Inhalation Device Manufacturing Cutting and Sealing
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Solution Overview
Problem
Current dry powder inhaler (DPI) manufacturing technologies face challenges in preventing caking and contamination of medicament doses, and in efficiently cutting and sealing medicament carriers to maintain dose integrity during the manufacturing process.
Innovation Solution
A method and apparatus for fabricating inhalation devices involve disposing a medicament carrier within a first member, engaging a second member with a cutting surface to cut a layer about the carrier, and expelling the carrier using a release actuator, ensuring precise cutting and sealing of the medicament doses to prevent contamination and caking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional DPI manufacturing methods are used, then production can proceed with simple processes, but medicament doses may suffer from caking and contamination
Solution Approach 1:
The manufacturing process is segmented into distinct functional zones within the single-piston mechanism: a cutting zone with a cutting edge for severing the foil web, a sealing zone for sealing medicament doses, and a containment zone with walls to prevent caking and contamination. This segmentation allows each function to be optimized independently while maintaining overall process simplicity.
Solution Approach 2:
The single piston mechanism performs multiple functions sequentially: it cuts the foil web, seals the medicament doses, and contains the carrier to prevent caking and contamination. By integrating these functions into one mechanism, the patent avoids the complexity of multiple separate mechanisms while ensuring dose integrity.
2Manufacturing precision
If efficient cutting and sealing mechanisms are implemented, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The cutting function is extracted as a distinct feature of the piston mechanism, with a cutting edge specifically designed for severing the foil web. This extraction allows the cutting function to be optimized for precision without requiring a separate cutting mechanism, thereby maintaining overall device simplicity.
Solution Approach 2:
The piston acts as an intermediary mechanism that translates linear motion into precise cutting and sealing actions. By using the piston as a mediator between the actuator and the foil web/carrier, the system achieves high manufacturing precision without requiring complex direct-drive mechanisms.
3Object-affected harmful factors
If carrier containment measures are implemented, then contamination and caking are prevented, but manufacturing time increases
Solution Approach 1:
The carrier is contained within the piston mechanism during the cutting and sealing operations, preventing caking and contamination before they can occur. By implementing containment as a preliminary measure rather than a post-processing step, the system prevents harmful effects without adding extra manufacturing steps or time.
Solution Approach 2:
The piston mechanism continuously performs cutting, sealing, and containment operations in a single integrated motion sequence. This continuous action eliminates idle time between operations and ensures that containment is maintained throughout the entire manufacturing cycle, preventing contamination and caking without extending manufacturing time.
Data Source
AI summary
A method for fabricating an inhalation device includes the steps of disposing a medicament carrier with a first member, the carrier being connected with a layer; engaging a second member with the first member to support the layer therebetween, the second member including a cutting surface and defining a cavity; and translating the carrier relative to the members to dispose the carrier with the cavity and cut the layer about the carrier. In some embodiments, manufacturing systems, manufacturing apparatus, inhalation devices, dispensing devices, and medicaments are disclosed.