WO2024180456A1

WO2024180456A1 - Inhaler article having triangular support

Info

Publication number: WO2024180456A1
Application number: PCT/IB2024/051828
Authority: WO
Inventors: Onur DAYIOĞLU; Frédéric LAVANCHY
Original assignee: Philip Morris Products S.A.
Priority date: 2023-02-27
Filing date: 2024-02-26
Publication date: 2024-09-06

Abstract

An inhaler article (10) comprising: a substrate portion (3) and a retainer portion (4), the substrate portion comprising a substrate (29), the retainer portion comprising a hollow tubular element (110) having a radius and an interior surface (112) and defining an interior cavity (120); a support (130) in the interior cavity of the retainer portion; wherein a portion of the support contacts the interior surface of the retainer portion and a portion of the support forms a triangular shape extending into the interior cavity of the retainer portion, wherein the length of at least one of the sides of the triangular shape is longer than the radius of the retainer portion.

Description

INHALER ARTICLE HAVING TRIANGULAR SUPPORT

The present disclosure relates to an inhaler article comprising a retainer portion. The retainer portion has a triangular support in the interior cavity of the retainer portion.

Inhaler articles, such as dry powder inhalers, are often manipulated before and during use. For example, inhaler articles may be subjected to longitudinal and transverse pressures as they are manufactured, packaged, unpackaged, inserted into holders, activated, used and discarded. Inhaler articles are not always fully suitable to withstand this manipulation and also provide dry powder particles to the lungs of a user, reliably, at inhalation or air flow rates that are within conventional smoking regime inhalation or air flow rates, and without leaking dry powder. Dry powder inhalers may be complex to operate or may involve moving parts. Dry powder inhalers often strive to provide a suitable dry powder dose or capsule load in a single draw.

Some dry powder inhalers have a component for storing the dry powder, such as a capsule. The capsule may be located within a substrate portion of the inhaler article. The capsule can be activated by being pierced by a separate piercing element. The separate piercing element may be provided by a holder that the inhaler article is inserted into prior to piercing and use. Once the capsule has been activated, or pierced, a consumer may use the inhaler article by drawing on the mouth end (downstream end or proximal end) of the inhaler to generate an air flow through the inhaler. As air flows through the inhaler article, the capsule rotates about itself inside the substrate portion of the inhaler article. The agitation of the capsule within the substrate portion of the inhaler article and the air flow pressure causes the release of dry powder from the pierced capsule. The powder shakes free of the capsule when the capsule is agitated. The released dry powder is carried by the air flow to the mouth of a user. For the inhaler article to operate properly to release powder from a capsule so that the powder can be delivered to the mouth of a user, the capsule should remain in the substrate portion of the inhaler article during operation.

Some inhaler articles comprise a retaining segment located downstream of the retainer portion. The retainer portion may have a support inside the retainer portion. Advantageously, the retainer portion having a support is provided to retain the capsule in the substrate portion of the inhaler before piercing, during piercing, after piercing, and during use. The support in the retainer portion is provided to block the capsule from leaving the substrate portion before piercing, during piercing, after piercing, and during use of the inhaler article. The support in the retainer portion also provides structural strength to the inhaler article. For example, the support of the retainer portion may be strong enough in the direction of the longitudinal axis of the inhaler article to prevent the capsule from leaving the substrate portion of the inhaler article before piercing, during piercing, after piercing, and during use of the inhaler article. The support of the retainer portion may be strong enough in the direction of the longitudinal axis of the inhaler article to prevent the support of the retainer portion from deforming when the capsule is pushed against the retainer portion when the capsule is pierced by a piercing element. The support of the retainer portion may be strong enough in the direction of the longitudinal axis of the inhaler article to prevent the capsule from being pushed out of the substrate portion during piercing. For example, the support of the retainer portion may be strong enough in the direction of the longitudinal axis of the inhaler article to prevent the inhaler article from being crushed during normal use, including manufacture, packaging, unpackaging, insertion into a holder, use of the inhaler article, and disposal of the inhaler article. Or, for example, the retainer portion may be strong enough in the direction perpendicular to the longitudinal axis of the inhaler article to prevent the inhaler article from being crushed during normal use, including manufacture, packaging, unpackaging, insertion into a holder, use of the inhaler article, and disposal of the inhaler article. The retainer portion may be hollow or porous to allow the dry powder to pass through.

The upstream end (distal end) of the retainer portion of a capsule-containing inhaler article sustains considerable longitudinal force during the activation process of the capsule. During such activation process, a piercing element extends into the upstream end of the inhaler article in order to contact and pierce the capsule located within the article. Upon first contact, the piercing element pushes the capsule against the upstream end of the retainer portion in order to successfully pierce the capsule. As the piercing element pierces the capsule, the capsule is pushed against the upstream end of the retainer portion. Therefore, the downstream components of the inhaler article, especially the retainer portion, should be relatively resistant to deformation in the longitudinal direction, and particularly under compression.

In addition, a consumer may hold the inhaler article in the region of the retainer portion. To facilitate activation of the capsule a consumer may exert considerable transverse force on the inhaler article in the region of the retainer portion. Therefore, the retainer portion should also be relatively resistant to deformation in the transverse direction, and particularly under compression.

Some inhaler articles are useful for providing aerosol to a user from heated (but not burned) tobacco located in the inhaler article. Sometimes, inhaler articles contain capsules that contain flavor. A user may hold the inhaler article in the region of the capsule. T o facilitate activation of the capsule a consumer may exert considerable transverse force on the inhaler article in the region of the capsule to crush the capsule to release flavor. The region of the capsule may be adjacent to the retainer portion. Therefore, for heat-not-burn inhaler articles, the region of the retainer portion of the inhaler article should also be relatively resistant to deformation in the transverse direction, and particularly under compression.

A retainer portion with a relatively low porosity may possess sufficient strength to facilitate activation of the capsule. However, when a consumer draws on an inhaler article comprising such a retainer portion, the resistance to draw of the inhaler article may be relatively high. Particles from the capsule may become trapped by the structure of the inhaler article downstream of the capsule. As a result, the consumer may not be able to adequately deplete the capsule and the doses drawn by the consumer are relatively small.

It would be desirable to provide an inhaler article having a retainer portion with a resistance to draw that allows the user to appropriately access the contents of the substrate portion of the inhaler article.

It would be desirable to provide an inhaler article that is cost-effective to manufacture and that performs effectively to provide a satisfactory experience for inhaler article consumers. Cost-effective means that the article can be manufactured with minimal manufacturing steps, using inexpensive materials, yielding high-performing articles at minimal cost.

In addition, it would be desirable to provide an inhaler article having sufficient rigidity to resist longitudinal force. Longitudinal force is provided when a capsule contained in a substrate portion of an inhaler article is pierced, forcing the capsule against the support of the retainer portion of the inhaler article in the longitudinal direction. It would be desirable to provide an inhaler article having sufficient rigidity to resist transverse force. Transverse force, force perpendicular to the longitudinal direction of the inhaler article, is provided as the inhaler article is manipulated, including manufacture, packaging, unpackaging, insertion into a holder, use of the inhaler article, and disposal of the inhaler article.

It would be desirable to enable piercing of the capsule located inside the inhaler article and to prevent pushing the capsule out of the substrate portion of the inhaler article when the capsule is pierced. That is, it would be desirable to provide an inhaler article having a retainer portion structured to retain a capsule in the inhaler article when a piercing element pushes the capsule against the retainer portion. It would be desirable to provide an inhaler article having sufficient rigidity to resist deforming or crushing of the inhaler article when the capsule is pierced. It would be desirable to provide an inhaler article having sufficient rigidity to resist deforming or crushing during manipulation of the inhaler article. It would also be desirable to provide an inhaler article having a retainer portion having sufficient rigidity or strength in the longitudinal direction to resist deforming or crushing when the capsule is pierced. It would be desirable to provide an inhaler article having a support inside the retainer portion that has sufficient rigidity or strength to resist deforming or crushing when the capsule is pierced. It would be desirable to provide an inhaler article having a support inside the retainer portion that has sufficient rigidity or strength to prevent or block a capsule from leaving the substrate portion or being pushed out of the substrate portion of the inhaler article as the capsule is being pierced. It would be desirable to provide an inhaler article that is easy to manufacture and cost effective while still providing necessary rigidity and low resistance to draw. It would also be desirable to provide an inhaler article made from biodegradable materials.

The inventors have found that the geometry of the support inside the retainer portion contributes to the strength of the retainer portion in the longitudinal direction and the direction perpendicular to the longitudinal axis of the inhaler article. The inventors have found that the claimed geometry of the support inside the retainer portion contributes to the ability of the retainer portion to prevent the capsule from leaving the substrate portion of the inhaler article during piercing of a capsule contained in the substrate portion. The inventors have found that a triangular support as claimed herein contributes to the strength of the retainer portion in the longitudinal direction and the direction perpendicular to the longitudinal axis of the inhaler article, prevents a capsule from being pushed out of the substrate portion of the inhaler article during piercing, while still providing a low resistance to draw through the inhaler article. The inventors have found that a support where the tip is an angle, not a curve, contributes to the strength of the retainer portion in the longitudinal direction and the direction perpendicular to the longitudinal axis of the inhaler article, prevents a capsule from being pushed out of the substrate portion of the inhaler article during piercing, while still providing a low resistance to draw through the inhaler article. The inventors have found that a support where at least one of the first leg and the second leg are longer than the radius of the retainer portion contributes to the strength of the retainer portion in the longitudinal direction and the direction perpendicular to the longitudinal axis of the inhaler article, prevents a capsule from being pushed out of the substrate portion of the inhaler article during piercing, while still providing a low resistance to draw through the inhaler article. The inventors have found that a support where the first leg and the second leg are both longer than the radius of the retainer portion contributes to the strength of the retainer portion in the longitudinal direction and the direction perpendicular to the longitudinal axis of the inhaler article, prevents a capsule from being pushed out of the substrate portion of the inhaler article during piercing, while still providing a low resistance to draw through the inhaler article. The inventors have found that a support where the first bend and the second bend are angles (and not curved) contributes to the strength of the retainer portion in the longitudinal direction and the direction perpendicular to the longitudinal axis of the inhaler article, prevents a capsule from being pushed out of the substrate portion of the inhaler article during piercing, while still providing a low resistance to draw through the inhaler article. The inventors have found that a flap and the second flap are shorter than the radius of the retainer contributes to the strength of the retainer portion in the longitudinal direction and the direction perpendicular to the longitudinal axis of the inhaler article, prevents a capsule from being pushed out of the substrate portion of the inhaler article during piercing and maintains the roundness of the retainer portion while still providing a low resistance to draw through the inhaler article. The inventors have found that a triangular support where the first flap and the second flap are attached to the interior surface of the retainer portion with an adhesive contributes to the strength of the retainer portion in the longitudinal direction and the direction perpendicular to the longitudinal axis of the inhaler article, prevents a capsule from being pushed out of the substrate portion of the inhaler article during piercing, while still providing a low resistance to draw through the inhaler article. The inventors have found that when the geometry of the support has the described features, thin or thinner material may be used for the support while providing sufficient strength of the retainer portion in the longitudinal direction and the direction perpendicular to the longitudinal axis of the inhaler article to prevent a capsule from being pushed out of the substrate portion of the inhaler article during piercing, while still providing a low resistance to draw through the inhaler article. The inventors have also found that the claimed retainer portion is efficient to manufacture.

The present disclosure relates to an inhaler article having a longitudinal axis between an upstream end and a downstream end. The inhaler article may comprise a substrate portion and a retainer portion. The inhaler, and each of the substrate portion and the retainer portion have a length “I”, a radius “r” and a central axis. The substrate portion comprises a substrate. The substrate may be vegetal matter such as tobacco. The substrate may be tobacco. The substrate may be a capsule. The capsule may be located in a cavity of the substrate portion. The capsule may contain dry powder. The retainer portion may comprise a hollow tubular element having an interior surface defining an interior cavity. The retainer portion may comprise a support in the interior cavity of the retainer portion. The support may be formed from a sheet of material. The support may comprise a first flap, a first bend, a first leg, a second bend, a second leg, a third bend and a second flap. The first flap of the support contacts the interior surface of the hollow tubular element of the retainer portion along the length of the first flap. The first leg of the support comprises a length between the first bend and the second bend. The second bend comprises a tip. The tip is an angle, not a curve or an arc. The second leg of the support comprises a length between the second bend and the third bend. The first leg, the second bend and the second leg form two legs of a triangle extending into the interior cavity of the retainer when the retainer is viewed from an upstream end of the retainer. The second flap contacts the interior surface of the hollow tubular element of the retainer portion. In embodiments, the length of at least one of the first leg and the second leg is greater than the radius of the retainer. In embodiments, the length of the first leg and the second leg are equal. In embodiments, the first leg and the second leg are straight. The length of the first flap and the second flap of the support may be less than the radius of the retainer.

The inventors have surprisingly found that the particular geometry of the support, contributes to the performance of the retainer portion. And, where the first leg, the second bend and the second leg form two legs of a triangle extending into the interior cavity of the retainer result in a retainer portion that performs very well to prevent a capsule from being pushed out of the substrate portion as the capsule is pierced. In particular, when the capsule is rounded on the end that contacts the support when the capsule is pushed against the support as the capsule is pierced by a piercing element, a triangular-shaped support keeps the capsule from being pushed into the retainer portion. In addition, a triangular-shaped support maintains the roundness of the retainer portion in the direction transverse to the longitudinal axis of the inhaler article.

The inventors have surprisingly found that a support wherein at least one of the first leg and the second leg is greater than the radius of the retainer contributes to the performance of the retainer portion. The inventors have found that this geometry is more effective in providing a retainer portion having rigidity in the longitudinal direction compared to triangular supports having a first leg and a second leg that are shorter than the radius of the retainer portion. The inventors have found that this geometry is more effective in providing a retainer portion having rigidity in the transverse direction compared to triangular supports having a first leg and a second leg that are shorter than the radius of the retainer portion. The inventors have found that the support is more rigid, and more resistant to deformation in the longitudinal and/or transverse direction when the length of the first or second leg, or both the first and second leg, is greater than the radius of the retainer portion. The first leg or the second leg may be greater than the radius of the retainer portion to retain the ovoid capsule in the substrate portion. The inventors have surprisingly found that when the first leg and the second leg both are longer than the radius of the retainer portion, the retainer portion is effective to retain an ovoid capsule in the substrate portion even when the capsule is being pierced. In addition, the inventors have found that the retainer having a support wherein the length of lest the first leg or the second leg are approximately equal is more cost effective to manufacture compared to supports that are triangular in shape but having a first leg and a second leg that are shorter than the radius of the retainer portion.

The inventors have surprisingly found that a capsule is better retained when a capsule is pushed against the support in the longitudinal direction if the length of at least one of the first leg and the second leg is greater than the radius of the retainer. This is especially true if the material of the support is thinner. If the length of at least one of the first leg and the second leg is greater than the radius of the retainer, the support may be made from thinner material.

The inventors have surprisingly found that a capsule is better retained when a capsule is pushed against the support in the longitudinal direction if the length of both the first leg and the second leg is greater than the radius of the retainer. This is especially true if the material of the support is thin or thinner. If the length of at least one of the first leg and the second leg is greater than the radius of the retainer, the support may be made from thin or thinner material. If the length of both the first leg and the second leg is greater than the radius of the retainer the support may be made from thin or thinner material.

The material of the retainer portion may be, for example, paper, cardboard, polymer, plastic, bioplastic, extruded bioplastic, metal, foil, or any suitable material. The material of the retainer portion may be the same as the material of the inhaler article. The material of the retainer portion may be different from the material of the inhaler article.

The material of the support may be flexible material capable of being shaped as desired. The material of the support may be, for example, paper, cardboard, board, polymer, plastic, bioplastic, extruded bioplastic, metal, foil, or any suitable material. The material of the support may be a sheet of material. As used herein, the term “sheet” denotes a material having a width and length substantially greater than the thickness thereof.

The sheet of material may be paper or cardboard. The sheet of material may be paper. The support may be made from a sheet of material having thickness of 250 microns or less. The support may be made from a sheet of material having a thickness of 200 microns or less. Support material having a thickness of 250 microns or less is considered thin. Similarly, support material having a thickness of 200 microns or less is considered thinner.

Because of the geometry of the support, where at least one of the first leg and the second leg is longer than the radius of the retainer portion, the support may be made from thinner material while maintaining sufficient rigidity in the longitudinal and/or transverse direction. Because of the geometry of the support, where the second bend, the tip, is angled and not curved, the support may be made from thinner material while maintaining sufficient rigidity in the longitudinal and/or transverse direction. Because of the geometry of the support, where the first bend and the third bend are angled (not curved), the support may be made from thinner material while maintaining sufficient rigidity in the longitudinal and/or transverse direction. For purposes of this disclosure, “angled” means a sharp angle, or a fold in material and is distinguished from an arc or a curve where there is no sharp fold in the material.

For example, because of the geometry of the support, where at least one of the first leg and the second leg is longer than the radius of the retainer portion, or where the tip is angled, or where the first bend and the third bend are angled, or wherein the first flap and the second flap are shorter than the radius of the retainer portion, or wherein the first flap and the second flap are affixed to the inner surface of the retainer portion with adhesive, or a combination of these geometries, the support may be made from paper that is thin or thinner. For example the support may be made from paper having a thickness of 124 microns and a grammage of 170 gsm. Because of the geometry of the support, where at least one of the first leg and the second leg is longer than the radius of the retainer portion, the support may be made from paper having a thickness of 124 microns and a grammage of 100 gsm. Because of the geometry of the support, where at least one of the first leg and the second leg is longer than the radius of the retainer portion, the support may be made from paper having a thickness of 10 microns and a grammage of 78 gsm.

Because of the geometry of the support, where the first leg and the second leg are longer than the radius of the retainer portion, the support may be made from thinner material. For example, because of the geometry of the support, where the first leg and the second leg are longer than the radius of the retainer portion, the support may be made from paper that is thin or thinner. Because of the geometry of the support, where the first leg and the second leg are longer than the radius of the retainer portion, the support may be made from material. For example, because of the geometry of the support, where the first leg and the second leg are longer than the radius of the retainer portion, the support may be made from paper having a thickness of 124 microns and a grammage of 170 gsm. Because of the geometry of the support, where the first leg and the second leg are longer than the radius of the retainer portion, the support may be made from paper having a thickness of 125 microns and a grammage of 100 gsm. Because of the geometry of the support, where the first leg and the second leg are longer than the radius of the retainer portion, the support may be made from paper having a thickness of 100 microns and a weight of 78 gsm. Using thin or thinner material reduces manufacturing complexity and cost. Using thin or thinner material makes manufacturing more efficient.

The inventors have surprisingly found that the second bend having a tip that is an angle (e.g., not rounded) contributes to the performance of the retainer portion. The tip may be a fold in the material of the support. The inventors have found that this geometry is more effective in providing a retainer portion having rigidity in the longitudinal direction compared to supports having a rounded profile (e.g., an “omega” shape). The inventors have found that this geometry is more effective in providing a retainer portion having rigidity in the transverse direction compared to supports having a rounded profile. The inventors have found that the support is more rigid, and more resistant to deformation in the longitudinal and/or transverse direction when the tip (the second bend) is an angle. In addition, the inventors have found that the retainer having an angled tip is more cost effective to manufacture compared to supports having rounded shapes. In addition, because of the geometry of the support, where the second bend has a tip that is an angle and not rounded, the support may be made from thinner material.

The inventors have surprisingly found that it is more efficient to manufacture the retainer portion having a support when the first bend and the third bend are angled (e.g., not rounded). Another way of stating that the first bend and the third bend are angled is to say that the first bend and the third bend are folds in the material of the support. In embodiments, the first bend and the third bend are not arcs.

The inventors have surprisingly found that the first leg and the second leg being straight (e.g., not curved) contributes to the performance of the retainer portion. The inventors have found that this geometry is more effective in providing a retainer portion having rigidity in the longitudinal direction compared to supports having a first and second leg that are not straight. The inventors have found that this geometry is more effective in providing a retainer portion having rigidity in the transverse direction compared to supports having a curved first leg or second leg. The inventors have found that the support is more rigid, and more resistant to deformation in the longitudinal and/or transverse direction when the first leg and the second leg are straight. Because of the geometry of the support, where the first leg and the second leg are straight (not curved) the support may be made from thinner material while retaining its rigidity in the face of longitudinal and/or transverse, the inventors have found that the retainer having straight first and second legs is more cost effective to manufacture compared to supports having curved legs.

The inventors have surprisingly found that the first flap and the second flap being shorter than the radius of the retainer portion contributes to the performance of the retainer portion. The inventors have found that this geometry is more effective in providing a retainer portion that does not deform if the first flap and second flap are shorter than the radius of the retainer portion. That is, with longer flaps, the retainer portion may deform. With longer flaps, the retainer portion may become less circular. The inventors have found that this geometry, where the first flap and the second flap are shorter than the radius of the retainer portion results in a retainer portion that is more rigid, more circular, and more resistant to deformation in the longitudinal and/or transverse direction. The inventors have also found that the retainer portion is more cost effective to manufacture when the first flap and the second flap are shorter than the radius of the retainer portion compared to retainer portions having longer first and second flaps.

The length of the support, where the first flap and the second flap are shorter than the radius of the retainer portion, where at least one of the first leg and the second leg is longer than the radius of the retainer portion and where the first, second and third bends are angles, is greater than 2d where d is the diameter of the retainer portion. For example, where the inner diameter of the retainer portion is 7 mm, the length of the support (when stretched out) will be more than 14 mm. Where the inner diameter of the retainer portion is 6.55 mm, and each of the first flap and second flap is, for example 2.7 mm, the length of the support (when stretched out) may be 14.3 mm or longer.

An inhaler article having a retainer portion having a support that has a first leg and a second leg that are longer than the radius of the retainer portion, having a second bend (a tip) that is angled and not rounded, where the first leg and the second leg are straight (not curved), where the first bend and the third bend are angled (not curved), and wherein the first flap and the second flap are shorter than the radius of the retainer portion is effective in retaining a capsule in the inhaler article when the capsule is pierced and in preventing deformation of the inhaler article in the longitudinal direction and in the direction transverse to the longitudinal direction. The following features contribute to the strength of the triangle insert shape: the paper thickness/grammage; the triangle sharp corner at the second bend between the first and second leg, and the area of glue applied to the sides of the flaps that are contacting the retainer portion inner surface.

The length of the retainer portion may be relatively small. For example, for an inhaler article having a length of 45 mm, the retainer portion may be between 5 and 9 mm. The inventors have surprisingly found that, by incorporating the geometry of the retainer portion, it is possible to keep the length of the retainer portion relative to the length of the inhaler article relatively small. The inventors have surprisingly found that a retainer portion having the described geometry, characteristics such as a support having a tip that is an angle, first and third bends that are angles, wherein the first leg and the second leg are straight, wherein the length of at least one of the first leg and the second leg is greater than the radius of the retainer portion, and wherein the length of the first flap and the second flap is shorter than the radius of the retainer portion, allow the length of the retainer portion to be relatively small relative to the overall length of the inhaler article while still retaining sufficient rigidity to withstand deformation in the longitudinal and/or transverse direction. Manufacturing an inhaler article that has a shorter retainer portion is more cost effective.

When the inhaler article contains a capsule containing dry powder active ingredient, the upstream end of the inhaler article may have a folded end. The folded end functions to retain the capsule in the cavity at the upstream end.

The retainer portion of the inhaler article may comprise two parts; a hollow tubular element and a support made from a separate sheet of material disposed inside the hollow tubular element. The retainer portion may be disposed downstream of the capsule. The retainer portion may comprise a hollow tubular element. The hollow tubular element may define a hollow inner region or an interior cavity of the retainer portion. The retainer portion may comprise a support element in the interior cavity of the retainer portion.

The support may comprise a first flap which contacts the interior surface of the hollow tubular element of the retainer portion. At a first bend, the support extends from the interior surface of the hollow tubular element of the retainer portion and extends into the interior cavity of the retainer portion, forming the first leg of a triangular shape in the interior cavity of the retainer portion when the retainer portion is viewed from the upstream end of the retainer portion. A second bend in the material of the support forms the tip of the triangle. The second leg forms the second leg of a triangular shape in the interior cavity of the retainer portion when the retainer portion is viewed from the upstream end of the retainer portion. The support then contacts the interior surface of the hollow tubular element of the retainer portion, and extends along the interior surface of the hollow tubular element of the retainer portion. That is, the support has a first flap, a first bend, a first leg, a second bend, a second leg, a third bend and a second flap and this overall structure forms a triangular shape that extends into the interior cavity of the retainer portion, attached to the interior surface of the retainer portion at its two ends . The two ends, the first and second flaps, may be attached to the interior surface. The two ends, the first and second flaps may be attached to the interior surface of the retainer portion by an adhesive.

The support element may retain the capsule in the cavity between the retainer portion and the upstream end. The support may be formed from a sheet. The support may extend from a first point at the interior surface of the hollow tubular element. The support element may extend into the interior cavity of the retainer portion. The support element may form a triangular shape extending into the interior cavity of the retainer portion from a first point to a second point at the interior surface of the hollow tubular element of the retainer portion.

According to the present invention, there is provided an inhaler article. When the inhaler article contains a capsule containing dry powder active ingredient, the inhaler article comprises a substrate portion which is a capsule cavity, containing a capsule. The capsule contains dry powder. The dry powder is an active ingredient. The retainer portion is disposed downstream of the capsule-containing substrate portion.

In contrast to prior art inhaler articles, the inhaler article of the present invention comprises a retainer portion having a hollow tubular element and a support. The support is attached to the interior surface of the hollow tubular element of the retainer portion, extending from a first and a second point at the hollow tubular element interior surface of the hollow tubular element into its interior cavity, forming a triangular-shaped support in the interior cavity of the retainer portion. The support acts to provide a support barrier for one or more components disposed upstream of the retainer portion. For example, the support can act to provide a barrier for the capsule located in the cavity. This can help to prevent or restrict downstream movement of one or more components disposed upstream of the retainer portion, such as the capsule. This may be particularly beneficial when a piercing element is used to pierce the capsule from the upstream end of the inhaler article. The support may prevent the capsule from being pushed out of the capsule cavity when the capsule is pierced from the upstream end of the inhaler article. When the substrate in the substrate portion is tobacco, the retainer portion functions to provide rigidity in the longitudinal and/or transverse direction in the inhaler article.

Furthermore, because the support is formed from a sheet and extends from a first and second point at the interior surface of the hollow tubular element into the interior cavity, to form a triangular shape, the retainer portion can still retain a suitably sized opening for one or both of air and dry powder to flow through the retainer portion, for example from the capsule. This means that the retainer portion can have a suitably low resistance to draw. This also means that the retainer portion can have a suitably low filtration effect and a suitably low resistance to draw.

In addition, forming the support element from a sheet can enable effective design of the support element. This is because the flexibility of the sheet can enable it to be easily formed into a shape that is most suitable for providing a support for one or more components disposed upstream of the retainer portion, such as the capsule. In addition, the optimized design of the support can provide rigidity in the longitudinal and transverse direction. This is particularly important for an inhaler article having a dry powder containing capsule, which may be provided in a range of shapes, sizes or both shapes and sizes. Thus, the design of the support element and of where the support element provides its support barrier can mean that the support element can be designed to provide effective support for the inhaler article in which it is provided. In addition, the support element can be provided in a conformation that can be manufactured efficiently.

As used herein, the term “retainer portion” is used to denote a generally cylindrical element defining a lumen or airflow passage along a longitudinal axis thereof. In particular, the term "retainer " will be used in the following with reference to a hollow tubular element having a hollow tubular body with a substantially cylindrical cross-section and defining at least one airflow conduit establishing an uninterrupted fluid communication between an upstream end of the retainer portion and a downstream end of the retainer portion. However, it will be understood that alternative geometries (for example, alternative cross-sectional shapes) of the retainer element may be possible. As used herein, the term “longitudinal” refers to the direction corresponding to the main longitudinal axis of the inhaler article, which extends between the upstream and downstream ends of the inhaler article.

The terms “upstream” and “downstream” refer to relative positions of elements of the holder, inhaler article and inhaler systems described in relation to the direction of inhalation air flow as it is drawn through the inhaler article, holder and inhaler systems. “Downstream” is the mouth end. “Upstream” is distal to the mouth end.

During use, air is drawn through the inhaler article in the longitudinal direction from the upstream end to the downstream end. The term “transverse” refers to the direction that is perpendicular to the longitudinal axis. Any reference to the “cross-section” of the inhaler article or a component thereof refers to the transverse cross-section unless stated otherwise.

The term “length” denotes the dimension of a component of the inhaler article in the longitudinal direction. For example, it may be used to denote the dimension of the capsule or retainer portion in the longitudinal direction. The term “tangential” refers to a direction that is at an angle from the referenced direction. For example, a tangential angle is not parallel with the referenced direction.

The terms “proximal” and “distal” are used to describe the relative positions of components, or portions of components, of the inhaler article, holder or inhaler system. Holders or elements (such as a sleeve) forming the holder, according to the disclosure have a proximal end which, in use, receives an inhaler article and an opposing distal end which may be a closed end, or have an end closer to the proximal end of the holder. Inhaler articles, according to the disclosure have a proximal end. In use, the powder particles exit the proximal end of the inhaler article for delivery to a user. The inhaler has a distal end opposing the proximal end. The proximal end of the inhaler article may also be referred to as the mouth end or downstream end. A distal end of a component may correspond to the upstream end of such a component. A proximal end of a component may correspond to the downstream end of such a component.

For the purposes of this disclosure, “tip” means a shape that is formed by the intersection of two legs sharing a common endpoint. The “tip” can be referred to as the angle of the intersection of the two legs, and also can be called the vertex of the angle. The “tip” is not rounded.

Unless otherwise specified, the resistance to draw (RTD) of a component or the inhaler article is measured in accordance with ISO 6565-2015. The RTD refers the pressure required to force air through the full length of a component. The terms “pressure drop” or “draw resistance” of a component or article may also refer to the “resistance to draw”. Such terms generally refer to the measurements in accordance with ISO 6565-2015 are normally carried out at under test at a volumetric flow rate of about 17.5 millilitres per second at the output or downstream end of the measured component at a temperature of about 22 degrees Celsius, a pressure of about 101 kPa (about 760 Torr) and a relative humidity of about 60%.

The inhaler article may comprise an upstream section. The upstream section may comprise a folded end. The upstream section may be the substrate portion. The inhaler article may comprise a downstream section located downstream of the upstream section. The retainer portion may be downstream from the upstream section. The downstream section may be spaced apart from the upstream section. The downstream section may comprise the retainer portion. Further, there may be multiple sections. For example, there may be an upstream section which may be a substrate portion. There may be a retainer portion downstream of the substrate portion. Optionally, there may also be a mouthpiece portion downstream of the retainer portion.

The inhaler article may comprise a cavity defined between the upstream section and the downstream section. The cavity may be configured to contain the capsule containing an inhalable material. The inhalable material may be dry powder. The dry powder may be an active ingredient. The active ingredient may be nicotine. The cavity may be configured to be in fluid communication with the exterior of the inhaler article. The cavity may include a capsule cavity, an interior cavity of the retainer portion, and optionally a mouthpiece having an internal cavity. The capsule cavity of the substrate portion, the interior cavity of the retainer portion and the optional mouthpiece having an internal cavity may abut each other to form one continuous cavity.

The Young’s modulus (or elastic modulus) of the material of the filter segment may be greater than about 10 MPa. Unless otherwise specified, the Young’s modulus of the filter segment material is measured in accordance with ASTM E111-17. The Young’s modulus (or elastic modulus) of the material of the filter segment may be greater than about 20 Mpa. The Young’s modulus (or elastic modulus) of the material of the filter segment may be greater than about 30 Mpa. The Young’s modulus (or elastic modulus) preferably refers to the Young’s modulus of the material of a component along the longitudinal axis, or direction, of the component.

The capsule may be defined by having a particular puncture strength (in Newtons). The puncture strength of the capsule refers to the particular piercing or puncture force (in Newtons) a piercing element or needle is required to exert on the capsule in order to pierce or activate the capsule. Methods for measuring the puncture strength of the capsule are known to the skilled person. For example, the puncture strength of the capsule may be measured in accordance with ASTM F1306-16. For example, the puncture strength of a sample capsule may be measured with a 3.2 mm (8 gauge) diameter piercing element or hemispherical probe. The capsule may be pierced by inserting a piercing element through the upstream end of the inhaler article and into the capsule. The piercing element may be solid. The piercing element may be hollow. The piercing element may be a needle. The piercing element may be a needle between 27 gauge (outer diameter = 0.42 mm) to 4 gauge (outer diameter = 5 mm). The piercing element may have a diameter in the range of from about 0.42 mm to about 0.9 mm. The piercing element may have a diameter in the range of from about 0.6 mm to about 0.9 mm. The piercing element may have a diameter may be in a range from about 0.6 mm to about 0.9 mm. The piercing element may have a diameter in a range from about 0.7 mm to about 0.9 mm. The piercing element may have a diameter in a range from about 0.75 mm to about 0.85 mm. The piercing element may have a diameter about 0.8 mm. The piercing element may have a bevelled piercing end. For example, the piercing element may have a single cutting plane or bevelled edge defining a cutting plane. The piercing element may have a cutting plane angle between the longitudinal axis of the piercing element and the single cutting plane. The cutting plane angle may be in a range from about 25 degrees and about 35 degrees. Preferably the cutting plane angle is in a range from about 28 degrees and about 32 degrees. Preferably the cutting plane angle is about 30 degrees. Piercing elements having these diameters and these cutting plane angles have been found to require a force of about 5 Newtons or less to activate or pierce the capsule contained in the inhaler article described herein.

The force applied on the upstream end of the capsule by the piercing element when piercing the capsule is transferred to the retainer portion. When the piercing element pushes against the capsule, this force is transferred to the retainer portion. Therefore, the retainer portion should be strong enough to remain intact when this longitudinal force is applied. In addition, the retainer portion should enable particles released from the capsule after it is pierced, and entrained in the airflow through the inhaler article, to be delivered to the mouthpiece of the inhaler article so that they can be delivered to a user. Or, the retainer portion should enable aerosol released from the substrate portion to be delivered to the user.

The retainer portion, which includes the support, may be configured to sustain a force of at least about 50% of the puncture strength of the capsule being applied to the upstream end of the retainer portion, being applied in the longitudinal direction, without deforming substantially. The retainer portion may be configured to substantially retain its structure upon the application of a longitudinal force of at least about 200% of the puncture strength of the capsule applied to the upstream end of the retainer portion. The retainer portion may be configured to withstand a force of up to about 200% of the puncture strength of the capsule being applied to the upstream end of the retainer portion in a longitudinal direction without deforming substantially. The retainer portion may be configured to sustain a force of up to about 100% of the puncture strength of the capsule being applied to the upstream end of the retainer portion without deforming substantially. The retainer portion may be configured to sustain a force of up to about 200% of the puncture strength of the capsule being applied to the upstream end of the retainer portion without deforming substantially. The retainer portion may be configured to sustain a force of at least 50% of the puncture strength of the capsule to about 100% of the puncture strength of the capsule being applied to the upstream end of the retainer portion without deforming substantially. The retainer portion may be configured to sustain a force of at least 50% of the puncture strength of the capsule to about 200% of the puncture strength of the capsule being applied to the upstream end of the retainer portion without deforming substantially. The retainer portion may be configured to sustain a force of between 50% and 200% of the force required to puncture the capsule with the piercing element. The retainer portion may be configured to sustain a force of between about 3 Newtons and about 10 Newtons.

The retainer portion may extend from the capsule cavity or the substrate portion to the downstream end of the inhaler article. In other words, the length of the downstream section of the inhaler article may be the same as the length of the retainer portion. Or, the retainer portion may be separate from a downstream section of the inhaler article. That is, there may be a mouthpiece portion between the retainer portion and the mouth end of the inhaler article.

The length of the inhaler article may be between 35 and 55 mm. The length of the inhaler article may be between 40 and 50 mm. The length of the inhaler article may be about 45 mm. The length of the retainer portion may be less than about 10 mm. The length of the retainer portion may be less than 9 mm. The length of the retainer portion may be between 4 and 10 mm. The length of the retainer portion may be between 4 and 9 mm. The length of the retainer portion may be between 5 and 9 mm. The length of the retainer portion may be between 5 and 8 mm. The length of the retainer portion may be between 10% and 40% of the length of the inhaler article. The length of the retainer portion may be between 10% and 30% of the length of the inhaler article. The length of the retainer portion may be between 10% and 25% of the length of the inhaler article. The length of the retainer portion may be between 10% and 20% of the length of the inhaler article. The length of the retainer portion may be between 20% and 40% of the length of the inhaler article. The length of the retainer portion may be between 20% and 35% of the length of the inhaler article. The length of the retainer portion may be between 20% and 30% of the length of the inhaler article. The length of the retainer portion may be 15% of the length of the inhaler article, retainer portion.

Preferably, the length of the retainer portion is between about 5 mm and 10 mm. preferably the length of the retainer portion is between 5 mm and 9 mm. Preferably, the length of the retainer portion is between 6 and 9 mm. Preferably the length of the retainer portion is between 6 and 8 mm. The retainer portion may be 7 mm. The particular geometry of the support, wherein the support is formed form a sheet of material and comprises a first flap, a first bend, a first leg, a second bend, a second leg, a third bend and a second flap, wherein the first flap of the support comprises a length and wherein the first flap of the support contacts the interior surface of the retainer portion, wherein the first leg of the support comprises a length between the first bend and the second bend, wherein the second bend comprises a tip, wherein the second leg of the support comprises a length between the second bend and the third bend, wherein the first leg, the second bend and the second leg form two legs of a triangle extending into the interior cavity of the retainer portion when the retainer portion is viewed from an upstream end of the retainer portion, wherein the support forms the second flap, wherein the second flap of the support comprises a length which contacts the interior surface of the retainer portion, and wherein the length of at least one of the first leg and the second leg is greater than the radius of the retainer portion provides a sufficient rigidity so that the length of the retainer portion can be as described above. That is, the particular geometry of the support allows the retainer portion to be shorter. A shorter retainer portion reduces the cost of the assembled inhaler article.

The inhaler article may have an outer diameter in a range from about 6 mm to about 10 mm, or from about 7 mm to about 10 mm, or from about 7 mm to about 9 mm, or from about 7 mm to about 8 mm, or about 7.2 mm. The inhaler article may have a length (along the longitudinal axis) in a range from about 30 mm to about 100 mm, or from about 40 mm to about 100 mm, or from about 40 mm to about 80 mm, or about 40 mm to about 60 mm. Preferably, the length of the inhaler article is about 45 mm. Preferably, the length of the inhaler article is selected such that the mouthpiece end of the inhaler article protrudes from a holder of the inhaler system, which is described in more detail below.

The (distal, front or upstream) end of the inhaler article may have a folded end. The folded end may fold back to expose the capsule in the cavity prior to piercing the capsule contained in the cavity. The folded end may fold back when the inhaler article is inserted into a holder having complimentary features to enable the folding of the distal end of the inhaler article.

The mouth end (downstream, proximal or mouthpiece end) of the inhaler article may have a curled end. The curled end is a toroidal shape. The toroidal shape is cut, like a bagel cut to form two round halves. The rounded side of the toroidal shape may form the mouth end of the inhaler article. The curled end has a central aperture. The curled end captures particles that do not flow through the central aperture when the inhaler article is used. The curled end prevents leakage of particles from the mouth end of the inhaler article. The inhaler article may be fitted into a holder. The piercing element may be provided by the holder. The piercing element may be inserted into the capsule and removed from the capsule by the operation of a spring in the holder. The piercing element, provided by the holder, may then be inserted into the inhaler article, piercing the capsule. The piercing element may then be retracted from the inhaler article, leaving the pierced capsule in the inhaler article.

The inhaler article may be placed in the holder. The inhaler article may be removed from the holder. The inhaler article may remain in the holder. Powder may be removed from the capsule located in the inhaler article by drawing air through inhaler article from an air inlet located at the upstream end of the inhaler article to the mouthpiece or downstream end of the inhaler article. When air is drawn through the inhaler article, from the upstream end of the inhaler article to the downstream end of the inhaler article, past the pierced capsule, particles are released from the capsule and entrained into the airflow passing through the inhaler article, delivering particles to the mouthpiece or downstream end of the inhaler article and to the user. The holder may provide a swirled airflow to the downstream end of the inhaler article to induce a rotational airflow around the capsule, enabling the capsule to rotate, and improving the release of particles from the capsule in the capsule cavity. The holder may provide a swirled airflow to the downstream end of the inhaler article to induce a rotational airflow around the capsule, agitating the capsule, and improving the release of particles from the capsule in the capsule cavity. The inhaler article may have an end plug to induce a rotational airflow around the capsule, agitating the capsule, and improving the release of particles from the capsule in the capsule cavity. The inhaler article may have an end plug to induce a rotational airflow around the capsule, rotating the capsule and improving the release of particles from the capsule in the capsule cavity.

The body of the inhaler article, or the “inhaler article”, may have any suitable shape. The body of the inhaler article, or “inhaler article” may resemble a smoking article or conventional cigarette in size and shape. The inhaler article may have a substantially uniform outer diameter along the length of the inhaler article. The inhaler article may have a substantially uniform inner diameter along the length of the inhaler article. The inhaler article may have any suitable transverse cross-sectional shape. For example, the transverse crosssection may be circular, elliptical, square or rectangular. The inhaler article preferably has a circular cross-section that may be uniform along the length of the inhaler article, forming an elongated cylindrical body.

The inhaler article may have an end plug. The end plug may be at the upstream end of the inhaler article. The end plug may provide an air inlet that creates a swirled airflow through the channel of the inhaler article extending from the upstream end of the inhaler article through the retainer portion to the mouthpiece end of the inhaler article. The end plug and the capsule may be located within the hollow tube. The channel may be formed by a capsule cavity of the substrate portion, the interior cavity of the retainer portion, and an interior cavity of a further downstream portion such as a mouthpiece portion. The interior cavities of these portions may abut each other, creating a channel extending from the capsule cavity to the downstream end of the inhaler article. The downstream end of the capsule cavity may abut the upstream end of the retainer portion. The capsule cavity, the hollow tubular element of the retainer portion, and the material of an optional downstream mouthpiece portion may be formed of a polymeric or cellulosic material, or any other suitable material.

The retainer portion of the inhaler article may be formed of a biodegradable material. Preferably, the retainer portion is formed of paperboard or cardboard. Preferably, the retainer portion is formed of paperboard or cardboard. The retainer portion may have a uniform thickness along its length. The hollow tubular element of the retainer portion may have a thickness in a range from about 1 mm to about 2 mm.

The inhaler article may comprise a filter wrapper circumscribing the substrate portion, the retainer portion and an optional mouthpiece portion. The wrapping material may be formed from a biodegradable material. The wrapping material may be formed from a paper wrapper.

The inhaler article may comprise an upstream section comprising a folded end. The folded end may define a central channel. The central channel may include a first end defining an upstream boundary of the substrate portion having a capsule cavity and a second opposing end defining the distal end of the inhaler article body. The second opposing end may define an open distal end of the inhaler article body. When the folded end is opened, the second opposing end may define an open distal end of the inhaler article body. The central channel may extend along the longitudinal axis of the inhaler article between the upstream end and the downstream end and may include the substrate portion and the retainer portion. The central channel may extend along the longitudinal axis of the inhaler article and may include the substrate portion, the retainer portion and a mouthpiece portion. The longitudinal axis may define an opening at the distal end of the inhaler article that is coaxial with the longitudinal axis of the inhaler article.

Advantageously, the inhaler article may comprise an open aperture along the longitudinal axis and may not have an element blocking or occluding the open distal end of the inhaler article, in order to reduce the complexity of the inhaler article. The consumer may simply occlude or block the open distal end with a holder or the consumer’s finger to direct inhalation air flow substantially through the air inlets on the inhaler article, once the capsule has been pierced. Air flow through the inhaler article preferably enters the inhaler article through the inhaler article upstream end via air flow inlet channels or through the open distal end of the inhaler article, and then along the longitudinal axis of the inhaler article, via the capsule cavity of the substrate portion, through the retainer portion, to exit at the mouthpiece or downstream end of the inhaler article.

The central channel may have a uniform inner or open diameter extending from the capsule cavity to the open distal end or upstream-most end of the inhaler article. The central channel may have a diameter that is at least about 50%, or at least about 70%, or at least about 75% of a diameter of the inhaler article. The central channel of the inhaler article may have a diameter that is in a range from about 50% to about 90% of a diameter of the capsule retained within the capsule cavity. The central channel may have a diameter in a range from about 3 mm to about 6.5 mm, or from about 4 mm to about 6 mm, or from about 5 mm to about 6 mm or about 5.5 mm. Alternatively, the central channel may have a diameter in a range from about 0.5 mm to about 2 mm. Such sizing of the central channel ensures that the capsule may not fall out of the inhaler article via the central channel.

As discussed above, an end plug or a holder may induce rotational air flow or swirling air flow as air is drawn through the air flow inlet channels of the end plug or the holder, and through the capsule cavity. Advantageously, this swirling air flow produced by the air flow inlet channels of the end plug or the holder is useful for effective depletion of the capsule during consumption, after the capsule has been pierced. Advantageously, the “swirling” effect may cause agitation or rotation of the capsule to provide a uniform entrainment of a portion or a fraction of nicotine particles from the capsule over two or more, or five or more, or ten or more inhalations or “puffs” by a user.

The inhalable material may comprise nicotine. Preferably, the capsule contains pharmaceutically active particles. The pharmaceutically active particles may comprise nicotine. The pharmaceutically active particles may have a mass median aerodynamic diameter of about 5 micrometers or less, or in a range from about 0.5 micrometers to about 4 micrometers, or in a range from about 1 micrometers to about 3 micrometers.

Advantageously, the inhaler article efficiently provides nicotine particles, either in form of pharmaceutically active particles or aerosol, to the lungs at inhalation or air flow rates that are within conventional smoking regime inhalation or air flow rates.

The inhaler article or system described herein may provide a dry powder to the lungs at inhalation or air flow rates that are within conventional smoking regime inhalation or air flow rates. A consumer may take a plurality of inhalations or “puffs” where each “puff” delivers a fractional amount of dry powder contained within a capsule contained within the capsule cavity. The inhaler article may have a form similar to a conventional cigarette and may mimic the ritual of conventional smoking. The inhaler article may be simple to manufacture and convenient to use by a consumer.

Air flow management through a capsule cavity of the inhaler article may cause a capsule contained therein to rotate during inhalation and consumption. The capsule may contain particles containing nicotine (also referred to as “nicotine powder” or “nicotine particles”) and optionally particles comprising flavour (also referred to as “flavour particles”). Rotation of the pierced capsule may suspend and aerosolize the nicotine particles released from the pierced capsule into the inhalation air moving through the inhaler article. The flavour particles may be larger than the nicotine particles and may assist in transporting the nicotine particles into the lungs of the user while the flavour particles preferentially remain in the mouth or buccal cavity of the user. The nicotine particles and optional flavour particles may be delivered with the inhaler article at inhalation or air flow rates that are within conventional smoking regime inhalation or air flow rates.

The term “nicotine” refers to nicotine and nicotine derivatives such as free-base nicotine, nicotine salts and the like.

The term “flavourant” or “flavour” refers to organoleptic compounds, compositions, or materials that alter and are intended to alter the taste or aroma characteristics of nicotine during consumption or inhalation thereof.

Alternatively, the substrate portion contains tobacco. The substrate portion may also have a heater. The heater may heat the tobacco, which also has an aerosolizing agent, to release aerosol containing nicotine from the substrate portion into the airflow through the retainer portion to the mouthpiece end of the inhaler article for delivery to a user. Where the substrate portion contains tobacco, the support functions to prevent a plug of tobacco from moving in the longitudinal direction in response to a force such as airflow moving in the longitudinal direction from the upstream end to the downstream end of an inhaler article.

According to an aspect of the present disclosure, there is provided an inhaler system comprising an inhaler article as described herein and a holder for receiving the inhaler article. The holder comprises a housing defining a housing cavity configured to receive the inhaler article. The holder comprises a piercing element configured to extend into the housing cavity and to pierce the capsule of the inhaler article.

The holder may comprise a piercing element extending into the housing cavity configured to pierce the capsule of the inhaler article.

The holder for an inhaler article may be combined with an inhaler article (described herein) containing a capsule. The inhaler article may be activated or primed by piercing the capsule. Piercing the capsule provides reliable activation of the capsule (by puncturing the capsule with the piercing element of the holder) within the inhaler article, releasing the particles contained inside the capsule and enabling the particles contained in the capsule to become entrained in an airflow through the inhaler article to deliver the particles to a consumer. The holder is separate from the inhaler article, but the consumer may utilize both the inhaler article and the holder while consuming the particles released within the inhaler article. A plurality of these inhaler articles may be combined with a holder to form a system or kit. A single holder may be utilized on 10 or more, or 25 or more, or 50 or more, or 100 or more, inhaler articles to activate (puncture or pierce) a capsule contained within each inhaler article and provide reliable activation. Optionally, a visual indication (marking) may be provided on each inhaler article indicating that the capsule of the inhaler article has been pierced. Such marking may indicate that the inhaler article has been used.

A holder for an inhaler article 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 sleeve comprising a sleeve cavity and being movable within the housing cavity along the longitudinal axis of the housing. The sleeve comprises a first open end and a second opposing end. The first open end is configured to receive the distal end of the inhaler article. The second opposing end of the sleeve is configured to contact the distal end of the inhaler article. The sleeve second opposing end is configured to direct substantially all inhalation air to flow through the inhaler article via the at least one air inlet extending in a direction that is non-parallel to the central channel.

The holder may include an opening structure to receive a folded distal end of the inhaler article and fold the folded end back so that the folded flaps of the distal end of the inhaler article fold back into the inhaler article, exposing the capsule in the capsule cavity to the interior of the holder.

Preferably the piercing element is fixed to and extends from a housing inner surface. The piercing element may be configured to extend through the second opposing end of the sleeve and into the capsule cavity to pierce the capsule along a longitudinal axis of the housing. The piercing element may be a metal or rigid needle. The piercing element may form a single aperture through the capsule received in the capsule cavity. The piercing element may be configured to pass through an end plug or a hollow tube of the inhaler article, precisely the central channel thereof, and into the capsule cavity.

The holder may further include a spring element configured to bias the sleeve toward the open proximal end of the housing, and between relaxed and compressed positions. The spring element may be contained within the housing cavity (also referred to as inhaler article cavity) of the holder and be compressed as the movable sleeve and inhaler article move toward the piercing element. The spring element may be located between the sleeve and distal end of the housing and contact the sleeve and distal end of the housing. The spring element may be between the distal end of the sleeve and the distal end of the housing. The spring element may contact the distal end of the sleeve and the distal end of the housing. The spring element may be disposed about the piercing element. The spring element may be co-axial with the piercing element. The spring element may be a conical spring.

The spring element biases the inhaler article away from the piercing element. In use, a user may insert an inhaler article into the inhaler article cavity of the holder. By doing this, the spring may be compressed allowing the inhaler article to move towards the distal end of the inhaler article cavity. Eventually, the piercing element may penetrate a capsule disposed within the inhaler article. Once this happens, the user may release the inhaler article, allowing the spring to bias the inhaler article towards the proximal end of the inhaler article cavity and away from the piercing element. The user may then inhale on the proximal end of the inhaler article.

The sleeve may define a first air inlet zone comprising at least one air aperture through the sleeve. The first air inlet zone is proximate to a proximal end of the sleeve. The first air inlet zone is configured to allow air to flow from an inside of the sleeve to an air flow channel formed between the sleeve and the housing inner surface. The sleeve may comprise a second air inlet zone comprising at least one air aperture through the sleeve. The second air inlet zone is proximate to a distal end of the sleeve. The second air inlet zone is configured to allow air to flow from the air flow channel to an inside of the sleeve.

The holder may include a marking element that extends into the housing (or inhaler article) cavity. The marking element may be configured to mark the surface of an inhaler article. The marking element may extend orthogonally to the holder or inhaler article longitudinal axis. The marking element may be configured to mark the outer surface of an inhaler article in a mechanical manner. For example, the marking element may be configured to scratch, cut, abrade, score, fold, or bend the outer surface of the inhaler article. The marking element may have a sharp end configured to scratch the inhaler outer surface when received within the housing cavity. The marking element may apply a colour to the inhaler article outer surface when received within the housing cavity. The marking element may mark the inhaler article outer surface when the piercing element penetrates a capsule disposed within the inhaler article. Thus, indicating that the inhaler article has been activated and may be consumed by a user. This may also advantageously prevent a user trying to reuse an inhaler article which has already been previously activated.

The marking element may extend orthogonally to the holder or inhaler article longitudinal axis. The marking element may be formed of a rigid material configured to provide a visual indication that the marking element has contacted the inhaler outer surface. The marking element may be fixed to the holder housing. The marking element may form the alignment pin, as described above.

The marking element may extend though at least a portion of a thickness of the holder. The marking element may extend through the sleeve. The marking element may extend into the housing cavity and into the sleeve. The marking element may extend beyond the at least the sleeve a marking distance so that the marking element contacts the inhaler outer surface when the inhaler article is received within the housing cavity. The marking element may be aligned with and mate with an elongated slot of the sleeve.

The inhaler article described herein may be combined with the piercing element or the holder including a piercing element to deliver the nicotine particles from the capsule to a user. The piercing element or piercing device (or holder) may be separate from or not form a portion of the inhaler article. A plurality of the inhaler articles may be combined with the piercing element or the piercing device (or holder) to form a kit.

A method includes, inserting an inhaler article into the sleeve of the holder for an inhaler article, as described herein, until the distal end of the inhaler article contacts the second opposing end of the sleeve. A method includes, inserting an inhaler article into the sleeve of the holder for an inhaler article, as described herein, until a distal folded end of the inhaler article contacts complimentary features of the holder to fold the flaps of the folded end into the distal end of the inhaler article and into the interior of the distal end of the inhaler article. The inhaler article includes a body, the body extending along an inhaler longitudinal axis from a mouthpiece end to a distal end, a body length, and a capsule disposed within the inhaler article body. Then, moving the inhaler article and sleeve toward the piercing element until the piercing element pierces the capsule. Then, moving the sleeve away from the piercing element until the piercing element is removed from the pierced capsule. Then drawing air into the second opposing end of the sleeve of the holder to direct inhalation air flow into the air inlets on the holder to form rotational or swirling air flow through the cavity of the inhaler article. This swirling inhalation air flow is transmitted into the capsule cavity while the inhaler article is disposed within the holder for an inhaler article. The swirling inhalation air flow rotates or agitates the capsule to release the particles contained therein. The particles become entrained into the airflow. The consumer inhales the particles. This may be repeated several times until the particles contained in the capsule are depleted. For example, the user may take several “puffs” to inhale the particles contained in the capsule. The consumed inhaler article may then be removed from the holder and discarded. Then a fresh inhaler article may be inserted into the holder and the method repeated.

A capsule may be sealed within the inhaler article prior to consumption. For transport and storage, the inhaler article may be contained within a sealed or airtight container or bag. The inhaler article may include one or more peelable seal layers to cover the one or more air inlet channels at the distal end or the air outlet at the mouthpiece end of the inhaler article. This may ensure the inhaler articles maintain appropriate hygiene and freshness or may prevent the capsule from drying out and becoming hard or friable. The retainer portion may increase the rigidity of the inhaler article as it is manufactured, packaged, transported, stored, removed from packaging, inserted into a holder, used and discarded.

The capsule may rotate about its longitudinal or central axis when air is drawn through the inhaler article. The capsule may be formed of an airtight material that substantially contains the particles inside the capsule. The capsule may be configured to be pierced or punctured by a piercing element when the capsule is within the capsule cavity. The piercing element may be separate from or combined with the inhaler article. The capsule may be formed of any suitable material. The capsule may be formed of a metallic or polymeric material that serves to keep contaminants out of the capsule but may be pierced or punctured by a piercing element prior to consumption to enable the release of the nicotine particles from within the capsule. The capsule may be formed of a polymer material. The polymer material may be hydroxypropylmethylcellulose (HPMC). The capsule may be any suitable size. The capsule may be a size 1 to size 4 capsule, or a size 3 capsule, or a size 3 capsule.

The capsule may contain pharmaceutically active particles comprising nicotine (also referred to as “nicotine powder” or “nicotine particles”) and optionally particles comprising flavour (also referred to as “flavour particles). The capsule may contain a predetermined amount of nicotine particles and optional flavour particles. The capsule may contain enough nicotine particles to provide at least 2 inhalations or “puffs”, or at least about 5 inhalations or “puffs”, or at least about 10 inhalations or “puffs”. The capsule may contain enough nicotine particles to provide from about 5 to about 50 inhalations or “puffs”, or from about 10 to about 30 inhalations or “puffs”. Each inhalation or “puff’ may deliver from about 0.1 mg to about 3 mg of nicotine particles to the lungs of the user or from about 0.2 mg to about 2 mg of nicotine particles to the lungs of the user or about 1 mg of nicotine particles to the lungs of the user.

The nicotine particles may have any useful concentration of nicotine based on the particular formulation employed. The nicotine particles may have at least about 1 %wt nicotine up to about 30%wt nicotine, or from about 2%wt to about 25%wt nicotine, or from about 3%wt to about 20%wt nicotine, or from about 4%wt to about 15%wt nicotine, or from about 5%wt to about 13%wt nicotine. Preferably, about 50 to about 150 micrograms of nicotine may be delivered to the lungs of the user with each inhalation or “puff”.

The capsule may hold or contain at least about 5 mg of nicotine particles or at least about 10 mg of nicotine particles. The capsule may hold or contain less than about 900 mg of nicotine particles, or less than about 300 mg of nicotine particles, or less than 150 mg of nicotine particles. The capsule may hold or contain from about 5 mg to about 300 mg of nicotine particles or from about 10 mg to about 200 mg of nicotine particles.

When flavour particles are blended or combined with the nicotine particles within the capsule, the flavour particles may be present in an amount that provides the desired flavour to each inhalation or “puff” delivered to the user.

The nicotine particles may have any useful size distribution for inhalation delivery preferentially into the lungs of a user. The capsule may include particles other than the nicotine particles. The nicotine particles and the other particles may form a powder system.

The capsule may hold or contain at least about 5 mg of a dry powder (also referred to as a powder system) or at least about 10 mg of a dry powder. The capsule may hold or contain less than about 900 mg of a dry powder, or less than about 300 mg of a dry powder, or less than about 150 mg of a dry powder. The capsule may hold or contain from about 5 mg to about 300 mg of a dry powder, or from about 10 mg to about 200 mg of a dry powder, or from about 25 mg to about 100 mg of a dry powder.

The dry powder or powder system may have at least about 40%, or at least about 60%, or at least about 80%, by weight of the powder system comprised in nicotine particles having a particle size of about 5 micrometers or less, or in a range from about 1 micrometer to about 5 micrometers.

The particles comprising nicotine may have a mass median aerodynamic diameter of about 5 micrometers or less, or in a range from about 0.5 micrometers to about 4 micrometers, or in a range from about 1 micrometers to about 3 micrometers or in a range from about 1.5 micrometers to about 2.5 micrometers. The mass median aerodynamic diameter is preferably measured with a cascade impactor.

The particles comprising flavour may have a mass median aerodynamic diameter of about 20 micrometers or greater, or about 50 micrometers or greater, or in a range from about 50 to about 200 micrometers, or from about 50 to about 150 micrometers. The mass median aerodynamic diameter is preferably measured with a cascade impactor.

The dry powder may have a mean diameter of about 60 micrometers or less, or in a range from about 1 micrometers to about 40 micrometers, or in a range from about 1.5 micrometers to about 25 micrometers. The mean diameter refers to the mean diameter per mass and is preferably measured by laser diffraction, laser diffusion or an electronic microscope.

Nicotine in the powder system or nicotine particles may be a pharmaceutically acceptable free-base nicotine, or nicotine salt or nicotine salt hydrate. Useful nicotine salts or nicotine salt hydrates include nicotine pyruvate, nicotine citrate, nicotine aspartate, nicotine lactate, nicotine bitartrate, nicotine salicylate, nicotine fumarate, nicotine mono-pyruvate, nicotine glutamate or nicotine hydrochloride, for example. The compound combining with nicotine to form the salt or salt hydrate may be chosen based on its expected pharmacological effect.

The nicotine particles preferably include an amino acid. Preferably the amino acid may be leucine such as L-leucine. Providing an amino acid such as L-leucine with the particles comprising nicotine, may reduce adhesion forces of the particles comprising nicotine and may reduce attraction between nicotine particles and thus reduce agglomeration of nicotine particles. Similarly, adhesion forces to particles comprising flavour may also be reduced thus agglomeration of nicotine particles with flavour particles is also reduced. The powder system described herein thus may be a free-flowing material and possess a stable relative particle size of each powder component even when the nicotine particles and the flavour particles are combined.

Preferably, the nicotine is a surface modified nicotine salt where the nicotine salt particle comprises a coated or composite particle. A preferred coating or composite material may be L-leucine. One particularly useful nicotine particle may be nicotine bitartrate with L- leucine.

The powder system may include a population of flavour particles. The flavour particles may have any useful size distribution for inhalation delivery selectively into the mouth or buccal cavity of a user.

The powder system may have at least about 40%, or at least about 60%, or at least about 80%, by weight of the population of flavour particles of the powder system comprised in particles having a particle size of about 20 micrometers or greater. The powder system may have at least about 40% or at least about 60%, or at least about 80%, by weight of the population of flavour particles of the powder system comprised in particles having a particle size of about 50 micrometers or greater. The powder system may have at least about 40% or at least about 60%, or at least about 80%, by weight of the population of flavour particles of the powder system comprised in particles having a particle size in a range from about 50 micrometer to about 150 micrometers.

The particles comprising flavour may include a compound to reduce adhesion forces or surface energy and resulting agglomeration. The flavour particle may be surface modified with an adhesion reducing compound to form a coated flavour particle. One preferred adhesion reducing compound may be magnesium stearate. Providing an adhesion reducing compound such as magnesium stearate with the flavour particle, especially coating the flavour particle, may reduce adhesion forces of the particles comprising flavour and may reduce attraction between flavour particles and thus reduce agglomeration of flavour particles. Thus, agglomeration of flavour particles with nicotine particles may also be reduced. The powder system described herein thus may possess a stable relative particle size of the particles comprising nicotine and the particles comprising flavour even when the nicotine particles and the flavour particles are combined. The powder system preferably may be free flowing.

Conventional formulations for dry powder inhalation contain carrier particles that serve to increase the fluidization of the active particles since the active particles may be too small to be influenced by simple air flow though the inhaler. The powder system may comprise carrier particles. These carrier particles may be a saccharide such as lactose or mannitol that may have a particle size greater than about 50 micrometers. The carrier particles may be utilized to improve dose uniformity by acting as a diluent or bulking agent in a formulation.

The powder system utilized with the nicotine powder delivery system described herein may be carrier-free or substantially free of a saccharide such as lactose or mannitol. Being carrier-free or substantially free of a saccharide such as lactose or mannitol may allow the nicotine and to be inhaled and delivered to the user’s lungs at inhalation or air flow rates that are similar to typical smoking regime inhalation or air flow rates.

The nicotine particles and a flavour may be combined in a single capsule. As described above, the nicotine particles and a flavour may each have reduced adhesion forces that result in a stable particle formulation where the particle size of each component does not substantially change when combined. Alternatively, the powder system includes nicotine particles contained within a single capsule and the flavour particles contained within a second capsule.

The nicotine particles and flavour particles may be combined in any useful relative amount so that the flavour particles are detected by the user when consumed with the nicotine particles. Preferably the nicotine particles and flavour particles form at least about 90%wt or at least about 95%wt or at least about 99%wt or 100%wt of the total weight of the powder system.

The inhaler and inhaler system may be less complex and have a simplified air flow path as compared to conventional dry powder inhalers. Advantageously, rotation of the capsule within the inhaler article aerosolizes the nicotine particles or powder system and may assist in maintaining a free-flowing powder. Thus, the inhaler article may not require the elevated inhalation rates typically utilized by conventional inhalers to deliver the nicotine particles described above deep into the lungs.

The inhaler article may use a flow rate of less than about 5 L/min or less than about 3 L/min or less than about 2 L/min or about 1 .6 L/min. Preferably, the flow rate may be in a range from about 1 L/min to about 3 L/min or from about 1.5 L/min to about 2.5 L/min. Preferably, the inhalation rate or flow rate may be similar to that of Health Canada smoking regime, that is, about 1.6 L/min. The inhaler system may be used by a consumer like smoking a conventional cigarette or vaping an electronic cigarette. Such smoking or vaping may be characterized by two steps: a first step during which a small volume containing the full amount of nicotine desired by the consumer is drawn into the mouth cavity, followed by a second step during which this small volume comprising the aerosol comprising the desired amount of nicotine is further diluted by fresh air and drawn deeper into the lungs. Both steps are controlled by the consumer. During the first inhalation step the consumer may determine the amount of nicotine to be inhaled. During the second step, the consumer may determine the volume for diluting the first volume to be drawn deeper into the lungs, maximizing the concentration of active agent delivered to the airway epithelial surface. This smoking mechanism is sometimes called “puff-inhale- exhale”.

The dry powder utilized with the dry powder inhaler of the disclosure may eliminate or substantially reduce any exhalation of pharmaceutically active particles during the “exhale” phase. Preferably nearly all, or at least about 99% or at least about 95% or at least 90% of the pharmaceutically active particle has a particle size that is delivered to the lungs but are not small enough to be exhaled by tidal breathing. This pharmaceutically active particle size may be in a range from about 0.75 micrometers to about 5 micrometers, or from 0.8 micrometers to about 3 micrometers, or from 0.8 micrometers to about 2 micrometers.

As noted above, the inhaler article comprises a retainer portion, which comprises a hollow tubular element having a length “I”, a radius “r”, a central axis, and an interior surface defining an interior cavity, hollow tubular element and a support formed from a sheet and extending from a first and second point at the interior surface into the interior cavity of the retainer portion to form a triangular support in the interior cavity of the retainer portion.

The hollow tubular element of the retainer portion may be formed from a sheet of material. The hollow tubular element of the retainer portion and the support may be formed from separate sheets of material.

The retainer portion may comprise a hollow tubular element or a tube. The tube may be distinct from the sheet which forms the support. The tube may be formed from a sheet that is the same material or a different material as the sheet of material which forms the support. For example, the tube of the retainer portion may comprise a tube which is distinct from the sheet that forms the support element. The support is a structure in the interior cavity of the retainer portion. The support is formed from a sheet of material and comprises a first flap, a first bend, a first leg, a second bend, a second leg, a third bend and a second flap; wherein the first flap of the support comprises a length and wherein the first flap of the support contacts the interior surface of the retainer portion; wherein the first leg of the support comprises a length between the first bend and the second bend; wherein the second bend comprises a tip; wherein the second leg of the support comprises a length between the second bend and the third bend; wherein the first leg, the second bend and the second leg form two legs of a triangle extending into the interior cavity of the retainer portion when the retainer portion is viewed from an upstream end of the retainer portion; wherein the support forms the second flap, wherein the second flap of the support comprises a length which contacts the interior surface of the retainer; wherein the length of at least one of the first leg and the second leg is greater than the radius of the retainer portion.

The retainer portion may comprise a hollow tubular element or a tube. The tube may be distinct from the sheet which forms the support. The tube may be formed from a sheet that is the same material or a different material as the sheet of material which forms the support. For example, the tube of the retainer portion may comprise a tube which is distinct from the sheet that forms the support element. The support is a structure in the interior cavity of the retainer portion. The support is formed from a sheet of material and comprises a first flap, a first bend, a first leg, a second bend, a second leg, a third bend and a second flap; wherein the first flap of the support comprises a length and wherein the first flap of the support contacts the interior surface of the retainer portion; wherein the first leg of the support comprises a length between the first bend and the second bend; wherein the second bend comprises a tip; wherein the second leg of the support comprises a length between the second bend and the third bend; wherein the first leg, the second bend and the second leg form two legs of a triangle extending into the interior cavity of the retainer portion when the retainer portion is viewed from an upstream end of the retainer portion; wherein the support forms the second flap, wherein the second flap of the support comprises a length which contacts the interior surface of the retainer; wherein the length of the first leg and the second leg are both greater than the radius of the retainer portion.

The first leg and the second leg may be equal to each other, within manufacturing tolerances. For example, the tip of the support may be spaced apart from the central axis of the retainer portion by ±0.5mm. The tip of the support may be spaced apart from the central axis to the left or right by ±0.5mm and the first leg and second leg may still be considered equal, within manufacturing tolerances.

The first flap and the second flap of the support may be attached to the hollow tubular element of the retainer portion by an adhesive where the first and second flaps of the support are in contact with the tube of the retainer portion.

The hollow tubular element may form an outer structure of the retainer portion. Substantially the entirety of the portion of the sheet forming the hollow tubular element may form an outer surface of the retainer portion. An outer surface of the retainer portion may be curved. The retainer portion may be cylindrical. The support element may extend along part of the length of the retainer portion. Preferably, the support is flush with the upstream end of the retainer portion. This means that the support may be at the end of the retainer portion closest to the capsule. As such, the support element may be better able to prevent or restrict movement of the capsule, for example when the capsule is being pierced. Preferably, the support element extends to the downstream end of the retainer portion. The support element may extend along between about 10 percent and about 100 percent of the length of the retainer portion, preferably along between about 25 percent and about 100 percent of the length of the retainer portion, more preferably along between about 50 and about 100 percent of the length of the retainer portion. Most preferably, the support element extends along substantially the entire length of the retainer portion. As such, the support element may have a length equal to the length of the retainer portion. This may provide the retainer portion with additional mechanical strength and stiffness along the entire length of the retainer portion.

The first flap and the second flap of the support may be attached to the interior surface of the retainer portion. At the first bend and the third bend, the support extends into the interior cavity of the retainer portion when the retainer portion is viewed from an upstream end of the retainer portion. Advantageously, this may simplify manufacturing of the retainer portion and may provide a suitable support barrier for one or more substrate components disposed upstream of the retainer portion, such as the capsule.

The first flap and the second flap of the support may be attached to the interior surface of the retainer portion by adhesive. The use of an adhesive can help to improve the mechanical strength of the retainer portion in one or both of the longitudinal direction and the transverse direction. As such, this can help to improve the retainer portion’s ability to provide a support barrier and its resistance to collapse or deformation.

The sheet of material of the support extends from the interior surface of the retainer portion at the first bend and the third bend. The first leg and the second leg form two sides of a triangle that extends into the interior cavity of the retainer portion. The first leg and the second leg form an angle at the second bend. The second bend forms a tip. The tip may comprise an angle of less than 90 degrees. The tip may comprise an angle of less than 70 degrees. The tip may comprise an angle of less than 67.5 degrees. The tip may comprise an angle of less than 45 degrees. The tip may comprise an angle of less than 40 degrees. The tip may comprise an angle of between 22 degrees and 68 degrees. The tip may comprise an angle of between 22.5 degrees and 67.5 degrees. The tip may comprise an angle of between 30 degrees and 45 degrees. The tip may comprise an angle of between 30 degrees and 44 degrees. The tip may comprise an angle of between 32.5 degrees and 43.5 degrees. The tip may comprise an angle of 37.5 degrees plus or minus 5 degrees. The tip may comprise an angle of 37.5 degrees.

The retainer portion is structured and arranged to provide the retainer portion with sufficient mechanical strength and stiffness in one or both of the longitudinal direction and the transverse direction to prevent or restrict movement of one or more components disposed upstream of the retainer portion, such as the capsule, without significant deformation of the retainer portion during use of the inhaler article. This mechanical strength and stiffness, or rigidity of the retainer portion also supports the inhaler article as it is manufactured, packaged, shipped, removed from packaging, inserted into a holder, used and discarded.

The first flap and the second flap each have a length. Preferably, the first flap and the second flap have approximately equal lengths. Advantageously, the first and second flaps having approximately equal lengths provides approximately equal reinforcement to the retainer portion along the length of the first flap and along the length of the second flap. The length of the first flap and the second flap may be approximately equal to the radius of the retainer portion. The length of the first flap and the second flap may be less than the radius of the retainer portion. Preferably, the length of the first flap and the second flap is less than the radius of the retainer portion. The length of the first and second flap may be, for example, less than 4.5 mm where the diameter of the inhaler article is approximately 7 mm. The length of the first and second flap may be between 2 mm and 4.5 mm. The length of the first and second flap may be between 2 mm and 4 mm. The length of the first and second flap may be between 2.3 mm and 3.5 mm. The length of the first and second flap may be between 2.5 mm and 3.3 mm. The length of the first and second flap may be 2.7 mm plus or minus 1 mm. the length of the first and second flap may be 2.7 mm. The inventors have found that if the length of the first flap and the second flap is less than the radius of the retainer, the retainer portion retains its round shape, or is less likely to deform from round.

The first bend of the support and the third bend of the support may be spaced apart from each other. The first bend and the second bend may by spaced apart from each other by less than 4 mm. The first bend and the second bend may by spaced apart from each other by less than 3 mm. The first bend and the second bend may by spaced apart from each other by between 2 mm and 4 mm. The first bend and the second bend may by spaced apart from each other by between 2.25mm and 2 mm. The first bend and the second bend may by spaced apart from each other by between 2.5 mm and 3 mm. The first bend and the second bend may by spaced apart from each other by 2.7 mm plus or minus 1 mm. The first bend and the second bend may be spaced apart from each other by 2.7 mm.

The first bend and the second bend may by spaced apart from each other by less than 30% of the circumference of the retainer portion. The first bend and the second bend may by spaced apart from each other by less than 25% of the circumference of the retainer portion. The first bend and the second bend may by spaced apart from each other by less than 20% of the circumference of the retainer portion. The first bend and the second bend may by spaced apart from each other by between 10% and 30% of the circumference of the retainer portion. The first bend and the second bend may be spaced apart from each other by between 15% and 30% of the circumference of the retainer portion. The first bend and the second bend may be spaced apart from each other by between 20% and 30% of the circumference of the retainer portion.

The first bend at the interior surface of the retainer portion and the third bend at the interior surface of the hollow tubular element of the retainer portion may be spaced apart from each other around the circumference of the retainer portion by between about 5 percent and about 50 percent of the circumference of the retainer portion, preferably between 10 percent and about 40 percent of the circumference of the retainer portion, more preferably between about 15 percent and about 30 percent of the circumference of the retainer portion.

The first flap and the second flap may be attached to the interior surface of the retainer portion. The first flap and the second flap may be attached to the interior surface of the hollow tubular element of the retainer portion by an adhesive. The use of an adhesive can help to improve the mechanical strength of the retainer portion in one or both of the longitudinal direction and the transverse direction. As such, this can help to improve the retainer portion’s resistance to collapse or deformation. This can help to improve the rigidity of the retainer portion.

The support may comprise a tip, the tip being positioned within the interior cavity of the retainer portion. The tip is the second bend. The second bend is a tip. The tip may extend into the interior cavity of the retainer portion by the length of the first leg and the second leg. The tip is an angle formed at the intersection of the first leg and the second leg. The tip may be spaced apart from the interior surface of the retainer at the first bend by the length of the first leg. The tip may be spaced apart from the interior surface of the retainer at the second bend by the length of the second leg. At least one of the first leg or the second leg is longer than the radius of the retainer portion.

The first leg or the second leg, or both the first leg and the second leg may be longer than the radius of the retainer portion by retainer portion by about 0.2 millimeters or more. The first leg or the second leg, or both the first leg and the second leg may be longer than the radius of the retainer portion by about 0.5 millimeters or more. The first leg or the second leg, or both the first leg and the second leg may be longer than the radius of the retainer portion by about 1 millimeter or more. The first leg or the second leg, or both the first leg and the second leg may be longer than the radius of the retainer portion by about 3 millimeters or less. The first leg or the second leg, or both the first leg and the second leg may be longer than the radius of the retainer portion by about 2.5 millimeters or less. The first leg or the second leg, or both the first leg and the second leg may be longer than the radius of the retainer portion by about 2 millimeters or less.

The first leg or the second leg, or both the first leg and the second leg may be longer than the radius of the retainer portion retainer portion by between about 0.2 millimeters and about 3 millimeters. The first leg or the second leg, or both the first leg and the second leg may be longer than the radius of the retainer portion by between about 0.5 millimeters and about 2.5 millimeters. The first leg or the second leg, or both the first leg and the second leg may be longer than the radius of the retainer portion by between about 1 millimeter and about 2 millimeters. The first leg or the second leg, or both the first leg and the second leg may be longer than the radius of the retainer portion by about 1 .5 millimeters. The tip may reside at a point which is adjacent to a point at the interior surface of the hollow tubular element of the retainer portion. The tip may be in contact with the interior surface of the hollow tubular element of the retainer portion. The tip may be positioned about equidistant from the first bend and the third bend.

As used herein, the term “radial centre” is used to refer to the centre of a transverse cross section of the retainer portion and is the same as the central axis. The tip may be pointed. For example, the support element may have a substantially triangular cross section where the tip is the vertex of the triangle which extends into the interior cavity of the retainer portion.

The term “substantially triangular” is used to describe the shape of the first leg, the second bend (or the tip) and the second leg, which form a shape that can be described as two sides of a triangle, extending into the interior cavity of the hollow tubular portion. The first leg of the support comprises a length between the first bend and the second bend. The second bend comprises the tip. The second leg of the support comprises a length between the second bend and the third bend. The first leg, the second bend and the second leg form two legs of a triangle extending into the interior cavity of the retainer portion when the retainer portion is viewed from an upstream end of the retainer portion.

The term “substantially triangular” is used for the purpose of describing the support. In describing the “substantially triangular” shape of the support, the third side of the triangle may not be present. Or, the third side of the “substantially triangular” shape may be an imaginary line between the first bend and the third bend. Or, the third side of the “substantially triangular” shape may formed by the interior surface of the hollow tubular element, although this makes the third side of the triangle curved. However, the shape of the support extending into the interior cavity of the retainer portion is best described as being two sides of a triangle. However, while the support may not form a three-sided triangle, the first leg, the second bend (or the tip) and the second leg form two sides of a triangle-shaped projection that extends into the interior cavity of the retainer portion.

The support does not form an actual triangle (defined as a closed, 2-dimensional shape with three sides, three angles, and 3 vertices), because the support does not connect the first bend and the second bend to form the third side of a triangle. Instead, the support extends along the interior surface of the hollow tubular portion at the first bend and the third bend, to form the first flap and the second flap. However, while the support may not form a three-sided triangle, the first leg, the second bend (or the tip) and the second leg form two sides of a triangle-shaped projection that extends into the interior cavity of the retainer portion. That is, the first leg, the second bend and the second leg form two legs of a triangle extending into the interior cavity of the retainer portion when the retainer portion is viewed from an upstream end of the retainer portion.

The support element may comprise three bends. That is, the sheet forming the support element may comprise a first bend at the interior surface of the hollow tubular element of the retainer portion, a second bend which is the tip, and a third bend at a second point on the interior surface of the hollow tubular element of the retainer portion. This may further strengthen the retainer portion in one or both of the longitudinal direction and the transverse direction to enable the retainer portion to withstand larger forces being applied to it in one or both of the longitudinal direction and the transverse direction before deforming substantially. As such, this may improve the retainer portion’s ability to prevent or restrict movement of one or more components disposed upstream of the retainer portion, such as the capsule.

The tip of the support may be positioned about equidistant from the first bend and the third bend. The tip may be positioned closer to the first bend than the third bend. That is, the first leg and the second leg may be of different lengths. Preferably, the first leg and the second leg have the same or essentially the same length. The first leg and the second leg may be substantially planar. That is, the first leg and the second leg may not be curved.

As such, a cross section of the retainer portion may show a triangle extending into the interior cavity of the retainer portion when the retainer portion is viewed from an upstream end of the retainer portion.

The support may be wholly enclosed by the hollow tubular element of the retainer portion and therefore, does not form an outer surface of the retainer portion. The angle defined by the intersection of the first leg and the second leg (the second bend or the tip) may be about 50 degrees or less. The angle defined by the intersection of the first leg and the second leg (the second bend or the tip) may be about 45 degrees or less. The angle defined by the intersection of the first leg and the second leg (the second bend or the tip) may be about 35 degrees or less. The angle defined by the intersection of the first leg and the second leg (the second bend or the tip) may be between about 5 degrees and about 50 degrees. The angle defined by the intersection of the first leg and the second leg (the second bend or the tip) may be between about 10 degrees and about 45 degrees. The angle defined by the intersection of the first leg and the second leg (the second bend or the tip) may be between about 15 degrees and about 40 degrees. The angle defined by the intersection of the first leg and the second leg (the second bend or the tip) may be between about 20 degrees and about 40 degrees. The angle defined by the intersection of the first leg and the second leg (the second bend or the tip) may be between about 25 degrees and 40 degrees. The angle defined by the intersection of the first leg and the second leg (the second bend or the tip) may be about 35 degrees and about 42 degrees. The angle defined by the intersection of the first leg and the second leg (the second bend or the tip) may be between about 32.5 degrees and 43.5 degrees. The angle defined by the intersection of the first leg and the second leg (the second bend or the tip) may be 37.5 degrees plus or minus 5 degrees.

The first flap of the support comprises a length which contacts the interior surface of the retainer portion. The second flap of the support comprises a length which contacts the interior surface of the retainer portion. The first flap and the second flap of the support contact the interior surface of the retainer portion. The first flap of the support may be attached to the interior surface of the retainer portion by an adhesive. The second flap of the support may be attached to the interior surface of the retainer portion by an adhesive. The first and second flaps of the support may be attached to the interior surface of the retainer surface by an adhesive. The use of an adhesive can help to improve the mechanical strength of the retainer portion in one or both of the longitudinal direction and the transverse direction. As such, this can help to improve the retainer portion’s resistance to collapse or deformation and the retainer portion’s ability to prevent or restrict movement of one or more components disposed upstream of the retainer portion, such as the capsule. In addition, the triangle shape formed by the first leg, the second bend and the third leg can help to improve the mechanical strength of the retainer portion in one or both of the longitudinal direction and the transverse direction. As such, this can help to improve the retainer portion’s resistance to collapse or deformation and the retainer portion’s ability to prevent or restrict movement of one or more components disposed upstream of the retainer portion, such as the capsule. The retainer portion may comprise at least one longitudinal plane of symmetry. The retainer portion may be radially symmetric. This may simplify assembling of the inhaler article, since the orientation in which the retainer portion is disposed in the inhaler article may be less important. In addition, this may also mean that the retainer portion is able to distribute load more evenly to be able to withstand increased forces being applied to it.

Preferably, the cross-sectional area of the retainer portion is substantially constant along the entire length of the retainer portion. This may be such that the resistance to draw of the inhaler article is also constant along the entire length of the retainer portion.

Preferably, the retainer portion has a substantially constant cross section along the entire length of the retainer portion. That is, the cross section of the retainer portion does not change substantially along the entire length of the retainer portion. This may simplify manufacturing of the retainer portion. Alternatively, the cross section of the retainer portion may vary along the length of the retainer portion. For example, the support may have a cross section that varies along the length of the retainer portion. For instance, the support may not extend along the entire length of the retainer portion.

The support may divide the hollow inner region of the retainer portion into a plurality of channels. The number of channels may be selected based on a desired nucleation of aerosol particles and a desired resistance to draw of the inhaler article. The support element may divide the cavity of the retainer portion into two channels. When the tip does not contact the interior surface of the retainer, the support element divides the cavity of the retainer portion into two channels. The support element may divide the cavity of the retainer portion into three channels. If the tip of the support contacts the interior surface of the retainer portion, the cavity may be divided into three channels.

The tip of the support element may be spaced apart from the radial centre of the retainer portion by a distance of about 5 percent or more of the radius of the retainer portion. The tip of the support element may be spaced apart from the radial centre of the retainer portion by a distance of about 5 percent or more of the radius of the retainer portion by about 10 percent or more of the radius of the retainer portion. The tip of the support element may be spaced apart from the radial centre of the retainer portion by a distance of about 5 percent or more of the radius of the retainer portion by about 15 percent or more of the radius of the retainer portion.

The tip of the support may be spaced apart from the radial centre of the retainer portion by a distance of about 5 percent or more of the radius of the retainer portion by a distance of about 90 percent or less of the radius of the retainer portion. The tip of the support may be spaced apart from the radial centre of the retainer portion by a distance of about 5 percent or more of the radius of the retainer portion by about 80 percent or less of the radius of the retainer portion. The tip of the support may be spaced apart from the radial centre of the retainer portion by a distance of about 5 percent or more of the radius of the retainer portion by about 70 percent or less of the radius of the retainer portion.

The tip of the support may be spaced apart from the radial centre of the retainer portion by a distance of between about 5 percent and about 90 percent of the radius of the retainer portion. The tip of the support may be spaced apart from the radial centre of the retainer portion by a distance of the tip of the support may be spaced apart from the radial centre of the retainer portion by a distance of between about 10 percent and about 80 percent of the radius of the retainer portion. The tip of the support may be spaced apart from the radial centre of the retainer portion by a distance of about 15 percent and about 70 percent of the radius of the retainer portion.

The tip of the support may be spaced apart from the radial centre of the retainer portion by a distance of about 0.2 millimeters or more. The tip of the support may be spaced apart from the radial centre of the retainer portion by a distance of about 0.5 millimeters or more. The tip of the support may be spaced apart from the radial centre of the retainer portion by a distance of about 1 millimeter or more. The tip of the support may be spaced apart from the radial centre of the retainer portion by a distance of about 1 .2 millimeters plus or minus .5 millimeters.

The tip of the support may be spaced apart from the radial centre of the retainer portion by a distance of about 3 millimeters or less. The tip of the support may be spaced apart from the radial centre of the retainer portion by a distance of about 2.5 millimeters or less. The tip of the support may be spaced apart from the radial centre of the retainer portion by a distance of about 2 millimeters or less. The tip of the support may be spaced apart from the radial centre of the retainer portion by a distance of about 1 .5 millimeter or less.

The tip of the support may be spaced apart from the radial centre of the retainer portion by a distance of between about 0.2 millimeters and about 3 millimeters. The tip of the support may be spaced apart from the radial centre of the retainer portion by a distance of between about 0.5 millimeters and about 2.5 millimeters. The tip of the support may be spaced apart from the radial centre of the retainer portion by a distance of about 1 millimeter. The tip of the support may be spaced apart from the radial centre of the retainer portion by a distance of about 2 millimeters. The tip of the support may be spaced apart from the radial centre of the retainer portion by a distance of between about 0.5 millimeters and about 1 millimeter.

The support element may have a depth equal to about the inner radius of the retainer portion. That is, at least one of the first leg and the second leg may have a length greater than the radius of the retainer portion. The first leg and the second leg may have a length greater than the radius of the retainer portion. As used herein, the term “depth” denotes the distance between the first bend at the interior surface of the retainer portion and the tip (the second bend) of the support. This is the length of the first leg. Or, “depth” denotes the distance between the tip (the second bend) and the third bend. This is the length of the second leg. Therefore, the term “depth” denotes the length of either the first or the second leg. The first and the second leg may have essentially equal lengths.

The support element may be the only support element of the retainer portion. That is, the retainer portion may comprise a single support element.

The retainer portion preferably has an outer diameter that is approximately equal to the outer diameter of the inhaler article.

The retainer portion may have an outer diameter of about 5 millimeters or more. The retainer portion may have an outer diameter of about 6 millimeters or more. The retainer portion may have an outer diameter of about 7 millimeters or more. The retainer portion may have an outer diameter of about 12 millimeters or less. The retainer portion may have an outer diameter of about 10 millimeters or less. The retainer portion may have an outer diameter of about 8 millimeters or less.

The retainer portion may have an outer diameter of between about 5 millimeters and about 12 millimeters. The retainer portion may have an outer diameter of between about 6 millimeters and about 10 millimeters. The retainer portion may have an outer diameter of between about 7 millimeters and about 8 millimeters. The retainer portion may have an outer diameter of about 7.2 millimeters.

The hollow tubular element of the retainer portion has a thickness. Therefore, the inner diameter of the retainer portion may be less than the outer diameter of the retainer portion. The retainer portion may have an inner diameter of about 4.5 millimeters or more. The retainer portion may have an inner diameter of about 5.5 millimeters or more. The retainer portion may have an inner diameter of about 6.5 millimeters or more. The retainer portion may have an inner diameter of about 11.5 millimeters or less. The retainer portion may have an inner diameter of about 9.5 millimeters or less. The retainer portion may have an inner diameter of about 7.5 millimeters or less. The retainer portion may have an inner diameter of between about 4.5 millimeters and about 11.5 millimeters. The retainer portion may have an inner diameter of between about 5.5 millimeters and about 9.5 millimeters The retainer portion may have an inner diameter of between about 6.5 millimeters and about 7.5 millimeters.

The hollow tubular element of the retainer portion may have a total internal surface area of about 25 millimeters squared per millimeter length or more, preferably about 28 millimeters squared per millimeter length or more, more preferably about 30 millimeters squared per millimeter length or more, or about 35 millimeters squared per millimeter length or more.

The hollow tubular element of the retainer portion may have a total internal surface area of about 70 millimeters squared per millimeter length or less, preferably about 60 millimeters squared per millimeter length or less, more preferably about 50 millimeters squared per millimeter length or less, or about 40 millimeters squared per millimeter length or less.

The hollow tubular element of the retainer portion may have a total internal surface area of between about 25 millimeters squared per millimeter length and about 70 millimeters squared per millimeter length, preferably between about 28 millimeters squared per millimeter length and about 60 millimeters squared per millimeter length, more preferably between about 30 millimeters squared per millimeter length and about 50 millimeters squared per millimeter length, or between about 30 millimeters squared per millimeter length and about 40 millimeters squared per millimeter length. The hollow tubular element of the retainer portion may have a total internal surface area of between about 35 millimeters squared per millimeter length and about 70 millimeters squared per millimeter length, preferably between about 40 millimeters squared per millimeter length and about 70 millimeters squared per millimeter length, more preferably between about 50 millimeters squared per millimeter length and about 70 millimeters squared per millimeter length, or between about 60 millimeters squared per millimeter length and about 70 millimeters squared per millimeter length.

The retainer portion may provide an unrestricted flow channel. This means that the hollow tubular segment preferably provides a negligible level of resistance to draw (RTD). The term “negligible level of RTD” is used to describe an RTD of less than 1 mm H2O per 10 millimeters of length of the retainer portion, preferably less than 0.4 mm H2O per 10 millimeters of length of the retainer portion, more preferably less than 0.1 mm H2O per 10 millimeters of length of the retainer portion. The profile of the support, in the shape of a triangle extending into the interior cavity of the retainer portion when the retainer portion is viewed from an upstream end of the retainer portion, provides negligible obstruction to the flow of air and particles through the retainer portion. Therefore, the flow channel is essentially free from any components that would obstruct the flow of air in a longitudinal direction. Preferably, the flow channel is substantially empty.

The retainer portion may have a porosity of about 90 percent or more in the longitudinal direction.

As used herein, the porosity of the retainer portion in the longitudinal direction is defined by the ratio of the cross-sectional area of material forming the retainer portion and the internal cross-sectional area of the inhaler article at the position of the retainer portion. The porosity in the longitudinal direction of the retainer portion may advantageously be selected in order to provide a desirable overall resistance to draw of the inhaler article.

The porosity in the longitudinal direction of the retainer portion may be substantially constant along the entire length of the retainer portion. For example, the cross-sectional area of material forming the retainer portion may be substantially constant along the entire length of the retainer portion and the inhaler article may also have a substantially constant internal cross-sectional area along the entire length of the retainer portion. The retainer portion may have a substantially constant cross section along the entire length of the retainer portion such that the cross-sectional area of material forming the retainer portion is substantially constant along the entire length of the retainer portion. The retainer portion may also have a cross section that varies along the length of the retainer portion and a substantially constant cross- sectional area of material forming the retainer portion along the entire length of the retainer portion.

The porosity in the longitudinal direction of the retainer portion may vary along the length of the retainer portion. For example, this may be the case where the retainer portion does not have a constant cross section along the entire length of the retainer portion such that the cross-sectional area of material forming the retainer portion varies along the length of the retainer portion.

The material forming one or both of the support and the hollow tubular element of the retainer portion may be the same or different material. Each of the retainer portion and the support may be formed from paper, any other paper-based material, any other cellulose-based material, a bioplastic-based material, or a metal. For example, the retainer portion and the support may be formed from one or more of paper, paperboard, cardboard, reconstituted tobacco paper, cellophane and aluminium.

The support is formed from a sheet of material. The retainer portion may also be formed from a sheet of material. The sheet that forms the support may be the same or different from the sheet that forms the retainer portion. Preferably, the sheet is formed from a biodegradable material.

The sheet may be formed from a paper-based material, such as paper, paperboard or cardboard. The paper-based material may be bleached or unbleached. Paper-based materials may be one or more of light, cheap and biodegradable. Where one or both of the support element and the hollow tubular element is formed from a paper sheet, the retainer portion is able to prevent or restrict movement of one or more components disposed upstream of the retainer portion, such as the capsule, whilst exhibiting sufficient mechanical strength and stiffness to withstand significant deformation during interaction of the inhaler article with holder for receiving the inhaler article. The sheet forming one or both of the retainer portion and the support may have a basis weight (grams per square meter or gsm) of about 15 gsm or more, preferably about 25 gsm or more, more preferably about 35 gsm or more, or about 45 gsm or more. A sheet with such basis weight may avoid one or both of crack formation and breakage during one or both of bending and folding of the sheet. As such, the sheet may retain its structural integrity when bent or folded to form the support element. This may improve the retainer portion’s resistance to collapse or deformation and the retainer portion’s ability to prevent or restrict movement of one or both of at least part of the aerosol-forming substrate and at least part of the susceptor element.

The sheet forming one or both of the retainer portion and the support may have a basis weight of about 150 gsm or less, preferably about 130 gsm or less, more preferably about 110 gsm or less, or about 80 gsm or less, or about 50 gsm or less. Providing a sheet with such basis weight may advantageously ensure that the retainer portion has a desired porosity in the longitudinal direction. This may be such that the retainer portion has a desired resistance to draw. In addition, providing a sheet with such basis weight may advantageously make the retainer portion easier to manufacture, for example, by making the sheet easier to at least one of roll, bend and fold the sheet.

The sheet forming one or both of the retainer portion and the support may have a basis weight of between about 15 gsm and about 150 gsm, between about 20 gsm and about 130 gsm, between about 60 gsm and about 100 gsm, between about 70 gsm and about 80 gsm.

The support may be made from a sheet of material having a thickness of between 250 and 200 microns. The support may be made from a sheet of material having a thickness of below 250 microns. The support may be made from a sheet of material having a thickness of below 125 microns. The support may be made from a sheet of material having a thickness of between 250 microns and 125 microns. The support may be made from a sheet of material having thickness of between 250 microns and 100 microns. The support may be made from a sheet of material having a thickness of between 200 microns and 100 microns. The support may be made from a sheet of material having a thickness of below 150 microns. The support may be made from a sheet of material having thickness around 100 microns. The support may be made from a sheet of material having thickness below 125 microns. The support may be made from a sheet of material having a thickness of between 150 microns and 100 microns. The support may be made from a sheet of material having a thickness of between 140 microns and 100 microns. The support may be made from a sheet of material having thickness between 125 microns and 100 microns. The support may be made from a sheet of material having thickness of between 120 microns and 130 microns. The support may be made from a sheet of material having thickness of between 75 and 125 microns. The support may be made from a sheet of material having thickness of between 75 and 140 microns. The support may be made from a sheet of material having thickness of between 75 and 150 microns.

Support material having a thickness of 250 microns or less is considered thin.

Similarly, support material having a thickness of 200 microns or less is considered thinner.

The support may be made from a sheet of material having grammage (or weight) of

250 gsm (grams per square meter) or less. The support may be made from a sheet of material weighing 200 gsm or less. The support may be made from a sheet of material weighing 175 gsm or less. The support may be made from a sheet of material weighing 170 gsm or less.

The support may be made from a sheet of material weighing 150 gsm or less. The support may be made from a sheet of material weighing 140 gsm or less. The support may be made from a sheet of material weighing 130 gsm or less. The support may be made from a sheet of material weighing 125 gsm or less. The support may be made from a sheet of material weighing 100 gsm or less. The support may be made from a sheet of material weighing between 50 gsm and 250 gsm. The support may be made from a sheet of material weighing between 50 gsm and 200 gsm. The support may be made from a sheet of material weighing between 50 gsm and 200 gsm. The support may be made from a sheet of material weighing between 50 gsm and 175 gsm. The support may be made from a sheet of material weighing between 50 gsm and 175 gsm. The support may be made from a sheet of material weighing between 75 and 200 gsm. The support may be made from a sheet of material weighing between 160 gsm and 180 gsm. The support may be made from a sheet of material weighing about 170 gsm. The support may be made from a sheet of material weighing below 170 gsm. The support may be made from a sheet of material weighing between 90 gsm and 110 gsm. The support may be made from a sheet of material weighing about 100 gsm. The support may be made from a sheet of material weighing between 68 gsm and 88 gsm. The support may be made from a sheet of material weighing about 78 gsm. The support may be made from a sheet of material weighting about 80 gsm.

The support may be made from paper having a thickness of 124 microns and a grammage of 170 gsm. The support may be made from paper having a thickness of 125 microns and a grammage of 100 gsm. The support may be made from paper having a thickness of 100 microns and a weight of 78 gsm.

The sheet forming the support may have a basis weight of between about 70 grams per square meter (gsm) and 200 gsm. The sheet forming the support may have a basis weight of between 75 and 200 gsm. The sheet forming the support may have a basis weight of between 75 and 125 gsm. The sheet forming the support may have a basis weight of between 90 and 180 gsm. The sheet forming the support may have a basis weight of between 90 and 120 gsm. The sheet forming the support may have a basis weight of between 70 and 90 gsm. The sheet forming the support may have basis weight of between about 45 gsm and about 110 gsm. The sheet forming the support may have a basis weight of about 45 gsm. The sheet forming the support may have a basis weight of about 60 gsm. The sheet forming the support may have a basis weight of about 78 gsm. The sheet forming the support may have a basis weight of 100 gsm. The sheet forming the support may have a basis weight of 110 gsm. The sheet forming the support may have a basis weight of 170 gsm. Providing a sheet with such basis weight may advantageously make the retainer portion easier to manufacture, for example, by making the sheet easier to at least one of roll, bend and fold the sheet.

The sheet forming one or both of the retainer portion and the support may have a thickness of about 15 micrometers or more, about 30 micrometers or more, about 45 micrometers or more. The sheet forming one or both of the retainer portion and the support may have a thickness of about 100 micrometers or more. The sheet forming one or both of the retainer portion and the support may have a thickness of between 100 micrometers and 130 micrometers. The sheet forming one or both of the retainer portion and the support may have a thickness of about 124 micrometers. The sheet forming one or both of the retainer portion and the support may have a thickness of about 125 micrometers. A sheet with such thickness may avoid one or both of crack formation and breakage during one or both of bending and folding of the sheet. As such, the sheet may retain its structural integrity when bent or folded to form the support element. This may improve the retainer portion’s resistance to collapse or deformation and the retainer portion’s ability to prevent or restrict movement of one or both of at least part of the aerosol-forming substrate and at least part of the susceptor element.

The sheet forming one or both of the retainer portion and the support may have a thickness of about 150 micrometers or less, preferably about 140 micrometers or less, more preferably about 130 micrometers or less. Providing a sheet with such thickness may advantageously ensure that the retainer portion has a desired porosity in the longitudinal direction. This may be such that the retainer portion has a desired resistance to draw. In addition, providing a sheet with such basis weight may advantageously make the retainer portion easier to manufacture, for example, by making the sheet easier to at least one of roll, bend and fold the sheet.

The sheet forming one or both of the retainer portion and the support may have a thickness of between about 15 micrometers and about 150 micrometers, preferably between about 30 micrometers and about 140 micrometers, more preferably between about 90 micrometers and about 130 micrometers. The sheet forming the support may have a thickness of between about 15 micrometers and about 150 micrometers, preferably between about 30 micrometers and about 140 micrometers, more preferably between about 90 micrometers and about 130 micrometers, providing a sheet with such basis weight may advantageously make the retainer portion easier to manufacture, for example, by making the sheet easier to at least one of roll, bend and fold the sheet.

Where the sheet forming one or both of the retainer portion and the support is an aluminium sheet, the sheet may have a thickness of between about 10 micrometers and about 20 micrometers. An aluminium sheet with such thickness may advantageously make the retainer portion easier to manufacture, for example, by making the sheet easier to at least one of roll, bend and fold the sheet. In addition, an aluminium sheet with such thickness may provide the retainer portion with sufficient strength and stiffness to prevent or resist movement of one or more components disposed upstream of the retainer portion, such as the capsule, whilst preventing deformation of the retainer portion. Furthermore, an aluminium sheet with such basis weight may advantageously ensure that the retainer portion has a desired porosity in the longitudinal direction.

The hollow tubular element of the retainer portion may have a thickness of about 15 micrometers or more, about 45 micrometers or more, about 100 micrometers or more. Providing a retainer portion with such thickness may provide the retainer portion with sufficient strength and stiffness to prevent or resist movement of one or both of the first element and the susceptor element, whilst preventing deformation of the retainer portion.

The hollow tubular element of the retainer portion may have a thickness of about 600 micrometers or less, about 500 micrometers or less, about 400 micrometers or less. Providing a hollow tubular element of the retainer portion with such thickness may advantageously ensure that the retainer portion has a desired porosity in the longitudinal direction. This may be such that the retainer portion has a desired resistance to draw. In addition, providing a retainer portion with such thickness may mean that individual retainer portions may be easily cut from a continuous rod of retainer portion. This may simplify manufacturing of the retainer portion.

The hollow tubular element hollow tubular element of the retainer portion may have a thickness of between about 15 micrometers and about 600 micrometers, between about 50 micrometers and about 500 micrometers, between about 100 micrometers and about 400 micrometers. Preferably, the hollow tubular element of the retainer portion hollow tubular element has a thickness of between about 100 micrometers and about 130 micrometers.

The inventors of the present invention have found that a retainer portion having a hardness of at least about 90 percent may enable the retainer portion to prevent or restrict movement of one or more components disposed upstream of the retainer portion, such as the capsule, whilst avoiding significant deformation during interaction of the inhaler article with a holder.

As used herein, the term “hardness” denotes the resistance to deformation. Hardness is generally expressed as a percentage. Figure 21 shows a retainer portion 50 before applying a load F and the same retainer portion 52 whilst applying load F. The retainer portion 50 before load F has been applied has an outer diameter Ds. The retainer portion 52 after applying a set load for a set duration (but with the load still applied) has a (reduced) outer diameter Dd. The depression is d = Ds - Dd. Referring to Figure 21 , hardness is given by:

Where Ds is the original (undepressed) retainer portion outer diameter, and Dd is the depressed outer diameter after applying a set load for a set duration. The harder the retainer portion, the closer the hardness is to 100%.

As is described in more detail below, to determine the hardness of a retainer portion, retainer portions should be aligned parallel in a plane and the same portion of each retainer portion to be tested should be subjected to a set load for a set duration. The test is the DD60A Test and is performed using a known DD60A Densimeter device (manufactured and made commercially available by Heinr. Borgwaldt GmbH, Germany), which is fitted with a measuring head for retainer portions and with a retainer portion receptacle.

The load is applied using two load applying cylindrical rods, which extend across the diameter of all of the retainer portions at once. According to the standard test method for this instrument, the test should be performed such that twenty contact points occur between the retainer portions and the load applying cylindrical rods. In some cases, the retainer portion to be tested may be long enough such that only ten retainer portions are needed to form twenty contact points, with each retainer portion contacting both load applying rods (because they are long enough to extend between the rods). In other cases, if the retainer portions are too short to achieve this, then twenty retainer portions should be used to form the twenty contact points, with each retainer portion contacting only one of the load applying rods, as further discussed below.

Two further stationary cylindrical rods are located underneath the retainer portions, to support the retainer portions and counteract the load applied by each of the load applying cylindrical rods. Such an arrangement is described in more detail below. For the standard operating procedure for such an apparatus, an overall load of 2 kg is applied for a duration of 20 seconds. After 20 seconds have elapsed (and with the load still being applied to the retainer portions), the depression in the load applying cylindrical rods is determined, and then used to calculate the hardness from the above equation. The temperature is kept in the region of 22 degrees Centigrade ± 2 degrees. The test described above is referred to as the DD60A T est. The hardness of a retainer portion of an inhaler article may not greatly differ between a retainer portion in an inhaler article that has been consumed and a retainer portion in an unused inhaler article. However, the standard way to measure the hardness of a retainer portion is when the retainer portion is not part of an inhaler article that has been consumed.

The hardness of the retainer portion may be at least about 90%. Preferably, the hardness of the retainer portion is at least about 92%. This provides even better resistance to movement for one or more components disposed upstream of the retainer portion, such as the capsule. This also provides even better resistance to deformation for the retainer portion during interaction of the inhaler article with a holder.

A retainer portion with a low overall weight has the advantage that it can be assembled in an inhaler article using high speed machines and processes. In particular, the inventors of the present invention have found that a retainer portion with an overall weight of about 150 milligrams or less can advantageously be assembled in an inhaler article using existing high speed inhaler article assembly machines.

The retainer portion may have an overall weight of about 150 milligrams or less, preferably about 100 milligrams or less, more preferably about 70 milligrams or less. The retainer portion may have an overall weight of between about 15 milligrams and about 150 milligrams, preferably between about 20 milligrams and about 100 milligrams, about 25 milligrams and about 70 milligrams. The retainer portion may have an overall weight of about 34 milligrams. The retainer portion may have an overall weight of about 76 milligrams. The retainer portion may have an average weight of about 10 milligrams per millimeter length of the retainer portion or less, preferably about 8 milligrams per millimeter length of the retainer portion or less, more preferably about 6 milligrams per millimeter length of the retainer portion or less. Providing a retainer portion with such average weight may advantageously enable the retainer portion to be assembled into an inhaler article using existing high speed inhaler article assembly machines. The retainer portion may have an average weight of between about 1 and about 10 milligrams per millimeter length of the retainer portion, preferably between about 1.5 and about 8 milligrams per millimeter length of the retainer portion, more preferably between about 2 and about 6 milligrams per millimeter length of the retainer portion. The retainer portion may have an average weight of about 4.25 milligrams per millimeter length of the retainer portion. As used herein, the average weight of the retainer portion is measured by dividing the total weight of the retainer portion by the length of the retainer portion.

Part of the retainer portion may be circumscribed by a wrapper. The entirety of the retainer portion may be circumscribed by a wrapper. The wrapper may be a paper wrapper.

Preferably, the retainer portion is connected to one or more of the adjacent components of the inhaler article by means of a wrapper. The wrapper may be a paper wrapper.

The retainer portion may comprise an adhesive. For example, where the retainer portion comprises a tube, the sheet forming the support may be attached to the tube by an adhesive at points where the sheet is in contact with the tube. That is, the first flap and the second flap of the support may be attached to the interior surface of the hollow tubular element of the retainer portion by an adhesive.

The adhesive may comprise at least one of PVA, PVOH and hot melt glue. The adhesive may comprise a binder. Suitable binders include, but are not limited to: gums such as, for example, guar gum, xanthan gum, arabic gum and locust bean gum; cellulosic binders such as, for example, hydroxypropyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, methyl cellulose and ethyl cellulose; polysaccharides such as, for example, starches, organic acids, such as alginic acid, conjugate base salts of organic acids, such as sodium-alginate, agar and pectins; and combinations thereof. Preferably, the binder comprises guar gum.

The present disclosure also relates to a method for forming a retainer portion for an inhaler article. The method may comprise providing an apparatus for forming the retainer portion. The apparatus may comprise a device. The device may have an internal surface. The internal surface may define a channel of the device. The channel may have a substantially constant cross section along the entire length of the first section of the device. For instance, the part of the channel extending through the first section of the device may be substantially cylindrical. The channel may extend from an upstream opening of the device. The channel may extend to a downstream opening of the device. The method may also comprise providing a hollow tube. The method may further comprise passing a sheet of material into the channel through the upstream opening of the device. The method may further comprise gluing the sheet of material to form a hollow tubular element. Forming the hollow tubular element from a sheet may comprise forming a seam by overlapping a portion of the sheet at a first end of the sheet with a portion of the sheet at an opposed second end of the sheet. Forming the seam may comprise attaching the portion of the sheet at the first end of the sheet to the portion of the sheet at the second end of the sheet by an adhesive. The seam may extend along the length of the hollow tube.

A diameter of the channel of the device may be about the same as a diameter of the hollow tube of the retainer portion. The diameter of the channel may be selected such that an outer surface of the hollow tube of the retainer portion remains in contact with an inner surface of the device, during a step of passing the hollow tube through the first section of the device, to assist with shaping of the hollow tube into a retainer portion.

The method may comprise attaching the first flap of the support and the second flap of the support to the interior surface of the hollow tubular element of the retainer portion. The attaching step may be performed before the retainer portion has exited the device. In this case, the attaching step may be performed whilst the hollow tubular element of the retainer portion is being passed through the channel. The attaching step may be performed after the retainer portion has exited the device.

The method may comprise circumscribing a wrapper around the retainer portion. The circumscribing step may be performed before the retainer portion has exited the device. The circumscribing step may be performed after the retainer portion has exited the device.

The method may comprise attaching a wrapper to the retainer portion, for example, by an adhesive. The step of attaching a wrapper to the retainer portion may be performed before the retainer portion has exited the device. The step of attaching a wrapper to the retainer portion may be performed after the retainer portion has exited the device.

Features described in relation to one example or embodiment may also be applicable to other examples and embodiments.

Below, there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more feature of another example, or embodiment described herein.

Ex1 : An inhaler article extending between an upstream end and a downstream end, comprising at least a substrate portion and a retainer portion, the inhaler article and each of the substrate portion and the retainer portion comprising a length “I”, a radius “r”, and a central axis; wherein the substrate portion comprises a substrate; wherein the retainer portion comprises a hollow tubular element having an interior surface and defining an interior cavity; a support in the interior cavity of the retainer portion; wherein the support is formed from a sheet of material and comprises a first flap, a first bend, a first leg, a second bend, a second leg, a third bend and a second flap; wherein the first flap of the support comprises a length and wherein the first flap of the support contacts the interior surface of the retainer portion; wherein the first leg of the support comprises a length between the first bend and the second bend; wherein the second bend comprises a tip; wherein the second leg of the support comprises a length between the second bend and the third bend; wherein the first leg, the second bend and the second leg form two legs of a triangle extending into the interior cavity of the retainer portion when the retainer portion is viewed from an upstream end of the retainer portion; wherein the support forms the second flap, wherein the second flap of the support comprises a length which contacts the interior surface of the retainer; characterized in that the length of at least one of the first leg and the second leg is greater than the radius “r” of the retainer portion.

EX2: An inhaler article of EX1 , wherein the retainer portion is downstream of the substrate portion.

EX3: The inhaler article of EX2, wherein the inhaler article further comprises a mouthpiece.

EX4: The inhaler article of EX3, wherein the inhaler article comprises a substrate portion, a retainer portion downstream of the substrate portion, and a mouthpiece downstream of the retainer portion, the mouthpiece forming the downstream end of the inhaler article.

EX5: The inhaler article of any one of the preceding examples, wherein the inhaler article comprises a cylinder.

EX6: The inhaler article of any one of the preceding examples wherein the first leg and the second leg are straight.

EX7: The inhaler article of any one of the preceding examples, wherein the length of at least one of the first flap and the second flap is shorter than the radius of the retainer portion.

EX8: The inhaler article of any one of the preceding examples wherein at least one of the first and second flap is attached to the interior surface of the retainer portion.

EX9: wherein the first flap and the second flap are attached to the interior surface of the retainer portion with adhesive.

EX10: The inhaler article of any one of the preceding examples wherein the support comprises paper or cardboard.

EX11 : The inhaler article of any one of the preceding examples wherein the substrate comprises powder.

EX12: The inhaler article of EX11 wherein the powder is contained in a capsule.

EX13: The inhaler article of any one of examples 1-10, wherein the substrate comprises tobacco.

EX14: The inhaler article of any one of the preceding examples, further comprising a wrapper surrounding at least a portion of the substrate portion and the retainer portion.

EX15: The inhaler article of any one of the preceding examples, wherein the length of the inhaler article is between 40 and 50 mm. EX16: The inhaler article of EX15 wherein the length of the retainer portion is between

5 and 9 mm.

EX17: The inhaler article of EX15 wherein the length of the retainer portion is between

6 and 8 mm.

EX18: The inhaler article of any one of the preceding examples wherein the length of the retainer portion is 10 to 20% of the length of the inhaler article.

EX19: The inhaler article of EX18 wherein the support is formed from a sheet of material that is different from the material of the retainer.

EX20: The inhaler article of any one of the preceding examples, wherein the support comprises a sheet of material having a thickness of from 100 to 125 pm.

EX21 : The inhaler article of any one of the preceding examples wherein the support comprises material of from 75 to 200 gsm.

EX22: The inhaler article of any one of the preceding examples wherein the radius of the retainer portion measured from the interior surface of the retainer portion to the central axis of the retainer is between 3 and 4 mm.

EX23: The inhaler article of any one of the preceding examples wherein the radius of the retainer portion measured from the interior surface of the retainer portion to the central axis of the retainer is between 3.2 and 3.75 mm.

EX24: The inhaler article of any one of the preceding examples wherein the length of the first leg and the length of the second leg are greater than the length of the radius of the retainer portion.

EX25: The inhaler article of any one of the preceding examples wherein the first bend and the third bend are angles, not curves.

EX26: The inhaler article of any one of the preceding examples wherein the tip is an angle of 32.5 degrees to 43.5 degrees.

EX27: An inhaler system comprising an inhaler article according to any one of the preceding examples and a holder for receiving the inhaler article, the holder comprising: a housing defining a housing cavity configured to receive the inhaler article; and a piercing element configured to extend into the housing cavity and pierce the capsule of the inhaler article.

Embodiments of the invention will now be described in detail, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 shows a schematic view of an inhaler article in accordance with an embodiment of the present invention;

Figure 2A shows a partially transparent perspective view of the inhaler article of Figure

1 ; Figure 2B shows a partially transparent perspective view of another embodiment of the inhaler article;

Figure 3 shows a schematic view of the inhaler article of Figure 1;

Figure 4 is a schematic view of the inhaler article inserted into a holder;

Figure 5 shows a schematic cross-sectional view of the inhaler article of Figure 1 in a holder, with a piercing element;

Figure 6A shows a cross-sectional view of the upstream end face of the retainer portion of the inhaler article of Figure 1 ;

Figure 6B shows a perspective view of the upstream end face of the retainer portion of the inhaler article of Figure 1 ;

Figure 1, Figure 2A and Figure 2B illustrate an inhaler article 10 in accordance with the present disclosure. The inhaler article 10 extends between its upstream end 1 and its downstream (or mouth) end 2. The inhaler article 10 comprises a substrate portion 3, a retainer portion 4 and a mouthpiece 6 located downstream of the substrate portion 3 and the retainer portion 4. The mouthpiece 6 is spaced apart from the substrate portion 3 by the retainer portion 4. The inhaler article 10 comprises, in linear arrangement from the upstream end 1 to the downstream end 2, a substrate portion 3, a retainer portion 4 and a mouthpiece 6. In embodiments, the retainer portion 4 may be the mouthpiece 6.

As shown in Figure 2A, the substrate portion 3 comprises a cavity 7 which contains substrate 29. As shown in Figure 2A, substrate 29 is contained in a capsule 9, which is contained in cavity 7. Cavity 7 is configured to contain capsule 9. The capsule 9 inside the cavity 7 contains substrate 29. The substrate portion 3 contains substrate 29. The substrate portion 3 contains a capsule 9 containing substrate material 29. The capsule 9 is between the upstream end 1 and the retainer portion 4 of the inhaler article 10. The inhalable material 29 inside the capsule 9 comprises nicotine. According to the embodiment shown in Figure 2A, the substrate material 29 is dry powder 299 contained in a capsule 9. As shown in Figure 2A, the substrate portion 3 comprises a folded upstream end 5, and a hollow tube 12 defining the cavity 7. The retainer portion 4 may extend from the cavity 7, or the downstream portion thereof, to the downstream end 2 of the inhaler article 10. Or, as shown in Figures 1, 2A and 2B, the retainer portion 4 may be a portion of the inhaler article 10 between the substrate portion 3 which contains substrate 29, and a mouthpiece 6 which forms the downstream end 2 of the inhaler article 10.

The inhaler article 10 further comprises a wrapper 8. The wrapper 8 may wrap the substrate portion 3. The wrapper 8 may wrap the substrate portion 3 and the retainer portion 4. The wrapper may wrap the substrate portion 3, the retainer portion 4 and the mouthpiece 6. The wrapper may wrap the hollow tube 12 and the retainer portion 4. The hollow tube 12 defines the cavity 7. The hollow tube 12 and the upstream end of the retainer portion 4 define the cavity 7. The downstream end of the hollow tube 12 abuts the upstream end of the retainer portion 4. The retainer portion 4 may form the downstream end 2 of the inhaler article 10. Or, there is a mouthpiece 6 which forms the downstream end 2 of the inhaler article 10. As shown in Figures 2A and 2B, the wrapper 8 circumscribes the hollow tube 12 of the substrate portion 3, the retainer portion 4 and the mouthpiece 6. In embodiments, the wrapper 8 secures the retainer portion 4 in axial alignment with the hollow tube 12. In embodiments, when the wrapper 8 circumscribes the substrate portion 3, the retainer portion 4 and the mouthpiece 6, the wrapper 8 secures the mouthpiece 6 and the retainer portion 4 in linear axial alignment with the hollow tube 12 of the substrate portion 3.

In the embodiment shown in Figure 2B, the substrate portion 3 contains substrate 29 which is tobacco 298. In the embodiment shown in Figure 2B, there is shown a substrate portion 3, a retainer portion 4 and a mouthpiece portion 6 in linear alignment. In addition, as shown in Figure 2B, an optional upstream element 11 is shown at the upstream end 1 of the inhaler article 10. In the embodiment shown in Figure 2B, the substrate 29 which is tobacco 298 may be wrapped by a hollow tubular element 12. In this embodiment, the hollow tubular element 12 may be a plug wrap. In the embodiment shown in Figure 2B, an inhaler article 10 is illustrated, having a substrate portion 3, a retainer portion 4 and a mouthpiece in linear axial alignment from the upstream end 1 to the downstream end 2. The substrate portion 3 and the retainer portion 4 may be circumscribed by a wrapper 8. The wrapper 8 secures the retainer portion 4 in axial alignment with the hollow tube 12 of the substrate portion 3. In embodiments, when the wrapper 8 circumscribes the substrate portion 3, the retainer portion 4 and the mouthpiece 6, the wrapper 8 secures the mouthpiece 6 and the retainer portion 4 in linear axial alignment with the hollow tube 12 of the substrate portion 3. Additionally, when the optional upstream element 11 is present, the wrapper 8 secures upstream element 11 , the substrate portion 3, the retainer portion 4 and the mouthpiece 6 in axial alignment with the hollow tube 12.

As shown in Figure 2A, and in cross-section in Figure 4, the folded end 5 of the hollow tube 12 defines a central channel or passage 55 extending through the centre of the folded end 5 from the upstream end of the folded end 5. The central channel 55 of the folded end 5 is arranged to provide access to the capsule cavity 7 to a piercing element 101 , for example, a piercing element 101 of a holder 1210 for the inhaler article 10. Such a piercing element is configured to pierce or puncture the capsule 9 in order to activate it for consumption. Piercing the capsule allows powder contained within the capsule to be released as air flows through the inhaler article, allowing powder to be delivered to a user. A diameter of the central channel 55 is less than about 6mm. The central channel is structured to accommodate a piercing element or needle from 27 gauge (outer diameter = 0.42 mm) to 4 gauge (outer diameter = 5 mm). As shown in Figure 3, the central channel 55 is 1 mm.

As shown in Figure 3, the overall length of the inhaler article 10 is about 45 mm. The length of the capsule cavity 7 is about 25 mm and the length of the retainer portion 4 is about 7 mm. The length of the hollow tube 12 surrounding the capsule cavity 7 is between about 25 mm and about 28 mm. The inner diameter of the hollow tube 12 surrounding the capsule cavity 7 is between about 6.47 and about 6.63 mm, depending on the thickness of the hollow tube 12 material. The outer diameter of the hollow tube 12 is between about 7.1 mm and about 7.5 mm. As shown in Figure 3, the outer diameter of the hollow tube 12 is 7.3 mm. The length of the wrapping material 8 is about 45 mm. The diameter of the inhaler article 10 is between about 7.1 and 7.5 mm. The relative RTD, or RTD per unit length, of the retainer portion 4 is about 0.02 mm of water per mm. The RTD of the retainer portion 100 is about 0.34 mm of water. A diameter of the capsule 9 is about 6 mm and the length of the capsule 9 is about 16 mm.

Figure 4 illustrates an inhaler system 1200. The inhaler system 1200 includes an inhaler article 10 and a separate holder 1210. The inhaler article 10 may be received within the holder 1210 to activate or pierce the capsule 9 (not shown in Figure 4, but see Figure 1 and Figures 2A and 2B) disposed within the inhaler article 10. The inhaler article 10 remains in the holder 1210 during use by the consumer. The holder 1210 is configured to induce swirling inhalation airflow entering the received inhaler article 10. The holder 1210 is configured to fold back or breach or open the folded end 5 of the inhaler article 10.

The inhaler system 1200 includes the inhaler article 10 and the holder 1210. The inhaler article 10 extends along an inhaler longitudinal axis LA. The holder 1210 includes a movable sleeve 1220 that retains the inhaler article 10 received in the sleeve cavity 122.

The holder 1210 for the inhaler article 10 includes a housing 111 comprising a housing cavity 112 for receiving the inhaler article 1050 and the sleeve 1220 configured to retain the inhaler article 1050 within the housing cavity 112. The sleeve 1220 defines a sleeve cavity 122 and is movable within the housing cavity 112 along the longitudinal axis LA of the housing 111. The sleeve 1220 comprises a first open end 124 and a second opposing end 1226. The second opposing end 1226 of the sleeve 1220 is configured to allow air to enter the sleeve cavity 122. Air may enter the sleeve cavity through an air inlet 127. The second opposing end 1226 of the sleeve 1220 is configured to induce a swirl on the air entering the sleeve cavity 122.

The holder 1210 may include a piercing element 101 fixed to and extending from a housing inner surface 109. The piercing element 101 may be configured to extend through the second opposing end 1226 of the sleeve 1220 and into the sleeve cavity 122 along a longitudinal axis LA of the housing 111. The holder 1210 may include a spring element 102 configured to bias the sleeve 1220 away from the piercing element 101.

Figure 5 shows a schematic cross-sectional view of the inhaler article 10 of Figure 1 in a holder 1210 (as shown in Figure 4), with a piercing element 101 poised to enter the upstream end 1 of the inhaler article 10 to pierce the capsule 9. As shown in Figure 5, the retainer portion 4 extends to the mouth end 2 of the inhaler article.

As best seen from Figure 6A and 6B, the retainer portion 4 of the inhaler article 10 has a length “I” 113, a radius “r” 114 (as shown in Figure 6B), and a central axis 115 (as shown in cross-section in Figure 6B). The length 113 of the retainer portion 4 as shown in Figure 6A and 6B is 7mm. The diameter of the retainer portion 4 may be between 7.5 and 6.4 mm. The diameter of the retainer portion 4 as shown in Figure 6A and 6B is 6.55mm plus or minus 0.08 mm. The radius 114 of the retainer portion 4 may be between 3.75 mm and 3.2 mm. The radius 114 of the retainer portion 4 as shown in Figure 6A and 6B is 3.2 to 3.3 mm. The central axis 115 is shown in Figure 6B as a point, as Figure 6B is a cross-sectional view. The retainer portion 4 comprises a hollow tubular element 110 of material defining an interior cavity 120 of the retainer portion 4. The hollow tubular element 110 has an interior surface 103. The retainer portion 4 also comprises a support 130 in the interior cavity 120 of the retainer portion 4 formed from a sheet.

The support 130 has a first flap 131 , a first bend 132, a first leg 133, a second bend 134, a second leg 135, a third bend 136 and a second flap 137. The first flap 131 of the support 130 has a length. The first flap 131 of the support contacts the interior surface 103 of the hollow tubular element 110 of the retainer portion 4. The first flap 131 of the support may be attached to the interior surface 103of the hollow tubular element 110 of the retainer portion 4. The first flap 131 of the support may be attached to the interior surface 103of the hollow tubular element 110 of the retainer portion 4 by adhesive.

As shown in Figure 6B, the length of the first flap 131 is less than the radius of the hollow tubular element 110 of the retainer portion 4. As shown in Figure 6B, the internal radius of the hollow tubular element of the retainer portion is 3.2 to 3.3 mm and the length of the first flap 131 is less than 3.2 mm or less than 3.3 mm. The length of the first flap 131 may be, for example, less than 3 mm. The length of the first flap 131 may be, for example, between 2.5 mm and 3.2 mm. The length of the first flap 131 may be, for example, 2.7 mm. The length of the first flap 131 may be less than the radius 114 of the hollow tubular element of the retainer portion 4.

At the first bend 132, the support 130 turns to extend into the interior cavity 120 of the retainer portion 4. The first bend 132 is a fold in the sheet material of the support 130. As shown in Figure 6B, the first bend 132 extends into the interior cavity 120 of the retainer portion 4 at an angle. To the extent that an angle can be defined between a straight leg and an arc, the angle can be, for example, between 65 degrees and 75 degrees. When viewed from an upstream end of the retainer portion 4, and as shown in Figure 6B, the first leg 133, the second bend 134 and the second leg 135 form two sides of a triangle extending into the interior cavity 120 of the retainer portion 4. The second bend 134 defines an angle 138. The angle 138 may be between 32.5 degrees and 43.5 degrees.

The second leg 135 extends between the second bend or tip 134 and the third bend

136 at the interior surface of the hollow tubular element 110 of the retainer portion 4. The second leg 135 has a length. The length of at least one of the first leg 133 and the second leg 135 is greater than the radius of the hollow tubular element 110 of the retainer portion 4. As shown in Figure 6A and 6B, the length of the second leg 135 is greater than the radius 114 of the retainer portion 4. As shown in Figure 6A and 6B, the length of both the first leg 133 and the second leg 135 are each greater than the radius 114 of the retainer portion.

At the third bend 136, the support 130 contacts the interior surface 103 of the hollow tubular element of the retainer portion 4. At the third bend 136, the support 130 turns to form the second flap 137. The third bend 136 may be a fold in the sheet material of the support 130. As shown in Figure 6B, the third bend 132 forms an angle between the third bend 132 and the interior surface 103 of the hollow tubular element 110 of the retainer portion 4. To the extent that an angle can be defined between a straight leg and an arc, the angle can be, for example, between 65 degrees and 75 degrees.

The second flap 137 of the support 130 may be attached to the interior surface 103of the hollow tubular element 110 of the retainer portion 4. The second flap 137 of the support may be attached to the interior surface 103 of the hollow tubular element 110 of the retainer portion 4 by adhesive. As shown in Figure 6B, the second flap 137 has a length. The length of the second flap 137 may be, for example, less than 3.2 mm or less than 3.3 mm. The length of the second flap 137 may be, for example, less than 3 mm. The length of the second flap

137 may be, for example, between 2.5 mm and 3.2 mm. the length of the second flap 137 may be, for example, 2.7 mm. The length of the second flap 137 may be less than the radius 114 of the hollow tubular element of the retainer portion 4.

The support 130 is formed from a paper sheet. The paper sheet has a basis weight of about 78 gsm. The support 130 is formed from a paper sheet scored at the first bend 132, the second bend 134 and the third bend 136. This scored sheet makes it easier to create the bends when manufacturing the support 130 and inserting the support 130 into the hollow tubular element 110 of the retainer portion 4. The length of the support 130, measured when the support 130 is not bent, and measured from the end of the first flap 131 to the end of the second flap 137, is about 14.3 mm. The width of the support 130 is equivalent to the length of the retainer portion 4, which is about 7 mm. That is, the support 130 extends along substantially the entire length of the retainer portion 4 from an upstream face of the retainer portion to a downstream face of the retainer portion. In effect, the support 130 has substantially the same width as the retainer portion 4.

The retainer portion 4 has a total weight of about 72 milligrams. As such, the retainer portion has an average weight of about 4.2 milligrams per millimeter. The retainer portion 4 has a constant cross section along the entire length of the retainer portion 4.

The first bend 132, the second bend 134 and the third bend 136 of the support 130 are parallel to the longitudinal axis of the retainer portion 4. As such, the first bend 132, the second bend 134 and the third bend 136 are parallel to each other. The first bend 132 and the third bend 136 are spaced apart from each other along the interior surface 103 of the hollow tubular element 110 of the retainer portion by a distance of about 2.68 mm.

The first leg 133 and the second leg 135 define an angle 138 at the second bend, or the tip, of 37.5 degrees plus or minus 5 degrees. The second bend or tip 134 of the support 130 is spaced apart from the radial centre 115 of the retainer portion 4 by a distance of about 1.2 mm.

The retainer portion is manufactured by first forming the hollow tubular element 110 of the retainer portion 4. The sheet of the support 130 is folded at the first bend 132, the second bend 134 and the third bend 136 to form the triangular shape of the support 130. Adhesive is then provided to the side of the first flap 131 and the second flap 137 intended to contact the interior surface 103 of the hollow tubular element 110 of the retainer portion 4. The support 130 is then inserted into the hollow tubular element 110 of the retainer portion 4 so that the first flap 131 and the second flap 137 contact the interior surface 103 of the hollow tubular element 110 of the retainer portion 4 and the first leg 133, the second bend or tip 134 and the second leg 135 extend into the interior cavity of the retainer portion forming a triangular shape. The adhesive may be heated, cured or hardened in a further step. The retainer portion 4 containing the support 130 may then be cut to the desired length.

For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term "about". Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A ± 10 % of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.

Claims

1. An inhaler article extending between an upstream end and a downstream end, comprising a substrate portion and a retainer portion, the inhaler article and each of the substrate portion and the retainer portion comprising a length “I”, a radius “r”, and a central axis; wherein the substrate portion comprises a substrate; wherein the retainer portion comprises a hollow tubular element having an interior surface and defining an interior cavity; a support in the interior cavity of the retainer portion; wherein the support is formed from a sheet of material and comprises a first flap, a first bend, a first leg, a second bend, a second leg, a third bend and a second flap; wherein the first flap of the support comprises a length and wherein the first flap of the support contacts the interior surface of the retainer portion; wherein the first leg of the support comprises a length between the first bend and the second bend; wherein the second bend comprises a tip; wherein the second leg of the support comprises a length between the second bend and the third bend; wherein the first leg, the second bend and the second leg form two legs of a triangle extending into the interior cavity of the retainer portion when the retainer portion is viewed from an upstream end of the retainer portion; wherein the support forms the second flap, wherein the second flap of the support comprises a length which contacts the interior surface of the retainer portion; wherein the length of at least one of the first leg and the second leg is greater than the radius of the retainer portion.

2. The inhaler article of claim 1 wherein the radius of the retainer portion is between 3 and 4 mm.

3. The inhaler article of claim 1 or claim 2 wherein the length of the first leg and the length of the second leg are greater than the radius of the retainer portion.

4. The inhaler article of any one of the preceding claims wherein the length of at least one of the first flap and the second flap is shorter than the radius of the retainer portion.

5. The inhaler article of any one of the preceding claims wherein the first flap and the second flap are attached to the interior surface of the retainer portion with adhesive.

6. The inhaler article of any one of the preceding claims wherein the first bend and the third bend are angled.

7. The inhaler article of any one of the preceding claims wherein the support is formed from a sheet of material that is different from the material of the retainer portion.

8. The inhaler article of any one of the preceding claims wherein the support comprises paper or cardboard.

9. The inhaler article of any one of the preceding claims wherein the support comprises a sheet of material having a thickness of from 100 to 125 pm.

10. The inhaler article of any one of the preceding claims wherein the support comprises material of from 75 to 200 gsm.

11. The inhaler article of any one of the preceding claims wherein the substrate comprises powder.

12. The inhaler article of claim 11 wherein the powder is contained in a capsule.

13. The inhaler article of any one of claims 1-10, wherein the substrate comprises tobacco.

14. The inhaler article of any one of the preceding claims, wherein the length of the inhaler article is between 40 and 50 mm and wherein the length of the retainer portion is between 5 and 9 mm.

15. An inhaler system comprising an inhaler article according to any one of the preceding claims and a holder for receiving the inhaler article, the holder comprising: a housing defining a housing cavity configured to receive the inhaler article; and a piercing element configured to extend into the housing cavity and pierce a capsule of the inhaler article.