Patent Description:
Dry powder inhalers are not always fully suitable to provide dry powder particles to the lungs at inhalation or air flow rates that are within conventional smoking regime inhalation or air flow rates. Dry powder inhalers may be complex to operate or may involve moving parts. Dry powder inhalers often strive to provide an entire dry powder dose or capsule load in a single breath.

Inhaler articles may retain capsules containing dry powder. These capsules may be activated by piercing an aperture though the capsule wall with a piercing element. A user then puffs (draws or inhales) from the consumable mouthpiece side. This action forces air flow through the dry powder inhaler.

Activating the dry powder capsule requires piercing the capsule to form an aperture. Dry powder particles then may exit the capsule through the aperture during inhalation and consumption of the dry powder particles by entraining the dry particles in the inhalation air flow to the consumer. Forming a reliable open aperture on the capsule hemispherical end has proven to be difficult. Piercing element are known to provide non-uniform apertures. The aperture may also tend to reclose once the piercing element is withdrawn from the capsule further leading to non-uniform apertures. These non-uniform apertures result in a non-uniform release of particles from the capsule or hinder particle release from the capsule altogether. This leads to unpredictable and variable dry powder delivery to the consumer.

It is desirable to provide an inhaler system that reliably pierces the capsule to form a uniform single stable aperture. It is desirable to provide an inhaler system that reliably pierces the capsule with a simple design. It is desirable to provide an inhaler system that reliably pierces the capsule and provides predictable and uniform dry powder delivery to the user over a multitude of inhalations. It is desirable to provide an inhaler system that comfortably pierces or activates a capsule containing dry powder particles.

<CIT> relates to an inhaler system including an inhaler article and a piercing article. The inhaler article may be received within the piercing article to activate or pierces a capsule disposed within a capsule cavity of the inhaler article. The piercing article contains a recessed piercing element and is configured to receive a distal end of the inhaler article. The piercing element pierces or punctures a single hole into the capsule contained within the inhaler article when the inhaler article is seated into the piercing article. The piercing element has a cutting surface at a piercing end. The cutting surface may be a planar surface forming an angle of about <NUM> degrees with the piercing element longitudinal axis. A diameter of a segment of the piercing element may be about <NUM>.

The present invention is defined by the appended independent claim.

According to an aspect of the present invention, there is provided an inhaler system comprising a housing defining a housing cavity, a sleeve extending along a sleeve longitudinal axis and positioned within the housing cavity, a capsule contained within the sleeve having a capsule longitudinal axis, and a piercing element comprising only a single shaft extending from a fixed end to a tip along a piercing element longitudinal axis. The piercing element longitudinal axis is parallel with the sleeve longitudinal axis. The piercing element has a piercing element diameter in a range from <NUM> to <NUM>. The single piercing element tip has only a single cutting plane and defines a cutting plane angle between the longitudinal axis of the piercing element and the single cutting plane. The cutting plane angle is in a range from about <NUM> degrees and about <NUM> degrees. The sleeve is movable within the housing cavity between a first position and a second position. Only a single aperture is formed in the capsule when the sleeve is moved from the first position to the second position.

Applicant has discovered utilizing a single piercing element having a single cutting plane with a cutting angle in a range from about <NUM> degrees and about <NUM> degrees coupled with a piercing element diameter in a range from <NUM> to <NUM>, advantageously results in reliable and repeatable activation of the capsule which provides a uniform or constant dose or release of particles over at least <NUM> inhalations of the inhaler system. In addition, this combination of piercing element features advantageously provides a comfortable piercing or activation force experienced by the user. This combination of piercing element features also advantageously provides a robust and simple mechanical design that is simple to assemble.

According to an aspect of the present invention, there is provided an inhaler system comprising a housing defining a housing cavity, a sleeve extending along a sleeve longitudinal axis and positioned within the housing cavity, a capsule is contained within the sleeve having a capsule longitudinal axis, and a piercing element comprising only a single shaft extending from a fixed end to a tip along a piercing element longitudinal axis. The piercing element may be solid. The piercing element may be hollow. The piercing element longitudinal axis is parallel with and offset from the sleeve longitudinal axis. The piercing element has a piercing element diameter in a range from <NUM> to <NUM>. The single piercing element tip has only a single cutting plane and defining a cutting plane angle between the longitudinal axis of the piercing element and the single cutting plane. The cutting plane angle is in a range from about <NUM> degrees and about <NUM> degrees. The sleeve is movable within the housing cavity between a first position and a second position. Only a single aperture is formed in the capsule when the sleeve is moved from the first position to the second position.

Inhaler systems that utilize a single piercing element to pierce a capsule place this single piercing element co-incident with a central longitudinal axis of the device or capsule cavity so that the piercing element strikes the capsule at the central axis of the capsule. It is expected that this configuration would provide a balanced piercing force onto the capsule and avoid a bending moment on the piercing element or the capsule during activation of the capsule.

Applicant has discovered that placing the single piercing element parallel with but offset from the longitudinal axis of the inhaler device or capsule cavity, improves the quality and reliability of the aperture formed in the capsule hemispherical end by the offset piercing element. Specifically, when this single offset piercing element starts cutting on a surface closer to the central longitudinal axis of the inhaler device (along the hemispherical surface of the capsule endcap) to a surface further away from the initial cut point, a hinge of capsule material is formed on the portion forming the apertures perimeter that is furthest from the initial cut point. This specific orientation of the piercing element cutting plane produces a stable open aperture as compared to any other orientation of this piercing element cutting plane.

Advantageously, providing a single offset piercing element forms a repeatably reliable single open aperture in the capsule. The single offset piercing element is a simple mechanical configuration. The single offset piercing element is relatively easy to assembly into an inhaler article holder. The single offset piercing element provides predictably improved uniform dosing over a multitude of inhalations.

This disclosure is directed to a holder for an inhaler article, referred to as an "inhaler article holder". The inhaler article holder includes a single offset piercing element. The inhaler article holder is configured to receive a consumable inhaler article, activate the capsule within the inhaler article by piercing the capsule, and induce swirling inhalation airflow into an inhaler article during consumption. The inhaler article holder and an inhaler article may form an inhaler system to which this disclosure is directed.

The inhaler article holder described herein may be combined with an inhaler article containing a capsule. The inhaler article may be used to activate the inhaler article by piercing the capsule, providing reliable activation of the capsule by puncturing the capsule with the piercing element of the inhaler article holder. Particles may be released from the capsule upon drawing or creating an airflow around the pierced capsule. The inhaler system thus delivers the dry powder particles to a consumer. The inhaler article holder is separate from the inhaler article, but the consumer utilizes both the inhaler article and the inhaler article holder while consuming the dry powder particles released within the inhaler article. A plurality of these inhaler articles may be combined with an inhaler article holder to form a system or kit. A single inhaler article holder may be utilized on <NUM> or more, or <NUM> or more, or <NUM> or more, or <NUM> or more, inhaler articles to activate (puncture or pierce) a capsule contained within each inhaler article and provide reliable activation. The inhaler article may optionally provide a visual indication (marking), for each inhaler article of the activation of the inhaler article.

The inhaler article has an airflow path. Airflow is introduced into the inhaler article by an inhalation (or puff) from a user. The inhaler article holder creates swirling inhalation airflow. This swirling inhalation airflow is introduced to the inhaler article. The distal end or upstream-most end of the inhaler article includes an open aperture that defines an open central passage of the open tubular element configured to receive swirling inhalation airflow.

The swirling inhalation airflow then continues downstream into the capsule cavity and induces rotation of a capsule in the capsule cavity. The activated capsule then releases a dose of particles into the swirling inhalation airflow downstream through the mouthpiece to the consumer. Thus, the swirling inhalation airflow is created upstream from the inhaler article and swirling inhalation airflow enters the distal end or upstream-most end of the inhaler article.

An inhaler article comprises an elongated tubular body extending along an inhaler longitudinal axis from a mouthpiece end to a distal end. The mouthpiece end is the proximal end, or the downstream end. The distal end is the upstream end. A capsule cavity is defined within the body bounded downstream by a filter element and bounded upstream by an open tubular element defining a central passage. Prior to insertion into an inhaler article holder, the distal end of the inhaler article may be closed. After insertion into an inhaler article holder, the distal end of the inhaler article may be open. The distal end of the inhaler article may interact with complimentary structures in the inhaler article holder so that, upon introducing the inhaler article into the inhaler article holder, the distal end of the inhaler article may open. When introduced into the inhaler article holder, the distal end of the inhaler article has a central passage which forms an open air-inlet aperture extending from the distal end of the body to the capsule cavity. A capsule is disposed within the capsule cavity, the central passage may have a smaller diameter then the capsule. Thus, the capsule may not pass through the central passage and is retained within the capsule cavity.

The inhaler article holder includes a housing comprising a housing cavity for receiving an inhaler article and a sleeve configured to retain an inhaler article within the housing cavity. The housing cavity is defined by a single housing opening that extends into the housing to a closed end along a housing longitudinal axis. The single housing opening is configured to receive the inhaler article.

The sleeve is contained within the housing cavity and is movable along the housing longitudinal axis between a first position and a second position. The sleeve may be slidable along the housing longitudinal axis between a first position and a second position. In the first position the sleeve is located adjacent to the single housing opening. In the second position the sleeve is further away from the single housing opening a lateral distance along the longitudinal axis.

The sleeve extends from an open end to a closed end (or restricted end) and defines a cylindrical lumen along a longitudinal axis of the sleeve. The open end of the sleeve aligns with the single housing opening.

The sleeve closed end includes an airflow element and an aperture to allow the piercing element to pass through the closed end and extend into the sleeve lumen. The airflow element includes one or more inhalation air inlets that provide airflow communication from the annular space around the sleeve into the sleeve cylindrical lumen. This airflow element is configured to induce rotating or swirling inhalation airflow into the sleeve cylindrical lumen and directly into the inhaler article capsule cavity. This swirling or rotational inhalation airflow may be transmitted into an inhaler article to rotate a capsule and release dry powder contained within the capsule.

The airflow element of the sleeve includes a tubular element having a central passage in fluid communication with the sleeve cavity. The airflow element has at least one air inlet allowing inhalation air to enter into the central passage. The at least one air inlet extends in a direction that is tangential to the central passage to generate the swirling or rotational inhalation airflow.

The airflow element of the sleeve includes a tubular element having a central passage in fluid communication with the sleeve cavity. The airflow element has at least two air inlets allowing inhalation air to enter into the central passage. The at least two air inlets extend in a direction that is tangential to the central passage to generate the swirling or rotational inhalation airflow.

The airflow element of the sleeve includes a tubular element having a central passage in fluid communication with the sleeve cavity. The airflow element has at least three air inlets allowing inhalation air to enter into the central passage. The at least three air inlets extend in a direction that is tangential to the central passage to generate the swirling or rotational inhalation airflow.

The airflow element may include an aperture to receive and allow the piercing element to pass through the airflow element.

Inhalation air may enter the inhaler article holder through the open aperture receiving the inhaler article and travel into the housing cavity along the length of the inhaler article to the airflow element at the sleeve closed end. Alternatively, inhalation air may enter the inhaler article holder through air inlets through the housing surface.

The inhaler article holder includes a piercing element fixed to and extending from a housing inner surface of the cavity. The piercing element includes a single solid shaft extending from a fixed end to a tip along the piercing element longitudinal axis. The piercing element is configured to extend through the closed end of the sleeve and into the sleeve cavity along a longitudinal axis of the housing. The piercing element contacts and pierces the capsule of a received inhaler article once the sleeve moves from the first position to the second position. Moving the sleeve from the second position to the first position removes the piercing element from the capsule and exposes an aperture in the capsule that allows dry particles contained within the capsule to be released from the capsule as inhalation air rotates the capsule.

The inhaler system or inhaler article holder piercing element described herein is a single piercing element that has a single cutting plane, a diameter in a range from <NUM> to <NUM>, and a cutting plane angle in a range from about <NUM> degrees and about <NUM> degrees. Preferably the piercing element shaft defines a solid cylinder with the single cutting plane defined on the free end tip of the piecing element. The piercing element may also be hollow with a single cutting plane defined on the free end tip of the piercing element. The inhaler system has less than two piercing elements. The inhaler system forms less than two apertures in the capsule containing dry powder particles.

The inhaler system or inhaler article holder piercing element described herein is a single piercing element that has a single cutting plane, a diameter in a range from <NUM> to <NUM>, and a cutting plane angle in a range from about <NUM> degrees and about <NUM> degrees, and the single piercing element may be offset from the longitudinal axis of the inhaler article holder, or offset from the inhaler article holder movable sleeve receiving an inhaler article, or offset from the capsule cavity containing a capsule, or offset from the longitudinal axis of the capsule or axis of rotation of the capsule when the capsule spins during inhalation and consumption of the dry particles released from an activated capsule. The inhaler system has less than two piercing elements. The inhaler system forms less than two apertures in the capsule containing dry powder particles.

The inhaler system or inhaler article holder piercing element described herein is a single piercing element that strikes and pierces a hemispherical endcap of the capsule, contained within the capsule cavity of the inhaler device. The single piercing element strikes and pierces a hemispherical endcap of the capsule. The single piercing element may strike and pierce the hemispherical endcap of the capsule offset from the central longitudinal axis of the capsule and the central longitudinal axis of the sleeve and central longitudinal axis of the capsule cavity. The single piercing element may strike and pierce the hemispherical endcap of the capsule not at the central longitudinal axis of the capsule.

The piercing element shaft has a shaft diameter. The shaft diameter is in a range from about <NUM> to about <NUM>. Preferably the shaft diameter is in a range from about <NUM> to about <NUM>. Preferably the shaft diameter is in a range from about <NUM> to about <NUM>. Preferably the shaft diameter is in a range from about <NUM> to about <NUM>. Preferably the shaft diameter is about <NUM>.

Applicant has discovered that a piercing element having a shaft diameter greater than about <NUM> results in non-uniform release of dry particles from the activated capsule during multiple inhalations. For example, a greater release of dry particles occurs during the first two inhalations substantially depleting the capsule within four or five inhalations.

The piercing element has only a single cutting plane defining a cutting plane angle between the longitudinal axis of piercing element and the single cutting plane in a range from about <NUM> degrees and about <NUM> degrees. Preferably the cutting plane angle is in a range from about <NUM> degrees and about <NUM> degrees. Preferably the cutting plane angle is about <NUM> degrees. These preferred cutting plane angles have been found to require a force of about <NUM> Newtons or less to activate or pierce the capsule with the inhaler system described herein.

Applicant has discovered that a piercing element having a cutting plane angle greater than about <NUM> degrees results in a piercing or activation force of about <NUM> Newtons or greater. Consumers report that a piercing or activation force of about <NUM> Newtons or greater is an uncomfortably high force to apply to the inhaler article holder or inhaler system.

Applicant has also discovered that a piercing element having a cutting plane angle less than about <NUM> degrees results in a non-robust piercing element. Piercing element having a cutting plane angle less than about <NUM> degrees may not provide uniform or repeatable aperture formation in the capsule.

The piercing element cutting plane may define a pointed oval shape. One point of the pointed oval shape may define the tip of the piercing element. The opposing tip of the pointed oval shape may define the termination of the cutting plane with the intersection of the shaft circumference.

The piercing element longitudinal axis may be offset from the sleeve longitudinal axis or capsule cavity longitudinal axis by at least one piercing element diameter or at least one shaft diameter, or at least <NUM> piercing element diameters or at least <NUM> shaft diameters, or at least <NUM> piercing element diameters or at least <NUM> shaft diameters, or in a range from <NUM> to <NUM> piercing element diameters, or in a range from <NUM> to <NUM> shaft diameters.

The hemispherical endcap of the capsule has a radius of <NUM>% at the central longitudinal axis of the capsule and a radius of <NUM>% at the outer circumference of the hemispherical endcap of the capsule. The single offset piercing element may pierce the capsule hemispherical endcap in a range from <NUM>% to <NUM>% of a capsule radius away from the capsule longitudinal axis, or from <NUM>% to <NUM>% of the capsule radius away from the capsule longitudinal axis, or <NUM>% to <NUM>% of the capsule radius away from the capsule longitudinal axis.

The hemispherical endcap of the capsule may have an outer radius in a range from <NUM> to <NUM> or about <NUM>, or a diameter in a range from about <NUM> to about <NUM>, or about <NUM>. The piercing element may pierce the capsule at the capsule curved end or hemispherical endcap at a radial distance of at least <NUM> from the capsule longitudinal axis, or in a range from about <NUM> to about <NUM> from the capsule longitudinal axis or in a range from about <NUM> to about <NUM> from the capsule longitudinal axis, or at about <NUM> from the capsule longitudinal axis.

The piercing element tip has only a single bevel or cutting plane. This single bevel or cutting plane may be specifically oriented relative to the piercing element offset to achieve reliable and repeatable piercing without orientating or aligning the capsule relative to the piercing element.

The piercing element single bevel or cutting plane may define a planar surface opposing the sleeve longitudinal axis. The piercing element single bevel or cutting plane may define a planar surface opposing the capsule longitudinal axis. The piercing element single bevel or cutting plane defines a planar surface that may face a sleeve inner diameter surface closest to the planar surface. The piercing element single bevel may face toward the capsule. The piercing element single bevel may face away from the capsule.

The piercing element forms a single aperture in the capsule defining only a single hinge of capsule material extending into the capsule cavity. The single hinge of capsule material may be located at a point around the single aperture furthest from the capsule longitudinal axis.

The piercing element forms a single aperture in the capsule defining only a single hinge of capsule material extending into the capsule cavity. The hinge is formed when the beveled tip of the piercing element pierces the capsule. As the beveled tip of the piercing element enters the capsule, the beveled tip of the piercing element cuts the capsule to form an aperture. Then, as the beveled tip of the piercing element continues to enter the capsule, it continues to cut the capsule. The hinge is formed as the end of the bevel enters the capsule. When piercing element is then removed from the capsule, an aperture with a hinge is formed in the capsule. Thus, an aperture is formed in the capsule substantially related to the size of the piercing element, with the hinge formed in the aperture opposite the tip of the piercing element. If the piercing element single bevel faces toward the capsule, the hinge is formed at the inside edge of the aperture, where the inside edge is closer to the longitudinal axis of the capsule. If the piercing element single bevel faces away from the capsule, the hinge is formed at the outside edge of the aperture, where the outside edge is farther away from the longitudinal axis of the capsule. When the beveled tip of the piercing element faces away from the longitudinal axis of the capsule, a single hinge of capsule material is formed located at a point of the single aperture furthest from the capsule longitudinal axis.

The sleeve closed end may further include a sleeve bottom element substantially forming the closed end of the sleeve. The sleeve bottom element may be fixed and contact the airflow element. The sleeve bottom element may extend away from the airflow element a distance along the sleeve longitudinal axis and toward the closed end of the housing cavity. The sleeve bottom element may have an aperture that contains the piercing element and allows the piercing element to pass through the sleeve bottom element aperture.

The inhaler article holder may further include a spring member configured to bias the sleeve away from the piercing element. The spring member may bias the sleeve away from the second position to the first position. The spring member may be in a relaxed state in the sleeve first position. The spring member may be in a compressed state in the second position. Preferably the piercing element is disposed within the spring member.

The sleeve may include an elongated slot extending along a longitudinal length of the sleeve. The housing may further include a pin extending from an inner surface of the housing cavity. The pin may be configured to mate with the elongated slot to maintain alignment of the sleeve as it moved between the first and second positions.

An inner housing may be contained within the housing cavity. The inner housing may separate at least a portion of the sleeve from the inner surface of the housing cavity. The inner housing may separate a fixed end of the piercing element from the inner surface of the housing cavity. The inner housing may separate at the spring member from the inner surface of the housing cavity.

Inhalable powders may include various active agents. The active agent may comprise an alkaloid such as nicotine or anatabine or anabasine, for example. Preferably, the active agent comprises solid salt of an alkaloid, such as a nicotine salt.

The amount of active agent may be selected based on the desired or intended use of the inhalable dry powder. For example, the amount of active agent may be between <NUM> wt-% and <NUM> wt-% of the total weight of the dry powder particles. The dry powder particles may comprises <NUM> wt-% or more, <NUM> wt-% or more, <NUM> wt-% or more, or <NUM> wt-% or more of the active agent, and <NUM> wt-% or less, <NUM> wt-% or less, <NUM> wt-% or less, <NUM> wt-% or less, or <NUM> wt-% or less, of the active agent, or from <NUM> wt-% to <NUM> wt-%, from <NUM> wt-% to <NUM> wt-%, from <NUM> wt-% to <NUM> wt-%, or from <NUM> wt-% to <NUM> wt-of the active agent.

The dry powder particles may comprises <NUM> wt-% or more, <NUM> wt-% or more, <NUM> wt-% or more, or <NUM> wt-% or more of nicotine, and <NUM> wt-% or less, <NUM> wt-% or less, <NUM> wt-% or less, <NUM> wt-% or less, or <NUM> wt-% or less, of nicotine, or from <NUM> wt-% to <NUM> wt-%, from <NUM> wt-% to <NUM> wt-%, from <NUM> wt-% to <NUM> wt-%, or from <NUM> wt-% to <NUM> wt-% nicotine.

The amount of active agent may also be selected on a per-dose basis. The inhalable powder may be packaged in a single dose form or in a multiple dose form. For example, the inhalable powder may comprise <NUM> or more, <NUM> or more, <NUM> or more, or <NUM> or more of the active agent per dose. The inhalable powder may comprise <NUM> or less, <NUM> or less, <NUM> or less, <NUM> or less, <NUM> or less, or <NUM> or less of the active agent per dose. In some embodiments, the inhalable powder comprises from <NUM> to <NUM> of anatabine or nicotine or anabasine per dose, <NUM> to <NUM> anatabine or nicotine or anabasine per dose, or <NUM> to <NUM> of anatabine or nicotine or anabasine per dose.

In embodiments, the capsule contains from <NUM> to <NUM> doses. In embodiments, the capsule contains from <NUM> to <NUM> doses. In embodiments the capsule contains from <NUM> to <NUM> doses. In embodiments, the capsule contains <NUM> dose. In embodiments, the capsule contains <NUM> doses. In embodiments, the capsule contains <NUM> doses. In embodiments, the capsule contains <NUM> doses. In embodiments, the capsule contains <NUM> doses. In embodiments, the capsule contains <NUM> doses. In embodiments, the capsule contains <NUM> doses. In embodiments, the capsule contains <NUM> doses. In embodiments, the capsule contains <NUM> doses. In embodiments, the capsule contains <NUM> doses. In embodiments, the capsule contains <NUM> doses. In embodiments, the capsule contains <NUM> doses. In embodiments, the capsule contains <NUM> doses. In embodiments, the capsule contains <NUM> doses. In embodiments, the capsule contains <NUM> doses. In embodiments, the capsule contains <NUM> doses. In embodiments, the capsule contains <NUM> doses. In embodiments, the capsule contains <NUM> doses. In embodiments, the capsule contains <NUM> doses. In embodiments, the capsule contains <NUM> doses.

The dry powder particles may have a particle size of <NUM> or less, <NUM> or less, or <NUM> or less, or <NUM> or greater, <NUM> or greater, or <NUM> or greater, or ranging from <NUM> to <NUM>, or from <NUM> to <NUM>, or from <NUM> to <NUM>, or from <NUM> to <NUM>, or from <NUM> to <NUM>. The desired particle size range may be achieved by spray drying, milling, sieving, or a combination thereof.

The dry powder particles may be further mixed with a second population of particles to form a powder system. Preferably, the second population of particles have a different particle size or larger particle size than the dry powder particles. For example, the second population of particles may have a particle size of about <NUM> or greater, or about <NUM> or greater, <NUM> or smaller, <NUM> or smaller, or in a range from <NUM> to <NUM>, or from <NUM> to <NUM>. The second population of particles may have any useful size distribution for inhalation delivery selectively into the mouth or buccal cavity of a user. The larger second population of flavourant particles may assist in delivery of the dry powder particles to the inhalation airflow to the user.

The dry powder particles and second population of particles may be combined in any useful relative amount so that the second population of particles are detected by the user when consumed with the dry powder particles. Preferably, the dry powder particles and second population of particles form at least about <NUM> wt-% or at least about <NUM> wt-% or at least about <NUM> wt-% or <NUM> wt-% of the total weight of the powder system.

The dry powder particles may be mixed with a second population of flavourant particles to form a powder system. Preferably, the second population of flavourant particles have a different particle size or larger particle size than the dry powder particles. For example, the flavor particles may have a particle size of about <NUM> or greater, or about <NUM> or greater, <NUM> or smaller, <NUM> or smaller, or in a range from <NUM> to <NUM>, or from <NUM> to <NUM>. The second population of flavourant particles may have any useful size distribution for inhalation delivery selectively into the mouth or buccal cavity of a user. The larger second population of flavourant particles may assist in delivery of the dry powder particles to the inhalation airflow to the user.

The dry powder particles and second population of flavourant particles may be combined in any useful relative amount so that the second population of flavourant particles are detected by the user when consumed with the dry powder particles. Preferably, the dry powder particles and second population of flavourant particles form at least about <NUM> wt-% or at least about <NUM> wt-% or at least about <NUM> wt-% or <NUM> wt-% of the total weight of the powder system.

The dry powder particles or powder system may be provided in a suitable dosage form. For example, the dry powder particles or powder system may be provided in a capsule. The dosage form (for example, capsule) may be configured for use in a suitable inhaler. For example, the capsule may be utilized in an inhaler device having a capsule cavity. Air flow management through a capsule cavity of the inhaler device may cause a capsule contained therein to rotate during inhalation and consumption. The capsule may contain dry powder particles or powder system.

The term "particle size" is used here to refer to the mass median aerodynamic diameter (MMAD) of the particle or set of particles, unless otherwise stated. Such values are based on the distribution of the aerodynamic particle diameters defined as the diameter of a sphere with a density of <NUM> gm/cm<NUM> that has the same aerodynamic behavior as the particle which is being characterized.

In particular, for a powder system reference is commonly made to the mass median aerodynamic diameter (MMAD), one of the metrics most widely adopted as a single number descriptor of aerodynamic particle-size distribution. The MMAD is a statistically derived figure for a particle sample: by way of example, an MMAD of <NUM> micrometres means that <NUM> percent of the total sample mass will be present in particles having aerodynamic diameters of less than <NUM> micrometres, and that the remaining <NUM> percent of the total sample mass will be present in particles having an aerodynamic diameter greater than <NUM> micrometres. In the context of the present invention, when describing a powder system, the term "particle size" preferably refers to the MMAD of the powder system.

The MMAD of a powder system is preferably measured with a cascade impactor. Cascade impactors are instruments which have been extensively used for sampling and separating airborne particles for determining the aerodynamic size classification of aerosol particles. In practice, cascade impactors separate an incoming sample into discrete fractions on the basis of particle inertia, which is a function of particle size, density and velocity. A cascade impactor typically comprises a series of stages, each of which comprises a plate with a specific nozzle arrangement and a collection surface. As nozzle size and total nozzle area both decrease with increasing stage number, the velocity of the sample-laden air increases as it proceeds through the instrument. At each stage, particles with sufficient inertia break free from the prevailing air stream to impact on the collection surface. Therefore, at any given flow rate, each stage is associated with a cut-off diameter, a figure that defines the size of particles collected. With increasing stage number, velocity increases and so stage cut-off diameter decreases. Thus, the cut-off diameter associated with a given stage is a function of the air-flow rate used for testing. To reflect in-use performance, nebulisers are routinely tested at <NUM>/min and dry powder inhalers may be tested at flow rates up to <NUM>/min.

Preferably, in the context of the present invention, the MMAD of a powder system is measured with a Next Generation Impactor (NGI) <NUM> (available from Copley Scientific AG). The NGI is a high performance, precision, particle classifying cascade impactor having seven stages plus a Micro-Orifice Collector (MOC). Characteristics and operation principle of a NGI are described, for example, in <NPL>). More preferably, measurements are carried out at <NUM> ±<NUM> degrees Celsius and relative humidity of <NUM> ± <NUM> percent.

A dry powder formulation typically contains less than or equal to about <NUM> percent by weight moisture, preferably less than or equal to about <NUM> percent moisture, even more preferably less than or equal to about <NUM> percent by weight moisture. Most preferably a dry powder formulation contains less than or equal to about <NUM> percent by weight moisture or even less than or equal to about <NUM> percent by weight moisture or even less than or equal to about <NUM> percent by weight moisture.

All values reported as a percentage are presumed to be weight percent based on the total weight.

As used herein, the singular forms "a", "an", and "the" encompass embodiments having plural referents, unless the content clearly dictates otherwise.

As used herein, "or" is generally employed in its sense including "and/or" unless the content clearly dictates otherwise.

As used herein, "have", "having", "include", "including", "comprise", "comprising" or the like are used in their open-ended sense, and generally mean "including, but not limited to". It will be understood that "consisting essentially of", "consisting of", and the like are subsumed in "comprising," and the like.

The words "preferred" and "preferably" refer to embodiments of the invention that may afford certain benefits, under certain circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful and is not intended to exclude other embodiments from the scope of the disclosure, including the claims.

The term "substantially" as used here has the same meaning as "significantly," and can be understood to modify the relevant term by at least about <NUM> %, at least about <NUM> %, or at least about <NUM> %. The term "not substantially" as used here has the same meaning as "not significantly," and can be understood to have the inverse meaning of "substantially," i.e., modifying the relevant term by not more than <NUM>%, not more than <NUM>%, or not more than <NUM>%.

Aspects of the present disclosure will now be further described with reference to the figures in which:.

The schematic drawings are not necessarily to scale and are presented for purposes of illustration and not limitation. The drawings depict one or more aspects described in this disclosure. However, it will be understood that other aspects not depicted in the drawing fall within the scope of this disclosure.

<FIG> is a schematic cross-sectional diagram of an illustrative inhaler system <NUM>. <FIG> is perspective exploded view of an illustrative inhaler article holder <NUM>. <FIG> is a schematic cross-sectional diagram of an illustrative inhaler system <NUM> where the inhaler article <NUM> is received in the inhaler article holder <NUM> and piercing the capsule <NUM> (contained within the inhaler article <NUM>) in a second or compressed position. <FIG> is a schematic cross-sectional diagram of the illustrative inhaler system <NUM> of <FIG> where the piercing element <NUM> is retracted from the capsule <NUM> in a first or relaxed position. <FIG> is another schematic cross-sectional diagram of <FIG> illustrating the inhalation airflow <NUM> path (arrows) through the inhaler system <NUM>.

The inhaler article holder <NUM> is configured to receive a separate consumable inhaler article <NUM> and induce swirling inhalation airflow into and through an inhaler article <NUM> during consumption. The inhaler article holder <NUM> and an inhaler article <NUM> form an inhaler system <NUM>. The inhaler article <NUM> remains in the inhaler article holder <NUM> during use by the consumer. The inhaler article holder <NUM> is configured to induce swirling inhalation airflow entering the received inhaler article <NUM>.

The illustrative inhaler article <NUM> includes a body <NUM> extending from a mouthpiece end <NUM> to a distal end <NUM>. A capsule cavity <NUM> is defined within the body <NUM>. A capsule <NUM> is contained within the capsule cavity <NUM>. Dry powder particles described above may be contained within the capsule <NUM>. The capsule <NUM> may be pierced to form an aperture through the body of the capsule <NUM> and inhalation air may flow through the inhaler article <NUM> to release dry powder particles from the pierced capsule <NUM> and into the inhalation airflow and out of the mouthpiece end <NUM>.

The inhaler article holder <NUM> includes a housing <NUM> defining a housing cavity defined by a housing inner surface <NUM>, and an outer surface <NUM>. A sleeve <NUM> is positioned within the housing cavity. The sleeve <NUM> is arranged to receive an inhaler article <NUM> and the sleeve <NUM> is movable within the housing cavity between a first position and a second position, along a longitudinal axis of the housing cavity.

A piercing element <NUM> is arranged to pierce the capsule <NUM> within the inhaler article <NUM> received within the sleeve <NUM> when the sleeve <NUM> is in the second position as illustrated in <FIG>.

The piercing element <NUM> may be configured to extend into the sleeve <NUM> along a longitudinal axis of the housing <NUM>. The inhaler article holder <NUM> may include a spring member <NUM> configured to bias the sleeve <NUM> and any received inhaler article <NUM> away from the piercing element <NUM>.

The sleeve <NUM> extends from an open end <NUM> to a closed end <NUM> (or restricted end) and defines a sleeve cavity <NUM> or cylindrical lumen <NUM> along a longitudinal axis of the sleeve <NUM>. The open end <NUM> of the sleeve aligns with the single housing opening <NUM>.

The sleeve closed end <NUM> includes an airflow element <NUM> and an aperture to allow the piercing element to pass through the closed end <NUM> and extend into the sleeve lumen <NUM>. The airflow element <NUM> includes one or more inhalation air inlets <NUM> that provide airflow communication from the annular space around the sleeve <NUM> into the sleeve cylindrical lumen <NUM>. This airflow element <NUM> is configured to induce rotating or swirling inhalation airflow into the sleeve cylindrical lumen <NUM> and directly into the inhaler article capsule cavity <NUM>. This swirling or rotational inhalation airflow may be transmitted into an inhaler article <NUM> to rotate a capsule <NUM> and release dry powder contained within the capsule <NUM>.

The airflow element <NUM> of the sleeve <NUM> includes a tubular element having a central passage in fluid communication with the sleeve cavity <NUM>. The airflow element <NUM> has at least one air inlet <NUM> allowing inhalation air <NUM> to enter into the central passage. The at least one air inlet <NUM> extends in a direction that is tangential to the central passage to generate the swirling or rotational inhalation airflow.

The sleeve <NUM> includes a tubular element that may extend into the sleeve cavity <NUM> about <NUM> and have an outer diameter of about <NUM> and an inner diameter of about <NUM>. The received inhaler article <NUM> open distal end <NUM> may have an inner diameter of about <NUM> to provide an interference fit with the airflow element <NUM> tubular element.

The sleeve closed end <NUM> may further include a sleeve bottom element <NUM> substantially forming the closed end of the sleeve <NUM>. The sleeve bottom element <NUM> may be fixed and contact the airflow element <NUM>. The sleeve bottom element <NUM> may extend away from the airflow element <NUM> a distance along the sleeve longitudinal axis and toward the closed end of the housing cavity. The sleeve bottom element <NUM> may have an aperture that contains the piercing element <NUM> and allows the piercing element <NUM> to pass through the sleeve bottom element <NUM> aperture.

An inner housing <NUM> may be contained within the housing cavity. The inner housing <NUM> may separate at least a portion of the sleeve <NUM> from the inner surface of the housing cavity. The inner housing <NUM> may separate a fixed end of the piercing element <NUM> from the inner surface of the housing cavity. The inner housing <NUM> may separate the spring member <NUM> from the inner surface of the housing cavity.

An annular cover <NUM> may secure the inner housing <NUM> and sleeve <NUM> into the housing cavity. The annular cover <NUM> defines the single housing opening <NUM> for receiving the inhaler article <NUM>. The annular cover <NUM> may be fixed to the housing <NUM> with a pin element <NUM>.

<FIG> illustrates the inhalation airflow <NUM> path through the inhaler system <NUM>. Inhalation airflow <NUM> enters the inhaler article holder <NUM> along the outer surface of the received inhaler article <NUM> and the annular cover <NUM>. Once inside the housing cavity, the inhalation air <NUM> travels along the sleeve <NUM> length to the closed end <NUM> of the sleeve <NUM>. The inhalation air <NUM> then enters the air inlet <NUM> of the airflow element <NUM> and forms swirling or rotating inhalation air <NUM> within the sleeve lumen <NUM>. This swirling or rotating inhalation air is then directly transmitted into the distal end <NUM> of the inhaler article <NUM> and into the capsule cavity <NUM>. The swirling inhalation airflow rotates or agitates the capsule <NUM> and dry powder particles are entrained in the inhalation airflow. The entrained inhalation airflow then flows out of the inhaler article via the mouthpiece end <NUM> and to the user <NUM>. The inhalation airflow <NUM> path is illustrated in <FIG> with arrows.

<FIG> a front elevation into the sleeve <NUM> of an illustrative inhaler article holder. <FIG> is a perspective view of an illustrative airflow element <NUM> with piercing element <NUM>. <FIG> is a perspective view of an airflow element <NUM> illustrating six alternative piercing element <NUM> offset locations about the centerline of the airflow element <NUM>.

The single cutting plane or bevel <NUM> is offset from or spaced away from and opposes or faces away from the centerline of the airflow element <NUM>. <FIG> illustrates solid line embodiment and five phantom line alternative piercing element <NUM> offset locations about the centerline of the airflow element <NUM>. Each alternative location illustrates that the single cutting plane or bevel <NUM> is offset from or spaced away from and opposes or faces away from the centerline of the airflow element <NUM>.

The central longitudinal axis LCL of the sleeve <NUM> is located at the intersection of the X and Y axis. The airflow element <NUM> defines the closed end of the sleeve <NUM>. An inner housing <NUM> is fixed to the sleeve <NUM>. The piercing element <NUM> extends through the airflow element <NUM> and is offset from the central longitudinal axis LCL a distance Ro. The central longitudinal axis LCL of the airflow element <NUM> is aligned with and co-incident with the central longitudinal axis LCL of the sleeve <NUM>. The cutting end of the piercing element is defined by a single cutting plane or bevel <NUM> terminating at a tip <NUM>.

<FIG> is a schematic cross-sectional diagram of an illustrative piercing element <NUM> contacting a capsule endcap <NUM>. <FIG> is a schematic cross-sectional diagram of an illustrative capsule cavity <NUM> of an inhaler article <NUM> with a capsule <NUM> and piercing element <NUM>.

The orientation of the cutting plane or bevel <NUM> is illustrated in <FIG>. The cutting place opposes the central longitudinal axis LCL of the sleeve <NUM>. The central longitudinal axis LCL of the capsule cavity <NUM> aligned with and co-incident with the central longitudinal axis LCL of the sleeve <NUM>. The tip <NUM> first penetrates the capsule hemispherical endcap <NUM> to form the aperture opening and continues to cut the capsule hemispherical endcap <NUM> until the entire circumference of the piercing element shaft enters the capsule <NUM>. The portion of the perimeter forming the aperture is closest to the central longitudinal axis LCL. A hinge of capsule material forming a portion of the aperture opposes the portion of the perimeter closest to the central longitudinal axis LCL.

The piercing element <NUM> is parallel with and offset from the central longitudinal axis LCL a distance Ro. The capsule hemispherical endcap <NUM> has a radius RC at the circumference of the capsule <NUM>. The piercing element <NUM> may contact the capsule hemispherical endcap <NUM> at a point closer to the circumference radius RC than the central longitudinal axis LCL as described above.

<FIG> is front elevation view of an illustrative capsule <NUM> endcap with aperture <NUM> after being pierced by the piercing element described herein. <FIG> is front elevation view of another illustrative capsule <NUM> endcap with aperture <NUM> after being pierced by the piercing element described herein.

<FIG> is a perspective view of an illustrative piercing element <NUM> tip <NUM>. The piercing element <NUM> has only a single shaft extending from a fixed end to a tip <NUM> along a piercing element longitudinal axis. The piercing element has a piercing element diameter D in a range from <NUM> to <NUM>, and the single piercing element tip <NUM> having only a single cutting plane <NUM> and defining a cutting plane angle Θ between the longitudinal axis of the piercing element and the single cutting plane <NUM>. The cutting plane angle Θ being in a range from about <NUM> degrees and about <NUM> degrees.

Claim 1:
An inhaler system (<NUM>), comprising:
a housing (<NUM>) defining a housing cavity;
a sleeve (<NUM>) extending along a sleeve longitudinal axis and positioned within the housing cavity, wherein the sleeve is movable within the housing cavity between a first position and a second position, wherein the sleeve extends from an open end (<NUM>) to a closed end (<NUM>) and defines a cylindrical lumen (<NUM>) for receiving an inhaler article (<NUM>), the open end of the sleeve is aligned with an opening in the housing for receiving the inhaler article;
a capsule (<NUM>) contained within the inhaler article and received within the sleeve, the capsule having a capsule longitudinal axis; and
a piercing element (<NUM>) comprising only a single shaft extending from a fixed end to a tip (<NUM>) along a piercing element longitudinal axis, the piercing element longitudinal axis being parallel with the sleeve longitudinal axis, the piercing element having a piercing element diameter in a range from <NUM> to <NUM>, and the single piercing element tip having only a single cutting plane (<NUM>) and defining a cutting plane angle between the longitudinal axis of the piercing element and the single cutting plane, the cutting plane angle being in a range from about <NUM> degrees and about <NUM> degrees;
wherein only a single aperture (<NUM>) is formed in the capsule when the sleeve is moved from the first position to the second position.