WO2025114922A1

WO2025114922A1 - Mouth plug for an inhaler article

Info

Publication number: WO2025114922A1
Application number: PCT/IB2024/061951
Authority: WO
Inventors: Antonio CONSOLANTE
Original assignee: Philip Morris Products SA
Current assignee: Philip Morris Products SA
Priority date: 2023-11-30
Filing date: 2024-11-27
Publication date: 2025-06-05
Anticipated expiration: 2026-05-30

Abstract

A mouth plug for an inhaler article, the mouth plug comprising: an upstream end comprising a support member, an internal tube and a downstream end, wherein the support member comprises an upstream face, wherein an upstream end of the internal tube is attached to a downstream face of the support member, and wherein the downstream end of the internal tube extends to an air outlet, wherein the external diameter of the internal tube is smaller than the diameter of the support member; wherein the support member comprises at least two support member airways comprising apertures extending from the upstream face of the support member to the downstream face of the support member and passing through the thickness of the support member.

Description

MOUTH PLUG FOR AN INHALER ARTICLE

The present disclosure relates to an inhaler article. An inhaler article is used to deliver dry powder to a user by releasing dry powder from a capsule in the inhaler article, entraining dry powder into an airflow through the inhaler article, so that the dry powder is inhaled by the user. The present disclosure relates to internal structures in an inhaler article to improve the delivery of dry particles to a user.

The present disclosure relates to an inhaler article having a support member structured to define airflow through the inhaler article. The present disclosure relates to a support member which improves the release of dry powder from a capsule contained in the inhaler article.

The present disclosure also relates to an inhaler article having a mouth plug that comprises the support member as well as an internal tube which improves the release of dry powder from a capsule contained in the inhaler article and also makes manufacturing of the inhaler article more efficient. The present disclosure also relates to an inhaler article for use with a holder to form an inhaler system. The present disclosure relates to a method for manufacturing the inhaler article.

Inhaler articles are used to deliver dry powder to the lungs of a user. Inhaler articles provide an airflow path. The airflow path through an inhaler article begins at an airflow inlet, travels through the inhaler article, and exits the inhaler article at a mouth end or downstream end where the air traveling in the airflow path is inhaled by a user. Inhaler articles may contain a capsule containing dry powder. The dry powder may comprise an active compound. The dry powder may comprise a pharmaceutically active compound. The dry powder may comprise an active compound that is delivered to a user when the dry powder is released from the capsule, is entrained in the airflow traveling through the inhaler article and is inhaled by a user. The dry powder may comprise nicotine. Nicotine may be in dry powder form. The dry powder may also comprise one or more flavor compounds. To release the dry powder from the capsule and to introduce dry powder into an airflow so that the dry powder can be delivered to a user, the capsule may be pierced. The pierced capsule releases its dry powder contents into airflow as the air flows around and past the pierced capsule. The inhaler article is depleted when the contents of the capsule have been released into the airflow. Once the inhaler article is depleted, the inhaler article is discarded.

The dose of dry powder is limited by the contents of the capsule. The dose of dry powder is also limited by the degree to which all of the contents of the capsule can be released from the capsule and delivered to the user. It would be desirable provide an inhaler article structured to enable the release of the contents of the capsule.

Inhaler articles are manipulated before, during and after use. For example, inhaler articles may be subjected to longitudinal and radial pressures as they are manufactured, packaged, unpackaged, inserted into devices, activated, pierced, used and discarded. Inhaler articles are not always fully suitable to withstand this manipulation. For example, when inhaler articles are manufactured, multiple parts may be assembled to form the final inhaler articles. It would be desirable to provide inhaler articles structured to enable manufacture and assembly of the inhaler article without damaging or bending the parts.

When using the inhaler article, the capsule may be pierced. Another word for piercing the capsule is activating the capsule. For example, when the capsule is pierced, a piercing element is pressed into the capsule. The piercing element may be pressed into the capsule from the upstream side of the capsule. When the piercing element is pressed into the upstream end of the capsule, the capsule may move in response to the pressure of the piercing element. The pressure may be transmitted to structures downstream of the capsule. This may cause the downstream structures to deform. This may cause the pierced capsule to be pushed downstream in the inhaler article. This may cause the pierced capsule to be pushed out of the inhaler article. It would be desirable to provide an inhaler article structured to reduce the deformation of the structures of the inhaler article. It would be desirable to provide an inhaler article that is structured to prevent the capsule from being pushed out of the inhaler article. It would be desirable to prevent the pierced capsule from being pushed out of the inhaler article.

It would be desirable to provide an inhaler article having improved stability. It would be desirable to provide an inhaler article providing sufficient rigidity to resist longitudinal force, such as the force provided by the piercing of the capsule. It would be desirable to provide an inhaler article providing sufficient rigidity to resist radial force such as crushing forces against the sidewalls of the inhaler article which may occur during manufacturing, packaging or use. It would be desirable to provide an inhaler article with sufficient stability to withstand compression forces exerted during one or more of manufacturing, packaging and use of the article. It would be desirable to provide an article having sufficient rigidity to resist deforming or crushing of the inhaler article when the capsule of the inhaler article is pierced. It would be desirable to provide an inhaler article structured to provide enhanced rigidity. For example, if the inhaler article is bent or deformed, or if the capsule or downstream structures are deformed, the ability of the capsule to move inside the inhaler article and release its contents to provide a dose of dry powder may be reduced. If the capsule is inhibited from moving inside the inhaler article, it may not fully release the dry powder contained in the capsule during use.

It would be desirable to provide an inhaler article structured to prevent the capsule from escaping from the inhaler article. If the capsule escapes from the inhaler article, it may be ingested. The capsule containing dry powder may be dangerous if ingested. It would be desirable to provide an inhaler article that is requires fewer manufacturing steps. It would be desirable to provide an inhaler article that is cost-effective to manufacture. It would be desirable to provide an article that can reliably contain the capsule before, during and after use, to prevent escape of the capsule containing dry powder. It would be desirable to provide an article offering improved sustainability. It would be desirable to provide a biodegradable article. It would be desirable to provide a biodegradable retainer portion. It would be desirable to provide a recyclable retainer portion. It would be desirable to provide a biodegradable retainer portion providing sufficient rigidity to the article during one or more of manufacturing, packaging and use of the article. It would be desirable to provide an article offering an improved user experience. It would be desirable to provide an article offering improved alignment of the capsule in the article.

It would also be desirable to provide an inhaler article having internal structures that allow the capsule to move with less contact points between the capsule and the internal structures of the inhaler article. Contact points create friction when the capsule moves. Contact points interfere with the movement of the capsule inside the inhaler article. It would be desirable to provide an inhaler article having internal structures that minimize contact points with the capsule and allow the capsule to move and agitate more freely, thus releasing dry powder more freely.

It would be desirable to provide an inhaler article having internal structures that improve the delivery of dry powder to the user. For example, it would be desirable to provide an inhaler article having an airflow path structured to control airspeed through the inhaler article to improve the agitation of the capsule in the inhaler article and therefore improve the emptying of the capsule, it would be desirable to provide an inhaler article having an airflow path structured to increase airspeed through the inhaler article to improve the agitation of the capsule in the inhaler article and therefore improve the emptying of the capsule.

It would be desirable to provide a support member that provides support member airways that allow airflow to pass from upstream of the support member where the capsule is located to downstream of the support member where the airflow outlet is located, so that the airflow may be inhaled by a user. This allows air to flow past the capsule, entraining particles of dry powder released from the capsule, through support member airways which have a smaller cross-section than the tubular inhaler article to accelerate the airflow and exit the inhaler article at an airflow outlet to be inhaled by a user. It would also be desirable to provide a support member that has an upstream face that is closed in a central area. This closed central area may provide a flat surface to contact the downstream end of the capsule. When the capsule contacts the flat surface of this central area, it provides a single contact point between the capsule and internal structures of the inhaler article. This closed central area provides less contact points between the capsule and the internal structures of the inhaler article compared to a support member having support member airways in the center of the support member, for example. For example, if support member airways are located where the capsule contacts the support member, the capsule may contact the edges of the support member airways, forming more contact points between the capsule and the upstream face of the support member. Contact points create friction when the capsule moves. Contact points interfere with the movement of the capsule inside the inhaler article. If the support member airways are located where the capsule contacts the support member, the capsule may block airflow through the support member airways. It would be desirable to provide an inhaler article that doesn’t have support member airways in the center of the support member where the capsule may contact the support member. It would be desirable to provide an inhaler article having internal structures that minimize contact points with the capsule and allow the capsule to move and agitate more freely, thus releasing dry powder more freely.

It would be desirable to provide an inhaler article containing a support member that provides rigidity and stability to the inhaler article. It would be desirable to provide an inhaler article containing a support member to provide rigidity and stability in the longitudinal direction. It would be desirable to provide an inhaler article containing a support member to provide rigidity and stability in radial direction. It would be desirable to provide an inhaler article containing a support member to hold the capsule inside the cavity of the inhaler article. It would be desirable to provide an inhaler article containing a support member to prevent the capsule from escaping from the inhaler article.

In a manufacturing environment, it can be difficult to predictably and reliably set a part within another part. It would be desirable to provide an inhaler article structured to predictably and reliably assemble an inhaler article having a support member. It would be desirable to provide an inhaler article structured so that the inhaler article can be predictably and reliably assembled, the inhaler article having a support member and a mouth plug so that the placement of the support member is predictable and reliable. It would be desirable to provide an inhaler article structured to be predictably and reliably assembled so that additional parts and manufacturing steps are not needed. For example, it would be desirable to assemble the parts without requiring adhesive. It would be desirable to assemble the parts without pins or fasteners. It would be desirable to assemble parts using adhesive where the structure of the inhaler article allows for placement of the adhesive in a location that is accessible during manufacture.

It would be desirable to provide an inhaler article containing a support member that is placed inside the inhaler article in a way that makes the manufacture of the inhaler article containing a support member easier and more predictable. Providing an inhaler article structured so that it is easier and more predictable to assemble the parts together and place the support member inside the cavity of the inhaler article would make manufacturing more efficient. In addition, providing an inhaler article structured so that it is easier and more predictable to assemble may result in an inhaler article that is more rigid and more stable as well.

It would be desirable to provide an inhaler article to prevent dry powder from escaping or leaking from the inhaler article before, during or after use. It would be desirable to design an inhaler article that is cheaper and easier and more efficient to assemble. It would be desirable to provide an inhaler article that is cheaper and easier to manufacture. It would be desirable to provide an inhaler article having an airflow path that maximizes the emptying of the contents of a dry powder containing capsule. According to an aspect of the present disclosure, there is provided a mouth plug for an inhaler article, the mouth plug comprising: an upstream end, a downstream end and a central axis; wherein the downstream end of the mouth plug comprises an air outlet; wherein the mouth plug comprises an internal tube extending along the central axis, the internal tube comprising an upstream end, a downstream end, an external perimeter, an external diameter, and an internal diameter which defines an internal tube cavity; wherein the upstream end of the mouth plug comprises a support member, wherein the support member comprises an upstream face, a downstream face, a thickness, an external diameter and a perimeter; wherein the upstream end of the internal tube is attached to the downstream face of the support member, and wherein the downstream end of the internal tube extends to the air outlet, wherein the external diameter of the internal tube is smaller than the external diameter of the support member; wherein the support member comprises at least two support member airways comprising apertures extending from the upstream face of the support member to the downstream face of the support member and passing through the thickness of the support member.

Advantageously, the mouth plug of the present disclosure can be used as a work in progress (WIP) part. For example, it would be desirable to provide an inhaler article that is pre-assembled and ready for the next step in a manufacturing process. Pre-manufacturing a WIP part may reduce the overall number of manufacturing steps, reduce the cost of manufacturing and improve the efficiency of manufacturing. The mouth plug may be a pre-assembled part that can be inserted into an outer tube body to form an inhaler article. Pre-assembling the mouth plug allows for more efficient manufacturing. For example, a mouth plug may be pre-manufactured and stored until needed. During later manufacturing steps, the mouth plug may be inserted into an outer tube body, and a capsule may be inserted into the outer tube body having a mouth plug. The capsule containing dry powder may have a shorter shelf life than the tube with the mouth plug. Providing the mouth plug as WIP may allow for more flexible inventory control for an inhaler article containing a capsule. For example, mouth plugs may be manufactured and stored until there is a call for inventory. Then, as needed, the mouth plug may be assembled into an outer tube body. For example, a mouth plug may be inserted into the downstream end of an outer tube body. Then, a capsule may be inserted into the upstream end of an outer tube body, upstream of the support member of the mouth plug. The inhaler article may then be finished to be packaged and delivered to the market. Providing the mouth plug inserted into an outer tube body as WIP may allow for more flexible inventory control for an inhaler article containing a capsule. Providing the mouth plug as WIP may improve safety of the product by improving inventory control to be sure that fresh products are supplied to the market.

The inhaler article may be assembled by inserting the upstream end of the pre-assembled mouth plug into an outer tube body. The upstream end of the mouth plug is a support member. The support member of the mouth plug can be inserted into the downstream end of the outer tube body. The mouth plug may be inserted into the downstream end of an outer tube body with the support member entering the outer tube body. The mouth plug can be inserted into the downstream end of the outer tube body until the downstream end of the mouth plug fits against the downstream end of the outer tube body. In this way, there is no need to fit the support member by itself into the outer tube body. Instead, the support member is fitted into an outer tube body and set into the desired position by means of the length of the inner tube body of the mouth plug. That is, the inner tube body acts as a jig to place the support member into an outer tube body in the desired location. The mouth plug is structured to be inserted into an outer tube body so that the support member of the mouth plug is placed in the desired location. Because of the structure of the mouth plug, manufacturing of the inhaler article is less complex. For example, the manufacturing machinery does not need to include a jig to place the support member into its desired position inside an outer tube body because the placement mechanism is provided by the structure of the mouth plug itself. Also, the downstream end of the mouth plug may be placed in the desired location at the downstream end of an outer tube body. This assembly step can be carried out in one manufacturing step. Advantageously, the structure of the mouth plug itself functions to place the support member into the desired location in the outer tube body of an inhaler article. The structure of the mouth plug reduces the number of manufacturing steps and simplifies the manufacturing process.

Advantageously, the structure of the mouth plug can increase the structural rigidity of an inhaler article when the mouth plug is assembled into an outer tube body, in several ways. The support member provides internal structure extending across the diameter of the cavity of the outer tube body. This support member structure provides rigidity in the radial direction by providing support in the radial direction, at least where the support member is placed inside the outer tube body. The support member may protect an assembled inhaler article from crushing. In addition, this structure provides a block to airflow from the upstream end of the outer tube body to the downstream end of the outer tube body.

According to an aspect of the present disclosure, there is provided a mouth plug having a support member wherein the support member airways are located between the perimeter of the support member and the perimeter of the internal tube on the downstream face of the support member. That is, the mouth plug is structured so that the upstream end of the internal tube attaches to the downstream face of the support member. The perimeter of the internal tube is smaller than the perimeter of the support member. This leaves an area around the periphery of the support member to allow for support member airways. The support member has at least two support member airways comprising apertures extending from the upstream face of the support member to the downstream face of the support member and passing through the thickness of the support member. These support member airways cannot provide apertures that extend from the upstream face of the support member to the downstream face of the support member and passing through the thickness of the support member where the internal tube meets the downstream face of the support member. If an airway or an aperture through the support member were place in the region where the inner tube is attached to the downstream face of the support member, the airway would pass through the support member and open at the downstream face of the support member into the internal tube. Therefore, at least on the downstream face of the support member, support member airways must be located between the perimeter of the support member and the perimeter of the internal tube. That is, support member airways open on the downstream face of the support member. The support member airways may be not parallel to the central axis of the mouth plug. The support member airways may be angled with respect to the central axis of the mouth plug. Advantageously, the structure of the mouth plug provides support member airways that open on the downstream face of the support member outside the perimeter of the internal tube. Advantageously, the structure of the mouth plug, and the structure of the support member and the support member airways manages the flow of air through the inhaler article from an airway inlet to an airway outlet. Because of the structure of the mouth plug, the inhalation experience, the resistance to draw, the dose of dry powder released from a capsule can be controlled and improved.

According to an aspect of the present disclosure, there is provided a mouth plug wherein the internal diameter of the upstream end of the internal tube is closed by the downstream face of the support member. Advantageously, the attachment of the downstream face of the support member to the upstream end of the internal tube makes the mouth plug more rigid and thereby lends stability to the inhaler article. Advantageously, when the upstream end of the internal tube is closed, air is forced to flow around the internal tube. This creates a convoluted airflow. This convoluted airflow is advantageous in reducing leakage of dry powder from the inhaler article and also in controlling the resistance to draw and the dose of dry powder provided by the inhaler article. Advantageously, the attachment of the upstream end of the internal tube to the downstream face of the support member makes the mouth plug resistant to bending or damage during manufacture of the mouth plug, storage, later manufacturing or assembly steps, use and disposal. Alternatively, the support member may have an open structure. In this case, the upstream end of the internal tube may be open, and airflow may pass into the internal tube through an open upstream end of the internal tube.

In an embodiment, the internal tube may be a hollow tube. In an embodiment, the internal tube may be a solid tube. When the internal tube is a solid tube, upstream end of the internal tube is closed. When the internal tube is a solid tube, the internal tube may have an internal tube air opening to direct airflow from outside of the solid internal tube to the airflow outlet. That is, a solid internal tube may have an airway to direct airflow in a circuitous path from outside the internal tube to the airflow outlet through the solid internal tube. Advantageously, the mouth plug having a support member provides structural rigidity by providing an internal structure extending across the diameter of the cavity of the outer tube body. The support member may have a disk shape where the disk has an upstream face, a downstream face, a thickness and a center. The support member may be cylindrical. The support member has a central axis that passes through the center of the support member. The support member upstream face may have a diameter. The support member downstream face may have a diameter. The upstream face diameter and the downstream face diameter may be the same. The upstream face of the support member may have a flat structure transverse to the central axis of the outer tube body. The support member may have a perimeter. The support member may be arranged transverse to the center axis of the outer tube body. The support member may be a disk arranged inside the outer tube body where the support member fits into the outer tube body so that the perimeter of the support member fits against the internal surface of the outer tube body. The support member may be made from biodegradable material.

The upstream face of the support member may have a closed central area. This closed central area does not have support member airways. The closed central area may provide a flat surface. A flat surface, which does not have support member airways, may provide an area that contacts the downstream end of the capsule. The closed central area may contact the downstream end of the capsule as the capsule is pierced. When the capsule is pierced, for example by a needle introduced into the upstream end of the capsule, this may push the capsule against the upstream face of the support member located downstream of the capsule. Where the upstream face of the support member has a closed central area, when the capsule is pierced the capsule is pressed against the closed central area of the upstream face of the support member. When air flows through the inhaler article, the air flows past the capsule. The flow of air past the capsule causes the capsule to shake or rotate or agitate. This capsule movement causes dry powder to be released from the capsule. To fully empty the capsule, it may be desirable to provide internal structures that reduce friction between the capsule and the internal structures of the inhaler article. When the upstream face of the support member has a closed central area, there are no support member airways located in the closed central area. This reduces friction between the capsule and the region where the capsule contacts the upstream face of the support member. When the closed central area of the upstream face of the support member is a flat structure, friction is reduced between the capsule and the region where the capsule contacts the upstream face of the support member.

According to an aspect of the present disclosure, there is provided a mouth plug wherein the downstream end of the mouth plug comprises a curved end. Advantageously, a mouth plug structured with a curved downstream end provides a curved downstream end for an inhaler article when the mouth plug is fitted into an outer tube body to form an inhaler article. This may eliminate a manufacturing step of bending or curving the downstream end of the outer tube body after the two parts are assembled together. Eliminating steps in the manufacturing process is advantageous.

According to an aspect of the present disclosure, there is provided an inhaler article comprising a mouth plug as described above and further comprising an outer tube body, the outer tube body comprising an upstream end, a downstream end, a central axis, an outer surface and an internal surface, wherein the internal surface defines a cavity inside the outer tube body; wherein the mouth plug is in the downstream end of the outer tube so that the upstream end of the mouth plug is contained in the outer tube body and the downstream end of the mouth plug fits with the downstream end of the outer tube body to form the air outlet.

According to an aspect of the present disclosure, the inhaler article is constructed from a single outer tube body. The outer tube body may be, for example, a tube. The outer tube body may be, for example, a paper wrapper. The outer tube may be, for example, wrapping paper. The outer tube body may be, for example, cardboard. A cardboard outer tube may be biodegradable. A cardboard outer tube may be stiffer than outer wrap paper traditionally used in the manufacture of aerosol-generating articles. Because the outer tube body is a single tube body, not constructed from multiple tube bodies abutted against each other and then assembled together by, for example, wrapping multiple tube elements with a wrapping paper, this outer tube body provides a rigid inhaler article compared to an inhaler article assembled from multiple tube elements. The abutment where tube elements are assembled together may be less rigid, less strong, more prone to bending or crushing, compared to a single tube body. In addition, the use of a single outer tube body decreases manufacturing complexity in the assembly of multiple tubular parts to form a tube body of an inhaler article because it requires fewer parts. Reducing the number of parts reduces the number of manufacturing steps. When an element such as a support element is to be inserted into an outer tube body, it can be difficult to place the support element in the correct location. Advantageously, the use of a mouth plug as disclosed herein, where the mouth plug has an internal tube having a length that places the support member into the correct location when the mouth plug is inserted into an outer tube body, reduces manufacturing complexity.

A wrapper may be wrapped around the outer tube body. The wrapper may be tipping paper. Where an outer tube body is used, the wrapper is optional and can be used decorate the inhaler article, or to provide bar codes, information, advertising, trademarks or other information to the consumer. Advantageously, wrapping paper or tipping paper is not necessary for the structural integrity of the inhaler article, but is instead optional. This reduces manufacturing steps and increases product flexibility.

The support member, including the internal structure of the support member, may be made from biodegradable materials. Support member airways may be provided punching or cutting support member airways into the support member. In embodiments, the at least two support member airways are peripheral to a closed central area of the upstream face of the support member. According to an embodiment, none of the support member airways pass through the center of the support member. Advantageously, the at least two support member airways are peripheral to the closed central area of the upstream face of the support member. The at least two support member airways are offset from the center of the support member.

The support member fits into the cavity of the outer tube body. The support member has a diameter. The center of the support member is the point at which diameters drawn from multiple points around the support member intersect. The center of the support member may be at the central axis of the outer tube body. The placement of the at least two support member airways peripheral to the closed central area of the support member ensures that air flowing through support member of the inhaler article must follow a circuitous or convoluted airflow pathway. It is desirable to provide an inhaler article that reduces leakage of dry powder. It is desirable to provide an inhaler article that reduces leakage of dry powder from the upstream end or from the downstream end of the inhaler article. This leakage may occur when the inhaler article is not in use. This leakage occurs more readily when there is a relatively unrestricted or open airflow path. This leakage occurs more readily when there is a direct and open pathway between the capsule and the airflow outlet. If there is a direct and open pathway between the capsule and the airflow outlet, dry powder released from the capsule may fall out of the inhaler article when the inhaler article is not in use. By introducing a more convoluted airflow pathway, dry powder released from the capsule gets caught in the convoluted airflow pathway. Dry powder that is caught in the convoluted airflow pathway cannot fall out of the inhaler article. Instead, in order for dry powder to find its way to the airflow outlet, it must be pulled along through the convoluted airflow pathway in an airflow initiated by the user. Advantageously, a convoluted airflow path reduces leakage of dry powder from the inhaler article. In embodiments, the support member airways may be placed in any location in the support member. In embodiments, support member airways may form straight passageways from the upstream face to the downstream face of the support member along the longitudinal axis of the inhaler article. Or the support member airways may be straight passageways that are angled with respect to the central axis of the inhaler article. Or, the support member airways may form curved or angled passageways between the upstream face and the downstream face of the support member. The support member airways may form circuitous or convoluted passageways between the upstream face and the downstream face of the support member.

In addition, this circuitous or convoluted airflow may prevent larger dry particles from exiting the inhaler article through the airflow outlet. That is, larger dry particles may not flow through the support member airways or through the circuitous or convoluted airflow pathway. Larger dry particles may fall out of the airflow. Larger dry particles may accumulate in the dead end of the airflow passageway. Advantageously, the circuitous or convoluted airflow passageway may filter larger dry particles and prevent them from being inhaled by the user.

The wrapping paper may be biodegradable. The front plug and the mouth plug may be made from biodegradable materials. The front plug, the mouth plug and the support member, including the internal structure of the support member, may be the same material. For example, the mouth plug may be made from more layers of material compared the number of layers of material used to produce the front plug, thus providing a mouth plug made from thicker material than the front plug. In providing an inhaler article made from multiple parts made from the same material, manufacture of the inhaler article is simplified. Reducing the number of materials may reduce the number of manufacturing steps to produce the inhaler article.

According to an aspect of the present disclosure, the downstream end, the mouth-end of the inhaler articled may be formed by the outer tube body. For example, the mouth plug may be inserted into the outer tube body, the downstream end of the mouth plug fitting inside the outer tube body cavity. The outer tube body may then be bent, folded or curved to form a curved downstream end of the inhaler.

According to an aspect of the present disclosure, an inhaler article is provided wherein a mouth plug as described above is inserted into an outer tube body, and wherein the space between the external surface of the internal tube and the internal surface of the outer tube body downstream of the support member provides an airflow passageway downstream of the support member. According to an aspect of the present disclosure, the internal tube of the mouth plug comprises an internal tube air opening. According to an aspect of the present disclosure, an inhaler article is provided comprising an airflow path wherein air flows from upstream of the support member, through the at least two support member airways to the airflow passageway, through the internal tube air opening to enter the internal tube cavity to exit the inhaler article at the air outlet. According to an aspect of the present disclosure, an inhaler article is provided comprising an airflow path wherein air flows from an air inlet upstream of the support member, through the at least two support member airways to the airflow passageway, through the internal tube air opening to enter the internal tube cavity to exit the inhaler article at the air outlet. The structure of the inhaler article and the mouth plug enable a convoluted airflow path. The convoluted airflow path passes through the support member through the support member airways. These support member airways may be located between the perimeter of the support member and the perimeter of the internal tube on the downstream face of the support member. This directs airflow to the airflow passageway between the external surface of the internal tube and the internal surface of the outer tube body provides an airflow passageway downstream of the support member. The airflow is generated by suction provided by a user at the airflow outlet of the inhaler article. The airflow outlet may be at the downstream end of the internal tube of the mouth plug. Airflow therefore flows to the airflow outlet at the downstream end of the internal tube of the mouth plug. In order to flow to the airflow outlet, airflow may cross from the airflow passageway downstream of the support member to the internal tube cavity. This airflow path is advantageous in several ways. Airflow passes to the internal tube cavity via internal tube air openings. These support member airways may have a smaller diameter than the cavity of the outer tube body of the inhaler article. These constrictions in airflow accelerate airflow through the support member airways. In addition, this airflow path is convoluted which may prevent leakage of dry powder from the capsule of the inhaler article as discussed below. Advantageously, the internal tube air openings allow for air to flow from the outside of the internal tube to the inside of the internal tube when an airflow is introduced into an inhaler article having a mouth plug. This internal tube air opening allows for air to flow from the inside of the internal tube to the outside of the internal tube when an airflow is introduced into an inhaler article having a mouth plug.

As the airflow passes through the internal tube air opening, some dry powder particles entrained in the airflow pass through the internal air opening to be carried to the airflow outlet. Some dry powder particles may not pass through the internal air opening and may be captured in the airflow passage between the internal tube of the mouth plug and the internal surface of the outer tube body downstream of the internal tube air opening. This may prevent leakage of the dry powder from the capsule of the inhaler article.

According to an aspect of the present disclosure, a method for manufacturing an inhaler article comprising the steps of: inserting a mouth plug as described herein into an outer tube body, the outer tube body comprising an upstream end, a downstream end, a central axis, an outer surface and an internal surface, wherein the internal surface defines a cavity inside the outer tube body; wherein the mouth plug is inserted into the outer tube body cavity at the downstream end of the outer tube body. The manufacturing method may include a step of placing an adhesive on a surface of a mouth plug before inserting the mouth plug into the outer tube body. The adhesive may be placed on the perimeter of the support member. The adhesive may be placed on the downstream end of the mouth plug. The manufacturing method may also include an additional step of inserting a capsule into the outer tube body upstream of the mouth plug. The manufacturing method may also include a step of applying an outer wrap. The manufacturing step may also include a step of flanging the upstream end of the outer tube body. The manufacturing step may also include a step of curving the downstream end of the outer tube body.

According to an aspect of the present disclosure, an inhaler article is provided wherein the downstream end of the mouth plug contacts the downstream end of the outer tube body. That is, when the mouth plug is inserted into the outer tube body, the downstream end of the mouth plug sits into the downstream end of the outer tube body. This lends rigidity and strength to the inhaler article as the mouth plug reinforces the downstream end of the inhaler article. The inhaler article may be further reinforced where the mouth plug is affixed to the outer tube body with adhesive. According to an aspect of the present disclosure, the inhaler article comprises a capsule contained in the cavity in the outer tube body upstream of the support member. The capsule may be in the outer tube cavity upstream of the support element. The center of the support member is at the central axis of the outer tube body. When the capsule is contained in the cavity of the outer tube body, the capsule is upstream of the support member and the capsule is aligned along the central axis of the outer tube body. The capsule may be in the shape of a cylinder with two hemispherical ends. The capsule may be symmetrical. The capsule may have an upstream end and a downstream end. The upstream end and the downstream end of the capsule may be considered the radial ends of the capsule. The radial ends of the capsule may be the points of the capsule that are furthest apart from each other. The radial ends of the capsule may be along the central longitudinal axis of the capsule. Because the capsule is centered in the outer tube body and because the capsule may be symmetrical, the downstream radial end of the capsule may contact the upstream face of the support member in the center of the upstream face of the support member. When air flows through the inhaler article and passes the capsule, the flow of air agitates and rotates the capsule. The capsule moves in response to the flow of air. The capsule may contain dry powder. The dry powder may comprise nicotine. The dry powder may comprise flavorants. This movement of the capsule shakes the capsule’s contents out of the capsule. It would be desirable to provide a support member that enables the capsule to agitate and rotate as freely as possible as air flows past the capsule, to allow the capsule to empty its contents as freely as possible.

The support member airways provide the only pathways for air to flow from the upstream side of the support member to the downstream side of the support member so that air flowing must pass through these support member airways. The structure of these support member airways are the controls, the valves, that control flow of air through the inhaler article. Advantageously, the at least two support member airways are smaller than the diameter of the cavity of the outer tube body. These restricted airways accelerate airflow. Accelerated airflow may be more able to entrain dry powder released from the capsule and carry that dry powder toward the air outlet at the downstream end of the outer tube of the inhaler article.

Advantageously, the at least two support member airways are offset from the center of the support member. None of the support member airways pass through the center of the support member. The placement of the at least two support member airways ensures that air flowing through the outer tube body of the inhaler article must follow circuitous or convoluted airflow pathway. It is desirable to provide an inhaler article that reduces leakage of dry powder. It is desirable to provide an inhaler article that reduces leakage of nicotine-containing powder from the upstream end or from the downstream end of the inhaler article. This leakage may occur when the inhaler article is not in use. This leakage occurs more readily when there is a relatively unrestricted or open airflow path. By introducing a more convoluted airflow pathway, dry powder released from the capsule cannot fall out of the inhaler article or is at least reduced. Instead, in order for dry powder to find its way to the airflow outlet, it must be pulled along in an airflow initiated by the user. Advantageously, a convoluted airflow path reduces leakage of dry powder from the outer tube body and from the inhaler article.

According to an aspect of the present disclosure, there is provided a support member wherein the upstream face of the support member comprises a flat surface. The upstream face of the support member may have a flat structure transverse to the central axis of the mouth plug. The support member may have a perimeter. The support member may be arranged transverse to the center axis of the mouth plug. Advantageously, the support member may be a disk arranged inside the outer tube body where the support member fits into the outer tube body so that the perimeter of the support member fits against the internal surface of the outer tube body. The support member may be made from biodegradable material.

According to an aspect of the present disclosure, there is provided an inhaler article comprising: an outer tube body, the outer tube body comprising an upstream end, a downstream end, a central axis, an outer surface and an internal surface, wherein the internal surface defines a cavity inside the outer tube body, the outer tube body cavity having a diameter; a support member in the outer tube body cavity, the support member comprising an upstream face, a downstream face, a thickness and a center, the support member arranged to extend across the diameter of the cavity of the outer tube body, wherein the support member comprises at least two support member airways comprising apertures extending from the upstream face to the downstream face through the thickness of the support member; wherein none of the support member airways pass through the center of the support member.

According to this aspect of the present disclosure, the inhaler article is constructed from a single outer tube body. The outer tube body may be, for example, a tube. The outer tube body may be, for example, a paper wrapper. The outer tube may be, for example, wrapping paper. The outer tube body may be, for example, cardboard. A cardboard outer tube may be biodegradable. A cardboard outer tube may be stiffer than outer wrap paper traditionally used in the manufacture of aerosol-generating articles. Because the outer tube body is a single tube body, not constructed from multiple tube bodies abutted against each other and then assembled together by, for example, wrapping multiple tube elements with a wrapping paper, this outer tube body provides a rigid inhaler article compared to an inhaler article assembled from multiple tube elements. The abutment where tube elements are assembled together may be less rigid, less strong, more prone to bending or crushing, compared to a single tube body. In addition, the use of a single outer tube body decreases manufacturing complexity in the assembly of multiple tubular parts to form a tube body of an inhaler article because it requires fewer parts. Reducing the number of parts reduces the number of manufacturing steps. On the other hand, in the manufacturing setting, when an element such as a support element is to be inserted into the tube body, the use of a single tube body may introduce different manufacturing complexity related to the placement of an internal element or affixing an internal element to the inside of single tube body. A wrapper may be wrapped around the outer tube body. The wrapper may be tipping paper. Where an outer tube body is used, the wrapper is optional and can be used decorate the inhaler article, or to provide bar codes, information, advertising, trademarks or other information to the consumer.

The support member, including the internal structure of the support member, may be made from biodegradable materials. The wrapping paper may be biodegradable. The front plug and the mouth plug may be made from biodegradable materials. The front plug, the mouth plug and the support member, including the internal structure of the support member, may be the same material. For example, the mouth plug may be made from more layers of material compared the number of layers of material used to produce the front plug, thus providing a mouth plug made from thicker material than the front plug. In providing an inhaler article made from multiple parts made from the same material, manufacture of the inhaler article is simplified. Reducing the number of materials may reduce the number of manufacturing steps to produce the inhaler article.

The wrapping paper material may be, for example, paper having a weight from 20 gsm to 200 gsm. The wrapping paper may have a weight of from 25 to 100 gsm. The wrapping paper may have a weight of from 30 to 100 gsm. The wrapping paper may have a weight of from 40 to 100 gsm. The wrapping paper may have a weight of from 50 to 100 gsm. The wrapping paper may have a weight of from 25 to 150 gsm. The wrapping paper may have a weight of from 30 to 150 gsm. The wrapping paper may have a weight of from 50 to 150 gsm.

The outer tube body material may be cardboard having a weight from 40 gsm to 600 gsm. The front plug may be cardboard having a weight from 50 gsm to 600 gsm. The front plug may be cardboard having a weight from 60 gsm to 600 gsm. The front plug may be cardboard having a weight from 40 gsm to 500 gsm. The front plug may be cardboard having a weight from 50 gsm to 600 gsm. The front plug may be cardboard having a weight from 60 gsm to 600 gsm. The front plug may be cardboard having a weight from 40 gsm to 400 gsm. The front plug may be cardboard having a weight from 50 gsm to 400 gsm. The front plug may be cardboard having a weight from 60 gsm to 600 gsm.

The mouth plug material may be, for example, cardboard having a weight from 40 gsm to 600 gsm. The front plug may be cardboard having a weight from 50 gsm to 600 gsm. The front plug may be cardboard having a weight from 60 gsm to 600 gsm. The front plug may be cardboard having a weight from 40 gsm to 500 gsm. The front plug may be cardboard having a weight from 50 gsm to 600 gsm. The front plug may be cardboard having a weight from 60 gsm to 600 gsm.

The support member material may be, for example, bioplastic or cardboard having a weight from 200 gsm to 700 gsm. The support member material may be, for example, bioplastic or cardboard having a weight from 250 gsm to 700 gsm. The support member material may be, for example, bioplastic or cardboard having a weight from 300 gsm to 700 gsm. The support member material may be, for example, bioplastic or cardboard having a weight from 400 gsm to 700 gsm.

Advantageously, the support member provides structural rigidity by providing an internal structure extending across the diameter of the cavity of the outer tube body. The support member may have a disk shape where the disk has an upstream face, a downstream face, a thickness and a center. The support member may be cylindrical. The support member has a central axis that passes through the center of the support member. The support member upstream face may have a diameter. The support member downstream face may have a diameter. The upstream face diameter and the downstream face diameter may be the same. The upstream face of the support member may have closed central area. The closed central area may be a flat structure transverse to the central axis of the outer tube body. The support member may have a perimeter. The support member may be arranged transverse to the center axis of the outer tube body. The support member may be a disk arranged inside the outer tube body where the support member fits into the outer tube body so that the perimeter of the support member fits against the internal surface of the outer tube body. The support member may be made from biodegradable material.

This support member structure provides rigidity in the radial direction by providing support in the radial direction, at least where the support member is placed inside the outer tube body. In addition, this structure provides a block to airflow from the upstream end of the outer tube body to the downstream end of the outer tube body. The support member airways provide the only pathways for air to flow from the upstream side of the support member to the downstream side of the support member so that air flowing must pass through these support member airways. The structure of these support member airways are the controls, the valves, that control flow of air through the inhaler article. Advantageously, the at least two support member airways are smaller than the diameter of the cavity of the outer tube body. These restricted airways accelerate airflow. Accelerated airflow may be more able to entrain dry powder released from the capsule and carry that dry powder toward the air outlet at the downstream end of the outer tube of the inhaler article.

Advantageously, the at least two support member airways are offset from the center of the support member. None of the support member airways pass through the center of the support member. The placement of the at least two support member airways ensures that air flowing through the outer tube body of the inhaler article must follow circuitous or convoluted airflow pathway. It is desirable to provide an inhaler article that reduces leakage of dry powder. It is desirable to provide an inhaler article that reduces leakage of active compound -containing dry powder from the upstream end or from the downstream end of the inhaler article. This leakage may occur when the inhaler article is not in use. This leakage occurs more readily when there is a relatively unrestricted or open airflow path. By introducing a more convoluted airflow pathway, dry powder released from the capsule cannot fall out of the inhaler article. Instead, in order for dry powder to find its way to the airflow outlet, it must be pulled along in an airflow initiated by the user. Advantageously, a convoluted airflow path reduces leakage of dry powder from the outer tube body and from the inhaler article.

According to an aspect of the present disclosure, the at least two support member airways may comprise spaces between the internal surface of the outer tube body and the support member. That is, the support airways may be partially defined by the internal surface of the outer tube body and partially defined by the perimeter of the support element. The at least two support member airways may comprise, in part, the internal surface of the outer tube body. The partial contour of a support member airway at the perimeter of the support element may be called a “flute”. Advantageously, this structure may create a convoluted airflow which may improve the delivery of dry particles to the user during use.

In an aspect of the present disclosure, the at least two support member airways are apertures extending form the upstream face to the downstream face of the support member. Advantageously, the support member airways allow air to pass from the area upstream of the support member to the area downstream of the support member. According to an aspect of the present disclosure, each of the at least two support member airways have a diameter, and the support member airway diameters are less than the diameter of the outer tube body cavity.

When the at least two support member airways have a narrower diameter than the diameter of the outer tube body, as air flows into the inhaler article through an air inlet, passes around the capsule, then flows through the at least two support member airways having diameters less than the diameter of the outer tube cavity, the flowing air accelerates due to the Venturi effect (using Bernoulli’s principle”). The at least two support member airways accelerate airflow. This acceleration of airflow can help to extract dry powder from the area surrounding the capsule.

In addition, the airpath of air flowing into the inhaler article, around the capsule, through the at least two support member airways, and then downstream to the air outlet, is a convoluted airpath. Advantageously, a convoluted airpath may reduce leakage of dry powder from the inhalator article because particles may be captured in this convoluted airpath instead of falling out of the air outlet.

According to an aspect of the disclosure, one or more of the support airways may have filter material. One or more of the at least two support airways may contain filter material. This filter material may span the airway so that particles released from the capsule are filtered by the filtered material. The filter material may be mesh. Advantageously, the presence of filter material, which may be mesh, filters out unwanted larger dry particles and prevents particles that are too large from being delivered to a user. According to an aspect of the disclosure, more than two support airways are present. For example, at least four support member airways may be present. Or more support member airways may be present. According to an aspect of the disclosure, a capsule may be in the cavity of the outer tube body. The capsule may be in the outer tube cavity upstream of the support element. The center of the support member is at the central axis of the mouth plug. When the capsule is contained in the cavity of the outer tube body, the capsule is upstream of the support member and the capsule is aligned along the central axis of the outer tube body. Because the capsule is centered in the outer tube body and because the capsule may be symmetrical, the radial end of the capsule may contact the upstream face of the support member in the center of the upstream face of the support member. It would be desirable to provide a support member that enables the capsule to rotate and empty its contents as freely as possible. One way to improve the rotation of the capsule and the emptying of the capsule is to reduce friction between the capsule and the structures that the capsule contacts as it rotates. Because the radial end of the capsule contacts the upstream face of the support member, reducing friction at that point improves the rotation of the capsule and emptying of the capsule. When the upstream face of the support member is flat, friction is reduced, providing the advantage of improved rotation of the capsule and improved emptying of the capsule. Support member airways require apertures in the upstream face of the support member. These apertures are not a flat, smooth surface. That is, the presence of an aperture introduces roughness to the upstream surface of the support element. This roughness may introduce friction between the upstream face of the support element. The friction created by the support element acting against the capsule limits the rotation speed of the capsule. If the capsule contacts an area of the upstream face of the support member where there is roughness, the roughness may inhibit the movement or agitation of the capsule during air movement. Advantageously, the at least two support member airways are not located at the central axis. Advantageously, the at least two support member airways are not located at the center point of the upstream face of the support member of the mouth plug. Keeping the center of the upstream face of the support member free of structures such as support member airways may reduce friction between the capsule and the upstream face of the support member and allows the capsule to move as freely as possible in this environment. Allowing the capsule to move more freely may allow the capsule to release its contents more efficiently. Therefore, a support member wherein none of the support member airways pass through the center of the support member is advantageous because that configuration reduces friction and may allow the capsule to rotate more freely and empty its contents more efficiently.

If the capsule contacts an area of the upstream face of the support member where there is roughness, the roughness may inhibit the movement or agitation of the capsule during air movement. Advantageously, the at least two support member airways are not located at the central axis. Advantageously, the at least two support member airways are not located at the center point of the upstream face of the support member of the mouth plug. Keeping the center of the upstream face of the support member free of structures such as support member airways may reduce friction between the capsule and the upstream face of the support member and allows the capsule to move as freely as possible in this environment. Allowing the capsule to move more freely may allow the capsule to release its contents more efficiently.

According to an aspect of the disclosure, a capsule is contained in the cavity of the outer tube body upstream of the support element. The capsule may be inserted outer tube body cavity upstream of the support member after the support member has been inserted into the outer tube body. The capsule may contain dry powder. The dry powder may comprise an active compound. The dry powder may comprise a pharmaceutically active compound. The dry powder may comprise nicotine.

For example, the capsule may dry powder comprising nicotine powder having a mean diameter particle size expressed as a volume-based particle size distribution having a D50 of the particle size distribution as measured by laser diffraction. For example, the capsule may contain nicotine powder have D50 mean diameter particle sizes of between 0.5 - 3 pm. The capsule may contain nicotine powder have D50 mean diameter particle sizes of between 0.5 pm to 2.5 pm. The capsule may contain nicotine powder have D50 mean diameter particle sizes of between 0.6 pm to 2.4 pm. The capsule may contain nicotine powder have D50 mean diameter particle sizes of between 0.7 pm to 2.3 pm. The capsule may contain nicotine powder have D50 mean diameter particle sizes of between 0.7 pm to 2.0 pm. The capsule may contain nicotine powder have D50 mean diameter particle sizes of between 0.7 pm to 1.8 pm. The capsule may contain nicotine powder have D50 mean diameter particle sizes of between 1.3 pm +/- 0.5 pm.

The dry powder may comprise flavor particles or flavorants. For example, the capsule may contain flavorants having D50 mean diameter particle sizes as measured by laser diffraction of between 50 and 200 pm. The capsule may contain flavorants having D50 mean diameter particle sizes of between 100 and 150 pm. The capsule shell may be, for example, hydroxypropyl methylcellulose (HPMC).

According to an aspect of the disclosure, the upstream end of the outer tube body is flanged. According to an aspect of the disclosure, the upstream end of the outer tube body is folded. A fold is formed by bending the upstream end of the outer tube body of the inhaler article. The fold may be an inward fold, toward the central axis of the outer tube body. Or, the upstream end of the outer tube body may be flanged. A flange is a closure or partial closure at the upstream end of the outer tube body made from multiple folds. A flanged end may have multiple folds in the form of a fan fold. This folded or flanged upstream end may be advantageous to contain the capsule inside the cavity of the outer tube body of the inhaler article. Advantageously, using an outer tube body made from stiff cardboard makes the manufacturing process more reliable by reducing the chance of damage during the folding or flanging process.

According to an aspect of the disclosure, the downstream end or mouth end of the inhaler article is curved. This curved downstream end provides a curved airflow exit. The curved downstream end may be a torus shape. When the user places the downstream end of the inhaler article into the mouth, this curved airflow exit may be more comfortable to the user. This curved airflow exit may allow the user to inhale dry powder released in the inhaler article while also controlling the pressure drop through the inhaler article. Advantageously, this curved end at the downstream end or mouth-end may prevent dry powder from leaking from the airflow exit. That is, as dry powder mixed with air flows through the inhaler article, air and dry powder that does not flow out of the air outlet to be inhaled by the user is captured in the internal space of the curve. The internal space of the curve may be a dead end that captures dry powder.

According to an aspect of the disclosure, the outer tube body may provide an airflow inlet. The airflow inlet may be at the upstream end of the outer tube body. The airflow inlet may be an aperture through the outer tube body. There may be multiple airflow inlets. The airflow inlets may be a combination of airflow inlets at the upstream end of the outer tube body and airflow inlets through the outer tube body. According to an aspect of the disclosure, the inhaler article may provide an airflow outlet. The airflow outlet may be the downstream end of the outer tube body. The airflow outlet may be defined by the curved downstream end of the outer tube body, the airflow outlet being the center of the torus-shaped curved downstream end.

According to an aspect of the disclosure, the diameter of the support member is equal to or slightly larger than the diameter of the outer tube body cavity so that the support member fits into the cavity of the outer tube body in an interference fit. According to an aspect of the disclosure, the support member is affixed to the upstream end of the inner tube body with adhesive.

According to an aspect of the disclosure, the disclosure provides an inhaler article comprising an outer tube body, the outer tube body comprising an upstream end, a downstream end, a central axis, an outer surface and an internal surface, wherein the internal surface defines a cavity inside the outer tube body, the outer tube body cavity having a diameter; a support member in the outer tube body cavity, the support member comprising an upstream face, a downstream face, a thickness and a center, the support member arranged to extend across the diameter of the cavity of the outer tube body, wherein the support member comprises at least two support member airways comprising apertures extending from the upstream face to the downstream face and passing through the thickness of the support member; wherein none of the support member airways pass through the center of the support member; a capsule in the outer tube body cavity upstream of the support member; wherein the upstream end of the outer tube body is flanged; and wherein the downstream end of the outer tube body is curved. According to an aspect of the disclosure, the inhaler article provides an airflow path from an airflow inlet, around the capsule, through the at least two support member airways, to an airflow outlet. Advantageously, the inhaler article provides a convoluted airflow path as air passes through the at least two support member airways wherein none of the support member airways pass through the center of the support member. According to an aspect of the disclosure, the downstream end or mouth end of the inhaler article is curved. This curved downstream end provides a curved airflow exit. When the user places the downstream end of the inhaler article into the mouth, this curved airflow exit may be more comfortable to the user. This curved airflow exit may allow the user to inhale dry powder released in the inhaler article while also controlling the pressure drop through the inhaler article. This curved end at the downstream end or mouth-end may prevent dry powder from leaking from the airflow exit. That is, as dry powder mixed with air flows through the inhaler article, air and dry powder that does not flow out of the air outlet to be inhaled by the user is captured in the curve. Dry powder captured in the internal contour of the curved downstream end is less likely to leak out of the inhaler article during or after use.

According to an aspect of the disclosure, the upstream end of the outer tube body is folded. The fold is formed by bending the upstream end of the outer tube body of the inhaler article. The fold may be an inward fold, toward the central axis of the outer tube body. Or, the upstream end of the outer tube body may be flanged. A flange is a closure or partial closure at the upstream end of the outer tube body made from multiple folds. This folded or flanged upstream end may be advantageous to contain the capsule inside the cavity of the outer tube body of the inhaler article.

According to an aspect of the disclosure, in use, air flows through the inhaler article via an airflow path. The airflow path through an inhaler article begins at an airflow inlet, travels through the inhaler article, past the capsule, through the support member, through the mouth plug and exits the inhaler article at a mouth end or downstream end where the air traveling in the airflow path is inhaled by a user. Air flows through the support member through the support member airways.

According to an aspect of the disclosure, activation or piercing of the inhaler article may occur by using a separate piercing element. The piercing element may be a needle, for example. The user may introduce a needle into the upstream end of the capsule to release dry powder prior to using the inhaler article.

According to an aspect of the disclosure, the piercing element may be a component of a holder. The inhaler article may be inserted into a cavity of the holder, the piercing element may extend into the inhaler article to pierce the capsule, and the piercing element may withdraw from the inhaler article. The holder may have an air inlet aligned with the air inlet of the inhaler article.

According to an aspect of the disclosure, the holder may have an airflow management system which provides spiral or angled airflow into the cavity of the inhaler article. This spiral or angled airflow may assist in moving the capsule inside the cavity of the inhaler article. The movement of the capsule in this spiral or angled airflow allows the dry powder contained in the capsule to shake loose. Advantageously, the presence of a spiral or angled airflow improves the emptying of dry powder from a capsule in an inhaler article. According to an aspect of the disclosure there is provided an inhaler article comprising: an outer tube body, the outer tube body comprising an upstream end, a downstream end, a central axis, an outer surface and an internal surface, wherein the internal surface defines a cavity inside the outer tube body, the outer tube body cavity having a diameter; a support member in the outer tube body cavity, the support member comprising an upstream face, a downstream face, a thickness and a center, the support member arranged to extend across the diameter of the cavity of the outer tube body, wherein the support member comprises at least two support member airways comprising apertures extending from the upstream face to the downstream face through the thickness of the support member; wherein none of the support member airways pass through the center of the support member further comprising a mouth plug in the outer tube body cavity downstream of the support member, the mouth plug comprising an upstream end in contact with the downstream face of the support member and a downstream end comprising an air outlet. Advantageously, the mouth plug downstream of the support member may lend more rigidity to the inhaler article.

According to an aspect of the present disclosure, there is provided an inhaler article comprising: an outer tube body, the outer tube body comprising an upstream end, a downstream end, a central axis, an outer surface and an internal surface, wherein the internal surface defines a cavity inside the tube body; a mouth plug comprising an upstream end, a downstream end and a central axis; wherein the central axis of the tube body and the central axis of the mouth plug are the same; the mouth plug inserted into the downstream end of the outer tube so that the upstream end of the mouth plug is contained in the outer tube body and the downstream end of the mouth plug fits with the downstream end of the outer tube body to form the downstream end of the inhaler article; wherein the downstream end of the mouth plug comprises an air outlet; wherein the upstream end of the mouth plug comprises a support member arranged transverse to the central axis of the outer tube body and the mouth plug, the support member comprising an upstream face, a downstream face, a perimeter and a diameter; wherein the support member comprises at least two support member airways structured to allow air to pass through the support member and wherein the at least two support member airways are not located at the central axis.

According to this aspect of the present disclosure, the inhaler article is constructed from a single outer tube body. Because the outer tube body is a single tube body, not constructed from multiple tube bodies abutted against each other and then assembled together by, for example, wrapping multiple tube elements with a wrapping paper, this outer tube body provides a rigid inhaler article compared to an inhaler article assembled from multiple tube elements. The abutment where tube elements are assembled together may be less rigid, less strong, more prone to bending or crushing, compared to a single tube body. In addition, the use of a single outer tube body decreases manufacturing complexity in the assembly of multiple tubular parts to form a tube body of an inhaler article because it requires fewer parts. On the other hand, in the manufacturing setting, when another element is to be inserted into the tube body the use of a single tube body may introduce different manufacturing complexity related to the placement of an internal element or affixing an internal element to the inside of single tube body.

According to an aspect of the present disclosure, a mouth plug having a support member arranged transverse to the central axis of the outer tube body is inserted into the outer tube body. Advantageously, the shape of the support member, a disk-like structure arranged transverse to the central axis of the outer tube body allows the mouth plug to orient with respect to the outer tube body as it is inserted into the outer tube body, ensuring that the mouth plug and the outer tube body are assembled properly. This improves the manufacturing process by leveraging the shape of the parts to improve the assembly of the parts.

The support member comprising an upstream face, a downstream face, a perimeter and a diameter; wherein the support member comprises at least two support member airways structured to allow air to pass through the support member and wherein the at least two support member airways are peripheral to the closed central area of the upstream face of the support member. For example, the at least two support member airways are not located at the central axis. The center of the support member is at the central axis of the outer tube.

The center of the support member is at the central axis of the mouth plug. The center of the support member is at the central axis of the outer tube body. The mouth plug may be centered in the outer tube body, so that the central axis of the mouth plug is the same as the central axis of the outer tube body. When the capsule is contained in the cavity of the outer tube body, the capsule is upstream of the support member and the capsule is aligned along the central axis of the mouth plug. Because the capsule is centered in the outer tube body and because the capsule may be symmetrical, the radial end of the capsule may contact the upstream face of the support member in the center of the upstream face of the support member. The center of the upstream face of the support member is collocated with the central axis of the outer tube and the central axis of the mouth plug. The support member airways are apertures. These apertures deviate from flat. That is, the presence of an aperture introduces roughness to the upstream surface of the support element. This roughness may introduce friction between the upstream face of the support element. The friction created by the support element acting against the capsule limits the rotation speed of the capsule.

If the capsule contacts an area of the upstream face of the support member where there is roughness, the roughness may inhibit the movement or agitation of the capsule during air movement. Advantageously, the upstream face of the support member is closed in the central area where the capsule may contact the upstream face of the support member. That is, the capsule may rotate more freely if it is not pressed against support member structure that is different from a flat surface. For example, the at least two support member airways are not located at the central axis. Advantageously, the at least two support member airways are not located at the center point of the upstream face of the support member of the mouth plug where the capsule might contact the upstream face of the support member. Providing the upstream face of the support member with a closed central area that is free of structures such as support member airways may reduce friction between the capsule and the upstream face of the support member and allows the capsule to move as freely as possible in this environment. Allowing the capsule to move more freely may allow the capsule to release its contents more efficiently.

In an aspect of the present disclosure, the at least two support member airways are apertures extending form the upstream face to the downstream face of the support member. Advantageously, the support member airways allow air to pass from the area upstream of the support member to the area downstream of the support member.

The at least two support member airways have a narrower diameter than the diameter of the outer tube body. Advantageously, as air flows into the inhaler article through an air inlet, passes around the capsule, then flows through the at least two support member airways, the flowing air accelerates due to the Venturi effect (using Bernoulli’s principle”) and this acceleration of airflow can help to extract dry powder from the area surrounding the capsule.

When a capsule is inserted into the outer tube body upstream of the mouth plug and upstream of the support member, the capsule may contact the upstream face of the support member. In an aspect of the present disclosure, the upstream face of the of the support member is a closed central area that is a flat feature, perpendicular to the central axis of the outer tube body. The radial endpoint of the capsule abuts the upstream face of the support member. Because the upstream face of the support member is flat, it provides less friction against the capsule. This allows the capsule to move more freely in the cavity of the outer tube body, allowing the capsule to release its dry powder contents more readily. Advantageously, a reduction in friction between the support member upstream face and the capsule may allow for a higher capsule rotation speed to be reached during the consumer inhalation process.

According to an aspect of the disclosure, more than two support airways are present. For example, at least four support member airways may be present. Or more support member airways may be present.

According to an aspect of the disclosure, the support airways may have filter material. This filter material may span the airway so that particles released from the capsule are filtered by the filtered material. The filter material may be mesh. Advantageously, the presence of filter material, which may be mesh, filters out unwanted larger dry particles and prevents particles that are too large from being delivered to a user.

According to an aspect of the disclosure, a capsule is contained in the cavity of the outer tube body upstream of the support element of the mouth plug. The capsule may be inserted into the upstream cavity after the mouth plug has been inserted into the outer tube body. The capsule may contain dry powder. The dry powder may comprise an active compound. The dry powder may comprise a pharmaceutically active compound. The dry powder may comprise nicotine. For example, the capsule may contain nicotine powder having mean diameter particle sizes of 1.3-2 pm. The dry powder may comprise flavor particles or flavorants. For example, the capsule may contain flavorants having a mean diameter particle size of from 50 to 200 pm and 100 to 150 pm. In embodiments, the dry powder comprises a pharmaceutically active agent. In embodiments, the dry powder is nicotine. In embodiments, the dry powder includes flavorants. In embodiments, the dry powder has a range of particle sizes of from 50 to 200 pm in average diameter. In embodiments the dry powder has a range of particle sizes of from 100 to 150 pm in average diameter.

According to an aspect of the disclosure, the downstream end or mouth end of the mouth plug of the inhaler article is curved. This curved downstream end provides a curved airflow exit. When the user places the downstream end of the inhaler article into the mouth, this curved airflow exit may be more comfortable to the user. This curved airflow exit may allow the user to inhale dry powder released in the inhaler article while also controlling the pressure drop through the inhaler article. This curved end at the downstream end or mouth-end may prevent dry powder from leaking from the airflow exit. That is, as dry powder mixed with air flows through the inhaler article, air and dry powder that does not flow out of the air outlet to be inhaled by the user is captured in the curve. The curved downstream end may be formed by folding the outer tube body. The curved downstream end may be provided by the curved downstream end of the mouth plug.

According to an aspect of the disclosure, the upstream end of the outer tube body is folded. The fold is formed by bending the upstream end of the outer tube body of the inhaler article. The fold may be an inward fold, toward the central axis of the outer tube body. The upstream end of the outer tube body may be flanged. A flange is a closure or partial closure at the upstream end of the outer tube body made from multiple folds. This folded or flanged upstream end may be advantageous to contain the capsule inside the cavity of the outer tube body of the inhaler article.

According to an aspect of the disclosure, activation of the inhaler article may occur by using a separate piercing element. The piercing element may be a needle, for example. The user may introduce a needle into the upstream end of the capsule to release dry powder prior to using the inhaler article.

According to an aspect of the disclosure, the piercing element may be a component of a holder. The inhaler article may be inserted into a cavity of the holder, the piercing element may extend into the inhaler article to pierce the capsule, and the piercing element may withdraw from the inhaler article. The holder may have an air inlet aligned with the air inlet of the inhaler article. According to an aspect of the disclosure, the holder may have an airflow management system which provides spiral or angled airflow into the cavity of the inhaler article. This spiral or angled airflow may assist in moving the capsule inside the cavity of the inhaler article. The movement of the capsule in this spiral or angled airflow allows the dry powder contained in the capsule to shake loose. Advantageously, the presence of a spiral or angled airflow improves the emptying of dry powder from a capsule in an inhaler article.

According to an aspect of the disclosure, adhesive may be used to attach the downstream face of the support member to the upstream end of the internal tube. The downstream face of the support member may be attached to the upstream end of the internal tube in any manner known in the art. For example, the downstream face of the support member may be attached to the upstream end of the internal tube by using adhesive, glue, a fastener, a clip, threaded connection, a rivet, welding, ultrasonic welding, spot welding, snap fittings, press fitting, solvent bonding, adhesive bonding, heat welding, vibration welding or by any other method. Or, the downstream face of the support member may be attached to the upstream end of the internal tube with a press fit, without adhesive. Examples of acceptable adhesives include PVA, gum Arabic, Pll, epoxy, cyanoacrylate and polychloroprene, while other adhesives may be used. Advantageously, with the use of adhesive, the inhaler article may be more stable and rigid.

According to an aspect of the disclosure, adhesive may be used to seat the mouth plug into the outer tube body. For example, during manufacturing, adhesive may be placed at a location on the interior surface of the outer tube body where the support member is intended to reside. When the mouth plug is introduced to into the cavity of the outer tube body, the mouth plug advances until the perimeter of the support member meets the adhesive. The adhesive sets the support member in place inside the outer tube body. Adhesive may be placed on the upstream end of the mouth plug. As the mouth plug is inserted into the cavity of the outer tube body, when the downstream face of the support member contacts the upstream end of the mouth plug containing adhesive, the support member may be adhered to the mouth plug. Or, alternatively, adhesive may be placed on the downstream end of the outer tube body so that when the mouth plug is placed into the outer tube body, it adheres to the outer tube body at the downstream or mouth end. Or, alternatively, adhesive may be placed on the perimeter of the support member so that when the support member is introduced into the outer tube body, a seal is formed between the inner surface of the outer tube body and the perimeter of the support member. Examples of acceptable adhesives include PVA, gum Arabic, Pll, epoxy, cyanoacrylate and polychloroprene, while other adhesives may be used. Advantageously, with the use of adhesive, the inhaler article may be more stable and rigid.

For the purpose of the present disclosure, a longitudinal axis of a component may extend between the upstream end of the component and the downstream end of the component. A longitudinal axis of a component may extend between the distal end of the component and the proximal end of the component.

Skilled artisans will understand that the elements described in this disclosure have been described individually but may be combined. Skilled artisans will understand that the advantages described in this disclosure may be described in view of one element or a combination of elements, but these advantages may also apply to any element described and claimed herein.

For the purpose of the present disclosure including 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.

All scientific and technical terms used herein have meanings commonly used in the art unless otherwise specified. The definitions provided herein are to facilitate understanding of certain terms used frequently herein. As used herein, the singular forms “a”, “an”, and “the” encompass embodiments having plural referents, unless the content clearly dictates otherwise.

As used herein, “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise. The term “and/or” means one or all of the listed elements or a combination of any two or more of the listed elements.

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

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

As used herein “plug” means an element of an inhaler article as described.

Any advantage described herein may result from or relate to any feature described or claimed herein. The invention is defined in the claims. However, 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 features of another example, embodiment, or aspect described herein.

Example Ex1 : The disclosure provides a mouth plug for an inhaler article, the mouth plug comprising: an upstream end, a downstream end and a central axis; wherein the downstream end of the mouth plug comprises an air outlet; wherein the mouth plug comprises an internal tube extending along the central axis, the internal tube comprising an upstream end, a downstream end, an external diameter, an external surface and an internal surface which defines an internal tube cavity; wherein the upstream end of the mouth plug comprises a support member, wherein the support member comprises an upstream face, a downstream face, a thickness and a diameter; wherein the upstream end of the internal tube is attached to the downstream face of the support member, and wherein the downstream end of the internal tube extends to the air outlet, wherein the external diameter of the internal tube is smaller than the diameter of the support member.

Example Ex2: A mouth plug for an inhaler article, the mouth plug comprising: an internal tube, the internal tube comprising an upstream end, a downstream end an external diameter, an external surface and an internal surface which defines an internal tube cavity; and, a support member comprising an upstream face, a downstream face and a thickness; wherein the downstream end of the internal tube comprises an air outlet; wherein the downstream face of the support member is attached to the upstream end of the internal tube; and wherein the external diameter of the internal tube is smaller than the diameter of the support member.

Example Ex3: The mouth plug of any one of the preceding Examples wherein the support member comprises at least two support member airways comprising apertures extending from the upstream face of the support member to the downstream face of the support member and passing through the thickness of the support member.

Example Ex4: The mouth plug according to any one of the preceding Examples wherein the upstream face of the support member comprises a closed central area having a flat surface.

Example Ex5: The mouth plug according to any one of the preceding Examples wherein the at least two support member airways comprise filter material.

Example Ex6: The mouth plug according to any one of the preceding Examples wherein the support member airways are located between the perimeter of the support member and the perimeter of the internal tube on the downstream face of the support member.

Example Ex7: The mouth plug according to any one of the preceding Examples wherein the internal diameter of the upstream end of the internal tube is closed by the downstream face of the support member.

Example Ex8: The mouth plug according to any one of the preceding Examples wherein the internal tube of the mouth plug comprises an internal tube air opening.

Example Ex9: The mouth plug according to any one of the preceding Examples wherein the downstream end of the mouth plug comprises a curved end.

Example Ex10: An inhaler article of any one of the preceding Examples further comprising an outer tube body, the outer tube body comprising an upstream end, a downstream end, a central axis, an outer surface and an internal surface, wherein the internal surface defines a cavity inside the outer tube body and wherein the mouth plug is in the cavity of the outer tube body.

Example Ex11 : An inhaler article comprising: an outer tube body comprising an upstream end, a downstream end and an internal surface which defines an outer tube cavity, the outer tube cavity comprising a diameter; a mouth plug partially within the outer tube cavity, the mouth plug comprising: an internal tube, the internal tube comprising an upstream end, a downstream end, an external diameter, an external surface, an internal surface wherein the internal surface of the internal tube defines an internal tube cavity, and wherein the downstream end of the internal tube comprises an air outlet; a support member comprising an upstream face, a downstream face, a perimeter, a thickness and at least two support member airways; wherein the downstream face of the support member is attached to the upstream end of the internal tube; wherein the diameter of the outer tube body cavity is larger than the outer diameter of the internal tube; wherein a space between the external surface of the internal tube and the internal surface of the outer tube body provides an airflow passageway downstream of the support member; wherein the internal tube comprises at least one internal tube air opening such that the airflow passageway and internal tube cavity are in fluid communication through the at least one internal tube air opening; and wherein the downstream end of the mouth plug and the perimeter of the support member each contact the internal surface of the outer tube body.

Example Ex12: An inhaler article according to Example 11, wherein the upstream face of the support member comprises a closed central area having a flat surface.

Example Ex13: An inhaler article according to any one of the preceding Examples wherein the internal diameter of the upstream end of the internal tube is closed by the downstream face of the support member.

Example Ex14: An inhaler article according to any one of the preceding Examples wherein the airflow passageway is closed at the downstream end of the outer tube body by the downstream end of the mouth plug.

Example Ex15: The inhaler article according to any one of the preceding Examples wherein the space between the external surface of the internal tube and the internal surface of the outer tube body provides an airflow passageway downstream of the support member.

Example Ex16: The inhaler article according to any one of the preceding Examples comprising an airflow path wherein air flows from upstream of the support member, through the at least two support member airways to the airflow passageway, through the internal tube air opening to enter the internal tube cavity to exit the inhaler article at the air outlet.

Example Ex17: The inhaler article according to any one of the previous Examples further comprising a capsule contained in the cavity in the outer tube body upstream of the support member, the capsule containing nicotine.

Example Ex18: A method for manufacturing an inhaler article comprising the steps of: placing an adhesive on a surface of a mouth plug, the mouth plug comprising an upstream end, a downstream end and a central axis; wherein the upstream end of the mouth plug comprises a support member having a diameter, wherein the downstream end of the mouth plug comprises an airflow outlet; inserting the mouth plug into an outer tube body, the outer tube body comprising an upstream end, a downstream end, a central axis, an outer surface and an internal surface, wherein the internal surface defines a cavity inside the outer tube body; wherein the mouth plug is inserted into the downstream end of the outer tube body.

Example Ex19. The method for manufacturing an inhaler article according to Example 18 further comprising the step of inserting a capsule into the outer tube body upstream of the mouth plug.

Examples will now be further described with reference to the figures in which:

Figure 1A shows a perspective view of an inhaler article according to the present disclosure. Figure 1 B shows a side perspective view of an inhaler article according to the present disclosure. Figure 1C shows a view of an embodiment of the upstream end of an inhaler article according to the present disclosure. Figure 1D shows a view of an embodiment of the downstream end of an inhaler article according to the present disclosure.

Figure 2A, Figure 2B, Figure 2C, Figure 2E, Figure 2F, Figure 2H, Figure 2I, Figure 2J, Figure 2K, Figure 2L, Figure 2M and Figure 2N are top views of embodiments of the support member. Figure 2D is a perspective view of an embodiment of the support member. Figure 2G is a view of the support member of Figure 2F placed into an outer tube body cavity.

Figure 3 is a perspective view of an embodiment of a mouth plug.

Figure 4 is a perspective view of an embodiment of a mouth plug.

Figure 5 is an exploded view of an embodiment of an inhaler article.

Figure 6 is a perspective exploded view of an embodiment of the inhaler article.

Figure 7 is a transparent view of an embodiment of an inhaler article containing a capsule.

Figure 8 is a cross-sectional view of an embodiment of an inhaler article containing a capsule.

Figure 9 is a cross-sectional view of an embodiment of an inhaler article containing a capsule.

Figure 10 is a cross-sectional view of an embodiment of an inhaler article containing a capsule.

Figure 11 is a flowchart illustrating a method of manufacturing an inhaler article.

Figure 12 is an illustration of a holder with an inhaler article inserted into the holder according to the present disclosure.

Figure 13 is an illustration of an embodiment of a spiral air inlet according to the present disclosure.

Figure 1A is a perspective view of an inhaler article 10 according to the present disclosure. Figure 1A shows that the inhaler article 10 has an outer tube body 20 which has an upstream end 21 , a downstream end 22, and a central axis 29. The optional outer wrapper 11 is also shown. Figure 1 B shows a side perspective view of an inhaler article 10 according to the present disclosure. Figure 1B illustrates the central axis 29 of the inhaler article 10. The downstream end 22 is curved 25. The upstream end 21 is flanged 23. Figure 1C shows a view of an embodiment of the upstream end 21 of an inhaler article 10 having flanges 23 which are folds that close the end of the outer tube body 20 according to the present disclosure. Figure 1 D shows a view of an embodiment of the downstream end 22 of an inhaler article according to the present disclosure. The downstream end 22 is curved 25. Also shown is an airflow outlet 201 on the downstream end 22 of the inhaler article 10.

Figure 2A and Figure 2B are views of embodiments of the support member 50 of the inhaler article from the top down, or from the upstream face 51 of the support member 50. The view from the downstream face 52 (not shown in Figure 2A) would be the same. As shown in Figure 2A, the support member 50 has an upstream face 51 , a center 54, at least two support member airways 69. The support member airways 69 have a diameter 66. The support member 50 has a diameter 56. The support member 50 fits into the outer tube body cavity 25 of the outer tube 20. The upstream face 51 of the support member 50 has a closed central area 690. The support member airways 69 are not located in the closed central area 690 of the upstream face 50 of the support member 50. The closed central area may be flat to reduce friction between the upstream face 51 of the support member 50 and a capsule 300. Eight support member airways 69 are shown in Figure 2A and Figure 2B. However, any number of support member airways 69 may be present. In embodiments at least two support member airways 69 are present. It may be that it is desirable to provide more than one support member airway 69, or at least two support member airways 69 so that the support member airways 69 can be arrange symmetrically around the periphery of the support member 50. The support member airways 69 may be peripheral to the closed central area 690. It may be that it is desirable to provide support member airways 69 that are symmetrical to promote appropriate air flow through the inhaler article 10. The support member airways 69 are not located at the center 54 of the support member 50. The support member airways 69 are not located at the center of the upstream face 51 of the support member 50. The support member airways 69 are not located in the closed central area 690 that encompasses the center 54 of the upstream face 51 of the support member 50. Support member airways 69 are not located at the center 54 of the support member 50 to force air to flow in a convoluted airflow path (see 100 in Figure 6 or Figure 8, for example) through the inhaler article. That is, there is no airflow path that flows through the center of the support member 50 or through the center of the inhaler article 10. Instead, the airflow path 100 (see Figure 6 or Figure 8) must follow a convoluted airflow path. The diameter 66 of the support member airways 69 is smaller than the diameter 28 of the outer tube body 20 of the inhaler article 10.

Advantageously, this convoluted airflow path prevents leakage of dry powder 303 from the inhaler article. Dry powder 303 is released into the outer tube body cavity 24 upstream of the support member 50. The dry powder 303 is released from the capsule 300 after the capsule 300 has been pierced because the capsule 300 is agitated or shaken or rotated by air that flows past the capsule 300. This airflow shakes the dry powder 303 from the capsule 300. Further, the dry powder 303 becomes entrained in the airflow. The airflow follows an airflow path (see Figure 6 or Figure 8, for example). Air does not flow unless there is a pressure drop across the inhaler article. This pressure drop may occur when a user places the downstream end 22 of the inhaler article 10 in the mouth and inhales. Because of this pressure drop, air carrying entrained dry powder 303 moves through the inhaler article 10. Because the diameter of the support member airways 69 is smaller than the diameter 28 of the outer tube body 20, air carrying entrained dry powder 303 will not pass through these support member airways 69 in the absence of a pressure drop. Therefore, when the inhaler is not in use, dry powder 303 from the outer tube body cavity 25 upstream of the support member 50 will not leak from the inhaler article 10.

Advantageously, because the diameter of the support member airways 69 is smaller than the diameter 28 of the outer tube body 20, as air passes from the outer tube body 20 upstream of the support member through the support member airways 69, the airflow accelerates. This is due to the venturi effect (using Bernoulli’s principle). This acceleration of airflow can help to extract powder 303 from the area surrounding the capsule 300.

Figure 2C illustrates another embodiment of the support member 50. As shown in Figure 2C, the support member may comprise an array of a plurality of tubular elements 61 , 62. Some of the tubular elements are hollow tubular elements 61. The tubular element in the center of the array of tubular elements is a closed tubular element 60. The closed tubular element 60 provides the closed central area 690 of the support member 50. The closed tubular element 60 provides an upstream face 51 of the support member 50. The upstream face 50 of the support member 50 provided by the closed tubular element 60 is a flat structure transverse to the central axis of the outer tube body 20. As discussed above, the advantages of the closed central area are realized. The hollow tubular elements 61 which form the support member airways 69 are peripheral to the closed central area 690 of the upstream face of the support member 50.

Such an array of tubular elements array of a plurality of tubular elements 61, 62 may provide sufficient rigidity to resist longitudinal force exerted on the outer tube body 20. Such an array of tubular elements array of a plurality of tubular elements 61, 62 may provide sufficient rigidity to resist radial force exerted on the outer tube body 20. Such an array of a plurality of tubular elements 61, 62 may provide the inhaler article 20 with sufficient stability to withstand compression forces exerted during one or more of manufacturing, packaging and use of the inhaler article 20. The support member may provide sufficient rigidity to the inhaler article 20 to resist deforming or crushing of the article when the capsule 300 is pierced. One or both of the article and the support member may be simple and cost-effective to manufacture. The article comprising the support member may offer improved sustainability. The article comprising the support member may be a biodegradable article. The support member may be a biodegradable support member. The support member may be a recyclable support member. The support member may be a biodegradable support member providing sufficient rigidity to the article during one or more of manufacturing, packaging and use of the article. The article comprising the support member may offer an improved user experience. The article comprising the support member 50 may offer improved alignment of the capsule 300 in the article.

This structure of a support member 50 may provide advantages. For example, this array of a plurality of tubular elements 61, 62 may provide improved stability of the inhaler article. This array of a plurality of tubular elements 61 , with the center tubular element 62 being a closed tubular element 62, may provide a rigid support member 50. Such an array of plurality of tubular elements 61, 62 may provide sufficient rigidity to resist longitudinal force exerted on the outer tube body 20. Such an array of tubular elements array of a plurality of tubular elements 61, 62 may provide sufficient rigidity to resist radial force exerted on the outer tube body 20. Such an array of tubular elements array of a plurality of tubular elements 61, 62 may provide the inhaler article 20 with sufficient stability to withstand compression forces exerted during one or more of manufacturing, packaging and use of the inhaler article 20. The support member may provide sufficient rigidity to the inhaler article 20 to resist deforming or crushing of the article when the capsule 300 is pierced. One or both of the article and the support member may be simple and cost-effective to manufacture. The article comprising the support member may offer improved sustainability. The article comprising the support member may be a biodegradable article. The support member may be a biodegradable support member. The support member may be a recyclable support member. The support member may be a biodegradable support member providing sufficient rigidity to the article during one or more of manufacturing, packaging and use of the article. The article comprising the support member may offer an improved user experience. The article comprising the support member 50 may offer improved alignment of the capsule 300 in the article.

Figure 2D is another illustration of an embodiment of the support member 50. The support member 50 has an upstream face 51 , a downstream face 52, a center 54 and a thickness 53. The support member airways 69 are apertures extending from the upstream face 51 to the downstream face 52 of the support member 50, passing through the thickness 53 of the support member 50. The upstream face 51 of the support member 50 is closed at the center 54 of the support member 50. That is, none of the support member airways 69 pass through the center 54 of the support member.

Figure 2E is another illustration of an embodiment of the support member 50. The upstream face 51 of the support member 50 is shown in Figure 2E. Support member airways 69 comprise filter material 68 which may be mesh material. One or more of the at least two support member airways 69 may contain filter material 68 which may be mesh material. Figure 2F is another illustration of an embodiment of the support member 50. In this embodiment, the support member airways 69 are located at the perimeter 56 of the support member 50. The support member airways 69 are indentations in the perimeter 56 of the support member 50. This divot or indentation in the perimeter 56 of the support member 50 is called a flute 55. When the support member shown in Figure 2F is placed into the outer tube body cavity 25, as shown in Figure 2G, the flute 55 forms part of the support member airway 69 and the internal surface 26 of the outer tube body 20 forms part of the support member airway. Figure 2F illustrates the outer tube body 20 and the inner diameter 28 of the outer tube body 20 for comparison with the diameter of the support member airways 66.

Figures 2H illustrates a support member 50 having a perimeter 56 and having a honeycomb structure 61. Figure 2I illustrates a support member 50 having a spoke structure 62. Figure 2J illustrates a support member having a triangular structure 63. Figure 2K illustrates a support member having an array of tubes structure 64. Figure 2L illustrates a support member having a central aperture structure 65. Figure 2M illustrates a support member having an omega structure 666. Figure 2N illustrates a support member having a flat upstream face 51 which is a damper 67. The damper 67 is structure that prevents air from flowing through the center 54 of the support member 50. In each example, the support member has at least one support member airway 69. In embodiments, the support member airways 69 may have filter material 68. This filter material may prevent larger particles from entering the mouth of the user.

Figure 3 and Figure 4 are perspective views of embodiments of a mouth plug 400. As shown in Figure 3 and Figure 4, the mouth plug 400 has an upstream end 401 , and a central axis 403. The downstream end of the mouth plug is an airflow outlet 201 . The downstream end of the mouth plug 400 may provide the downstream end 202 of the inhaler article 10. That is, the downstream end 402 of the mouth plug 400 may fit into the downstream end of the outer tube body 20 so that the downstream end of the assembled inhaler article 10 is the downstream end of the mouth plug 402. The downstream end 402 of the mouth plug 400 provides an airflow outlet 201. The mouth plug 400 has an internal tube 405 extending along the central axis 403. The internal tube 405 has an upstream end 406, a downstream end 402, and an external perimeter 421 , an external diameter 408 and an internal surface 409 which defines an internal tube cavity 410. The upstream end 401 of the mouth plug 400 is a support member 50. The support member 50 has an upstream face 51 , a downstream face 52, a center 54, a thickness 53, a perimeter 56 and a diameter 57. The upstream end 406 of the internal tube 405 is attached to the downstream face 52 of the support member 50. The downstream end 407 of the internal tube 405 extends to the air outlet 201 . The external diameter 421 of the internal tube 405 is smaller than the diameter 57 of the support member 50. The support member airways 69 are apertures extending from the upstream face 51 to the downstream face 52 of the support member 50, passing through the thickness 53 of the support member 50. In the embodiments shown in Figure 3 and Figure 4, the upstream face 51 of the support member 50 is closed at the center 54 of the support member 50. That is, none of the support member airways 69 pass through the center 54 of the support member. However, this may not be the case, as in when support members having the structures shown in Figure 2H, Figure 2I, Figure 2J, Figure 2K, Figure 2E and Figure 2M are employed.

As shown in Figure 3, the support member airways 69 are located between the perimeter 56 of the support member 50 and the perimeter 421 of the internal tube 405 attached to the downstream face 52 of the support member 50. As shown in Figure 4, the support member airways 69 may be provided by indentations or flutes 55 in the perimeter 56 of the support member 50. When the mouth plug 400 is inserted into an outer tube body cavity 25, the flute 55 forms part of the support member airway 69 and the internal surface 26 of the outer tube body 20 forms part of the support member airway 69. As shown in Figure 3 and Figure 4, the downstream end 402 of the mouth plug 400 may be a curved end 425.

Figure 5 is an exploded view of an embodiment of an inhaler article 10 showing the mouth plug 400, the outer tube body 20, the capsule 300 and the upstream end 21. Figure 5 shows a mouth plug 400 having a support member 50, an internal tube 405, the internal tube 405 having an internal tube air opening 420. Figure 5 shows an outer tube body 20 having an upstream end 21 and a capsule 300. When the mouth plug 400 is inserted into the outer tube body 20, the downstream end of the mouth plug 402 forms the downstream end 202 or mouth end 202 of the inhaler article 10. The downstream end of the mouth plug 402, forming the downstream end or mouth end 202 of the inhaler article, may be curved 25, 425. As the inhaler article 10 is assemble, as shown in Figure 6, the mouth plug 400 is inserted into the downstream end 22 of the outer tube body 20. As shown in Figure 6, when the mouth plug 400 is inserted into the outer tube body 20, the downstream end of the mouth plug 402 abuts the downstream end of the outer tube body 20 to form the downstream end of the inhaler article 10. In this embodiment, when the user puts the downstream end of the inhaler article into the mouth, the user contacts the downstream end of the mouth plug 400. The capsule 300 is inserted into the upstream end 21 of the outer tube body 20. Figure 7 is a transparent view of an embodiment of an inhaler article 10 containing a capsule 300 and a mouth plug 400. As shown in Figure 7, the downstream end 202 of the inhaler article 10 is formed by folding the outer tube body 20 to form a curved downstream end 25. The mouth plug fits into the outer tube body 20. As shown in Figure 7, when the user puts the downstream end of the inhaler article 10 into the mouth, the user contacts the curved downstream end of the outer tube body 20.

Figure 8 is a cross-sectional view of an embodiment of the inhaler article 10. The outer tube body 20 is shown. The outer tube body has an upstream end 21 , a downstream end 22, an outer surface 27 and an internal surface 26 defining a cavity 24 inside the outer tube body 20. The support member 50 is in the outer tube body cavity 24. The outer tube body cavity 24 is upstream and downstream of the support member 50 of the mouth plug 400. The support member 50 has support member airways 69. The support member airways 69 are apertures extending from the upstream face 51 to the downstream face 52 of the support member 50 through the thickness 53 of the support member. A wrapper 11 may be present or absent. The wrapper 11 may be used to decorate the inhaler article, or to provide bar codes, information, advertising, trademarks or other information to the consumer. The inhaler article 10 has a capsule 300 in the outer tube body cavity 24 upstream of the support member 50.

Air flows through the inhaler article because the user applies suction at the downstream end 22 or the mouth-end of the inhaler article. In order to inhale a dose of dry powder, the airflow having entrained particles 303 released from the capsule 300 must reach the airflow outlet 201 of the inhaler article 10. Air may flow via the airflow path 100 shown in the embodiment of Figure 8. Or, air may flow via the airflow path 100 shown in the embodiment of Figure 9.

As shown in Figure 8, a capsule 300 is inserted into the outer tube body 20 upstream of the mouth plug 400 and upstream of the support member 50. After the capsule is pierced 311 , the capsule 300 releases its dry powder 303 contents when an airflow 100 moves into the inhaler article through the airflow inlet 200 past the capsule 300. Air flows through the inhaler article 10 in an airflow path 100 through the outer tube body 20 cavity 24 and agitates or rotates or shakes the capsule 300. When the support member 50 is open in the center, for example where there are support member airways 69 as shown in Figure 2H, Figure 2I, Figure 2J, Figure 2K, Figure 2L, and Figure 2M, the airflow 100 carrying entrained dry particles 303, travels through support member airways 69, into the internal tube cavity 410 of the mouth plug 400, and then exits the inhaler article via the airflow outlet 201.

As shown in Figure 9, the upstream face 51 of the support member 50 is a flat structure transverse to the central axis 29 of the outer tube body 20. The support member 50 of the inhaler article 10 shown in Figure 9 is like the support member illustrated in, for example, Figure 2A, Figure 2B, Figure 2C, Figure 2D, figure 2E, Figure 2F, Figure 2G or Figure 2N.

The capsule 300 is shown contained in the outer tube body cavity 24 upstream of the support element 50. The capsule 300 contains dry powder 303. The capsule 300 may contain nicotine. The dry powder 303 may comprise nicotine powder. The capsule 300 may contain one or more flavorants. The capsule 300 may contain nicotine and one or more flavorants. The capsule 300 may comprise nicotine powder and powdered flavorant.

The capsule 300 may contact the upstream face 51 of the support member 50. The capsule

300 is oriented along the center axis 29 of the inhaler article. This may bring the radial center

301 of the capsule 300 in contact with the upstream face 51 of the support member 50. In an aspect of the present disclosure, the upstream face 51 of the of the support member is a flat feature, perpendicular to the central axis of the outer tube body 20. If the upstream face 51 of the support member 50 is flat, friction between the upstream face 51 of the support member and the capsule 300 is reduced. Reducing friction allows the capsule to move, or agitate, or rotate more freely in the inhaler article 10. This increased freedom of movement of the capsule 300 may lead to improved emptying of the capsule.

An airflow path 100 is shown in Figure 9. Air enters the inhaler article 20 through an airflow inlet 200, flows through the outer tube body cavity 24, through the support member 50 via the support member airways 69 to the outer tube body cavity 24 downstream of the support member 50, and exits the inhaler article via the airflow outlet 201 at the downstream end 22 of the inhaler article. Once the capsule 300 is pierced, dry powder 303 is released from the capsule 300 and is entrained into the airflow path 100 as the airflow path 100 flows around the capsule 300. The capsule 300 may be pierced with a needle 101 introduced into the upstream end 21 of the inhaler article by the user. Or, the capsule 300 may be pierced when the inhaler article is introduced into a holder having a piercing mechanism as shown in Figure 12. Particles 303 entrained in the airflow path 100 flow through the support member airways 69. When the airflow 100, and particles 303 entrained in the airflow 100, pass through the support member airways 69, the airflow 100 and particles 303 entrained in the airflow 100 enter the airflow passageway 450 between the external surface 408 of the internal tube 405 and the internal surface 26 of the outer tube body 20. Airflow 100 and particles 303 enter the internal tube cavity 410 from the airflow passageway 450 by passing through the internal tube air opening(s) 420. Airflow 100 and particles 303 flow from upstream of the support member, through the at least two support member airways 69, to the airflow passageway 450, through the internal tube air opening(s) 420 to enter the internal tube cavity 410 to exit the inhaler article 10 at the air outlet 201 to be inhaled by a user. Air flows through the inhaler article in an airflow path 100.

When the capsule 300 is pierced, and air flows through the inhaler article, particles 303 are released from the capsule. Particles 303 are entrained in the airflow path 100. The airflow path 100 moves across the capsule 300 to the support member 50. Air flows through the support member airways 69. The support member airways 69 are apertures that extend from the upstream face of the support member 50 to the downstream face 52 of the support member 50 through the thickness 53 of the support member 50. The support member airways 69 are located between the perimeter of the support member 50 and the perimeter of the internal tube 405 on the downstream face 52 of the support member 50. When the airflow 100, and particles 303 entrained in the airflow 100, pass through the support member airways 69, the airflow and particles 303 entrained in the airflow 100 enter the space between the external surface 408 of the internal tube 405 and the internal surface 26 of the outer tube body 20. That space between the external surface 408 of the internal tube 405 and the internal surface 26 of the outer tube body 20 is an airflow passageway 450 downstream of the support member 50. Because the downstream end 402 of the mouth plug 400 contacts the downstream end 22 of the outer tube body 20, the downstream end of the airflow passageway is a dead end 451. Particles 303 that do not pass through the internal tube air opening(s) 420 to exit the inhaler article 10 at the air outlet 201 remain in the airflow passageway 450. For example, if the user stops inhaling while there are still particles in the airflow passageway 450, and there is no suction to move those particles across the internal tube air openings 420, the particles will not pass into the inner tube cavity 410. In this case, particles 303 in the airflow passageway 450 will remain in the airflow passageway 450. If the particles 303 do not pass through the internal tube air opening(s) 420, the particles remain in the airflow passageway 450. Particles 303 may accumulate at the downstream end of the airflow passageway 450. The downstream end of the airflow passageway 450 is the dead end 451. The internal tube air opening(s) 420 are located upstream of the downstream end of the airflow passageway 450 by a distance shown as L8 in Figure 10. The area of the airflow passageway 450 downstream of the internal tube air opening(s) 420 is the dead end. In embodiments, the inside of the curved downstream end 25 may also be dead end where particles may accumulate. This structure including the airflow passageway 450 and the support member airways 69 directing airflow and particles into the airflow passageway

450 reduces leakage from the inhaler article during and after use of the inhaler article 10. Instead of falling out of the airflow outlet 201 when suction stops, particles 303 will remain in the dead end

451 or in the airflow passageway 450. In addition, the movement of particles 303 through the support member airways 60, through the airflow passageway 450, and through the internal tube air openings 420 before reaching the airflow outlet 201 is a convoluted airflow path. This convoluted airflow path is advantageous in reducing leakage of particles. Airflow may pass through the support member 50 and flow into the inner tube cavity 410 as shown in Figure 8. Or, airflow 100 may pass through the support member 50 and flow into the airflow passageway 450. Or, airflow 100 may follow airflow pathways and may pass into the inner tube cavity 410 and into the airflow passageways 450. Airflow 100 is directed through the inhaler article because of the placement of the support member airways 69 in relation to the structures of the mouth plug downstream of the support member.

Also shown in Figure 9 is an upstream end that may be a folded upstream end 20 or a flanged upstream end 20. A fold is formed by bending the upstream end 21 of the outer tube body 20 of the inhaler article 10. A flange is a closure or partial closure at the upstream end of the outer tube body 20 made from multiple folds. Figured 8, 9 and 10 also shows the curved 25 downstream end 22.

Figure 10 is an illustration of an embodiment of the inhaler article 10. according to the present disclosure. Figure 10 provides measurements of features of the inhaler article 10. The parameters shown in Figure 10 are defined below in Table 1. Table 1

Parameter Range A (mm) Range B (mm) Range C (mm)

L1 30 to 80 35 to 60 40 to 50

L2 15 to 40 18 to 35 20 to 30

L3 O to 6 0 to 4 O to 3

L4 10 to 20 12 to 18 14 to 17

L5 3 to 10 5 to 9 6 to 8

L6 10 to 20 11 to 18 12 to 15

L7 5 to 45 10 to 35 15 to 25

L8 O to 10 1-8 3 to 6

L9 0 to 4 O to 3 O to 2

D1 4 to 12 5 to 10 6 to 8

D2 3 to 10 4 to 8 5 to 7

D3 D1 + 1 D1+0.2 D1+0.025

D4 2 to 7 3 to 6 3.5 to 5.5

D5 0.5 to 6 1 to 5 2 to 4

Figure 10 shows ranges of diameters and lengths of elements of the inhaler article. L1 is the length of the inhaler article 10 from the upstream end 21 to the downstream end 22. L2 is the length of the inhaler article 10 from the upstream end 21 to the upstream face 51 of the support member 50. L3 is the length of the fold or flange on the upstream end 21 of the inhaler article 10. L4 is the length of capsule 300. L5 is the thickness of the support member 50. L6 is the length of the internal tube 405 of the mouth plug 400 from the downstream face 52 of the support member 50 to the downstream end 402 of the mouth plug 400. L7 is the length of the wrapper 11. L8 is the length from the internal tube air opening 420 of the internal tube 405 to the dead end of the airflow passageway 450. L8 is the depth of the dead end 451 at the end of the airflow passageway 450. The dead end 451 is the area where particles may accumulate to prevent particles from falling out of the inhaler article. L9 is the length of the curved end 425 of the mouth plug 400. D1 is the inner diameter 28 of the outer tube body 20. D2 is the diameter of the capsule 300. D3 is the diameter of the support member 50. D4 is the outer diameter 418 of the internal tube 405. D5 is the internal diameter 419 of the internal tube 405. Three ranges of each of these measurements are provided in Table 1. Each of these measurements are shown in millimeters in Table 1. As illustrated in Figure 10 and Table 1 , the diameter D3 of the support member is slightly larger than the diameter D1 of the outer tube body cavity 24 so that the support member 50 fits into the cavity 24 of the outer tube body 20 in an interference fit. In embodiments, D3 and D1 are the same diameter, so that the support member 50 fits into the cavity 24 of the outer tube body 20 in an interference fit.

Figure 11 is a flowchart illustrating a method of manufacturing an inhaler article. As shown in Figure 11 , the manufacturing process begins at Step 1 with attaching an internal tube 405 to a support member 50 to form a mouth plug 400. In embodiments, the upstream end 406 of the internal tube 405 may be attached to the downstream face 52 of the support member 50. The internal tube 405 may be attached to the support member 50 by gluing. At step 2, the assembled mouth plug 400 is inserted into the outer tube body 20. The mouth plug 400 may be inserted into the downstream end 22 of the outer tube body 20. At step 3a the capsule 300 is inserted into the outer tube body 20 containing the mouth plug 400. The capsule 300 may be inserted into upstream end 21 of the outer tube body 20. At step 3b a quality control check may be performed to ensure that the capsule 300 has been inserted into the outer tube body 20. If the capsule 300 is not present in the outer tube body 20, the article is rejected and reworked. If the capsule 300 is present in the outer tube body, the manufacturing method proceeds to step 4. At step 4a, the upstream end 21 of the outer tube body 20 is folded to form a flange 23. At step 4b, a quality control check may be performed to ensure that the flange has been formed correctly. If the flange 23 has not been formed correctly, the article is rejected and reworked. At step 5a, a wrapping paper 11 which may be a tipping paper 11 is wrapped around the outer tube body 20. At step 5b, a quality control check may be performed to ensure that the wrapping paper 11 or tipping paper 11 has been applied correctly. If the wrapping or tipping paper 11 has not been formed correctly, the article is rejected and reworked. If the article passes the quality control check of step 5b, the article proceeds to Step 6, packaging and packing so that it can be sold as finished goods.

Figure 12 is an illustration of a holder with an inhaler article inserted into the holder according to the present disclosure. Figure 12 is an illustration of a holder 1200 with an inhaler article 10 according to the present disclosure inserted into the holder 1200. In use, the capsule 300 inside the inhaler article is pierced. As shown in Figure 12, the inhaler article 10 may be inserted into a holder that has a piercing mechanism 109. This piercing mechanism 109 may include a needle 101 , that can be pushed into the capsule by a lever 127 activated by the user. The needle 101 may automatically retract from the capsule by a spring 102. The holder may have a case 111 that defines a cavity 112 into which the inhaler article 10 is inserted. The holder 1200 may also have a spiral air inlet 205 which introduces air into the front plug cavity 24 which contains the capsule 300. Air introduced into the front plug cavity 24, especially air that moves in a spiral fashion, causes the capsule 300 contained therein to be agitated. This agitation releases dry powder from the pierced capsule 300. LA is the longitudinal axis of the inhaler article 10.

Figure 13 is an illustration of an embodiment of a spiral air inlet 205 according to the present disclosure. The spiral air inlet 205 brings air into the holder 1200, spins the air in a spiral as shown by the arrow of Figure 10, and introduces this spirally flowing air into the front plug cavity 24 to agitate the capsule 300 and release dry powder 303.

Claims

1. A mouth plug for an inhaler article, the mouth plug comprising: an internal tube, the internal tube comprising an upstream end, a downstream end an external diameter, an external surface and an internal surface which defines an internal tube cavity; and, a support member comprising an upstream face, a downstream face and a thickness; wherein the downstream end of the internal tube comprises an air outlet; wherein the downstream face of the support member is attached to the upstream end of the internal tube; wherein the external diameter of the internal tube is smaller than the diameter of the support member; and wherein the internal diameter of the upstream end of the internal tube is closed by the downstream face of the support member.

2. The mouth plug according to claim 1 wherein the support member comprises at least two support member airways comprising apertures extending from the upstream face of the support member to the downstream face of the support member and passing through the thickness of the support member.

3. The mouth plug according to any one of the preceding claims wherein the upstream face of the support member comprises a closed central area having a flat surface.

4. The mouth plug according to claim 2 wherein the at least two support member airways comprise filter material.

5. The mouth plug according to claim 2 or 4 wherein the support member airways are located between a perimeter of the support member and a perimeter of the internal tube on the downstream face of the support member.

6. The mouth plug according to any one of the preceding claims wherein the internal tube of the mouth plug comprises an internal tube air opening.

7. The mouth plug according to any one of the preceding claims wherein the downstream end of the mouth plug comprises a curved end.

8. An inhaler article comprising: an outer tube body comprising an upstream end, a downstream end and an internal surface which defines an outer tube cavity, the outer tube cavity comprising a diameter; a mouth plug partially within the outer tube cavity, the mouth plug comprising: an internal tube, the internal tube comprising an upstream end, a downstream end, an external diameter, an external surface, an internal surface wherein the internal surface of the internal tube defines an internal tube cavity, and wherein the downstream end of the internal tube comprises an air outlet; a support member comprising an upstream face, a downstream face, a perimeter, a thickness and at least two support member airways; wherein the downstream face of the support member is attached to the upstream end of the internal tube; wherein the diameter of the outer tube body cavity is larger than the outer diameter of the internal tube; wherein a space between the external surface of the internal tube and the internal surface of the outer tube body provides an airflow passageway downstream of the support member; wherein the internal tube comprises at least one internal tube air opening such that the airflow passageway and internal tube cavity are in fluid communication through the at least one internal tube air opening; wherein the downstream end of the mouth plug and the perimeter of the support member each contact the internal surface of the outer tube body.

9. The inhaler article according to claim 8 wherein the upstream face of the support member comprises a closed central area having a flat surface.

10. The inhaler article according to any one of claims 8 or 9 wherein the internal diameter of the upstream end of the internal tube is closed by the downstream face of the support member.

11. The inhaler article according to any one of claims 8 to 10 wherein the airflow passageway is closed at the downstream end of the outer tube body by the downstream end of the mouth plug.

12. The inhaler article according to any one of claims 8 to 11 further comprising a capsule contained in the cavity in the outer tube body upstream of the support member, the capsule containing nicotine.

13. The inhaler article according to any one of claims 8 to 12 configured such that during an inhalation using the article essentially all air passing through the article flows from the upstream of the support member through the at least two support member airways to the airflow passageway, from the airflow passageway through the at least one internal tube air opening to the internal tube cavity and from the internal tube cavity through the air outlet to leave the inhaler article.

14. A method for manufacturing an inhaler article comprising the steps of: placing an adhesive on a surface of a mouth plug, the mouth plug comprising an upstream end, a downstream end and a central axis; wherein the upstream end of the mouth plug comprises a support member having a diameter, wherein the downstream end of the mouth plug comprises an airflow outlet; inserting the mouth plug into an outer tube body, the outer tube body comprising an upstream end, a downstream end, a central axis, an outer surface and an internal surface, wherein the internal surface defines a cavity inside the outer tube body; wherein the mouth plug is inserted into the downstream end of the outer tube body; and wherein the internal diameter of the upstream end of the internal tube is closed by the downstream end of the support member.