the three sections, or four or more sections together.

[0036] The end-piece element may be disposed within the distal or end-piece end of the inhaler body. The end-piece element is configured to restrict or prevent airflow through the distal or end-piece end of the body of the inhaler article. The end-piece element is configured to promote airflow along the sidewall of the body through the air inlet and into the inhaler body preferentially, as described below, over air flowing through the end-piece element.

[0037] If the end piece element allows air to enter some inhaler body through the distal end, the end piece element will generally have a high resistance to withdrawal (RTD). The end piece element may have an RTD greater than about 30 mm water column, or greater than about 50 mm water column, or greater than about 75 mm water column, or greater than 100 mm water column, or greater than about 200 mm water column, or an RTD in the range of 30 mm water column to 100 mm water column.

[0038] The endpiece element may extend longitudinally along the longitudinal axis of the inhaler body, and may have a length in the range of about 5 mm to about 10 mm.

[0039] The end piece element may be formed of any suitable material. For example, the end piece element may be formed of viscose paper. The end piece element may be formed of fibres forming a tow material, or plugs of tow material. The end piece element may be formed of a biodegradable material. The end piece element may be formed of cellulose or cellulose acetate. The end piece element may be formed of acetate tow. The end piece element may be formed of cellulose tow. The end piece element may be formed of acetate and cellulose tow. The end piece element may be formed of cellulose and viscose paper.

[0040] The end piece element may form a cylindrical plug of material that may occupy the distal end of the inhaler article body. The cylindrical plug material may be a tow material. The cylindrical plug material may be a cellulose or cellulose acetate material. The cylindrical plug material may be acetate tow. The cylindrical plug material may be cellulose tow. The cylindrical plug material may be acetate and cellulose tow. The cylindrical plug material may be cellulose and viscose paper. In one or more embodiments, the end piece element may be formed of cellulose or acetate, fiber or tow, or viscose paper.

[0041] The end-piece element may be penetrable. A piercing element, such as a rigid elongated needle, may penetrate the end-piece element and pass through the vortex tunnel to contact the capsule in the capsule cavity and form a hole in the capsule. Particles contained in the capsule may then exit the hole formed by the piercing element during use of the inhaler article. In some embodiments, when the piercing element is withdrawn from the end-piece element, the end-piece element may at least partially reseal.

[0042] The vortex tunnel is positioned between the endpiece element and the capsule cavity. The vortex tunnel may be adjacent to the endpiece element. The vortex tunnel may be axially aligned and disposed in-line with the endpiece element. The vortex tunnel may form an upstream or distal end or boundary of the capsule cavity.

[0043] The vortex tunnel is configured to induce or induce a swirl of the inhalation airflow through the capsule cavity of the inhaler. This swirl or vortex of the inhalation airflow induces a rotation of the capsule present within the capsule cavity.

[0044] The vortex tunnel may define an open cylinder with the air passage extending substantially coaxially along the axis of the cylinder. The axis of the open cylinder may be coextensive with the longitudinal axis of the inhaler article body. The vortex tunnel may extend longitudinally along the longitudinal axis of the inhaler article body a length greater than the inner diameter of the vortex tunnel.

[0045] The vortex tunnel includes an air inlet in fluid communication with the air passage. The air passage may define an open, cylindrical interior passage. The air passage is defined by an inner diameter or vortex tunnel. The inner diameter of the vortex tunnel is smaller than the inner diameter of the inhaler body. The air inlet provides an opening for air to enter the air passage or open cylinder from outside the inhaler article. The air inlet may extend through a sidewall (or thickness) of the vortex tunnel. In some embodiments, the air inlet extends through the body of the inhaler article. In some embodiments, the body of the inhaler article also comprises an air inlet. The air inlet of the body of the inhaler article may be aligned with the air inlet of the vortex tunnel. When the vortex tunnel comprises multiple air inlets, the body of the inhaler article may comprise a complementary number of air inlets, with each air inlet of the inhaler body being aligned or registered with an air inlet of the vortex tunnel.

[0046] The vortex tunnel may have an outer diameter that is in contact with the inner diameter of the body. The vortex tunnel may have an inner diameter that is in a range of about 60% to about 25% of the outer diameter of the vortex tunnel or the inner diameter of the body, or the inner diameter may be in a range of about 50% to about 35% of the outer diameter of the vortex tunnel or the inner diameter of the body. The vortex tunnel may have a length that is greater than the inner diameter of the vortex tunnel. In other words, the inner diameter of the vortex tunnel may be narrow or thin compared to the outer diameter of the vortex tunnel.

[0047] The vortex tunnel may have an outer diameter substantially equal to the inner diameter of the inhaler article body. The vortex tunnel may have an inner diameter smaller than the outer diameter of the capsule disposed within the capsule cavity. The vortex tunnel may have an outer diameter of about 7 mm to about 8 mm. The vortex tunnel may have an inner diameter of about 2 mm to about 4.5 mm, or about 3 mm to about 4 mm. The vortex tunnel may have a wall thickness in the range of about 2 mm to about 3 mm. The vortex tunnel may extend longitudinally along the longitudinal axis of the inhaler article body for a length in the range of about 5 mm to about 10 mm.

[0048] The air inlet may merge or enter the air passage of the vortex tunnel at a tangent to at least one of the surface (the inner diameter of the vortex tunnel) and the air passage. In particular, the air inlet may extend substantially tangent to the axis of the inhaler body. The vortex tunnel may include two air inlets in communication with the air passage. The vortex tunnel may include two opposing air inlets that enter the open cylinder at a tangent to the inner diameter of the open cylinder. Providing one or two opposing air inlets at a tangent to the inner diameter of the open cylinder induces a swirl or vortex airflow pattern within the capsule cavity of the inhaler body.

[0049] The one or more air inlets may have any suitable or useful shape. The one or more air inlets may have a cylindrical shape or a circular cross section. The one or more air inlets may have a diameter ranging from about 0.8 to about 1.2 mm, or a diameter of about 1 mm. The one or more air inlets may be formed by mechanical puncture or by laser drilling.

[0050] The vortex tunnel may be formed of any useful material. For example, the vortex tunnel may be formed of cellulose acetate tow. The vortex tunnel may be formed of paperboard or cardboard. The vortex tunnel may be formed of a polymeric material.

[0051] The vortex tunnel may be constructed from a hollow cellulose acetate tube (sometimes referred to as a "HAT"). The vortex tunnel may be formed from a hollow cellulose acetate tube or an open cylinder of cellulose acetate tow. At least one of the inner and outer diameters of the vortex tunnel may be covered with paper. The vortex tunnel may be formed from an open cylinder of cellulose acetate tow with paper covering the inner diameter. The vortex tunnel may be formed from an open cylinder of cellulose acetate tow with paper covering the outer diameter. The vortex tunnel may be formed from an open cylinder of cellulose acetate tow with paper covering both the inner and outer diameters of the vortex tunnel (sometimes referred to as a diffuser plug).

[0052] The capsule cavity may be immediately downstream from the vortex tunnel. The capsule cavity may be adjacent to the vortex tunnel. The capsule cavity may be axially aligned and disposed in-line with the vortex tunnel. The vortex tunnel may form an upstream or distal end or boundary of the capsule cavity.

[0053] The capsule cavity may define a cylindrical space configured to contain the capsule. The capsule cavity may define a space configured to receive a capsule having an oval or rounded rectangular shape. The capsule cavity may have a substantially uniform or uniform diameter along the length of the capsule cavity. The capsule cavity may have a circular cross-section along the length of the capsule cavity. The capsule may have a cylindrical shape. The configuration of the capsule cavity relative to the capsule may allow the capsule to rotate with stability within the capsule cavity. The longitudinal axis of the capsule may rotate with stability about the longitudinal axis of the inhaler body during inhalation.

[0054] Stable rotation means that the longitudinal axis of the inhaler body is substantially parallel to the axis of rotation of the capsule. Stable rotation may mean a lack of forward movement of the rotating capsule. The longitudinal axis of the inhaler body is preferably substantially coextensive with the axis of rotation of the capsule. Stable rotation of the capsule may provide a uniform incorporation of a portion of the nicotine particles from the capsule over two or more, or five or more, or ten or more "puffs" by the consumer.

[0055] The capsule cavity may have a fixed cavity length bounded by a vortex tunnel on the upstream or distal end and by a porous element on the downstream end. The capsule cavity may have a cavity length of at least about 110% to less than about 200% of the length of the capsule contained therein, or a cavity length of about 120% to about 130% of the length of the capsule, or a cavity length of about 125% of the length of the capsule. The cavity length may be in the range of about 15 mm to about 25 mm and the capsule length may be in the range of about 14 mm to about 18 mm, or the cavity length may be about 20 mm and the capsule length may be about 16 mm.

[0056] The capsule cavity has an inner diameter perpendicular to the longitudinal axis, and the capsule has an outer diameter. The outer diameter may be in the range of about 80% to about 99% of the inner diameter of the cavity, or the outer diameter may be in the range of about 85% to about 95% of the inner diameter of the cavity, or the outer diameter may be about 90% of the inner diameter of the cavity. The outer diameter may be in the range of about 5.4 mm to about 6.4 mm, and the inner diameter may be in the range of about 6 mm to about 7 mm.

[0057] The capsule cavity may be bounded by a vortex tunnel on the upstream distal side and by a porous support element on the downstream or mouthpiece side. The vortex tunnel and the porous support element may cooperate to longitudinally contain the capsule within the capsule cavity. The porous support element may occupy the inner diameter of the elongated inhaler body. The porous support element may allow the airflow to exhibit a uniform airflow through the porous support element along the cross-section of the elongated inhaler body. The porous support element may act as a diffuser to reduce turbulence or edge effects and ensure or maintain a desired airflow pattern through the capsule cavity. The porous support element may support the capsule inside the capsule cavity during capsule activation, such as by providing support to the capsule when a piercing element is received in the inhaler article at the distal end and pierces the capsule to activate the capsule.

[0058] The porous support element may have a length extending along the longitudinal axis of the inhaler body. The porous support element may have any suitable length, such as from about 5 mm to about 10 mm. The porous support element may substantially occupy the inner diameter of the inhaler body. The porous support element may have an outer diameter sufficient to form a friction fit with the inner diameter of the inhaler body. The porous support element may have an outer diameter in the range of from about 7 mm to about 8 mm.

[0059] The porous support element may have a very low resistance to withdrawal (RTD), for example, the porous support element may have an RTD of less than about 20 mm of water column, less than about 10 mm of water column, or less than about 1 mm of water column.

[0060] The porous support element may define a filter element. The filter element may comprise a low efficiency filtration material. In other words, the filter element may allow particles released from the capsule to pass substantially uninhibited or unhindered from the capsule cavity to the mouthpiece end. The filtration material is generally a highly porous material. The filter element may be formed of a network of fibers. The network of fibers may be a non-woven fiber element. The porous support element may be a plug of filtration material. The fibers forming the porous support element may be derived from polylactic acid. The fibers forming the porous support element may be cellulose acetate. The filter element may be a plug of cellulose acetate or a plug of polylactic acid.

[0061] In some embodiments, the porous support element may include a mesh. The mesh may be formed of any suitable material, for example, the porous support element may include a mesh. The mesh may have any suitable number of holes or network of holes, and any suitable size and shape of holes. The mesh may be about 1 mm. 2 ~about 4mm 2 , or about 2 mm 2 The hole may have a diameter of 10 mm or more.

[0062] The capsule may be sealed in 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 seal layers for covering one or more air inlet channels, or air outlets, or mouthpieces of the inhaler article. This may ensure that the inhaler article maintains proper hygiene and freshness.

[0063] 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 inside the capsule. The capsule may be configured to be penetrated or pierced by a piercing element when the capsule is in the capsule cavity. The piercing element may be separate from or 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 penetrated or pierced by a piercing element prior to consumption to allow release of the 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 have any suitable size. The capsule may be a size 1 to size 4 capsule, or a size 3 capsule.

[0064] The system may comprise a separate piercing element, such as a metal or rigid needle. The piercing article forms a single opening through the capsule received within the capsule cavity. The piercing element may be configured to pass through the end piece element and through the air passage of the vortex tunnel into the capsule cavity. In some embodiments, the end piece element may be resealable after the piercing element is withdrawn from the inhaler article. In some embodiments, the inhaler article may comprise a resealable element for sealing the end piece element after the piercing element is withdrawn from the inhaler article.

[0065] A capsule typically contains nicotine particles that contain nicotine (also referred to as "nicotine powder" or "nicotine particles"), and optionally, flavor-containing particles (also referred to as "flavor particles"). A capsule may contain a predetermined amount of nicotine particles and optional flavor particles. A capsule may contain sufficient nicotine particles to provide at least 2 inhalations or "puffs", or at least about 5 inhalations or "puffs", or at least about 10 inhalations or "puffs". A 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.

[0066] The nicotine particles may have any suitable or 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 can be delivered to the user's lungs.

[0067] 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.

[0068] When the flavor particles are blended or combined with the nicotine particles in the capsule, the flavor particles may be present in an amount that provides the desired flavor to each inhalation or "puff" delivered to the user.

[0069] The nicotine particles may have any size distribution useful for preferential inhalation delivery into the lungs of the user. The capsule may contain particles other than nicotine particles. The nicotine particles and other particles may form a powder system.

[0070] The 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. The 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. The 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.

[0071] 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 consisting of nicotine particles having a particle size less than about 10 micrometers, or less than about 5 micrometers, or within the range of about 1 micrometer to about 3 micrometers.

[0072] The nicotine-containing particles may have an aerodynamic mass median diameter of about 5 micrometers or less, or an aerodynamic mass median diameter in the range of about 0.5 micrometers to about 4 micrometers, or an aerodynamic mass median diameter in the range of about 1 micrometer to about 3 micrometers, or an aerodynamic mass median diameter in the range of about 1.5 micrometers to about 2.5 micrometers. The aerodynamic mass median diameter is preferably measured with a cascade impactor.

[0073] The flavor-containing particles may have a mass median aerodynamic diameter of about 20 micrometers or more, or a mass median aerodynamic diameter of about 50 micrometers or more, or a mass median aerodynamic diameter in the range of about 50 to about 200 micrometers, or a mass median aerodynamic diameter in the range of about 50 to about 150 micrometers. The mass median aerodynamic diameter is preferably measured with a cascade impactor.

[0074] The dry powder may have a median particle size of about 60 micrometers or less, or a median particle size in the range of about 1 micrometer to about 40 micrometers, or a median particle size in the range of about 1.5 micrometers to about 25 micrometers, where median particle size means the median particle size per mass and is preferably measured by laser diffraction, laser diffusion, or electron microscopy.

[0075] The nicotine in the powder system or the nicotine particles in the system may be nicotine free base, or nicotine salt or nicotine salt hydrate that is pharma- ceutically acceptable.Suitable or useful nicotine salt or nicotine salt hydrate include, 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 may be selected based on its expected pharmacological effect.

[0076] Preferably, the nicotine particles include 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 reduce the attractive force between the nicotine particles, and therefore reduce the aggregation of the nicotine particles. Similarly, the adhesive force to the flavor-containing particles may also be reduced, and therefore the aggregation of the nicotine particles with the flavor particles may also be reduced. 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 the nicotine particles and flavor particles are combined.

[0077] The nicotine may preferably be a surface-modified nicotine salt, in which case the nicotine salt particles include coated 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.

[0078] The powder system may include flavour particles, which may optionally have any size distribution useful for inhalation delivery into the mouth or oral cavity of a user.

[0079] 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 flavor of the powder system consisting of particles with a particle size of about 20 micrometers or more. 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 flavor of the powder system consisting of particles with a particle size of about 50 micrometers or more. 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 flavor of the powder system consisting of particles with a particle size in the range of about 50 micrometers to about 150 micrometers.

[0080] Flavoring agents or flavors may be provided as solid flavors (at room temperature of about 22 degrees Celsius and 1 atmosphere pressure) and may include flavor formulations, flavor-containing materials, and flavor precursors. Flavoring agents may include one or more natural flavoring agents, one or more synthetic flavoring agents, or a combination of natural and synthetic flavoring agents. Flavoring agents as described herein are organoleptic compounds, compositions, or materials selected and utilized to alter, or intended to alter, the taste or aroma characteristics of the nicotine component during its consumption or inhalation.

[0081] Flavorants or flavors refer to a variety of flavor materials of natural or synthetic origin. These include single compounds and mixtures. Flavors or flavorants have flavor properties that may enhance the experience of the nicotine component during consumption. Flavors may be selected to provide an experience similar to that resulting from smoking a combustible smoking article. For example, flavors or flavorants may enhance flavor properties such as mouthfulness and complexity. Complexity is commonly known as an overall balance of richer flavors without any single sensory attribute dominating. Mouthfulness is described as the perception of richness and volume in the consumer's mouth and throat.

[0082] Suitable flavors include, for example, any natural or synthetic flavor, such as, but not limited to, tobacco, smoke, menthol, mint (such as peppermint and spearmint), chocolate, licorice, citrus and other fruit flavors, gamma octamer, vanillin, ethyl vanillin, breath freshening flavors, spice flavors (such as cinnamon), methyl salicylate, linalool, bergamot oil, geranium oil, lemon oil, and ginger oil, and the like.

[0083] Other suitable flavors may include flavor compounds selected from the group consisting of acids, alcohols, esters, aldehydes, ketones, pyrazines, combinations or blends thereof, and the like. Suitable flavor compounds may, for example, be selected from the group consisting of phenylacetic acid, solanone, megastigmatrienone, 2-heptanone, benzyl alcohol, cis-3-hexenyl acetate, valeric acid, valeric aldehyde, esters, terpenes, sesquiterpenes, nootkatone, maltol, damascenone, pyrazines, lactones, anethole, isovaleric acid, combinations thereof, and the like.

[0084] Further specific examples of flavours may be found in the current literature and are well known to those skilled in the art of flavouring, ie imparting an odour or taste, to products.

[0085] Flavorants may be potent flavorants and may be used and detected at levels that result in less than 200 ppm in the inhaled airstream. Examples of such flavorants are the major tobacco aroma compounds, such as β-damascenone, 2-ethyl-3,5-dimethylpyrazine, phenylacetaldehyde, guaiacol, and furaneol. Other flavorants may only be detected by humans at higher concentration levels. These flavorants, referred to herein as lower potency flavorants, are generally used at levels that result in orders of magnitude greater amounts of flavorant being released into the inhaled air. Suitable lower potency flavorants include, but are not limited to, natural or synthetic menthol, peppermint, spearmint, coffee, tea, spices (such as cinnamon, clove, and ginger), cocoa, vanilla, fruit flavors, chocolate, eucalyptus, geranium, eugenol, and linalool.

[0086] The flavour-containing particles may include a compound that reduces adhesion or surface energy and the resulting agglomeration. The flavour particles may be surface modified with an adhesion-reducing compound to form coated flavour particles. One preferred adhesion-reducing compound may be magnesium stearate. Providing flavour particles, particularly coating the flavour particles, with an adhesion-reducing compound such as magnesium stearate may reduce the adhesion of the flavour-containing particles and may also reduce the attractive forces between the flavour particles and therefore reduce the agglomeration of the flavour particles. Therefore, the agglomeration of flavour 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 flavour-containing particles even when the nicotine particles and flavour particles are combined. Preferably, the powder system may be free-flowing.

[0087] Conventional formulations for dry powder inhalation contain carrier particles that function to increase the fluidization of active particles, since the active particles may be too small to be affected by simple airflow through the inhaler. Powder systems may include 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 may be utilized in the formulation to improve dose uniformity by acting as a diluent or bulking agent.

[0088] The nicotine particles and the flavor may be combined in a single capsule. As mentioned above, the nicotine particles and the flavor may each have a reduced adhesive force, which results in a stable particle formulation, in which the particle size of each component does not change substantially when the nicotine-containing particles and the flavor-containing particles are combined. Alternatively, the powder system includes nicotine particles contained in a single capsule and flavor particles contained in a second capsule.

[0089] The nicotine particles and flavor particles may 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.

[0090] The inhaler and inhaler system are less complicated and have a simplified airflow path compared to conventional dry powder inhalers. Advantageously, the rotation of the capsule in the inhaler body 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 volume typically utilized by conventional inhalers to deliver the above-mentioned nicotine particles deep to the lungs.

[0091] 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 within 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.

[0092] The inhaler may be used by the consumer as in smoking a conventional cigarette or vaping an electronic cigarette. Such smoking or vaping can be characterized by two steps, in the first step, a small amount 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 amount, containing an aerosol containing the desired amount of nicotine, is further diluted by fresh air and drawn deeper into the lungs. Both steps are controlled by the consumer. During the first inhalation step, the consumer may decide the amount of nicotine to be inhaled. During the second step, the consumer may decide the amount to dilute the first amount drawn deeper into the lungs, maximizing the concentration of active agent delivered to the epithelial surface of the airway. This mechanism of smoking is sometimes called "puff-inhale-exhale".

[0093] All scientific and technical terms used herein have meanings commonly used in the art unless otherwise specified. The definitions provided herein are provided to facilitate understanding of certain terms used frequently herein.

[0094] The terms "upstream" and "downstream" refer to the relative location of the elements of the described inhaler with respect to the direction of the inhalation airflow as it is drawn through the body of the inhaler from the distal end portion or vortex tunnel to the mouthpiece portion.

[0095] As used herein, the singular forms "a," "an," and "the" include embodiments having plural referents unless the content clearly dictates otherwise.

[0096] As used herein, "or" is generally used in its inclusive sense, unless the context clearly dictates otherwise. The term "and / or" refers to one or all of the listed elements or a combination of any two or more of the listed elements.

[0097] As used herein, the words "have," "having," "include," "including," "comprise," "comprising," and the like are used in an open-ended sense and generally mean "including, but not limited to." It should be understood that "consisting essentially of," "consisting of," and the like are encompassed by "comprising" and the like.

[0098] The words "preferred" and "preferably" refer to embodiments of the invention that may, under particular circumstances, offer certain advantages. However, other embodiments may also be preferred, under the same or other circumstances. Moreover, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the present disclosure, including the claims. [Brief description of the drawings]

[0099] [Figure 1] FIG. 1 is a perspective view of an exemplary inhaler article. [Diagram 2] FIG. 2 is a schematic cross-sectional view of the exemplary inhaler article of FIG. 1 taken along its longitudinal axis. [Diagram 3] FIG. 3 is a cross-sectional schematic diagram of an exemplary vortex tunnel along an axial axis. [Figure 4] FIG. 4 is a perspective view of an exemplary two-part inhaler article. [Diagram 5] FIG. 5 is a schematic cross-sectional view of the exemplary inhaler article of FIG. 4 taken along its longitudinal axis.

[0100] The schematic drawings are not necessarily to scale and are presented for purposes of illustration, not limitation. The drawings depict one or more aspects described in the present disclosure. However, it will be understood that other aspects not depicted in the drawings fall within the scope and spirit of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0101] 1 and 2 illustrate an exemplary inhaler article 100. FIG. A FIG. 3 is a schematic cross-sectional view of the exemplary inhaler article 100 of FIG. 1 along the longitudinal axis L. A 1 is a cross-sectional schematic diagram of an exemplary vortex tunnel 150 along a longitudinal axis L. A 1 includes a body 110 extending from a mouthpiece end 112 to a distal end 114 along a length thereof, and a capsule cavity 116 defined within the body 110 .

[0102] The mouthpiece air channel 111 extends from the capsule cavity 116 to the mouthpiece end 112. The endpiece element 120 is disposed within the distal end 114 and extends to the vortex tunnel 150. The endpiece element 120 is configured to restrict or prevent airflow therethrough. In this embodiment, the endpiece element 120 is formed from a body of cellulose acetate tow and has a high resistance to withdrawal (RTD) of at least 100 mm of water per millimeter.

[0103] A vortex tunnel 150 is disposed within the body 110 and extends into the capsule cavity 116. The vortex tunnel 150 has an inner diameter D1 defined by an inner surface 152 and an outer diameter D2 defined by an outer surface 151. The inner diameter D1 defined by the inner surface 152 forms an air passage 155 in the form of an open cylinder.

[0104] The vortex tunnel 150 may include two air inlets or air channels 113 extending from an outer surface 151 of the vortex tunnel 150 to an air passage 155. The vortex tunnel 150 includes two air inlets 113 in communication with the air passage 155 on opposite sides of the inhaler article 100. The two opposing air inlets 113 extend substantially linearly into the air passage 155 at a tangent to the inner diameter D1 of the open cylinder 155 between the outer surface 151 and the inner surface 152 of the vortex tunnel 150. The openings of the two opposing air inlets 113 on the inner surface 152 are not aligned, and in this particular embodiment, the two opposing air inlets 113 are aligned along the central longitudinal axis L of the vortex tunnel 150 and the inhaler article 100. A Providing two opposing air inlets 113 at tangents to the inside diameter D1 of the open cylinder 155 induces a swirling or vortex airflow pattern within the capsule cavity 116 of the inhaler body 110.

[0105] The vortex tunnel 150 and the porous support element 140 border the capsule cavity 116. A capsule 130 may be disposed within the cavity 116. The capsule 130 contains particles including nicotine. The vortex tunnel 150 and the porous support element 140 cooperate to longitudinally contain the capsule 130 within the capsule cavity 116. The mouthpiece end 112 is illustrated with the body 110 having a recessed end that borders an open space at the mouthpiece end 112. Alternatively, the porous support element 140 may extend into the mouthpiece end 112 to occupy the entire mouthpiece end 112. The capsule 130 is oriented along a longitudinal axis L A The capsule has an axis of rotation coextensive with the axis of rotation of the capsule cavity.

[0106] Using a separate piercing element (not shown), a consumer may pierce the end-piece element 120 and puncture the capsule 130 contained within the capsule cavity 116. Before a user or consumer inhales the inhaler article 100, the piercing element may be withdrawn from the inhaler article 100 and the end-piece element 120. The consumer may then inhale the inhaler article 100 and utilize the inhaler. The piercing element creates an opening in the end-piece element 120, which is typically a small opening that does not significantly reduce the withdrawal resistance of the end-piece element 120. In some embodiments, the end-piece element 120 is resealable after the piercing element is withdrawn from said end-piece element 120.

[0107] 4 is a perspective view of an exemplary two-part inhaler article 101 with the wrapper 160 partially unwrapped from the two-part inhaler article 101. FIG. A 5 is a schematic cross-sectional view of the exemplary inhaler article 101 of FIG. 4 along a line.

[0108] The inhaler article 101 is oriented along a longitudinal axis L A The article 101 includes a body 110 formed from a first portion 102 and a second portion 103 extending from a mouthpiece end 112 to a distal end 114 along a longitudinal axis, and a capsule cavity 116 defined within the body 110. A wrapper 160 surrounds the first portion 102 and the second portion 103 and joins the first portion 102 to the second portion 103. The wrapper 160 may be a paper or a polymeric film. The wrapper 160 includes a hole 162 that is aligned with the air inlet 113. The aligned hole 162 and the air inlet 113 are made simultaneously by laser drilling using a laser source after assembly of the article 101.

[0109] The first portion 102 includes the mouthpiece air channel 111 and the porous support element 140. The second portion 103 includes the endpiece element 120, the vortex tunnel 150, the capsule cavity 116, and the capsule 130. In this embodiment, the first portion 102 and the second portion 103 are assembled separately and then aligned along the longitudinal axis L.A The first and second portions 102, 103 are then wrapped around the first and second portions 102, 103 such that the wrapper 160 surrounds the first and second portions 102, 103 and joins the first portion 102 to the second portion 103 to form the inhaler article 101.

Claims

1. 1. An inhaler article comprising: a body extending along a longitudinal axis from a mouthpiece end to a distal end; an endpiece element at the distal end; a capsule cavity defined within the body and extending along the longitudinal axis; a mouthpiece air channel extending from the capsule cavity to the mouthpiece end; a vortex tunnel axially aligned with and adjacent to the end piece element and disposed between the end piece element and the capsule cavity, the vortex tunnel having an air inlet extending through a sidewall of the vortex tunnel and an air passageway extending from the air inlet to the capsule cavity, the vortex tunnel having an outer diameter in contact with an inner diameter of the body, the air passageway of the vortex tunnel being defined by an inner diameter of the vortex tunnel, the inner diameter of the vortex tunnel being smaller than an inner diameter of the body; a porous element between the capsule cavity and the mouthpiece air channel; the endpiece element is configured to restrict or prevent airflow through the distal end and into the capsule cavity; The air inlet and air passage of the vortex tunnel are configured to allow air to be drawn into the capsule cavity to form a vortex of inhaled air through the capsule cavity.

2. 2. The inhaler article of claim 1, wherein the mouthpiece air channel and porous element are contained within a first body portion, the capsule cavity, vortex tunnel and end piece are contained within a second body portion, the first body portion is axially aligned in series with the second body portion, and a wrapper covers and joins the first body portion to the second body portion.

3. The inhaler article of any one of claims 1 to 2, wherein the endpiece element has a resistance to withdrawal (RTD) greater than about 100 mm of water.

4. The inhaler article of any one of claims 1 to 3, wherein the end piece elements are formed from at least one of cellulose and acetate, fibre and tow, and viscose paper.

5. The inhaler article of any one of claims 1 to 4, wherein an inner diameter of the vortex tunnel is in the range of about 50% to about 35% of the outer diameter of the vortex tunnel or the inner diameter of the body.

6. The inhaler article of any one of claims 1 to 5, wherein the vortex tunnel comprises two air inlets in communication with the air passage.

7. The inhaler article of any one of claims 1 to 6, wherein the vortex tunnel defines an open cylinder, the air passage extends substantially coaxially along an axis of the open cylinder, and the vortex tunnel comprises two opposing air inlets entering the open cylinder at tangents to the inner diameter of the open cylinder.

8. 8. The inhaler article of any one of claims 1 to 7, wherein the body has a substantially cylindrical shape and an outer diameter that is substantially constant from the distal end to the mouthpiece end, the outer diameter being within the range of about 6 mm to about 10 mm, or about 7 mm to about 8 mm.

9. The inhaler article of any one of claims 1 to 8, wherein the endpiece element extends longitudinally along the longitudinal axis of the body for a length in the range of about 5 mm to about 10 mm, and the vortex tunnel extends longitudinally along the longitudinal axis of the body for a length in the range of about 5 mm to about 10 mm.

10. 10. An inhaler system comprising: an inhaler article according to any one of claims 1 to 9; and a capsule disposed within the capsule cavity of the inhaler article, wherein the capsule contains particles, the particles having 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.

11. The system of claim 10 , wherein the capsule contains particles comprising nicotine.

12. 12. The system of claim 10 or claim 11, wherein the capsule further contains a second population of flavor particles having 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.

13. The system of any one of claims 10 to 12, further comprising a piercing element releasably engageable with the inhaler article to activate the capsule, the end piece element being configured to be pierced by the piercing element when activating the capsule.

14. The inhaler article of claim 1, wherein the inner diameter of the vortex tunnel is smaller than the inner diameter of the capsule cavity.

15. The inhaler article of claim 1, wherein the inner diameter of the vortex tunnel is smaller than the outer diameter of the capsule cavity.

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