Unit dose dry powder inhaler with blister cavity including a bowl, channel and tube
The invention provides a unit dose dispenser in the form of a blister containing a dry powder for inhalation. The blister comprises a base material in which a cavity is formed comprising a bowl that contains the powder and a channel that opens into the bowl. The channel contains a tube that has separate sections that provide an air outlet and an air inlet. The air outlet is further from the bowl than the air inlet. The upper side of the tube is flat and level with the top of the channel A lid material, such as a foil or foil laminate, seals the cavity. The blister has a detachable portion which, when removed, exposes the air inlet and the air outlet. A process for making the unit dose dispensers is also provided, which is based on the conventional process for manufacturing blister strips for dry powder inhalers.
1 . A unit dose dispenser in the form of a blister containing a dry powder for inhalation, wherein the blister comprises:
a base material in which a cavity is formed, wherein the cavity comprises a bowl that contains the powder and a channel that opens into the bowl;
a lid material which seals the cavity; and
at least one detachable portion which, when removed from the remainder of the blister, exposes an air inlet to the bowl and an air outlet from the bowl via the channel;
wherein the channel contains a tube that has separate sections which provide the air outlet and the air inlet, and the air outlet is farther from the bowl than the air inlet, wherein the tube has a flat upper side which is level with a top of the channel and wherein the tube is divided longitudinally into a central air outlet section and two air inlet sections, one on either side of the central section, wherein the two air inlet sections comprise extensions that extend farther into the bowl than the central outlet section.
2 . The unit dose dispenser according to claim 1 , wherein the tube has a semi-circular cross-section and a curved lower side corresponds in size and shape to the channel so that it is held in the channel by an interference fit.
3 . The unit dose dispenser according to claim 1 ,
wherein the lid material is bonded to the flat upper side of the tube.
4 . The unit dose dispenser according to claim 1 , wherein the extensions of the air inlet sections into the bowl are shaped to match an inner surface of the bowl.
5 . The unit dose dispenser according to claim 1 , which has a line of weakness between the at least one detachable portion and the rest of the blister, wherein the location of the line of weakness is selected from the group consisting of the base material, the lid material, and combinations thereof.
6 . The unit dose dispenser according to claim 5 , wherein the line of weakness is comprised of perforations.
7 . The unit dose dispenser according to claim 5 , wherein the line of weakness is comprised of scores.
8 . The unit dose dispenser according to claim 5 , which has an at least one notch between the at least one detachable portion and the rest of the blister, wherein the location of the at least one notch is selected from the group consisting of a first edge of the base material, the first edge of the base material and a second edge of the base material, a first edge of the lid material, the first edge of the lid material and a second edge of the lid material and combinations thereof.
9 . The unit dose dispenser according to claim 1 , which has an at least one notch between the at least one detachable portion and the rest of the blister, wherein the location of the at least one notch is selected from the group consisting of a first edge of the base material, the first edge of the base material and a second edge of the base material, a first edge of the lid material, the first edge of the lid material and a second edge of the lid material and combinations thereof.
10 . The unit dose dispenser in the form of a blister containing a dry powder for inhalation of claim 1 , wherein the lid material is a foil or foil laminate.
11 . A pair of dispensers according to claim 1 , which are joined together so that the powders in both blisters can be inhaled simultaneously.
12 . A strip comprising a plurality of dispensers according to claim 1 , which provide a multi-day supply of powder, wherein each dispenser is detachable from the rest of the strip.
13 . A process for producing unit dose dispensers according to claim 1 , the process comprising:
forming cavities in a base material, each cavity comprising a bowl, and a channel that opens into the respective bowl;
filling a powder into the respective bowl;
placing a tube that has separate sections which provide an air outlet and
an air inlet into each channel, wherein each air outlet is farther from the respective bowl than each air inlet and wherein each tube has a flat upper side which is level with the top of the respective channel and further wherein each tube is divided longitudinally into a central air outlet section and two air inlet sections, one on either side of the central section, wherein the two air inlet sections comprise extensions that extend farther into the bowl than the central outlet section;
sealing each cavity with a lid material; and, simultaneously or in either order:
forming at least one detachable portion which, when removed from the remainder of an associated unit dose dispenser, exposes an associated air inlet and an associated air outlet;
cutting the base and lid materials to form individual dispensers, or pairs of dispensers, or strips with a plurality of dispensers.
14 . The process according to claim 13 , wherein the at least one detachable portion is formed by creating a line of weakness, wherein the location of the line of weakness is selected from the group consisting of the base material, the lid material, and combinations thereof.
15 . The process according to claim 14 , wherein the line of weakness is comprised of perforations.
16 . The process according to claim 14 , wherein the line of weakness is comprised of scores.
17 . The process according to claim 14 , wherein the at least one detachable portion is formed by creating an at least one notch between the at least one detachable portion and the rest of an associated unit dose dispenser, wherein the location of the at least one notch is selected from the group consisting of a first edge of the base material, the first edge of the base material and a second edge of the base material, a first edge of the lid material, the first edge of the lid material and a second edge of the lid material and combinations thereof.
18 . The process according to claim 13 , wherein the at least one detachable portion is formed by creating an at least one notch between the at least one detachable portion and the rest of an associated unit dose dispenser, wherein the location of the at least one notch is selected from the group consisting of a first edge of the base material, the first edge of the base material and a second edge of the base material, a first edge of the lid material, the first edge of the lid material and a second edge of the lid material and combinations thereof.
19 . The process according to claim 13 , further comprising bonding the lid material to the flat upper side of each tube.