Inhaler Article With Foldable Tubular Element
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Solution Overview
Problem
Dry powder inhalers often fail to deliver dry powder particles effectively to the lungs at conventional inhalation airflow rates and can be complex to operate, lacking reproducibility and efficiency in manufacturing.
Innovation Solution
A method and device for manufacturing an inhaler article with a deformable tubular element that is pre-treated and folded inward by at least 90 degrees to create a capsule cavity, using standard foldable materials like paper or cellulose, allowing for high-speed and reproducible production that can be integrated into existing aerosol-generating article manufacturing lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If dry powder inhalers use conventional design, then they can deliver dry powder particles to lungs, but they are complex to operate and may involve moving parts
Solution Approach 1:
The inhaler article is divided into distinct functional segments: a deformable tubular element forming the capsule cavity, a separate capsule containing the dry powder dose, and a mouthpiece element. This segmentation allows each component to be simple in itself while collectively providing the complete function, eliminating complex moving parts.
Solution Approach 2:
The patent employs a single-use disposable inhaler article where the deformable tubular element, capsule, and mouthpiece are designed as a non-reusable unit. This eliminates the need for complex reusable mechanisms, cleaning systems, and maintenance components, significantly simplifying the device while ensuring hygiene and consistent performance.
2Reliability
If dry powder inhalers deliver entire dry powder dose in single breath, then they provide complete dose delivery, but they are not suitable for conventional smoking regime inhalation airflow rates
Solution Approach 1:
The patent modifies the physical parameters of the deformable tubular element, specifically its structural stability and deformability characteristics. By controlling the degree of folding (at least 90 degrees) and the pretreatment of the distal end, the device enables complete capsule delivery to occur at lower inhalation airflow rates comparable to conventional smoking regimes, rather than requiring high peak flows.
Solution Approach 2:
The deformable tubular element transitions from a stable closed configuration during storage and handling to a dynamically deformable state during use. The pretreated distal end allows the structure to collapse inward under inhalation pressure, dynamically opening the capsule cavity and enabling complete dose delivery without requiring complex mechanical actuation.
3Ease of manufacture
If deformable tubular element is folded to close distal end, then it provides protective cover for capsule, but it requires manufacturing process to create folded structure
Solution Approach 1:
The manufacturing process performs preliminary actions by pretreating the distal end of the deformable tubular element before folding. This pretreatment (such as creasing, scoring, or partial cutting) pre-prepares the material to facilitate easy and rapid folding during assembly, eliminating the need for complex real-time manipulation during manufacturing and enabling high-speed production.
Solution Approach 2:
The deformable tubular element is constructed from flexible materials such as paper, plastic, or foil that can be easily folded and creased. These materials inherently support the folding operation required to close the distal end, allowing simple manufacturing processes while maintaining the protective function. The flexibility of these materials enables rapid assembly without requiring sophisticated forming equipment.
Data Source
AI summary
The invention relates to a method for manufacturing an inhaler article, the inhaler article comprising a body, a capsule cavity holding a capsule, a mouthpiece element and a deformable tubular element having an open distal end, the method comprising pre-treating the distal end of the deformable tubular element to obtain a pre-treated portion with reduced structural stability, and folding the pre-treated portion inwards by at least 90 degrees to at least partially close the distal end. The invention relates also to a device for manufacturing an inhaler article and to an inhaler article obtainable by the device.