Dry Powder Inhaler Cover Coupling for Consistent Dose Actuation
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Solution Overview
Problem
Inhalers with rotatable mouthpiece covers are prone to unintentional actuation and contamination due to inconsistent force requirements and accidental movement, leading to poor dosing consistency and contamination risks.
Innovation Solution
A dry powder inhaler design with a mouthpiece cover that rotates sequentially from a fully covered to fully uncovered position, coupled to a dispensing mechanism such that movement from the first to second position does not actuate the mechanism, and movement from the second to third position drives the next medicament dose to the dispensing position, using a gear system with varying gear ratios to ensure smooth operation and prevent contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the mouthpiece cover is made rotatable for cleaning access, then ease of cleaning is improved, but unintentional actuation and contamination risk increase
Solution Approach 1:
The rotation path of the mouthpiece cover is segmented into distinct positions: a first position (fully covering the mouthpiece), a second intermediate position (partially uncovering), and a third position (fully uncovering for use). By segmenting the rotation and associating different functions with different segments, the design allows cleaning access at the first position without triggering actuation, while actuation only occurs when deliberately moved to the third position.
Solution Approach 2:
Different functional properties are applied to different angular positions of the mouthpiece cover. At the first position (0-45 degrees), the cover provides protection and cleaning access without actuating the dispensing mechanism. At the third position (greater than 45 degrees), the cover fully uncovers the mouthpiece and actuates the dispensing mechanism. This local differentiation of function resolves the contradiction between cleaning access and unintentional actuation prevention.
2Ease of operation
If the mouthpiece cover rotates freely to uncover the mouthpiece, then ease of access is improved, but contamination susceptibility increases
Solution Approach 1:
The mouthpiece cover is designed to remain in a closed first position during storage and transport, preliminarily protecting the mouthpiece from contamination before use. The cover is only opened deliberately when the user intends to use the inhaler, ensuring the mouthpiece remains protected until the moment of intended access.
Solution Approach 2:
The rotational position of the mouthpiece cover provides visual feedback to the user about the state of the mouthpiece. When the cover is in the first position, the mouthpiece is clearly covered and protected. When rotated to the third position, the mouthpiece is fully uncovered and ready for use. This feedback mechanism helps users understand the contamination status and prevents accidental exposure.
3Ease of operation
If the dispensing mechanism is actuated by mouthpiece cover rotation, then ease of operation is improved, but force variation and component stress increase
Solution Approach 1:
A lever mechanism serves as an intermediary between the mouthpiece cover rotation and the dispensing mechanism actuation. The lever translates the rotational motion into linear motion that opens the blister, distributing the mechanical stress more evenly across the dispensing mechanism components and reducing peak forces on individual parts.
Solution Approach 2:
The system transitions from a static closed position to a dynamic opening process. The mouthpiece cover rotation dynamically actuates the lever, which in turn dynamically opens the blister and positions the medicament for dispensing. This dynamic sequence allows for controlled force application throughout the actuation process, reducing sudden stress spikes.
Data Source
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AI summary
Provided is a dry powder inhaler for delivering medicament from at least one medicament carrier having a plurality of spaced-apart medicament doses. The inhaler comprises: a housing having regions for accommodating unused and used portions of the medicament carrier; a mouthpiece component extending from the housing and through which a user is able to inhale; a manifold arranged in the housing and defining at least part of an air flow path extending from an air inlet to the mouthpiece, the manifold further defining a dispensing position for the medicament carrier; a dispensing mechanism arranged in the housing for moving a medicament dose of the medicament carrier to the dispensing position and for placing the medicament dose in fluid communication with the air flow path ready for inhalation by the user; and a mouthpiece cover being rotatably connected to the housing for sequential movement about a rotation axis from a first position to a second position, and from the second position to a third position in which the mouthpiece component is completely uncovered. The invention provides arrangements in which the coupling of the mouthpiece cover to the dispensing mechanism is arranged to be non-linear, such that movement of the mouthpiece cover from the first position to the second position causes the medicament dose to be moved with a first movement ratio, and movement of the mouthpiece cover from the second position to the third position causes the medicament dose to be moved with a second movement ratio which is different to the first movement ratio.