This application is the national phase entry under 35 U.S.C. § 371 of International Application No. PCT/EP2013/060272, filed May 17, 2013, which claims priority to pct/ep2012/059234, filed May 21, 2012, the contents of which are hereby incorporated by reference in their entireties.
The present invention relates to a system composed of a capsule for holding medicinal formulations for use in an inhaler and an associated inhaler. In particular the invention relates to systems comprising capsules that are filled with a powdered pharmaceutical preparation and to inhalers with which a powdered pharmaceutical preparation is to be provided for inhalation, the powder being contained in a capsule and being expelled from the capsule for inhalation through at least one hole in the capsule wall.
Capsules are known from the prior art that are used in specific medical devices such as powder inhalers. The outer shape of capsules used in inhalers of this kind is often (as in the present specification) that of a closed cylinder with hemispherical ends, the length of the cylinder being greater than its diameter. Such capsules usually consist of two cup-shaped parts, namely a capsule body and a capsule cap which are fitted telescopically into one another. Various materials are known for such capsules. Many capsules used in medicine consist of gelatine or hard gelatine.
WO2000/07572 discloses plastic capsules for use in powder inhalers. The capsules consist of a capsule cap and capsule cap which may be jointed together so as to form a stable sealed cavity of a defined volume. The capsule may comprise latching elements that securely connect the capsule cap to the capsule body. An example of latching elements of this kind are dot-like elevations in the inner casing of the capsule cap, which engage in rather larger dot-shaped depressions on the outer casing of the capsule body. The capsule cap and capsule body both consist of the same water-insoluble, hydrophobic plastics, preferably polyethylene.
WO2006/074982 A2 discloses a closure concept for capsule cap and capsule body by means of which it is possible to join the two parts together temporarily for transporting the capsule to the filling apparatus, by means of a preliminary closure which, unlike the main closure, can be opened non-destructively. The closures are formed in the inner casing of the capsule cap by annularly extending or segment-shaped elevations and matching depressions arranged annularly around the periphery of the outer casing of the capsule body.
Various powder inhalers are known from the prior art, in which the powder is contained in capsules before inhalation. In these devices the capsules are generally opened in some way to give access to the powder for nebulisation: in some devices the capsules are cut open with cutting blades, while in others their interior is brought into communication with air passages in the inhaler by means of hollow needles. In one group of inhalers that particularly form the background to the present invention, holes are pierced in the capsules by means of needle devices.
WO2004/082750 A1 shows an example of such an inhaler in which a capsule is pierced at both ends by two opposing needles. During the inhalation process the capsule rotates about its transverse axis, being driven by air flowing in tangentially. Particles that are driven out of the interior of the capsule by its rotation then travel through the air current to the mouthpiece.
U.S. Pat. No. 5,896,855 shows an inhaler in which a plurality of capsules are stored in a rotatable magazine and are supplied by a selectively motor-controlled mechanism to a spin chamber, where the powder is also expelled from holes at the ends of the capsule by rotation of said capsule. In the magazine, the capsules are held at both ends by needles or stoppers. The capsules are either pierced at their polar ends before they are inserted in the magazine and these holes are closed up by the stoppers in the magazine until the capsule in question is delivered to the spin chamber; or the capsules are pierced by these very needles as the capsules are inserted in the magazine and the piercing needles remain in the holes to form a seal until the capsule in question is delivered to the spin chamber.
WO04/052435 A1 shows different capsule-based powder inhalers in which the nebulisation takes place using the so-called Bernoulli effect. One inhaler shown has a mouthpiece which is of similar configuration to a cap and on which a lower part is fitted which contains a capsule chamber. On the lower housing part is provided a cutting device for opening the capsules. To replace the used capsules with new ones, the mouthpiece is flipped up or a plug-in connection is released which is located between the mouthpiece and lower housing part or between the mouthpiece and a plate inserted in the lower housing part and connected to the capsule chamber. Another inhaler shown has a rotatably mounted, exchangeable or refillable revolver magazine having a plurality of chambers each loaded with a capsule.
Powder inhalers of this kind using the Bernoulli effect constitute the starting point for the invention described here and the mode of operation described hereinafter also applies to the inhalers which are the subject of the present inventions.
In the inhalers under discussion here, the active substance that is to be delivered is stored in a substantially cylindrical capsule and this capsule is inserted in the inhalation chamber of an inhaler. The capsule chamber is adapted to the size of the capsule so that it is also substantially cylindrical in configuration, its length and diameter being somewhat greater than the corresponding dimensions of the capsule. As a result the capsule inserted in the capsule chamber has enough clearance to enable it to perform vibratory movements in both the axial and radial direction, while nevertheless remaining substantially aligned along the chamber axis. The capsule chamber comprises an air inlet in the region of one of its two ends and an air outlet opening in the region of the other end. The air outlet is attached to an inhalation channel which leads to the mouthpiece of the inhaler. As a rule, the capsule chamber, air outlet, inhalation channel and opening in the mouthpiece are arranged along a common axis.
In order to deliver the contents of the capsule, the capsule is first opened normally at two points along the length of the casing. As a rule the openings are located close to the two longitudinal ends of the capsule. If an air current is then generated in the capsule chamber from the air inlet to the air outlet, this leads along the longitudinal axis of the capsule and has two effects: on the one hand, the capsule vibrates, with its preferable direction of movement running along the longitudinal axis as a result of the air current. On the other hand, the air flowing along the two capsule openings generates a negative pressure relative to the capsule interior, so that the powder contained in the capsule is sucked out by the air current and thereby nebulised.
The problem on which the present invention is based is to provide a system composed of a capsule and inhaler which is an improvement on the prior art, in which the reproducibility of the nebulisation, particularly the expulsion of powder from the capsule, is improved. Preferably, a system is to be provided in which irregularities in the opening of the capsules are reduced or minimised. Particularly preferably, a system and an inhaler are to be provided which are suitable for single use or for use as a disposable system or disposable product.
This problem is solved according to the invention by a system composed of an inhaler and a capsule according to claim 1 and a method for assembling a system of this kind according to claim 21 and an inhaler according to claim 24.
One feature of the system according to the invention which is formed by a capsule and an inhaler is that the inhaler comprises a capsule chamber and before the inhaler is used the capsule is stored in a capsule receptacle belonging to the system or to the inhaler. The capsule is used as a reservoir for a pharmaceutical preparation or medicinal formulation and comprises two capsule elements open at one end, namely a capsule body and a capsule cap, which can be fitted telescopically into one another through their openings to form a cavity. The capsule body and capsule cap are characterised in that at least one of the two, and preferably both, have at least one prefabricated hole in addition to the opening at one end.
The capsule receptacle seals off at least one hole and/or all the holes that lead(s) into the cavity of the capsule after the capsule elements have been fitted together. The capsule receptacle is arranged at least partially in the capsule chamber and can be removed from the capsule chamber in such a way that the capsule is left behind in the capsule chamber when the capsule receptacle is removed.
Another feature of the present invention is that a capsule filled with a pharmaceutical preparation which comprises a capsule cap and/or a capsule body with prefabricated holes is used in an inhaler, the prefabricated holes being covered at the moment of insertion of the capsule in a capsule chamber of the inhaler and being exposed by the actuation of a pulling element in the inhaler.
This makes it possible to provide a capsule-based inhaler preferably using the Bernoulli effect for nebulisation, in which no piercing devices have to be provided to perforate the capsule. The exposing of prefabricated holes offers various advantages over the use of piercing means in the inhaler: as a result of the manufacturing process, e.g. by plastics extrusion, the prefabricated holes are highly reproducible in size and shape from one capsule to another, whereas holes produced by piercing may vary individually depending on the capsule material, capsule size and equipment as well as the piercing position and geometry of the needles, and/or may lead to irregular hole geometries. Moreover, when capsules are pierced, it is possible for a certain spring-back to occur in the capsule surface in the region of the piercing site. The prefabricated holes envisaged here, by contrast, are stable in shape after being exposed and have no protrusions in the capsule material. Such protrusions in the capsule material are formed for example when the capsule wall is pressed in by a piercing device and may possibly lead to the accumulation of, in particular, powdered pharmaceutical preparation and hence to a slightly reduced delivery of the preparation from the capsule on nebulisation. Because of the high precision in the size and shape of the capsule holes which is made possible by the prefabrication of the holes, both the amount and also, in particular, the distribution of the powder expelled from capsules in the airflow in the capsule chamber of an inhaler are more reproducible. The nebulisation of the pharmaceutical preparation itself is thus made more reproducible, particularly compared with inhalers having capsule piercing means.
Another feature of the present invention is that the inhaler for use with capsules having prefabricated hole comprises a pulling element and for actuating the pulling element channels or openings are used, which are required in any case on account of the operating principle of the inhaler. This means, in particular, that the pulling element is arranged in an air channel of the inhaler. For opening the capsule, therefore, no additional openings need to be formed on the capsule chamber which might adversely affect the flow characteristics during nebulisation. There is no formation of unwanted secondary air or false air besides the air channels required for the nebulisation. The system is stable and reproducible in terms of the flow resistance.
By comparison, when using a piercing device, the associated piercing element has to be introduced into the capsule chamber through one or more openings, which may lead to additional unwanted air flow through these openings during inhalation. Such openings in addition to an air inlet and air outlet for the capsule chamber are not needed in the inhaler according to the invention, if they are not in turn designed to improve the airflow in the capsule chamber.
The use of a pulling element to expose prefabricated holes has an additional advantage, over the use of piercing elements: when using piercing elements, as a result of the clearance required for movement of the capsule in the capsule chamber that is necessary for the nebulisation process, there may be fluctuations in the position of the capsule relative to the piercing tips when the capsule is pierced in the capsule chamber. Compared with numerous similar capsule-inhaler systems this leads to fluctuations in the exact position of the holes in the respective capsule.
As a result of the use of a pulling mechanism for exposing prefabricated holes on capsules, all the fluctuations in the shape, size and position of the holes resulting from the use of piercing devices and the consequent fluctuations in the delivery of the pharmaceutical preparation are avoided. The nebulisation of the pharmaceutical preparation is then independent of the mechanism for opening the holes in the capsule. This also means that when brittle capsule material is used, the risk of splintering, which may occur particularly in piercing processes, is minimised. In this way the range of possible capsule materials for use in inhalers is widened.
The use of a pulling mechanism for exposing prefabricated hole has the additional advantage, depending on the configuration of the pulling element, that the same mechanism can be used to expose all kinds of hole arrangements on capsules. For example, in cylindrical arrangements of capsule, capsule chamber and pulling element, there may be a plurality of holes on the capsule at different locations relative to its circumference. The size, shape, position and number of holes in a capsule are very variable in this design, particularly when the capsule parts are produced by injection moulding processes. Here, the results of flow simulations matched to the nebulisation of specific pharmaceutical preparations or specific powders may be used to make use of optimum hole structures for capsules for this particular preparation or this particular powder.
A further feature of the invention, which may also be applicable to inhalers in general, independently of the other features of the invention, is that the inhaler comprises a body (100) which forms a chamber such as, in particular, a vibration chamber of preferably a capsule chamber (74) for holding a preferably powder-filled capsule (71), and the material of this body (100) consists essentially of a thermoformed film or a blister film. The use of materials of this kind which have been well researched in the field of the packaging of medicinal tablets with regard to their compatibility with medicinal active substances allows for very cheap production of inhalers which would otherwise be manufactured at greater cost in materials, e.g. by plastics extrusion moulding.
Preferably, the body is formed from two halves or parts which are joined together by sealing, laminating, gluing or welding. Preferably, the reservoir which contains a medicinal preparation that is to be nebulised or expelled, or particularly, as is preferred here, a capsule receptacle containing a powder-filled capsule, is placed in the chamber before the two halves or parts of the body are joined together. This process consisting of just a few operating steps makes for an uncomplicated and hence quick and inexpensive assembly process. As a result of the manufacturing costs which are reduced overall, compared with the production of standard commercial inhalers, the inhalers thus produced from thermoformed parts are highly suitable for use as one way inhalers, i.e. as products for single use or as so-called disposable items.
In addition, the principle of the inexpensive assembly of two inhaler parts which form an inner chamber, preferably for an enclosed object, can also be applied to components produced by plastics extrusion (instead of thermoformed components): Two such components can be joined together along their connecting surfaces by ultrasound welding, for example.
Advantageous further features are described hereinafter and in detail by reference to the drawings.
In one embodiment, the at least one hole prefabricated in the capsule is closed off by a pulling element, the pulling element forming a capsule receptacle, or a capsule receptacle is part of the pulling element. This capsule receptacle is substantially in the shape of a cylindrical tube which is of such dimensions as to fit exactly around the cylindrical part of the capsule. The at least one prefabricated hole in the capsule is located in the cylindrical casing region of the capsule and is thus closed off by the wall of the capsule receptacle while the capsule is being stored or held in the inhaler. Preferably, the powder-filled capsule stored in this way has two holes at top and bottom, i.e. one hole at the start and one at the finish of the cylindrical casing region. Preferably, the capsule consists of a capsule body and a capsule cap, both of which have at least one prefabricated hole, while after the capsule body and capsule cap have been pushed into one another the holes remain exposed, i.e. not covered by the respective other capsule element. Alternatively the holes may also be prefabricated after the filling of the capsule and after the assembly of the capsule cap and capsule body outside the inhaler. In the capsules, amounts of powder of between 0.1 milligrams and 100 milligrams of a pure active substance or an active substance mixture may be stored, for delivery later.
In a preferred embodiment of the system according to the invention, the system of inhaler and capsule, particularly in the case of a system for one-time use (single-use system), this system comprises a pulling mechanism for exposing the prefabricated capsule holes. The pulling mechanism is preferably constructed so that the capsule is located in a capsule receptacle and the capsule receptacle is located in the capsule chamber in a state of the system suitable for transporting and storage. To make the system ready for use, the capsule receptacle is pulled out of the capsule chamber, preferably also pulled completely out of the inhaler. A device is provided which prevents the capsule with the capsule receptacle from being pulled out of the capsule chamber and/or prevents the capsule from being released from the capsule receptacle when the capsule receptacle is pulled out.
Preferably, the capsule receptacle is pulled out through a mouth tube on the inhaler. The mouth tube forms the air outlet from the capsule chamber towards the mouth end of the inhaler. This device for retaining the capsule in the capsule chamber preferably contains a bar or crosspiece which at the same time forms the upper boundary of the capsule chamber. This bar or crosspiece preferably passes through the capsule receptacle, in the storage state of the system, on the side opposite an air inlet of the capsule chamber. The capsule receptacle preferably comprises slot-like recesses as a result of which the capsule receptacle is able to slide past the crosspiece as it is pulled out of the inhaler and thus be separated from it.
Preferably, the component forming the capsule receptacle in the transporting state of the system comprises a region protruding from the inhaler, on which is formed a gripping surface which the user can grasp in order to pull the capsule receptacle out of the inhaler. Also particularly preferably the component forming the capsule receptacle is configured as a cap which covers the mouth end of the inhaler in the transporting state.
The capsule receptacle or the pulling element by means of which the holes are sealed off or exposed is designed as a function of the sealing concept of the prefabricated holes in the capsule. In a preferred embodiment, the capsule receptacle is formed by the pulling element. Preferably, the capsule receptacle and pulling element are produced as one or more thermoformed components from a blister film. Preferably, the capsules in the capsule receptacle are sealed in the region of the prefabricated holes by a sealing process at the pulling element. Preferably, the capsule receptacle is flexibly arranged such that the capsule can be released from the capsule receptacle non-destructively by pressure along the longitudinal axis of the pulling element; for example, as described above, by the capsule being held back by a bar or other obstacle as the pulling mechanism is actuated while the capsule receptacle can slide past the bar or obstacle by means of a suitable slot.
Another feature of the invention is that in the case of systems for single use, the components involved in the respective pulling mechanism comprise devices that ensure that the respective pulling movement cannot be reversed non-destructively. In particular, the pusher or the capsule receptacle comprises for this purpose spring arms or other elements which, in the event of the capsule receptacle being pulled out, prevents the capsule receptacle from being non-destructively returned to the capsule chamber.
The systems described above for single use may alternatively also be designed as systems with two capsules. In embodiments of this kind for two capsules the inhaler also comprises two associated two capsule chambers and two capsule receptacles. Depending on the intended use of a system of this kind having two capsules, the two capsules are optionally filled with different formulations and/or different amounts of formulation. A system of this kind comprising an inhaler and two capsules may be used for example in therapies in which two different medical formulations have to be administered simultaneously to a patient. With capsules having different fillings it may be useful to tailor the size of the capsules to the respective amount of filling. In a very particular embodiment of this kind the respective capsule chambers and capsule receptacle are also adapted in size to the respective capsules. Irrespective of the fact that this is an embodiment with two identical or two different capsules, in a system of this kind with two capsules the pulling mechanism on the inhaler is configured so that with one movement the holes on both capsules are exposed simultaneously. If the system comprises capsule receptacles for example that extend in mouth tubes of the inhaler, and a cap with a gripping surface or a tab for pulling, when the cap is pulled the two capsule receptacles preferably joined together in the region of the cap are pulled out of the inhaler simultaneously.
In another embodiment of a system according to the invention, the system is formed from an inhaler and an assembled capsule with at least one prefabricated hole, the capsule being in the inhaler in the portable state of the system and thus at least partially surrounded by a preferably extensible and/or flexible film such that the film closes off the at least one prefabricated hole and/or all the holes in the capsule in the portable state of the system. The film is preferably connected to a pull strip or other gripping element and/or projects partially beyond the capsule at one end of the capsule (the film with the pull strip or the protruding film itself is therefore the “pulling element” in these embodiments). The inhaler comprises an opening through which the film can be pulled out of the inhaler at its projecting portion and/or at its pull strip, thereby exposing the prefabricated holes on the capsule.
Because of the low complexity of a system based on a pull mechanism and the associated low manufacturing costs, a system of this kind comprising a capsule with prefabricated, initially covered holes and a capsule receptacle or pulling element inserted into a capsule chamber, is also suitable for the production of single dose inhalers (disposable items). Particularly in applications where sticky, powdered pharmaceutical preparations are to be provided for inhalation, deposits rapidly form in the capsule chamber, air outlet and mouthpiece, so that frequent changing of such a system is desirable, as by using a disposable product.
In one embodiment of the system composed of inhaler and capsule according to the invention, the assembled capsule may be present in two different states: in the first state, the at least one prefabricated hole is closed, and in the second, it is open.
Thus, the two capsule elements comprise prefabricated holes and, when fitted telescopically into one another, two insertion positions relative to one another (these two insertion positions correspond in their configuration to the so-called first and second states of the capsule): a first insertion position in which the two elements are fitted into one another such that the prefabricated holes are covered and the cavity of the capsule as a whole is closed off, and a second insertion position in which the prefabricated holes in the capsule body and capsule cap overlap with one another, such that the entire capsule has one hole at the place of overlap of the two holes.
Preferably, both capsule elements are cup-shaped: The cavity open at one end which they form is laterally bounded by a surrounding capsule casing and by a closed end relative to the open side. Preferably, the capsule casing forms a cylindrical or elliptically surrounding wall, so that no corners are formed on the inside of the assembled capsule in which, in particular, powdered pharmaceutical preparation could accumulate and thus be left behind when powder is subsequently expelled from the capsule. For the same reason, the undersides of the capsule body and capsule cap and hence both ends of the capsule produced by fitting them together have a convex, particularly substantially hemispherical or ellipsoid shape.
The prefabricated holes in the capsule cap and capsule body are preferably located in the respective casing area, so that when they are fitted together the casing of the other capsule element covers the respective hole until the insertion position in which the two holes are brought into registry is reached.
By the use of the term “prefabricated” for a hole is meant that the hole is produced in the respective capsule element during the capsule manufacturing process at the factory. The hole in the respective capsule element is already present before the individual capsule has been finally assembled. In particular, the hole or holes is or are already present in the capsule elements before the capsule as a whole is inserted in an inhaler.
Preferably, the capsule cap and capsule body are structured, on the sides of the capsule casing region that fit against one another in the assembled state. This structuring is preferably designed to perform different functions. On the one hand, the structures of the capsule cap and capsule body have alternate latching elements. Preferably, when the capsule elements are fitted into one another, this structure causes the capsule cap and the capsule body to latch together in relation to one another in at least two positions, particularly the insertion positions referred to. Latching in the first insertion position ensures that on the one hand the holes in the capsules are not accidentally exposed prematurely, e.g. as a result of vibration during transporting, and a defined process such as pushing the two elements together while applying a defined pressure is needed in order to expose the holes. Moreover, the cooperating latching elements of the capsule cap and capsule body are preferably configured so that after being fitted together up to the first insertion position the two capsule elements can no longer be non-destructively separated from one another. This prevents the capsule from opening accidentally. Preferably, in the contact region between the capsule cap and capsule body, structuring elements are also provided which serve as a guide for the two capsule elements as they are fitted into one another. These structuring elements on the casing regions of the capsule cap and capsule body that are directed towards one another ensure that the two capsule elements can only be fitted into one another in defined alignments. The “defined alignment” refers to the rotation of the capsule elements about the longitudinal axis of the capsule and is therefore an azimuthal alignment. Preferably, these structuring elements are in the form of at least one groove in the outer/inner casing surface of the capsule cap/capsule body and, respectively, in the form of at least one guide rail in the inner/outer casing surface of the capsule body/capsule cap. This ensures that when the capsule elements are fitted into one another the prefabricated holes in the capsule cap and capsule body are brought safely into registry. Preferably, the guides used are straight, particularly parallel to the main axis of the capsule. Variants in which the structuring elements guide the movement of the capsule elements along a curved path during the assembly are also possible. This would be achieved for example by a helical guide groove or guide rail.
Another feature of the present invention that may be implemented both independently and in conjunction with the above-mentioned aspects is that the capsule instead of being cylindrical in cross-section has an elliptical cross-section. Preferably the ellipse is one that deviates only slightly from the shape of a circle (the ratio of longitudinal to transverse axis of the ellipse should be less than 75%, preferably between 90% and 85%). An elliptical cross-section of this kind forces a defined azimuthal alignment of the two capsule elements as they are fitted together and/or a defined orientation when a resulting capsule is fitted into a capsule receptacle.
According to a further feature of the present invention, the hole in the outer capsule element is preferably configured as an oblong hole, or an elliptical hole or somewhat larger than the associated hole in the inner capsule element. When the outer hole is formed as an oblong hole or an ellipse, the small diameter of the hole is preferably at least as great as the diameter of the hole in the inner capsule element. The outer capsule element is the one that is formed by the outer wall of the capsule, by means of the capsule body and capsule cap in the assembled state in the region of the capsule casings abutting on one another. As a result of this enlargement of the outer hole relative to the inner one, the tolerances with respect to the accuracy of insertion of the capsule elements are broadened. This ensures that even if they are not pushed together precisely, the entire capsule opening is still available.
The individual features of the present invention may be used independently of one another or combined with one another.
Further advantages, features, properties and aspects of the present invention will become apparent from the claims and the following description of preferred embodiments by reference to the drawings. In the drawings:
The embodiments of the inhalers under consideration here, which are operated with a capsule, are preferably based on the so-called Bernoulli principle: The inhalers (e.g. shown in
Various special capsules for use in inhalers operating by the Bernoulli method will be described hereinafter.
The capsules shown in this and subsequent Figures are preferably filled with a powdered medicament preparation. Preferably, the capsule cap (1) and the capsule body (2) are in the form of a cylinder open at one end with a round cross-section and convex, virtually hemispherical at the other, closed end. The capsule cap (1) and capsule body (2) both preferably consist of polypropylene (PP) or polyethylene (PE), particularly preferably high-density polyethylene with a density of between 950 and 1000 kg/m3. Alternatively embodiments are also possible in which the capsule cap (1) and capsule body (2) are made of different materials, for example the capsule body of PP or PE and the capsule cap of gelatine. The capsule sizes are matched to the respective inhalers or the dimensions of the capsule chambers contained therein in which they are to be inserted. Typical lengths of the assembled capsules are for example 9 mm to 22 mm with external diameters of 4 mm to 10 mm. Examples of the capsule dimensions can be found in the disclosure of WO2006/074982 A2 on page 6 lines 6 to 27. The contents of all the lines quoted are to be incorporated in full herein.
With regard to the material design of the capsule, for which all pharmaceutically acceptable plastics may be used, besides the preferred material polyethylene, reference is made in this respect to the disclosure in the application WO2006/074982 A2 on page 5, lines 6 to 31. The contents of these lines are hereby incorporated in full in the present application, including the features.
In the first insertion position (cf.
In the first insertion position (cf.
In the second insertion position (cf.
In addition to the structuring of the capsule elements, which is to be regarded as macroscopic, another embodiment of the capsule according to the invention has a micro- or nanostructure or surface coating on the inside on a capsule element. This is, in particular, the capsule element that forms the outer wall of the capsule when the capsule casings are abutting on one another—the capsule cap (1) in the example of
This microstructure gives rise to a so-called lotus effect, i.e. it reduces the adhesion of certain materials to this surface. To achieve the optimum effect, the nature of the microstructure must be selected such that it offers the least adhesion properties for the specific pharmaceutical preparation that is to be stored in the corresponding capsule type. As a result, no or very little material from the pharmaceutical preparation, for example powder, adheres to the inner wall of the capsule. This has the effect, particularly in the annular region described, that when the capsule is pushed together from the first to the second insertion position there is no friction caused by material adhering to the wall. Expansion of the microstructure to all the inner wall regions of the capsule is also possible and has the effect that no material is left behind in the capsule as a result of adhesion to the wall when the material is expelled during a nebulisation process. The microstructure is formed by elevations and/or depressions in the surface. The elevations and/or depressions may take the form of points, hemispheres, planar surfaces, wedges, etc. They may have a random arrangement or may be ordered, e.g. in rows, circles, zigzags, in a meandering shape, etc.
The distance between the elevations on the surface structure is in the range from 0.1 to 200 microns, preferably 0.1 to 100 microns. In the case of powdered pharmaceutical preparations, structural dimensions are preferred which are less than the particles sizes of the powder. Most preferred are heights of elevations or depths of depressions in the range from 0.1 to 50 microns and distances of from 0.1 to 10 microns.
With regard to methods of producing such a microstructure and its properties, reference is made here to the disclosure of WO2004/062716 A1 on page 11 line 1 to page 13 line 13. The contents of these lines are hereby incorporated in the present application in full, including their features.
Preferred methods of applying a microstructure to inner capsule walls are those methods that do not introduce any additional material into the capsules, i.e. those microstructures that may be formed solely in the material that constitutes the respective capsule element. In the preferred case of capsule elements produced by injection moulding, the microstructures have preferably already been reproduced in mirror symmetry in the mould inserts of the injection moulding tools, so to speak, so that the capsule elements are provided with these microstructures and also the prefabricated holes during the first manufacturing step. Alternatively microstructures of this kind may be created on the inner capsule walls by subtractive surface treatment such as etching or galvanic material removal or by subsequent embossing, for example using an expandable punch that is inserted in the main opening of the capsule element.
In the embodiment according to
In an embodiment not shown here, the structural pair comprising the tongue (8) and groove (9) shown may also have a curved configuration as a result of which the pushing together of the capsule elements forces them to rotate relative to one another. This may be advantageous particularly for the objective of covering and exposing a plurality of holes in the capsule.
In
In
In
In another embodiment according to the invention, not shown, the capsule is already stored in the vibration chamber or capsule chamber (74) and the capsule (71) is enveloped in a preferably tubular film. The film fits closely against the cylindrical casing region of the capsule (71) and closes off the holes (72). Preferably, the materials of the film and capsule wall may be selected so that the preferably elastic and/or easily flexible film fits tightly against the capsule wall by electrostatic attraction. At one end point the capsule (71) is preferably not fixedly enclosed by the film and at the other end it projects significantly beyond the capsule (71) and/or is connected to a pull strip. This film portion projecting at the end of the capsule and/or the pull strip is located in the air inlet, in the transporting state of the inhaler, such that at this point part of the film and/or of a pull strip protrudes from the inhaler. Before the inhaler is used the film is pulled off by means of this protruding part and/or this pull strip through the air inlet of the capsule which does not fit through the air inlet. For example, in the air inlet, there is a bar (75) or another obstacle which stops the capsule (71) (in this example, the film or the film tube rests only on one side of the strip in the air channel). If the film or the film tube is pulled away but the capsule is retained, the capsule slides out of the preferably flexible film or film tube. As a result the holes (72) are exposed, the capsule (71) is given full room to manoeuvre in the capsule chamber (74) and the inhaler is ready for use.
Alternatively, the protruding part of the film or the pull strip may also be located in the mouth piece of the inhaler and may be pulled out of the system through the mouth tube. Generally, the opening through which the film is pulled out of the system may also be closed off in the transporting state. In the embodiment in which the protruding film portion or the pull strip is located in the mouth tube, the mouth tube may for example be closed off by a cap fitted to the mouthpiece (78) which has to be removed before the film can be pulled out. A cap of this kind may also be directly connected to the pull strip or the film.
The inhaler is then ready for use, as shown in
First of all (
The bar (75) forms the upper boundary of the capsule chamber (74) inside the mouthpiece (78). Apart from the bar (75), all the other components of the capsule chamber (74) are formed in one piece by the mouthpiece (78). At the lower end of the capsule chamber (74), i.e. at its end opposite the bar (75) and the mouthpiece opening, the mouthpiece comprises an inlet (76) which, in the embodiment shown, is formed as a central passage along the main axis of the system.
The inhaler shown here preferably consists of only three parts—mouthpiece (78), tube (73) and bar (75), all of which can be cheaply manufactured by plastics extrusion, so that an inhaler of this design is highly suitable for single use, i.e. as a disposable item to be discarded after one use.
In order to use the inhaler the tube (73) is pulled out of the mouthpiece (78), as shown in
Depending on the intended use of the inhaler the two capsules (71) may be identical or different in terms of their filling and/or external configuration. The use of a device with two identical capsules (71) has the advantage that double the formulation dose can be delivered with a single disposable device, thus saving the cost of disposable materials. The use of a device in which two capsules (71) with different fillings are stored is suitable particularly for use in therapies in which two active substances are administered simultaneously which, in some cases, cannot be stored in stable manner in a single formulation. A device of this kind ensures that the two active substances are taken in the correct proportion with one another. This rules out the possibility, for example, of a user taking the same preparation twice instead of taking two different preparations in one dosage cycle.
The capsules (71) and their associated capsule chambers (74), mouth tubes (78d) and tubes (73) may be adapted to the active substance or formulation dose for this purpose, for example they may be of different sizes or have different diameters and/or lengths.
Preferably, the pulling element (173) consists of a partly flexible and/or formable material, particularly preferably a blister film which has been structured in a thermoforming process.
Preferably the pulling element (173) (as shown in
In the assembly process, a pre-perforated and filled capsule (71) may be placed in one half of the capsule receptacle (173a), after which the pulling element (173) is folded up and the second half of the capsule receptacle (173a) also covers the capsule (71). After the folding operation, a slot (173d) remains on the pulling element (which is closed off by sealing, particularly in the region of the gripping aid (173e), as described hereinbefore). The capsule (71) should therefore be inserted in oriented manner in the capsule receptacle (173a), so that the holes (72) are actually totally covered by the shells of the capsule receptacle (173a). Preferably, prefabricated holes (72) are located on the capsule (71) only along a longitudinal side of the capsule (71) (or distributed over the periphery of the capsule (71) over less than 180 degrees). As a result, when placed in oriented manner in the first half of the capsule receptacle (173a)—namely, in an orientation such that the holes (72) point upwards, in relation to gravity, and preferably into the second half of the capsule receptacle (173a)—the pre-filled capsule (71) can be installed without any loss of powder through the holes.
A filling operation occurring earlier in the process may proceed as follows: The capsule (71) is filled in a positively locking capsule carrier in a filling apparatus, the capsule carrier initially receiving the capsule body (2). This capsule carrier holds the capsule body (2) during the filling process and closes off the holes (72) in the capsule body (2) during filling. After the capsule (71) has been sealed by pushing the capsule cap (1) on, the capsule carrier is rotated through 90° (with the holes pointing upwards, i.e. in the opposite direction to gravity) and the capsule (71) is pushed into the pulling element (173) by the capsule carrier or is alternatively placed in the still open pulling element, which is then folded shut and then closed or sealed. Optionally, the closure of the holes (72) in the capsule (71) by the shells of the capsule receptacle (173a) is improved by a pressing step.
As an alternative to the placing of the filled, pre-perforated capsule (71) into one half of the capsule receptacle (173a), if the material of the pulling element (173) has the requisite flexibility, it is also possible to use a process analogous to
Alternatively, the capsule (71) may be filled in a positively locking capsule carrier in a filling apparatus. This capsule carrier closes the holes in the capsule body (2) during filling. After the capsule (71) has been closed off by the capsule cap (2), the capsule (71) can then be pushed directly into the pulling element (173) located perpendicularly above it (from below, so to speak, in relation to the direction of gravity).
Yet another alternative method comprises using a capsule (1) with two different insertion positions, as described for example by reference to
Preferably, the body (100) of the inhaler (the capsule chamber (74) being formed by the body (100)) consists of two halves, particularly preferably two thermoformed parts which divide the body (100) into two halves along a longitudinal axis (for example,
Moreover, the body (100) preferably also comprises the region of the mouthpiece (78) on which the user's lips are placed; this lip region of the mouthpiece (78) may, however, also be formed by an additional component which is connected to the body (100).
In the assembly process, the pulling element (173) with capsule (71) is then, for example, placed in a half of the body (100) formed by a thermoformed part, for example, so that the capsule receptacle (173a) with the capsule (71) is located in the capsule chamber (74) and the bar (75) between the gripping aid (173e) and the capsule receptacle (173a) protrudes into the slot (173d) on the pulling element. Then the second half of the body (100), i.e. the second thermoformed part, for example, is placed and/or fitted onto the first half (preferably in mirror symmetry). To ensure that the two halves are joined together with no gap between the halves, the halves or the two thermoformed parts are joined together, for example by welding, gluing, laminating or preferably by joining in a sealing process. Sealing may be done using a sealing process conventionally used in the manufacture of blisters. One possible manufacturing process may comprise, for example, the application of an active sealing layer (sealing lacquer) to the halves of the body (100) directly after the thermoforming process. Sealing by pressure and heat is then only carried out later when the parts are assembled.
When thermoformed parts are used as halves of the body (100), the halves may for example be moulded from a thermoformed film which is shaped as a bead in the region of the junction, so that a support surface for the sealing or welding, etc., is retained at the otherwise thin-walled components. Alternatively, the two halves may also be manufactured as thicker-walled parts without a bead in a plastics extrusion process and welded to one another later, preferably in an ultrasound welding process.
To use the inhaler, the capsule receptacle (173a) is then pulled out of the mouthpiece (78). The slots (173d) on the capsule receptacle (173a) and pulling element (173) as a whole make it possible to pull the capsule receptacle (173a) out past the bar (75) (analogously to the function of the slot (73d) in
To assist the user with pulling the pulling element (173) with the capsule receptacle (173a) out of the mouthpiece (78), the pulling element (173) preferably comprises a gripping aid (173e). This gripping aid (173e) may, for example, be formed, as shown in
Preferably, the systems described here are operated with a medicinal formulation which contains an ingredient specified in the disclosure of the European Patent Application with application Ser. No. 12/151,105.9 on page 26 line 12 to page 63 line 2, or which corresponds to one of the formulations mentioned therein. The contents of these lines are hereby incorporated in their entirety in the present application, including the features therein.
Number | Date | Country | Kind |
---|---|---|---|
PCT/EP2012/059324 | May 2012 | WO | international |
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/EP2013/060272 | 5/17/2013 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO2013/174752 | 11/28/2013 | WO | A |
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