Single Aperture Capsule for Dry Powder Inhaler Leakage
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Solution Overview
Problem
Dry powder inhalers face issues with unintentional powder leakage when not in use, and their complex designs make them difficult to manufacture and assemble at high speeds, especially when designed to deliver powder at conventional smoking inhalation airflow rates.
Innovation Solution
A dry powder capsule with a single aperture on the side wall, positioned closer to the upstream end, reduces powder leakage by allowing inhalation at conventional smoking regime airflow rates while maintaining a simple inhaler design that is easy to manufacture and assemble.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a linear airflow path is used to deliver powder at conventional smoking inhalation rates, then powder delivery efficiency is improved, but device complexity increases
Solution Approach 1:
The inhaler is divided into distinct functional components: a simple body housing, a separate capsule receptacle, and a mouthpiece assembly. This segmentation allows each component to be optimized independently while maintaining overall simplicity, resolving the contradiction between delivery efficiency and design complexity
Solution Approach 2:
The capsule is extracted as a separate, removable component from the inhaler body. This allows the inhaler mechanism itself to remain simple while the capsule contains the powder and delivery interface, enabling efficient powder delivery without complicating the main inhaler design
2Ease of operation
If apertures are placed at the ends of the capsule, then powder delivery is simplified, but unintentional powder leakage increases
Solution Approach 1:
The aperture position is moved from the traditional end-cap location (vertical dimension) to the side wall of the capsule (horizontal dimension). This dimensional change allows the aperture to be positioned at an angle that facilitates powder delivery while the capsule's orientation in the receptacle prevents leakage when the inhaler is inverted or held horizontally
3Reliability
If multiple apertures are provided in the capsule, then powder delivery reliability is improved, but manufacturing complexity increases
Solution Approach 1:
Instead of providing multiple apertures as traditionally done, the design uses a single strategically positioned aperture. The aperture is sized and positioned to provide sufficient powder delivery reliability through optimized airflow dynamics, avoiding the need for multiple apertures and their associated manufacturing complexity
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 capsule design effectively minimizes powder loss by positioning the single aperture on the side wall, ensuring powder remains inside until inhaled, without requiring changes to the inhaler or capsule manufacturing, and provides efficient powder delivery comparable to apertures at the upstream end.
Implementation Method 1
an airflow path extending from the capsule receptacle to an opening at the downstream end
Data Source
Figure 1A~1B
Figure 2A~4
AI summary
An inhaler article has a body comprising an upstream end and a downstream end, a capsule receptacle, and an airflow path extending from the capsule receptacle to an opening at the downstream end. A capsule is disposed inside the capsule receptacle, the capsule having a first end and a second end; a tubular side wall extending between the first and second ends; only a single aperture in the capsule, the single aperture extending through the tubular side wall; and an inhalable powder disposed inside the capsule.