Disposable Monodose Inhaler with Secondary Air Stream
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Solution Overview
Problem
Disposable monodose inhalers for powdered medicaments face issues such as medicament deposition in the oropharyngeal cavity, complex assembly, high manufacturing costs, and potential malfunctions due to defective assembly, leading to ineffective drug delivery and side effects from overdose.
Innovation Solution
A monolithic inhaler design featuring a bottom duct that generates a secondary stream to support and direct the primary medicament stream, preventing deposition in the oropharyngeal cavity and enhancing lung delivery, while eliminating the need for separate assembly components and using an autoperforating cartridge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a monodose inhaler with separate assembly components (button, spring, capsule support) is used, then the structure is simpler and cheaper, but the risk of malfunction due to defective assembly increases
Solution Approach 1:
The patent integrates the button, spring, and capsule support into a single monolithic piece formed by injection molding. This merging of previously separate components eliminates assembly errors while maintaining manufacturing simplicity, as the entire assembly is produced in one molding operation without requiring subsequent assembly steps.
Solution Approach 2:
The monolithic component performs multiple functions simultaneously: the button provides user activation, the spring provides mechanical force for capsule piercing, and the integrated structure provides structural support. This multi-functionality in a single component reduces both assembly complexity and malfunction risk.
2Device complexity
If the medicament is delivered through a single duct, then the device structure is simpler, but the medicament deposits excessively in the oropharyngeal cavity before reaching the lungs
Solution Approach 1:
The delivery system is segmented into two separate ducts: a primary duct that delivers medicament directly toward the lungs, and a secondary duct that delivers air to the oropharyngeal cavity. This segmentation allows each duct to perform its specific function optimally, preventing medicament deposition while ensuring effective lung delivery.
Solution Approach 2:
The secondary air stream acts as an intermediary that carries the medicament from the primary duct through the oropharyngeal cavity without direct contact, preventing deposition. The air stream mediates the transport of medicament particles, ensuring they reach the lungs rather than settling in the throat.
3Ease of manufacture
If a monolithic structure with bottom duct is used, then manufacturing cost is reduced through injection molding, but the device complexity increases due to integrated design
Solution Approach 1:
The patent replaces complex mechanical assembly operations with a single injection molding process. The monolithic structure is formed directly in the mold with integrated features (buttons, springs, ducts, capsule support) that would otherwise require multiple assembly steps, thereby simplifying manufacturing despite the complex geometry.
Solution Approach 2:
The injection molding process parameters are optimized to produce the complex monolithic structure in one operation. By controlling molding parameters such as pressure, temperature, and cooling rates, the complex integrated design is manufactured efficiently without requiring post-processing assembly operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The secondary stream effectively directs the medicament to the lungs, increasing treatment effectiveness, reducing side effects, and lowering manufacturing costs through a simplified, plastic injection molding process, with adjustable design parameters for varying inhalation characteristics.
Implementation Method 1
the presence of the bottom duct, which delivers a secondary stream, supporting and directing the primary stream, which carries the powdered medicament, so that the primary stream can climb over the patient's tongue
Implementation Method 2
the better separation of the drug from the excipient (usually lactose) due to the secondary stream that hits and directs the primary stream
Data Source
AI summary
A monodose inhaler for powdered medicaments consists of a hollow substantially pipe-shaped body that has a first portion (H), for housing a capsule or cartridge of powdered medicament, defined by a wall (W) in which there are formed slots (S) as air intakes to an inner region where the powder drops, and a second portion (M) connected to the first portion (H) for delivering the medicament by means of a primary stream (F) that carries the powder from the drop region along a delivery duct (D) whose end is suitable to be placed in the patient's mouth, and it further includes a secondary duct (D′) located under the delivery duct (D) and provided with its own air intake (S′) for delivering a powderless secondary stream (F′).