Inhaler article with a folded end having a uniform appearance

Abstract

The present invention relates to a method for manufacturing an inhaler article. The method comprises providing a plurality of semi-finished inhaler articles, each of which comprises a longitudinal axis, a proximal end and an open distal end. The method comprises aligning the semi-finished inhaler articles such that the longitudinal axes of the semi-finished inhaler articles are arranged in parallel and the open distal ends of the semi-finished inhaler articles are located at exactly the same height in a direction parallel to the longitudinal axis. The method comprises at least partially closing the distal ends of the aligned semi-finished inhaler articles. The present invention further relates to a package of inhaler articles having uniformly closed ends. The present invention further relates to a holder for an equipment for manufacturing inhaler articles. The present invention further relates to an equipment for manufacturing inhaler articles.

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing an inhaler article. The present disclosure further relates to a package of an inhaler article having a uniformly closed end. The present disclosure further relates to a holder for equipment for manufacturing an inhaler article. The present disclosure further relates to equipment for manufacturing an inhaler article.

Background Art

[0002] In the field of inhaler article manufacturing, it is known to provide a deformable tubular element and to fold the distal end of the deformable tubular element inwardly by about 90 degrees to at least partially close the distal end of the deformable tubular element. Due to manufacturing tolerances in the production of the tubular elements, there can be small differences in length between individual tubular elements. These differences in the length of the tubular elements can result in the distal portions of the semi-finished articles to be folded having different lengths. This can lead to variations in the closed distal end of the inhaler article. This can lead to a non-uniform visual appearance of the closed distal end of the inhaler article.

[0003] Variations in the closed distal end of the inhaler article can result in differences in the force required by the user to insert the finished inhaler article into a user holder device. This can then potentially lead to excessive force being applied and breaking the article. Generally, due to the material properties of a paper tubular element, there may be a limit to the maximum bendable length of the paper tubular element. This can mean that the more the tube is bent, the more force needs to be applied by the user when inserting the tube into the user holder device.

Summary of the Invention

Problems to be Solved by the Invention

[0004] It is desirable to provide a method and apparatus for manufacturing inhaler articles in a reproducible and automated manner. It is also desirable to provide a method and apparatus for manufacturing inhaler articles having a uniform appearance at the closed distal end of the article.

[0005] It is desirable to provide a method and apparatus for manufacturing inhaler articles at a sufficiently high speed.

[0006] It is desirable to provide a method and apparatus for manufacturing inhaler articles, the manufacturing method being carried out on an existing production line used for manufacturing inhaler articles.

[0007] It is desirable to provide a method and apparatus for manufacturing inhaler articles that reduce the risk of the article rupturing when used by a user in a user holder device. [Brief explanation of the drawing]

[0008] [Figure 1A] An exemplary inhaler article is shown. [Figure 1B] An exemplary inhaler article is shown. [Figure 1C] An exemplary inhaler article is shown. [Figure 2A] This shows the process of closing the open end of an inhaler article without alignment. [Figure 2B] This shows the process of closing the open end of an inhaler article without alignment. [Figure 2C] This shows the process of closing the open end of an inhaler article without alignment. [Figure 2D] This shows the process of closing the open end of an inhaler article without alignment. [Figure 3A] This shows the process of aligning inhaler articles. [Figure 3B] This shows the process of aligning inhaler articles. [Figure 3C] This shows the process of aligning inhaler articles. [Figure 3D] This shows the process of aligning inhaler articles. [Figure 3E] This shows the process of aligning inhaler articles. [Figure 3F] This shows the process of aligning inhaler articles. [Figure 4A] This shows the process of closing the open end of an inhaler article without alignment. [Figure 4B] This shows the process of closing the open end of an inhaler article without alignment. [Figure 4C] This shows the process of closing the open end of an inhaler article without alignment. [Figure 4D] This shows the process of closing the open end of an inhaler article without alignment. [Modes for carrying out the invention]

[0009] According to one embodiment of the present invention, a method for manufacturing an inhaler article is provided. The method may include providing a plurality of semi-finished inhaler articles. Each inhaler article may have a longitudinal axis, a proximal end, and an open distal end. The method may include aligning the semi-finished inhaler articles such that their longitudinal axes are arranged parallel to each other and their open distal ends are at exactly the same height with respect to a direction parallel to the longitudinal axis. The method may also include at least partially closing the distal ends of the aligned semi-finished inhaler articles.

[0010] According to one embodiment of the present invention, a method for manufacturing inhaler articles is provided. The method comprises providing a plurality of semi-finished inhaler articles. Each inhaler article comprises a longitudinal axis, a proximal end, and an open distal end. The method comprises aligning the semi-finished inhaler articles such that their longitudinal axes are arranged parallel to each other and their open distal ends are at exactly the same height with respect to a direction parallel to the longitudinal axis. The method comprises at least partially closing the distal ends of the aligned semi-finished inhaler articles.

[0011] The semi-finished inhaler articles may be aligned simultaneously such that the longitudinal axes of the semi-finished inhaler articles are disposed in parallel and the open distal ends of the semi-finished inhaler articles are located at exactly the same height with respect to the direction parallel to the longitudinal axis. The alignment may be performed simultaneously for a plurality of articles. Closing at least partially the distal ends of the aligned semi-finished inhaler articles may be performed simultaneously. Closing may be performed simultaneously for a plurality of articles.

[0012] The method may include simultaneously aligning a plurality of semi-finished inhaler articles received in a holder, whereby the longitudinal axes of the articles in the holder are disposed in parallel simultaneously and the open distal ends of the semi-finished inhaler articles are located at exactly the same height with respect to the direction parallel to the longitudinal axis. The method may include simultaneously at least partially closing the distal ends of the aligned semi-finished inhaler articles received in the holder.

[0013] By the step of aligning the heights of the articles, the effect that differences in the lengths of individual articles due to manufacturing tolerances have on the step of at least partially closing the distal ends of the articles can be offset or reduced. Typical manufacturing tolerances in the length of semi-finished inhaler articles can be about + / -0.5 millimeters.

[0014] The step of aligning the heights of the semi-finished inhaler articles provides a method for manufacturing the inhaler articles in a reproducible and automatic manner. The step of aligning the heights of the semi-finished inhaler articles provides a method for manufacturing inhaler articles having a uniform appearance of at least partially closed distal ends of the articles.

[0015] By providing articles having uniformly closed ends, a method and apparatus for manufacturing an inhaler article that reduces the risk of the article rupturing when used in a user holder device by a user are provided.

[0016] A method for manufacturing an inhaler article at a sufficiently high speed is provided. A method that can be implemented on an existing manufacturing line used for manufacturing an inhaler article is provided.

[0017] As used herein, the term "exactly the same height" can refer to a height difference of less than about 100 micrometers, preferably less than about 75 micrometers, more preferably less than or equal to about 50 micrometers.

[0018] Aligning the open distal ends of the semi-finished inhaler articles to exactly the same height may involve moving one semi-finished inhaler article relative to another semi-finished inhaler article to compensate for differences in the length of the semi-finished inhaler articles due to manufacturing tolerances.

[0019] Aligning the open distal ends of the semi-finished inhaler articles to exactly the same height may involve providing a holder with a plurality of slot elements having movable end faces. The semi-finished inhaler articles may be inserted into each slot element such that the proximal end of the semi-finished inhaler article contacts the movable end face of the slot. The holder may then be brought near the flat surface of the alignment element such that the flat surface is perpendicular to the longitudinal axis of the semi-finished inhaler article. The holder and the alignment element may then be inverted 180 degrees such that gravity moves the open distal ends of the semi-finished inhaler articles downward to contact the flat surface. The movable end face may then be moved downward to contact the proximal end 14 of the semi-finished inhaler article. The movement may be achieved by gravity. The position of the movable end face may then be fixed.

[0020] The method may include, after the step of fixing the position of the movable end face, inverting the holder 180 degrees such that the aligned semi-finished inhaler articles are in an upright position with open distal ends at the top.

[0021] The method may include, after the step of inverting the holder 180 degrees such that the semi-finished inhaler articles are in an upright position with open distal ends at the top, inserting a capsule into each open distal end of the semi-finished inhaler articles.

[0022] The capsules may contain nicotine.

[0023] The capsules may contain dried powder.

[0024] The inhaler article may have a capsule cavity for receiving a capsule. The capsule cavity may define a cylindrical space configured to enclose the capsule. For example, the capsule may have an oval or circular cross-section. The capsule cavity may have a substantially uniform or uniform diameter along the length of the capsule cavity. The capsule cavity may have a fixed cavity length. The capsule cavity has an internal diameter perpendicular to its longitudinal axis, and the capsule has an external diameter. The capsule cavity may be sized to enclose an oval capsule. The capsule cavity may have a substantially cylindrical or cylindrical cross-section along the length of the capsule cavity. The capsule cavity may have a uniform internal diameter. The capsule may have an external diameter of about 80 percent to about 95 percent of the internal diameter of the capsule cavity. The configuration of the capsule cavity relative to the capsule may facilitate restricted movement of the capsule during capsule activation or penetration.

[0025] The capsule cavity may be defined by a deformable element having a diameter ranging from approximately 6 mm to approximately 8 mm, or approximately 6.6 mm.

[0026] 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.

[0027] 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 optionally 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.

[0028] Nicotine particles may have any useful concentration of nicotine based on the specific formulation adopted. Nicotine particles may have at least about 1 weight percent nicotine to a maximum of about 30 weight percent nicotine, or about 2 weight percent to about 25 weight percent nicotine, or about 3 weight percent to about 20 weight percent nicotine, or about 4 weight percent to about 15 weight percent nicotine, or about 5 weight percent to about 13 weight percent nicotine. Preferably, about 50 to about 150 micrograms of nicotine may be delivered to the user's lungs with each inhalation or "smoke-in".

[0029] The capsule may contain or hold at least about 5 milligrams of nicotine particles, or at least about 10 milligrams of nicotine particles. The capsule may 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.

[0030] The capsule may contain or hold approximately 5 milligrams to approximately 300 milligrams of nicotine particles, or approximately 10 milligrams to approximately 200 milligrams of nicotine particles.

[0031] When flavor particles are blended or combined with nicotine particles within a capsule, there may be an amount of flavor particles present in each inhalation or "smoke" delivered to the user that provides the desired flavor.

[0032] Nicotine particles may have any size distribution useful for preferential inhalation delivery into the user's lungs. Capsules may contain particles other than nicotine particles. Nicotine particles and other particles may form a powder system.

[0033] The capsule may hold or contain at least about 5 milligrams of dry powder (also called powder form) 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.

[0034] 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.

[0035] Nicotine-containing particles may have an aerodynamic median particle size 5 of approximately 5 micrometers or less, or in the range of approximately 0.5 micrometers to approximately 4 micrometers, or in the range of approximately 1 micrometer to approximately 3 micrometers, or in the range of approximately 1.5 micrometers to approximately 2.5 micrometers. The aerodynamic median particle size is preferably measured with a cascade impactor.

[0036] The flavor particles may have an aerodynamic median particle size of approximately 20 micrometers or more, or approximately 50 micrometers or more, or in the range of approximately 50 to approximately 200 micrometers, or in the range of approximately 50 to approximately 150 micrometers. The aerodynamic median particle size is preferably measured using a cascade impactor.

[0037] The dried powder may have an average particle diameter 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 diameter refers to the average particle diameter per unit mass and is preferably measured by laser diffraction, laser diffusion, or electron microscopy.

[0038] Nicotine in the powder or nicotine particles may be pharmaceutically acceptable free base nicotine, or nicotine salts or nicotine salt hydrates. Examples of useful nicotine salts or nicotine salt hydrates include nicotine pyruvate, nicotine citrate, nicotine aspartate, nicotine lactate, nicotine beetartrate, 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.

[0039] 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.

[0040] 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 system described herein may be a free-flowing material, and even when nicotine particles and flavor particles are combined, each powder component may have a stable relative particle size.

[0041] Preferably, the nicotine may be a surface-modified nicotine salt, in which case the nicotine salt particles include coated particles or composite particles. A preferred coating or composite material may be L-leucine. One particularly useful nicotine particle may be 5-nicotine bitartarate having L-leucine.

[0042] The powder may contain a collection of flavor particles. The flavor particles may have any useful size distribution for selective inhalation delivery into the user's mouth or oral cavity.

[0043] The powder system may have a collection of at least about 40 weight percent, or at least about 60 weight percent, or at least about 80 weight percent, of powdered flavor particles consisting of particles with a particle size of about 20 micrometers or larger. The powder system may have a collection of at least about 40 weight percent, or at least about 60 weight percent, or at least about 80 weight percent, of powdered flavor particles consisting of particles with a particle size of about 50 micrometers or larger. The powder system may have a collection of at least about 40 weight percent, or at least about 60 weight percent, or at least about 80 weight percent, of powdered flavor particles consisting of particles with a particle size in the range of about 50 micrometers to about 150 micrometers.

[0044] Flavor particles may contain compounds that 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 and reduce the attractive forces between flavor particles, thus reducing the aggregation of flavor particles. Thus, aggregation of flavor particles containing nicotine particles may also be reduced. Therefore, 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. Preferably, the powder system may be free-flowing.

[0045] 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 in the formulation to improve dose uniformity by acting as a diluent or swelling agent.

[0046] The powder system used with the nicotine powder delivery system described herein may not contain a carrier, or may substantially not contain a saccharide such as lactose or mannitol. The absence of a carrier, or substantially the absence of a saccharide 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.

[0047] Nicotine particles and flavors may be combined in a single capsule. As described above, the nicotine particles and flavors may each have reduced adhesion, which results in a stable particle formulation in which the particle size of each component does not substantially change when the nicotine particles and flavors are combined. Alternatively, the powder system may include nicotine particles contained in a single capsule and flavor particles contained in a second capsule.

[0048] Nicotine particles and flavor particles may be combined in any useful relative amounts so that the user can detect the flavor particles when consumed together with the nicotine particles.

[0049] It is preferable that 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.

[0050] The step of inserting capsules into each open distal end of a semi-finished inhaler article may include providing a filling station adjacent to the semi-finished inhaler article. The filling station may be stationary or may be brought near the semi-finished inhaler article by the movement of a holder. The filling station may be movable and may be brought near the semi-finished inhaler article by moving the filling station toward the semi-finished inhaler article.

[0051] The process of aligning semi-finished inhaler articles such that their longitudinal axes are parallel and their open distal ends are at exactly the same height in a direction parallel to their longitudinal axes may include providing an alignment element adjacent to the semi-finished inhaler articles. The alignment element may be stationary or may be brought near the semi-finished inhaler articles by the movement of a holder. The alignment element may be movable and may be brought near the semi-finished inhaler articles by moving the alignment element toward the semi-finished inhaler articles.

[0052] The step of at least partially closing the distal ends of aligned semi-finished inhaler articles may include providing a closing station adjacent to the semi-finished inhaler articles. The closing station may be stationary or brought near the semi-finished inhaler articles by the movement of a holder. The closing station may be movable and brought near the semi-finished inhaler articles by moving the closing station toward the semi-finished inhaler articles.

[0053] One or both of the filling station, alignment element, and closing station may be stationary or movable.

[0054] The distal end portion of the semi-finished inhaler article may include a deformable element. The deformable element may be a cardboard tube.

[0055] The term "deformable" should be understood to mean that the shape of the deformable element can be changed. Deformation of the deformable element may include elastic deformation, in which the deformable element returns to a closed configuration when no force is applied. Alternatively, deformation of the deformable element may include plastic deformation, in which the deformable element is maintained in an open configuration after the application of a force.

[0056] At least a portion of the deformable element may be made of a foldable material. The deformable element may have fan-shaped folds. At least a portion of the deformable element may be made of a cellulose-based material. At least a portion of the deformable element may be made of paper.

[0057] Advantageously, forming a deformable element from a foldable material allows the deformable element to be reliably broken or opened. The foldable material may also improve the assembly of the capsule cavity and provide rapid assembly of the inhaler article.

[0058] Advantageously, deformable elements formed from cellulose-based materials or paper may be substantially biodegradable, thus reducing the impact of inhaler articles on the environment.

[0059] The deformable element may define at least a portion of the longitudinal side wall of the cavity of the inhaler article. The cavity may hold the capsule. The deformable element may define most of the capsule cavity. The deformable element may define the upstream boundary and side wall of the capsule cavity.

[0060] Advantageously, the deformable element may provide a protective cover or sanitary barrier for the held capsule and inhaler article before consumption of the inhaler article.

[0061] The wrapping layer may surround the mouthpiece element and the deformable element. The wrapping layer may connect the mouthpiece element, capsule cavity, and deformable element by a continuous axial bond. The deformable element may extend beyond the wrapping layer. The deformable element may extend beyond the wrapping layer in the range of about 0.5 mm to about 5 mm, or about 1 mm to about 4 mm, or about 2 mm to about 3 mm. The wrapping layer may be formed from a cellulose-based material or paper.

[0062] Advantageously, the wrapping layer formed from cellulosic material is substantially biodegradable, which may reduce the environmental impact of the inhaler article. Bonding the inhaler article elements with a wrapping layer provides rapid assembly of the inhaler article.

[0063] The capsule cavity and deformable elements may have substantially equal inner diameters in the range of about 6 mm to about 8 mm.

[0064] 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.

[0065] The terms “proximal” and “distal” are used to describe the relative positions of components or parts of components of an inhaler article or system. According to the present invention, an inhaler article 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.

[0066] The inhaler article may resemble a smoking article or cigarette in size and shape. The inhaler article may have an elongated body extending along the longitudinal axis of the inhaler article. The inhaler article 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 article 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.

[0067] The inhaler article may include a mouthpiece element. The mouthpiece element may be located downstream of the capsule cavity or 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.

[0068] 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.

[0069] The deformable element may be configured to deform and expose the capsule cavity. The deformable element may be configured to rupture or open up to expose the capsule cavity. The deformable element may be configured to substantially expose the entire opening of the capsule cavity. The deformable element may be configured to expose the entire opening of the capsule cavity.

[0070] The deformable element may define at least a portion of the side wall in the longitudinal direction of the capsule cavity. The deformable element may define most of the capsule cavity. The deformable element may define the closure distal end or upstream end of the capsule cavity.

[0071] The deformable element may be formed from a cellulosic material. At least a portion of the deformable element may be formed from paper. The deformable element may provide a barrier to reduce or prevent contaminants or foreign matter from entering the capsule cavity.

[0072] The capsule cavity sidewall may extend parallel to the longitudinal axis of the inhaler article. The deformable element may define the closure distal end or upstream end of the capsule cavity and at least a portion of the capsule cavity sidewall.

[0073] The deformable element may define a tubular element having a closed upstream end. The deformable element may define the closed distal or upstream end of the capsule cavity and at least 50 percent of the capsule cavity sidewall. The deformable element may define the closed distal or upstream end of the capsule cavity and at least 75 percent of the capsule cavity sidewall. The deformable element may define the closed distal or upstream end of the capsule cavity and the entire capsule cavity sidewall. The deformable element may define the entire capsule cavity except for the downstream boundary surface defined by the mouthpiece element. The deformable element may be a paper layer extending from the mouthpiece element to the closed upstream end.

[0074] Intake air may flow directly into the capsule cavity through the center of the deformable element when the deformable element ruptures or opens. The deformable element may have a diameter substantially equal to the inner diameter of the capsule cavity.

[0075] The deformable element may have an outer diameter in the range of approximately 6 mm to 8 mm, or approximately 7.0 mm to 7.1 mm. The deformable element may have an inner diameter in the range of approximately 6 mm to 7.2 mm, or approximately 6.5 mm to 6.7 mm.

[0076] The deformable element may be formed of paper. The deformable element may be formed of one or more layers of paper. The deformable element may be formed of paper having a weight in the range of approximately 50 grams per square meter to approximately 150 grams per square meter, or approximately 75 grams per square meter to approximately 125 grams per square meter, or approximately 90 grams per square meter to approximately 110 grams per square meter.

[0077] The deformable element may have a thickness in the range of approximately 50 micrometers to approximately 200 micrometers, or approximately 100 micrometers to approximately 150 micrometers, or approximately 110 micrometers to approximately 130 micrometers.

[0078] When the deformable element is broken or opened, it may define an opening having an opening diameter of at least about 80 percent or at least about 90 percent of the diameter of the capsule cavity.

[0079] The deformable element may be easily ruptured to allow inhaled air to enter the capsule cavity. For example, the deformable element may be configured to rupture when the user manually inserts the inhaler article into the user holder device without the use of additional tools to assist the user in applying force. The deformable element may rupture or open to substantially expose the entire upstream end of the capsule cavity. The deformable element may provide a protective cover or sanitary barrier for the held capsule and inhaler article before consumption of the inhaler article.

[0080] The wrapping layer may define the body of the inhaler article. The wrapping layer may surround the mouthpiece element and the deformable element. The wrapping layer may bond the mouthpiece element and the deformable element. The wrapping layer may bond the mouthpiece element and the deformable element by a continuous axial bond. The wrapping layer may be formed from a cellulose-based material.

[0081] The deformable element may extend beyond the wrapping layer. The deformable element may extend beyond the wrapping layer in the range of approximately 0.5 mm to approximately 5 mm, or approximately 1 mm to approximately 4 mm, or approximately 2 mm to approximately 3 mm.

[0082] The method may include a step of pre-treating the distal end portion of the semi-finished inhaler articles to obtain a pre-treated portion with reduced structural stability, prior to the step of at least partially closing the distal end of the aligned semi-finished inhaler articles.

[0083] The pretreatment may include providing a pretreatment station. The pretreatment station may include processing heads for creating crease lines on the distal end of a deformable tubular element, cutting the distal end of a deformable tubular element, or creating score lines on the distal end of a deformable tubular element.

[0084] The pretreatment step may include crimping the edges of the distal end of the deformable tubular element. When crimped, the edges of the deformable tubular element are folded along one or more lines that are essentially parallel to the axial direction of the inhaler article.

[0085] The pretreatment step may include cutting the edge of the distal end of the deformable tubular element along one or more lines that extend generally parallel to the axial direction of the inhaler article.

[0086] The pretreatment step may include scoring the edge of the distal end of the deformable tubular element along one or more lines that extend generally parallel to the axial direction of the inhaler article. Scoring may provide discontinuous cutting lines in the deformable element.

[0087] The length of the crimped line, score line, or cut line may be in the range of 0.5 to 5 millimeters, preferably about 1 to 4 millimeters, and preferably about 2.5 to 3.5 millimeters. Generally, the length of these lines determines the length of the pre-treated portion where structural stability is reduced.

[0088] The required length of the pre-treatment section depends on the diameter of the inhaler article.

[0089] A typical inhaler article may have a diameter of 7.2 millimeters. In such an article, the useful length of the pre-processed portion may be at least about 3 millimeters and at most equal to the radius (3.6 millimeters). Using a pre-processed portion of such dimensions, sufficient closure of the distal end of the deformable tubular element may be achieved.

[0090] During the pretreatment process, the distal end of the deformable tubular element may be provided with 4 to 15 crease lines, cutting lines, or score lines. Preferably, the deformable tubular element may be provided with 6 to 12 crease lines, cutting lines, or score lines. Preferably, the deformable tubular element may be provided with 8 to 10 crease lines, cutting lines, or score lines. The more crease lines, cutting lines, or score lines provided, the better the deformable tubular element can be folded into a cylindrical shape. However, increasing the number of crease lines, cutting lines, or score lines increases the complexity of the folding process. For typical paper materials used in the manufacture of inhaler articles with a diameter of approximately 7.2 mm, a number of 8 to 10 crease lines, cutting lines, or score lines has been shown to yield the best results.

[0091] Generally, crease lines, cutting lines, or score lines may be formed to extend parallel to the longitudinal axis of the deformable tubular element. However, these lines can also be formed to extend at any desired angle with respect to the longitudinal axis of the inhaler article. These lines may be formed to extend at an angle of 0 to 45 degrees with respect to the longitudinal axis of the inhaler article.

[0092] The step of at least partially closing the distal end of the aligned semi-finished inhaler articles may include folding the distal end portion of the semi-finished inhaler articles inward by at least 90 degrees. The distal end portion of the semi-finished inhaler articles may be folded inward at an angle of 90 to 110 degrees.

[0093] In some embodiments, the distal end of a semi-finished inhaler article is completely closed by folding the distal end portion of the semi-finished inhaler article inward by at least 90 degrees. Without the process of aligning the semi-finished inhaler article as disclosed herein, shorter portions of the semi-finished inhaler article may unfortunately not be completely closed due to the folding of the shorter distal end portion.

[0094] In some embodiments, the distal end of a semi-finished inhaler article is partially closed by folding the distal portion of the semi-finished inhaler article inward by at least 90 degrees such that a central opening at the center of the folded distal end remains open. Without the alignment step of the semi-finished inhaler article as disclosed herein, shorter portions of the semi-finished inhaler article may, unfortunately, have a wider opening due to the folding of the shorter distal portion. Without the alignment step of the semi-finished inhaler article as disclosed herein, longer portions of the semi-finished inhaler article may, unfortunately, have a smaller opening due to the folding of the longer distal portion. This may result in an uneven appearance of the folded distal end.

[0095] The distal ends of all semi-finished inhaler articles received in the holder may be closed simultaneously.

[0096] The distal ends of all semi-finished inhaler articles received within the holder may be closed by applying the same force.

[0097] As used herein, the term “method for manufacturing an inhaler article” may refer to a method for manufacturing a fully completed inhaler article, or to a method for manufacturing a subunit of an inhaler article or a double-length inhaler article.

[0098] As used herein, the term “inhaler article” may refer to any type of inhaler article known to those skilled in the art. The term “inhaler article” may refer to an aerosol generating article comprising an aerosol generating substrate that is heated to produce and deliver an inhalable aerosol to a user. The term “inhaler article” may refer to a dry powder inhaler.

[0099] The completed inhaler article may comprise a main body, a capsule cavity for holding a capsule, a mouthpiece element at the proximal end, and a deformable tubular element having at least a partially closed distal end.

[0100] The present invention further relates to a package containing a plurality of inhaler articles manufactured by the method described herein.

[0101] The package may contain 5 to 40 inhaler articles, preferably 10 to 30 inhaler articles, more preferably 15 to 25 inhaler articles, and most preferably 18 to 22 inhaler articles.

[0102] At least the partially closed end of the inhaler article inside the package may have a uniform appearance.

[0103] The difference in diameter of the central opening of the partially closed distal end of the inhaler article in the package may be less than 20%, preferably less than 15%, more preferably less than 10%, more preferably less than 5%, more preferably less than 2%, and most preferably less than 1%.

[0104] The present invention further relates to a holder for equipment for manufacturing inhaler articles. The holder comprises a plurality of slot elements. Each slot element comprises a recess for inserting a semi-finished inhaler article and a movable end face for adjusting the longitudinal position of the semi-finished inhaler article within the recess. The holder comprises a releasable fixing means for holding the movable end faces in place. The releasable fixing means may comprise a separate releasable fixing element for each movable end face. Multiple movable end faces may be fixed by a common releasable fixing element of the releasable fixing means.

[0105] The present invention further relates to equipment for manufacturing inhaler articles, comprising a holder as described herein and an alignment element having a flat surface.

[0106] The equipment may include a reversing mechanism for rotating the holder by at least 180 degrees.

[0107] 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 other embodiments, forms, or aspects described herein.

[0108] Example A: A method for manufacturing an inhaler article, A process for providing multiple semi-finished inhaler articles having a long axis, a proximal end, and an open distal end, A step of aligning semi-finished inhaler articles such that they are arranged in parallel and the open distal ends of the semi-finished inhaler articles are at exactly the same height in a direction parallel to the longitudinal axis, A method comprising the step of at least partially closing the distal ends of aligned semi-finished inhaler articles. Example B: The method according to Example A, wherein the open distal ends of the semi-finished inhaler articles are aligned to the exact same height, and the semi-finished inhaler articles are moved relative to one semi-finished inhaler article to compensate for differences in length of the semi-finished inhaler articles due to manufacturing tolerances. Example C: The process of aligning the open distal ends of semi-finished inhaler articles to exactly the same height is as follows: A step of providing a holder comprising a plurality of slot elements having movable end faces, A step of inserting a semi-finished inhaler article into each slot element such that the proximal end of the semi-finished inhaler article contacts the movable end face of the slot, A step of bringing the holder close to the flat surface of the alignment element such that the flat surface is perpendicular to the long axis of the semi-finished inhaler article, The process involves inverting the holder and alignment elements by 180 degrees so that gravity moves the open distal end of the semi-finished inhaler article downwards and into contact with a flat surface, A step of moving the movable end face downward to bring it into contact with the proximal end of the semi-finished inhaler article, The method according to Example A or Example B, comprising the step of fixing the position of a movable end face. Example D: After the step of fixing the position of the movable end face, The method according to Example C, comprising the step of inverting the holder 180 degrees so that the aligned semi-finished inhaler articles are in an upright position with an open distal end at the top. Example E: After the step of inverting the holder 180 degrees so that the semi-finished inhaler article is in an upright position with an open distal end at the top, The method according to Example D, comprising the step of inserting a capsule into each open distal end of a semi-finished inhaler article. Example F: The method according to Example E, wherein the capsule contains nicotine. Example G: The method according to Example E or Example F, wherein the capsule contains a dry powder. Example H: The method according to any one of Examples A to G, wherein the distal end portion of the semi-finished inhaler article comprises a deformable cardboard tube. Example I: The method according to any one of Examples A to H, further comprising the step of pre-treating the distal end portion of the semi-finished inhaler articles to obtain a pre-treated portion with reduced structural stability, prior to the step of at least partially closing the distal end of the aligned semi-finished inhaler articles. Example J: The method according to any one of Examples A to I, wherein the step of at least partially closing the distal end of the aligned semi-finished inhaler articles includes folding the distal end portion of the semi-finished inhaler articles inward by at least 90 degrees. Example K: The method according to any of Examples A to J, wherein the distal ends of all semi-finished inhaler articles received in the holder are closed simultaneously. Example L: The method according to any of Examples A to K, wherein the distal ends of all semi-finished inhaler articles received in the holder are closed by applying the same force. Example M: ​​A package containing multiple inhaler articles manufactured by any of the methods of Examples A to L. Example N: The package according to Example M, comprising 5 to 40 inhaler articles, preferably 10 to 30 inhaler articles, more preferably 15 to 25 inhaler articles, and most preferably 18 to 22 inhaler articles. Example O: The package according to Example M or Example N, wherein at least the partially closed end of the inhaler article has a uniform appearance. Example P: The package according to any of Examples M, N, and O, wherein the difference in diameter of the central opening of the partially closed distal end of the inhaler article is less than 20%, preferably less than 15%, more preferably less than 10%, more preferably less than 5%, more preferably less than 2%, and most preferably less than 1%. Example Q: A holder for equipment used to manufacture inhaler articles, A plurality of slot elements, each slot element comprising a recess for inserting a semi-finished inhaler article and a movable end face for adjusting the longitudinal position of the semi-finished inhaler article within the recess, A holder comprising a releaseable fixing means for holding a movable end face in a predetermined position. Example R: Equipment for manufacturing inhaler articles, The holder described in Example Q, An assembly comprising an alignment element having a flat surface. Example S: The apparatus of Example R, comprising a reversing mechanism for rotating the holder by at least 180 degrees.

[0109] Features described in reference to one embodiment may also apply equally to other embodiments of the present invention.

[0110] The present invention will be further explained with reference to the attached drawings, for illustrative purposes only.

[0111] Figure 1A is a schematic cross-sectional view of an exemplary inhaler article 10. The inhaler article 10 includes a body 12 extending along the longitudinal axis of the inhaler article 10 from a proximal end 14 to a distal end 16, a capsule cavity 18, and a capsule 20 held within the capsule cavity 18. The body 12 includes paper material wound around a mouthpiece element 22 that forms a deformable tubular element 24. The deformable tubular element 24 defines the capsule cavity 18, bounded downstream by the mouthpiece element 22 and bound upstream by at least a partially closed distal end 16 of the deformable tubular element 24.

[0112] In the embodiment shown in Figure 1, the deformable tubular element 24 is formed of paper having a thickness of about 125 micrometers and a basis weight of about 100 grams per square meter. The illustrated inhaler article 10 has a mouthpiece element length of about 20 mm, and the deformable tubular element 24 has a length of about 45 mm and a uniform outer diameter of about 7.2 mm.

[0113] Figure 1B is a front perspective view of an exemplary inhaler article 10, in which the distal end 16 of a deformable tubular element 24 is partially closed except for the central opening 26. The deformable element 24 folds over itself to form overlapping pie-shaped sections, partially closing the distal end 16 of the capsule cavity 18.

[0114] Figure 1C is a front perspective view of an exemplary inhaler article having a deformable tubular element 24 with an open distal end 16. The folded section of the distal end 16 of the deformable tubular element 24 may be opened to expose the capsule cavity 18. To open the distal end 16, the deformable tubular element 24 may be inserted into a suitable user holder device not described herein. After the folded section of the distal end 16 of the deformable element 24 is opened, an opening is formed for receiving a swirling or rotating inhalation airflow.

[0115] Figures 2A to 2D illustrate the process of closing the open end of an inhaler article without alignment according to the present invention.

[0116] Figure 2A shows a semi-finished inhaler article 10 having an open distal end 16 and filled with a capsule 20. The semi-finished inhaler article 10 is positioned in a slot of a holder 30. Due to manufacturing tolerances, the semi-finished inhaler articles 10 vary in length. As a result, the height of the open distal end 16 of the article 10 in the holder 30 varies. This is indicated by the three dotted lines in Figure 2A. The middle line indicates the desired height due to the nominal length of the article 10. The upper and lower dotted lines indicate the height differences of longer and shorter articles 10, respectively, due to manufacturing tolerances. The folding head 32, which forms part of the closure station, is also shown in Figure 2A.

[0117] Figure 2B shows a subsequent step, in which the folding head 32 is moved downward to at least partially close the open distal end 16 of the semi-finished inhaler article 10 by folding the distal end portion of the semi-finished inhaler article 10 inward by at least 90 degrees.

[0118] Figure 2C shows the subsequent step, where the folding head 32 is moved upward again after closing the distal end 16 of the article 10.

[0119] Figure 2D shows a top view of the partially closed distal end 16. The holder 30 is also shown. The size of the central opening 26 of the partially closed distal end 16 is different. In other words, the inner diameter of the central opening 26 is different. This is caused by the different heights of the distal end 16 before folding (Figure 2A), which in turn results in different lengths of the folded distal end portion. Hence, as shown in Figure 2D, this results in the non-uniform appearance of the distal end 16 of the inhaler article 10.

[0120] Figures 3A to 3F show the process of aligning semi-finished inhaler articles according to one embodiment of the present invention.

[0121] Figure 3A shows a semi-finished inhaler article 10 having an open distal end 16. The semi-finished inhaler article 10 is disposed within a slot of a holder 30. The slot is equipped with movable end faces 34. The end faces 34 are in their stored positions. Similar to the embodiment in Figure 2A, the different heights of the open distal end 16 due to manufacturing tolerances are indicated by three dotted lines in Figure 3A.

[0122] Figure 3B shows the provision of a flat surface of the alignment element 36 adjacent to the holder 30. The flat surface is perpendicular to the long axis of the semi-finished inhaler article 10.

[0123] Figure 3C shows the holder 30 and alignment element 36 rotated 180 degrees. As a result, gravity moves the open distal end 16 of the semi-finished inhaler article 10 downwards, bringing it into contact with the flat surface of the alignment element 36. This movement is indicated by an arrow in Figure 3C.

[0124] Figure 3D shows the subsequent step of moving the movable end face 34 downward to contact the proximal end 14 of the semi-finished inhaler article 10. This movement is indicated by an arrow in Figure 3D. The position of the movable end face is then fixed by a releasable fixing means 38.

[0125] Figure 3E shows the holder 30 and alignment element 36 rotated 180 degrees to return to an upright position.

[0126] As shown in Figure 3F, after the removal of the alignment element 36, the capsule 20 may be inserted into the open distal end 16. This movement is indicated by the arrow in Figure 3F. Since the article 10 has been inverted to return to the upright position, the capsule 20 may also be inserted by gravity.

[0127] Figures 4A to 4D show the process of closing the open end of the semi-finished inhaler article 10 after the alignment process shown in Figures 3A to 3F.

[0128] Figure 4A shows that, after alignment, the semi-finished inhaler articles are arranged so that their longitudinal axes are parallel and the open distal end 16 of the semi-finished inhaler article 10 is at exactly the same height with respect to the direction parallel to the longitudinal axis. The location at exactly the same height is indicated by a dotted line in Figure 4A. The folding head 32 of the closing station is also shown in Figure 4A.

[0129] Figure 4B shows a subsequent step, in which the folding head 32 is moved downward to at least partially close the open distal end 16 of the semi-finished inhaler article 10 by folding the distal end portion of the semi-finished inhaler article 10 inward by at least 90 degrees.

[0130] Figure 4C shows the subsequent step, in which the folding head 32 is moved upward again after at least partially closing the distal end 16 of the article 10.

[0131] Figure 4D shows a top view of the partially closed distal end 16. The holder 30 is also shown. The size of the central opening 26 of the partially closed distal end 16 is the same. In other words, the inner diameter of the central opening 26 is the same. This is achieved by the same height of the distal end 16 before folding (Figure 4A), which then results in the same length of the folded distal end portion. Hence, the result is a uniform appearance of the distal end 16 of the inhaler article 10, as shown in Figure 4D.

Claims

1. A method for manufacturing an inhaler article, A process for providing multiple semi-finished inhaler articles having a long axis, a proximal end, and an open distal end, A step of aligning the semi-finished inhaler articles such that they are arranged in parallel and the open distal ends of the semi-finished inhaler articles are at exactly the same height in a direction parallel to the longitudinal axis, A method comprising the step of at least partially closing the distal ends of the aligned semi-finished inhaler articles.

2. The method according to claim 1, wherein aligning the open distal ends of the semi-finished inhaler articles to the exact same height includes moving one semi-finished inhaler article relative to another semi-finished inhaler article to compensate for differences in length of the semi-finished inhaler articles due to manufacturing tolerances.

3. The step of aligning the open distal ends of the semi-finished inhaler articles to exactly the same height is: A step of providing a holder comprising a plurality of slot elements having movable end faces, A step of inserting the semi-finished inhaler article into each slot element such that the proximal end of the semi-finished inhaler article contacts the movable end face of the slot, A step of bringing the holder close to the flat surface of the alignment element such that the flat surface is perpendicular to the long axis of the semi-finished inhaler article, A step of inverting the holder and the alignment element by 180 degrees so that gravity moves the open distal end of the semi-finished inhaler article downward and into contact with the flat surface, A step of moving the movable end face downward to bring it into contact with the proximal end of the semi-finished inhaler article, The method according to claim 1 or claim 2, comprising the step of fixing the position of the movable end face.

4. After the step of fixing the position of the movable end face, The method according to claim 3, further comprising the step of inverting the holder by 180 degrees so that the aligned semi-finished inhaler articles are in an upright position with the open distal end at the top.

5. After the step of inverting the holder by 180 degrees so that the semi-finished inhaler article is in an upright position with the open distal end at the top, The method according to claim 4, comprising the step of inserting a capsule into each open distal end of the semi-finished inhaler article.

6. The method according to claim 5, wherein the capsule contains nicotine.

7. The method according to claim 5, wherein the capsule contains a dried powder.

8. The method according to claim 1 or 2, further comprising the step of pre-treating the distal end portion of the semi-finished inhaler articles to obtain a pre-treated portion with reduced structural stability, prior to the step of at least partially closing the distal end of the aligned semi-finished inhaler articles.

9. The method according to claim 1 or 2, wherein the step of at least partially closing the distal end of the aligned semi-finished inhaler articles includes folding the distal end portion of the semi-finished inhaler articles inward by at least 90 degrees.

10. A holder for equipment used to manufacture inhaler articles, A plurality of slot elements, each slot element comprising a recess for inserting a semi-finished inhaler article and a movable end face for adjusting the longitudinal position of the semi-finished inhaler article within the recess, A holder comprising a releasable fixing means for holding the movable end face in a predetermined position.

11. Equipment for manufacturing inhaler articles, The holder according to claim 10, An assembly comprising an alignment element having a flat surface.

12. The apparatus according to claim 11, further comprising a reversing mechanism for rotating the holder by at least 180 degrees.

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