An apparatus for manufacturing delivery systems

Abstract

The present invention relates to an apparatus for manufacturing delivery systems. The present invention also relates to a method for manufacturing a delivery system and a delivery system. The apparatus comprises a first pair of profiled rollers, a powder insertion device, and a second pair of rollers. The first pair of rollers is configured to form a first seal on a web of sheet material to form a web of partially formed delivery systems. The powder insertion device is configured to insert powder into a partially formed delivery systems of the web of partially formed delivery systems. The a second pair of profiled rollers is configured to form a second seal on a web of sheet material to form web of sealed delivery systems.

Description

[0001] An Apparatus for Manufacturing Delivery Systems

[0002] Technical Field of the Invention The present invention relates to an apparatus for manufacturing delivery systems. The present invention also relates to a method of manufacturing delivery systems and a delivery system.

[0003] Background of the Invention

[0004] It is known to provide alternatives to combustible aerosol provision systems. Such systems are referred to a non-combustible aerosol provision systems and aerosol-free delivery systems. In such systems at least one substance is delivered to a user. In noncombustible aerosol provision systems an aerosol is generated from an aerosol- generating material, whereas in aerosol-free delivery systems a substance is delivered without generating an aerosol. It is also known to provide the substance to be delivered in a deliveiy system. Some deliveiy systems may be configured to be placed in a receptacle section of an aerosol-generating apparatus. Some delivery systems may be configured to be placed into a consumer’s mouth.

[0005] Summary of the Invention

[0006] In a first aspect of the present invention, there is provided an apparatus for manufacturing delivery systems. The apparatus comprises a first pair of profiled rollers configured to form a first seal on a web of sheet material to form a web of partially formed deliveiy systems; a powder insertion device configured to insert powder into a partially formed delivery systems of the web of partially formed delivery systems; and a second pair of profiled rollers configured to form a second seal on a web of sheet material to form web of sealed delivery systems.

[0007] In some embodiments, the delivery system may be a pouch.

[0008] In some embodiments, the first pair of rollers may comprise a first roller and a second roller, wherein the first roller may comprise a first profile configured to form a first seal to close a first end of a delivery system. In some embodiments, the first profile may be heated to form the first seal on the web of sheet material.

[0009] In some embodiments, the second roller may comprise a second profile which matches the shape of the first profile on the first roller.

[0010] In some embodiments, the second profile may be heated to form the first seal on the web of sheet material. In some embodiments, the first profile may be non-linear. In some embodiments, the first roller may have a first profile that forms a part of a non-square and non- rectangular contour.

[0011] In some embodiments, the first profile may comprise a first part and a second part that extend substantially circumferentially about the first roller.

[0012] In some embodiments, the first profile may comprise a third part and a fourth part located between the first and second parts, the third and fourth parts may extend such that they are non-parallel.

[0013] In some embodiments, the first profile may comprise an intermediate part that is nonlinear.

[0014] In some embodiments, the first profile and / or the second profile may be raised from the circumferential surface of the first roller and / or the second roller.

[0015] In some embodiments, the first profile and / or the second profile may be raised in the range of about 0.2 mm to about 5 mm. In some embodiments, the second pair of rollers may comprise a first roller and a second roller, wherein the first roller may comprise a first profile configured to form a second seal to close a second end of a deliveiy system.

[0016] In some embodiments, the first profile may be heated to form the first seal on the web of sheet material. In some embodiments, the second roller may comprise a second profile which matches the shape of the first profile on the first roller.

[0017] In some embodiments, the second profile may be heated to form the second seal on the web of sheet material.

[0018] In some embodiments, the first roller may have a first profile that forms a part of a non-square and non-rectangular contour. In some embodiments, the first profile may be non-linear.

[0019] In some embodiments the first profile may comprise a first part and a second part, wherein the first and second parts may extend such that they are non-parallel. In some embodiments, the first profile and / or the second profile may be raised from the circumferential surface of the first roller and / or the second roller.

[0020] In some embodiments, the first profile and / or the second profile may be raised in the range of about 0.2 mm to about 5 mm.

[0021] In some embodiments, the first profile on the first pair of profiled rollers and the first profile on the second pair of profiled rollers may form a non-square and non- rectangular contour when they form first and second seals on the web of sheet material. In some embodiments, the apparatus may further comprise a cutting apparatus configured to cut individual delivery systems from a web of sealed delivery systems.

[0022] In some embodiments, the cutting apparatus may comprise a pair of cutting drums In some embodiments, the pair of cutting drums may comprise a first cutting drum and a second cutting drum, the first cutting drum may comprise a plurality of shaped cutting knife.

[0023] In some embodiments, any one of the plurality of shaped cutting knives may be configured to make a cut in the web of delivery systems to separate an upstream end of a delivery system from the web of deliveiy systems. In some embodiment, the plurality of cutting knives may be shaped to cut through the web of deliveiy systems through the first and second seals. In some embodiments, the powder insertion device may comprise a powder storage container, a dosing compartment, and a pneumatic nozzle configured to blow powder into the partially formed deliveiy systems.

[0024] In some embodiments, the apparatus may further comprise a tube forming wheel configured to fold a web of sheet material into a tubular web of sheet material.

[0025] In some embodiments, the tube forming wheel may be heated to form a seal line along the tubular web of sheet material. In some embodiments, the apparatus may further comprise a first feed path for a first web of sheet material and a second feed path for a second web of sheet material, the first and second feed paths may align at or before the first pair of roller drums.

[0026] In some embodiments, the apparatus may further comprise a crimping roller configured to form longitudinal seals between the first and second webs of sheet material.

[0027] In a second aspect of the present invention, there is provided a method of forming a delivery system. The method comprises providing a web of sheet material; forming a first seal on the web of sheet material to create a partially formed delivery system; inserting powder into the partially formed delivery system; forming a second seal on the web of sheet material to form a web of delivery systems; and cutting individual delivery systems from the web of delivery systems. In a third aspect of the present invention, there is provided a delivery system. The delivery system comprises a first web of sheet material and a second web of sheet material sealed together around the periphery to define a cavity therebetween; wherein the seal is a continuous seal around the periphery of the delivery system; and powder for delivering a substance located in the cavity. In some embodiments, the delivery system may be non-square and non-rectangular in shape.

[0028] In some embodiments, the powder may occupy in the range of about 60 % to about 95 % of the volume of the cavity.

[0029] In some embodiments, the powder may have a moisture content of in the range of about 18 % to about 50 %. Brief Description of the Drawings

[0030] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Fig. 1 shows a schematic perspective view of an apparatus for manufacturing delivery systems;

[0031] Fig. 2 shows a schematic side view of an apparatus for manufacturing delivery systems and a diagrammatic view of the steps undergone at each stage of the process;

[0032] Figs. 3a to 3d show schematic top views of exemplaiy delivery systems and the seals used to form the delivery systems;

[0033] Fig. 4 shows a schematic side view of an apparatus for manufacturing delivery systems and a diagrammatic view of the steps undergone at each stage of the process;

[0034] Fig. 5 shows a schematic side view of an apparatus for manufacturing delivery systems and a diagrammatic view of the steps undergone at each stage of the process; Figs. 6a to 6f show schematic top views of exemplary delivery systems and the seals used to form the delivery systems; and

[0035] Fig. 7a to 7g show embodiments of delivery systems manufactured by an apparatus.

[0036] Detailed Description of the Invention

[0037] As used herein, the term “delivery system” is intended to encompass systems that deliver at least one substance to a user, and includes: non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials; and aerosol-free delivery systems that deliver the at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not comprise nicotine.

[0038] According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

[0039] In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system. In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement. In some embodiments, the non-combustible aerosol provision system is an aerosolgenerating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

[0040] In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.

[0041] Typically, the non-combustible aerosol provision system may comprise a non- combustible aerosol provision device and a consumable for use with the non- combustible aerosol provision device. In some embodiments, the disclosure relates to consumables comprising aerosolgenerating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.

[0042] In some embodiments, the non-combustible aerosol provision system, such as a noncombustible aerosol provision device thp thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.

[0043] In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and / or an aerosol-modifying agent.

[0044] In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol-modifying agent.

[0045] In some embodiments, the delivery system is an aerosol-free delivery system that delivers at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not comprise nicotine.

[0046] In some embodiments, the substance to be delivered may be an aerosol-generating material or a material that is not intended to be aerosolised. As appropriate, either material may comprise one or more active constituents, one or more flavours, one or more aerosol-former materials, and / or one or more other functional materials.

[0047] In some embodiments, the substance to be delivered comprises an active substance. The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.

[0048] In one embodiment the active substance is a legally permissible recreational drug

[0049] In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.

[0050] As noted herein, the active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0051] The active substance may be CBD or a derivative thereof

[0052] As noted herein, the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemaiy, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, maijoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberiy, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens

[0053] In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco.

[0054] In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp. In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.

[0055] In some embodiments, the substance to be delivered comprises a flavour.

[0056] As used herein, the terms "flavour" and "flavourant" refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice

[0057] (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cheriy, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberiy, citrus fruits,

[0058] Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang- ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, maijoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.

[0059] In some embodiments, the flavour comprises menthol, spearmint and / or peppermint. In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and / or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco. In some embodiments, the flavour comprises flavour components extracted from cannabis.

[0060] In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not alimited to eucolyptol, WS-3.

[0061] Aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or semi-solid (such as a gel) which may or may not contain an active substance and / or flavourants.

[0062] The aerosol-generating material may comprise one or more active substances and / or flavours, one or more aerosol-former materials, and optionally one or more other functional material. The aerosol-generating material may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and / or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free. The aerosol-generating material may comprise or be in the form of an aerosolgenerating film. The aerosol-generating film may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and / or filler may also be present. The aerosol-generating film may be substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free.

[0063] The aerosol-generating film may have a thickness of about 0.015 mm to about 1 mm. For example, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm.

[0064] The aerosol-generating film may be continuous. For example, the film may comprise or be a continuous sheet of material. The sheet may be in the form of a wrapper, it may be gathered to form a gathered sheet or it may be shredded to form a shredded sheet. The shredded sheet may comprise one or more strands or strips of aerosol-generating material.

[0065] The aerosol-generating film maybe discontinuous. For example, the aerosol-generating film may comprise one or more discrete portions or regions of aerosol-generating material, such as dots, stripes or lines, which may be supported on a support. In such embodiments, the support may be planar or non-planar.

[0066] The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosolgenerating film. The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent. The aerosol-generating material may comprise or be an “amorphous solid”. In some embodiments, the aerosol-generating materiel comprises an aerosol-generating film that is an amorphous solid. The amorphous solid may be a “monolithic solid”. The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the amorphous solid may, for example, comprise from about 50wt%, 6owt% or owt% of amorphous solid, to about 90wt%, 95wt% or ioowt% of amorphous solid.

[0067] The amorphous solid may be substantially free from botanical material. The amorphous solid may be substantially tobacco free.

[0068] The aerosol-former material may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol-former material may comprise one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Eiythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauiyl acetate, lauric acid, myristic acid, and propylene carbonate. The one or more other functional materials may comprise one or more of a pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0069] An aerosol-modifying agent is a substance that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol. The aerosol-modifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent may be in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material.

[0070] An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to cause an aerosol to be generated from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy. Referring now to Fig. 1, there is shown a schematic perspective view of an apparatus 1 for manufacturing delivery systems 2, such as those shown in Figs. 3a to 3d. The apparatus 1 comprises a first pair of profiled rollers 3. The first pair of profiled rollers 3 are configured to form a first seal 4, see all other Figs., on a web 5 of sheet material to form a partially formed delivery system 6 on the web of sheet material 5. The apparatus 1 further comprises a powder insertion device 7. The powder insertion device 7 is configured to insert powder into a partially formed delivery system 6 on the web of sheet material 5. The apparatus 1 may further comprise a second pair of profiled rollers 8. The second pair of profiled rollers 9 are configured to form a second seal 9, see all other Figs., on the web of sheet material 5 to form a sealed deliveiy system 10 on the web of sheet material 5.

[0071] In some embodiment, the deliveiy system 2 may be a pouch.

[0072] The web of sheet material 5 may be formed from a material, such as, for example, but not limited to, fleece, film, non-woven webs, or foil with a binder layer, or any other material that may be sealed via the application of heat or ultrasound.

[0073] Whilst some of the embodiments described herein mainly deal with unconnected first and second webs of sheet material, it will be appreciated that in some embodiments the first and second webs of sheet material may correspond to upper and lower or first and second portions of a single web of sheet material that are connected by a fold. The fold may be an angled fold within the web of sheet material along a fold line or a curved portion of the web where the web has been bent over on itself.

[0074] The first pair of profiled rollers 3 may comprise a first roller 11 and a second roller 12. The first roller 11 may be generally cylinder shaped or cylindrical. The first roller 11 may be rotatable about a longitudinal axis A, also referred to as its rotational axis. In practice, the rotational axis of the first roller 11 may lie substantially horizontal. The rotational axis of the first roller 11 may coincide with the centre line of the first roller 11. The first roller 11 may comprise a circumferential surface 14.

[0075] The first roller 11 may comprise a first profile 15. The first profile 15 may be configured to form the first seal 4 on the web of sheet material 5, as will be explained in more detail hereinafter. The first profile 15 may be configured to form the first seal 4, as shown in for example Fig. 2, of the web of sheet material 5 to close a first end 16, see Fig. 2, of the delivery system 2 to form a partially formed delivery system 6 on the web of sheet material 5.

[0076] The first profile 15 of the first roller 11 may be a projection extending from the circumferential surface 14 of the first roller 11. That is, the circumferential surface 14 of the first roller 11 may comprise the first profile 15. The first profile 15 may extend radially outwards from the circumferential surface 14 of the first roller 11. In some embodiments, the first profile 15 may be raised from the circumferential surface 14 of the first roller 11 by a distance in the range of about 0.2 mm to about 5 mm. The first profile 15 of the first roller 11 may comprise an end face 17. The end face 17 may define the shape and size of the first seal 4 formed on the web of sheet material 5. The first profile 15 may further comprise a leading edge 18 and trailing edge 19. The leading edge 18 and trailing edge 1918 may define the end face 17. The leading edge 18 may be the forward edge of the first profile 15 in the direction of rotation of the first roller 11. The trailing edge 19 may be the rearward edge of the first profile 15 in the direction of rotation of the first roller 11.

[0077] The first profile 15 of the first roller 11 may be heated to form the first seal 4 on the web of sheet material 5. In some embodiments, the first profile 15 of the first roller 11 may be heated to a temperature in the range of about 160 °C to about 220 °C. In some embodiments, the first profile 15 may be heated to about 180 °C. In some embodiments, the first profile 15 may be non-linear. The first profile 15 on the first roller 11 may form a part of a non-square and non- rectangular contour. That is, the first profile 15 may be contoured such that it when the contour is completed, i.e. by the second pair of rollers 9 as explained in more detail hereinafter, the completed contour is non-square and non-rectangular. In some embodiments, the first profile 15 may be multi-linear and / or curved. Preferably, the first profile 15 may be continuous.

[0078] In some embodiments, the first profile 15 may form a part of a non-square parallelogram contour but may have perpendicular adjacent sides. It this context a non- square parallelogram is a shape that does not have square corners. In some embodiments, the first profile may comprise rounded corners.

[0079] For example, referring to Fig. 1, the first profile 15 may comprise a first part 21 and a second part 22. The first part 21 and the second part 22 may extend substantially circumferentially about the first roller 11. The first profile 15 may further comprise a third part 23 and a fourth part 24. The third part and the fourth part 23, 24 may be located between the first and second parts 21, 22. The third and fourth parts 23, 24 may extend such that they are non-parallel. In the present embodiment, the first, second, third, and fourth parts 21, 22, 23, 24 may be arranged such that they form four sides of a hexagonal perimeter.

[0080] In some embodiments, the first profile 15 may comprise an intermediate part 25. The intermediate part 25 may be a part that extends between the first and second parts 21, 22. The intermediate part 25 may be non-linear.

[0081] In some embodiments, such as illustrated in Fig. 2, the first profile 15 may comprise a first part 21 and a second part 22 only The first and second parts 21, 22 may be angled relative to the circumferential direction of the circumferential surface 14 of the first roller 11. The first and second part 21, 22 may be angled relative to each other so that they do not extend perpendicularly to one another. That is, the first and second parts 21, 22 may be angled such that the first seal 4 they form on the web of sheet material 5 does not comprise a right-angle. Referring back to Fig. 1, the second roller 12 may be generally cylinder shaped or cylindrical. The second roller 12 may be rotatable about a longitudinal axis A, also referred to as its rotational axis. In practice, the rotational axis of the second roller 12 may lie substantially horizontal. The rotational axis of the second roller 12 may coincide with the centre line of the second roller 12. The rotational axis of the second roller 12 may extend parallel to the rotational axis of the first roller 11. The second roller 12 may comprise a circumferential surface 34.

[0082] The second roller 12 may comprise a second profile 35. The second profile 35 may be configured to form the first seal 4 on the web of sheet material 5 in conjunction with the first profile 15 on the first roller 11, as will be explained in more detail hereinafter. The second profile 35 may be configured to form the first seal 4, as shown in for example

[0083] Fig. 2, on the web of sheet material 5 to close a first end 16, see Fig. 2, of the delivery system 2 to form a partially formed deliveiy system 6 on the web of sheet material 5.

[0084] The second profile 35 of the second roller 12 may be a projection extending from the circumferential surface 34 of the second roller 12. That is, the circumferential surface

[0085] 34 of the second roller 12 may comprise the second profile 35. The second profile 35 may extend radially outwards from the circumferential surface 34 of the second roller 12. In some embodiments, the second profile 35 may be raised from the circumferential surface 34 of the second roller 12 by a distance in the range of about 0.2 mm to about 5 mm.

[0086] The second profile 35 of the second roller 12 may comprise an end face 36. The end face

[0087] 36 may define the shape and size of the first seal 4 formed on the web of sheet material 5. The second profile 35 may further comprise a leading edge 37 and trailing edge 38. The leading edge 37 and trailing edge 38 may define the end face 36. The leading edge

[0088] 37 may be the forward edge of the second profile 35 in the direction of rotation of the second roller 12. The trailing edge 38 may be the rearward edge of the second profile 35 in the direction of rotation of the second roller 12. The second profile 35 of the second roller 12 may be heated to form the first seal 4 on the web of sheet material 5. In some embodiments, the second profile 35 of the second roller 12 may be heated to a temperature in the range of about 160 °C to about 220 °C. In some embodiments, the second profile 35 may be heated to 180 °C. In some embodiments, the second profile 35 may be non-linear. The second profile 35 on the second roller 12 may form a part of a non-square and non-rectangular contour. That is, the second profile 35 may be contoured such that it when the contour is completed, i.e. by the second pair of rollers 9 as explained in more detail hereinafter, the completed contour is non-square and non-rectangular. In some embodiments, the second profile 35 may be multi-linear and / or curved. Preferably, the second profile 35 may be continuous.

[0089] In some embodiments, the second profile 35 may form a part of a non-square parallelogram contour but may have perpendicular adjacent sides. It this context a non- square parallelogram is a shape that does not have square corners. In some embodiments, the second profile may comprise rounded corners.

[0090] It will be appreciated that the second roller 12 may comprise a second profile 35 that substantially matches the shape of the first profile 15 on the first roller 11, and so further detailed explanation of the second profile 35 which be omitted herein.

[0091] The second pair of profiled rollers 9 may comprise a first roller 41 and a second roller 42. The first roller 41 may be generally cylinder shaped or cylindrical. The first roller 41 may be rotatable about a longitudinal axis A, also referred to as its rotational axis. In practice, the rotational axis of the first roller 41 may lie substantially horizontal. The rotational axis of the first roller 41 may coincide with the centre line of the first roller 41. The first roller 41 may comprise a circumferential surface 44.

[0092] The first roller 41 may comprise a first profile 45. The first profile 45 may be configured to form the second seal 9 on the web of sheet material 5, as will be explained in more detail hereinafter. The first profile 45 may be configured to form the second seal 9, as shown in for example Fig. 2, of the web of sheet material 5 to close a second end 16, see Fig. 2, of the delivery system 2 to form a sealed delivery system 10 on the web of sheet material 5. The first profile 45 of the first roller 41 may be a projection extending from the circumferential surface 44 of the first roller 45. That is, the circumferential surface 44 of the first roller 41 may comprise the first profile 45. The first profile 45 may extend radially outwards from the circumferential surface 44 of the first roller 41. In some embodiments, the first profile 45 may be raised from the circumferential surface 44 of the first roller 41 by a distance in the range of about 0.2 mm to about 5 mm. The first profile 45 of the first roller 41 may comprise an end face 47. The end face 47 may define the shape and size of the second seal 9 formed on the web of sheet material 5. The first profile 45 may further comprise a leading edge 48 and trailing edge 49. The leading edge 48 and trailing edge 49 may define the end face 47. The leading edge 48 may be the forward edge of the first profile 45 in the direction of rotation of the first roller 41. The trailing edge 49 may be the rearward edge of the first profile 45 in the direction of rotation of the first roller 41.

[0093] The first profile 45 of the first roller 41 of the second pair of profiled rollers 8 may be heated to form the second seal 9 on the web of sheet material 5. In some embodiments, the first profile 45 of the first roller 41 may be heated to a temperature in the range of about 160 °C to about 220 °C. In some embodiment, the first profile 45 may be heated to about 180 °C. By forming the second seal 9, a complete seal is formed in the web of sheet material 5 to enclose the powder within a cavity in the web of sheet material 5.

[0094] In some embodiments, the first profile 45 may be non-linear. The first profile 45 on the first roller 41 of the second pair of profiled rollers 8 may form a part of a non-square and non-rectangular contour. That is, the first profile 45 may be contoured such that it when the contour is completed, the completed contour is non-square and non- rectangular. In some embodiments, the first profile 45 may be multi-linear and / or curved, i.e. non-linear. Preferably, the first profile 45 may be continuous.

[0095] In some embodiments, the first profile 45 may form a part of a non-square parallelogram contour but may have perpendicular adjacent sides. It this context a non- square parallelogram is a shape that does not have square corners. In some embodiments, the first profile may comprise rounded corners.

[0096] For example, referring to Fig. 1, the first profile 45 of the first roller 41 of the second pair of profiled rollers 8 may comprise a first part 51 and a second part 52. The first and second parts 51, 52 may be angled relative to the circumferential direction of the circumferential surface 44 of the first roller 41. The first and second parts 51, 52 may extend such that they are non-parallel. The first and second part 51, 52 may be angled relative to each other so that they do not extend perpendicularly to one another. That is, the first and second parts 51, 52 may be angled such that the second seal 9 they form on the web of sheet material 5 does not comprise a right-angle. In the present embodiment, the first and second parts 51, 52 of the first profile 45 on the first roller 41 of the second pair of profiled rollers 8 may be arranged such that they form two sides of a hexagonal perimeter, which when combined with the first seal form a hexagon shaped seal to form a hexagonal shaped deliveiy system 2. Referring back to Fig. 1, the second roller 42 may be generally cylinder shaped or cylindrical. The second roller 42 may be rotatable about a longitudinal axis A, also referred to as its rotational axis. In practice, the rotational axis of the second roller 42 may lie substantially horizontal. The rotational axis of the second roller 42 may coincide with the centre line of the second roller 42. The rotational axis of the second roller 42 may extend parallel to the rotational axis of the first roller 41. The second roller 42 may comprise a circumferential surface 54.

[0097] The second roller 42 may comprise a second profile 55. The second profile 55 may be configured to form the second seal 9 on the web of sheet material 5 in conjunction with the first profile 45 on the first roller 41, as will be explained in more detail hereinafter.

[0098] The second profile 45 may be configured to form the second seal 9, as shown in for example Fig. 2, on the web of sheet material 5 to close a second end 46, see Fig. 2, of the delivery system 2 to form a sealed deliveiy system 10 on the web of sheet material 5. The second profile 55 of the second roller 42 may be a projection extending from the circumferential surface 54 of the second roller 42. That is, the circumferential surface 54 of the second roller 42 may comprise the second profile 55. The second profile 55 may extend radially outwards from the circumferential surface 54 of the second roller 42. In some embodiments, the second profile 55 may be raised from the circumferential surface 54 of the second roller 42 by a distance in the range of about 0.2 mm to about 5 mm. In some embodiments, the second profile 55 may be heated to about t8o°C.

[0099] The second profile 55 of the second roller 42 may comprise an end face 57. The end face 57 may define the shape and size of the second seal 9 formed on the web of sheet material 5. The second profile 55 may further comprise a leading edge 58 and trailing edge 59. The leading edge 58 and trailing edge 59 may define the end face 57. The leading edge 58 may be the forward edge of the second profile 55 in the direction of rotation of the second roller 42. The trailing edge 59 may be the rearward edge of the second profile 55 in the direction of rotation of the second roller 42. The second profile 55 of the second roller 42 may be heated to form the second seal 9 on the web of sheet material 5. In some embodiments, the second profile 55 of the second roller 42 may be heated to a temperature in the range of about 160 °C to about 200 °C. In some embodiments, the second profile 55 may be heated to about t8o°C.

[0100] In some embodiments, the second profile 55 may be non-linear. The second profile 55 on the second roller 42 may form a part of a non-square and non-rectangular contour. That is, the second profile 55 may be contoured such that it when the contour is completed, the completed contour is non-square and non-rectangular. In some embodiments, the second profile 55 may be multi-linear and / or curved, i.e. non-linear. Preferably, the second profile 55 may be continuous.

[0101] In some embodiments, the second profile 55 may form a part of a non-square parallelogram contour but may have perpendicular adjacent sides. It this context a non- square parallelogram is a shape that does not have square corners. In some embodiments, the second profile may comprise rounded corners.

[0102] It will be appreciated that the second roller 42 may comprise a second profile 55 that substantially matches the shape of the first profile 45 on the first roller 41, and so further detailed explanation of the second profile 55 which be omitted herein.

[0103] The first profiles 15, 35 on the first and second rollers 11, 12 of the first pair of profiled rollers 3 and the first profile 45, 55 on the first and second rollers 41, 42 of the second pair of profiled rollers 8 may form a non-square and non-rectangular contour when they form first and second seals 4, 9 on the web of sheet material 5.

[0104] As shown in the drawings, the first roller 11 and the second roller 12 of the first pair of profiled rollers 3 and the first roller 41 and the second roller 42 of the second pair of profiled rollers 8 may comprise a plurality of profiles 15, 35, 45, 55, respectively. That is, the first roller 11 of the first pair of profiled rollers 3 may comprise a plurality of profiles 15. The plurality of profiles 15 may be circumferentially spaced around the circumferential surface 14 of the first roller 11. It will be appreciated that the other rollers 12, 41, 42 may be configured int eh same way with circumferentially space profiles 35, 45, 55 spaced around their circumferential surfaces 34, 44, 54, respectively. This increases the output of delivery systems 2 by the apparatus 1. It will be further appreciated that, the first roller n and the second roller 12 of the first pair of profiled rollers 3 and the first roller 41 and the second roller 42 of the second pair of profiled rollers 8 may comprise a plurality of profiles 15, 35, 45, 55 may comprise a plurality of profiles 15, 35, 45, 55 spaced across the width, also referred to as transversely, of the rollers 11, 12, 41, 42, respectively.

[0105] When a plurality of profiles are provided on a roller that are spaced circumferentially and transversely, the roller may comprise an array of profiles that are arranged in columns and rows. This may further increase the apparatus’ 1 output of delivery systems 2.

[0106] In some embodiments, the plurality of profiles in the arrays may be tessellated. In the context of the present invention, the term ‘tessellated’ is used to mean that the plurality of profiles fit together closely without large gaps. Thus, the available surface area of the circumferential surfaces of the rollers is used more efficiently in order to provide a greater number of delivery systems 2 in the web of sheet material 5. This helps to maximise output for a given size of roller.

[0107] In some embodiments, one column of profiles extending around the circumference of the rollers may have a different profile to another column of profiles extending around the circumference of the rollers. In some embodiment, one row of profiles extending transversely across the circumferential surface of the rollers may have a different profile to another row of profiles extending across the circumferential surfaces of the rollers.

[0108] In some embodiment, the circumferential surfaces 44, 54 of the first and second delivery system forming rollers 41, 42 may be covered in a coating. In some embodiments, the first and second profiles 44, 54 of the first and second deliveiy system forming rollers 41, 42 may be covered in a coating. The coating may be a non- stick coating. The coating may be, for example, but not limited to Teflon ® or a similar material.

[0109] The non-stick coating may prevent the parts of the material forming the web of sheet material 5 or loose powder, or any adhesive used on the web from sticking to the forming rollers 41, 42. Thus, the apparatus 1 may run continuously for a shift without having to be stopped to be cleaned. Referring still to Fig. 1, the apparatus 1 may further comprise a cutting apparatus 61.

[0110] The cutting apparatus 61 may be configured to cut individual deliveiy systems 2 from the web of sheet material 5. The cutting apparatus 61 may comprise a pair of cutting drums 62. The pair of cutting drums 62 may comprise a first cutting drum 63 and a second cutting drum 64.

[0111] In some embodiments, as shown in Fig. 1, the cutting drums 63, 64 may comprise a plurality of circumferentially spaced cutting knives 65, 66. That is ,the first cutting drum 63 may comprise at least one first cutting knife. The second cutting drum 66 may comprise at least one second cutting knife 66. The cutting knives 65, 66 may be configured to cooperate as a sealed delivery system 10 on the web of sheet material 5 passes through the pair of cutting drums 62 to separate a deliveiy system 2 from the web of sheet material 5 by performing a sheer cut. That is, the plurality of cutting knives 65, 66 may be configured to make a cut in the web of sheet material 5 comprising sealed delivery systems 10 to separate a downstream end, or first end 16, of a delivery system 2 from the web of sheet material 5.

[0112] In the present embodiment, the cutting knives 65, 66 extend parallel to the rotational axis of the cutting drums 63, 64. However, it will be appreciated that in alternative embodiments, the cutting knives 65, 66 may be profiled to match the non-square and non-rectangular seal formed by profiles 15, 35, 45, 55 on the first and second pairs of profiled rollers 3, 8. That is, the plurality of cutting knives 65, 66 may define the same contour as the contour formed by the first and second profiles 15, 35 of the first pair of profiled rollers 3 and the first and second profiles 45, 55 of the second pair of profiled rollers 8. Thus, the plurality of cutting knives 65, 66 may be shaped to cut through the web of sheet material 5 through the first and second seals 4, 9.

[0113] As shown in Fig. 1, the apparatus may further comprise a powder insertion device 71. The powder insertion device 71 may be configured to insert powder into the partially formed delivery system 6 after the first seal 4 has been formed. The powder insertion device 1 may comprise a powder storage container 72 configured to store powder to be inserted into the deliveiy systems 2. The powder insertion device 71 may further comprise a dosing compartment 73. The dosing compartment 73 may be configured to measure out a dose of powder to be inserted into the delivery system 2 from the powder storage container 72. The powder insertion device 71 may further comprise a pneumatic nozzle 74. The pneumatic nozzle 74 may be configured to blow the measured out dose of powder into the partially formed deliveiy system 6 after the first seal 4 is formed on the web of sheet material 5 by the first pair of profiled rollers 3. It will be appreciated that in embodiments with multiple columns of profiles on the first and second pairs of rollers 3, 8, a plurality of powder insertion devices 71 may be provided adjacent to one another.

[0114] The apparatus 1 for manufacturing delivery systems 2 may further comprise a tube forming wheel 81. The tube forming wheel 81 may be configured to fold a web of sheet material 5 into a tubular web of sheet material, as will be explained in more detail in relation to Fig. 2 hereinafter. The tube forming wheel 81 may be heated. The tube forming wheel 91 may be heated to a temperature in the range of about X °C to about Y °C. The tube forming wheel 81 may be heated to form a longitudinal seal line 82 along the tubular web of sheet material 5. The apparatus 1 may further comprise a garniture

[0115] 83. The garniture 83 may be configured to gather the web of sheet material into tube.

[0116] In some embodiments, a first web of sheet material 5a and a second sheet of web material 5b are used to form the delivery system 2 rather than a single web of sheet material. Therefore, the tube forming wheel 81 is not required. Instead, the apparatus 1 may comprise a first feed path for a first web of sheet material and a second feed path for a second web of sheet material 5b. The apparatus 1 may be configured to align the first and second feed paths at or before the first pair of profiled roller drums 3, as will be explained in more detail with reference to Fig. 4 hereinafter. In some embodiments, the apparatus 1 may further comprise a crimping roller 85. The crimping roller 95 may be configured to form longitudinal seals 86 between the first and second webs of sheet material 5a, 5b.

[0117] Referring now to Fig. 2, a schematic view of the apparatus 1 for manufacturing delivery systems 2 is shown along side a diagrammatic view of the steps undergone at each stage of the process. The apparatus 1 shown in Fig. 2 is configured to form delivery systems 2 from a single web of sheet material 5.

[0118] The web of sheet material 5 is fed from a bobbin (not shown) along a feed path where it first encounters the garniture 83. The garniture 83 may be configured to gather the web of sheet material 5 into a tube. This may be achieved by providing an aperture whose diameter becomes gradually smaller causing the edges of the web of sheet material to curl up around the aperture. The edges of the web of sheet material 5 continue to curl up as they pass through the garniture 83 until the edges overlap. The tubular web of sheet material 5 is then transferred to the tube forming wheel 81. As the tube forming wheel 81 rotates it contacts the overlapping edges of the tubular web of sheet material 5. The heated tube forming wheel 81 heats the overlapping edges of the tubular web of sheet material 5 and causes the edges to seal together to create a longitudinal seal 82, shown in dotted lines and then removed for clarity, along the tubular web of sheet material 5.

[0119] The tubular web of sheet material 5 is then transferred to the first pair of profiled rollers 3. The first and second rollers 11, 12 of the first pair of profiled rollers rotate in opposite directions so that at their closest point, the nip point, they are moving in the same direction. Around the nip point, the heated profiles 15, 35 of the first and second rollers 11, 12 come into contact with the tubular web of sheet material 5. The distance between the end faces 17, 37 of the first and second profiles 15, 37 is such that the pair of first profiled rollers 3 may compress the tubular web of sheet material 5 between them whilst the heat is transferred to the sheet material 5 to form the first seal 4. Thus, a partially formed delivery system 6 is created.

[0120] As the first seal 4 is formed, the pneumatic nozzle 74 fires a jet of gas to blow powder 90 down the tubular web of sheet material 5 into the partially formed delivery system 6. The powder is prevented from going any further by the first seal 4 and prevented from dispersing by the tubular shape of the web of sheet material 5. As shown in Fig. 1, the outlet of the pneumatic nozzle 74 may be located in the aperture of the garniture 83. The powder insertion device 71 may be controlled by a system controller to time its insertion of the powder to the creation of the first seal 4. The first pair of profiled rollers 3 and the powder insertion device 7 may repeat this process for each of the first seals 4 formed in the web of sheet material by the first and second profiles 15, 35 of the first pair of profiled rollers 3.

[0121] The web of sheet material 5, which now comprises a partially formed deliveiy system 6 is then transferred to the second pair of profiled rollers 8. The first and second rollers

[0122] 41, 42 of the second pair of profiled rollers 8 rotate in opposite directions so that at their closest point, the nip point, they are moving in the same direction. Around the nip point, the heated profiles 45, 55 of the first and second rollers 41, 42 come into contact with the web of sheet material 5. The distance between the end faces 47, 57 of the first and second profiles 45, 57 is such that the pair of second profiled rollers 8 may compress the tubular web of sheet material 5 between them whilst the heat is transferred to the sheet material 5 to form the second seal 9. Thus, a sealed delivery system 10 is created.

[0123] The web of sheet material 5 is then transferred to the cutting apparatus 61. At the cutting apparatus 61, cutting knives 65, 66 are used to separate individual delivery systems 2 from the web of sealed delivery systems leaving the second pair of profiled rollers 8. The cutting knives 65, 66 may cooperate at the nip between the first and second rollers 41, 42 of the second pair of profiled rollers 8 to form the cut. The cutting knives 65, 66 may cut along the first and second seals 4, 9 to produce a non-square and non-rectangular delivery system 2.

[0124] It will be appreciated that in alternative embodiments, the cutting apparatus may comprise a laser cutter. From the above, it will be appreciated that the process may be a continuous process in which delivery systems are being formed sequentially as the web passes through each of the rollers.

[0125] Referring briefly to Figs. 3a to 3d, schematic top views of exemplaiy delivery systems 2 and the seals 4, 9 used to form the deliveiy systems 2 are shown. The seals 4, 9 are formed such that the delivery system 2 comprises a single continuous seal extending around its periphery. For example, Fig. 3a shows a hexagonal delivery system 2. It can be seen from Fig. 3a that the first seal 4 may form four sides of the delivery system 2. The first seal may form a concave boundary for receiving the powder from the powder insertion device 71. The second seal 9 may form the remaining two sides of the hexagon and seals off the inside of the delivery system 2 from the outside.

[0126] Fig. 3b shows a diamond shaped delivery system 2. It can be seen from Fig. 3b that the first seal 4 may form two sides of the delivery system 2. The first seal may form a concave boundary for receiving the powder from the powder insertion device 71. The second seal 9 may form the remaining two sides of the diamond and seals off the inside of the delivery system 2 from the outside.

[0127] Fig. 3c shows a delivery system 2 having an irregular pentagon shape. It can be seen from Fig. 3c that the first seal 4 may form four sides of the delivery system 2. The first seal may form a concave boundary, or almost complete boundary with a small unsealed portion, for receiving the powder from the powder insertion device 71. The second seal 9 may form the remaining side of the pentagon and seals off the inside of the delivery system 2 from the outside.

[0128] Fig. 3d shows a pillow-shaped delivery system 2. The pillow shaped delivery system may be generally rectangular with rounded corners. It can be seen from Fig. 3d that the first seal 4 may form three sides of the delivery system 2. The first seal may form a concave boundary for receiving the powder from the powder insertion device 71. The second seal 9 may form the remaining side of the pillow shaped delivery system 2 and seals off the inside of the delivery system 2 from the outside.

[0129] Referring now to Fig. 4, a schematic view of an apparatus 1 for manufacturing delivery systems 2 is shown along side a diagrammatic view of the steps undergone at each stage of the process. The apparatus 1 shown in Fig. 4 is configured to form delivery systems 2 from a two webs of sheet material 5.

[0130] The apparatus 1 shown in Fig. 4 is essentially the same as the apparatus 1 shown in Fig.

[0131] 2. However, the apparatus 1 of Fig. 4 does not require the tube forming wheel 81 or garniture 83 of Fig. 2 and instead makes use of a pair of crimping rollers 85.

[0132] The first web of sheet material 5a is fed from a first bobbin (not shown) along a first feed path and the second web of sheet material 5b is fed from a second bobbin (not shown) along a second feed path. The first and second webs of sheet material 5a, 5b are brought into alignment upstream of the pair of crimping rollers 85. The pair of crimping rollers 85 may be configured to form longitudinal seals 86 between the first and second webs of sheet material 5a, 5b along their longitudinal edges. The pair of crimping rollers 85 may be heated to form the longitudinal seals. The tubular web of sheet material 5 is then transferred to the first pair of profiled rollers 3, where the process of forming a first seal, inserting the powder using a powder insertion device 7, forming a second seal, and cutting individual delivery systems 2 form the web of sheet material is the same as described above in relation to Fig. 2.

[0133] Referring now to Fig. 5, a schematic view of an apparatus 1 for manufacturing delivery systems 2 is shown along side a diagrammatic view of the steps undergone at each stage of the process. The apparatus 1 shown in Fig. 5 is configured to form delivery systems 2 from a two webs of sheet material 5.

[0134] The apparatus 1 shown in Fig. 5 is essentially the same as the apparatus 1 shown in Fig. 4. However, the apparatus 1 of Fig. 5 does not require a separate pair of crimping rollers 85 and first pair of profiled rollers 3. Instead, the apparatus 1 of Fig. 5 combines the pair of crimping rollers 85 and the first pair of profiled rollers into one pair of crimping and sealing pair of rollers 89, which comprise a profile similar to that of the first pair of profiled rollers 3 in Fig. 1, which comprise profiles having circumferentially extending parts that are able to form longitudinally extending seals.

[0135] Thus, in the apparatus 1 of Fig. 5, the first web of sheet material 5a is fed from a first bobbin (not shown) along a first feed path and the second web of sheet material 5b is fed from a second bobbin (not shown) along a second feed path. The first and second webs of sheet material 5a, 5b are brought into alignment upstream of the crimping and sealing pair of rollers 89. The pair of rollers 89 may be configured to form longitudinal seals between the first and second webs of sheet material 5a, 5b along their longitudinal edges and to form the first seal 4. The pair of rollers 89 roller may be heated to form the longitudinal seals and the first seal.

[0136] The remaining processes of inserting the powder using a powder insertion device 71, forming a second seal, and cutting individual delivery systems 2 form the web of sheet material is the same as described above in relation to Fig. 2 and so a detailed description thereof will be omitted herein.

[0137] In the context of the present invention, the continuous seal extending around the periphery of the delivery system 2 may be considered to be a seal without any gaps in the outline it forms around the powder in between the first and second webs of sheet material. The continuous seal may be formed by the first and second seals that are formed on the webs of sheet material. The continuous seal is the part of the delivery system 2 where the first and second webs of sheet material are adhered or affixed to each other. It will be appreciated that in some embodiments, there may be more than two webs of sheet material used to form the delivery system. In some embodiments, the continuous seal may be formed in all of the webs of sheet material or in only some of the webs of sheet material but at least in two. The continuous seal may be largely planar. In some embodiments, the continuous seal may have a contact width. The width of the seal will depend on the profile of the delivery system forming rollers. In some embodiments, the continuous seal may have a constant thickness.

[0138] Referring briefly to Figs. 6a to 6f, schematic top views of exemplaiy delivery systems 2 and the seals 4, 9 used to form the delivery systems 2 using the apparatus 1 of Fig. 5 are shown. It will be appreciated that the shape of the deliveiy system 2 manufactured can be changed by changing the shape of the profiles 15, 35, 45, 55 on the first and second pair of profiled rollers 3, 8. Although described in detail above, a method of forming a delivery system 2 will be briefly described for clarity. The method comprises providing a web of sheet material 5, forming a first seal 4 on the web of sheet material 5 to create a partially formed delivery system 6 on the web of sheet material 5, inserting powder into the partially formed delivery system 6, forming a second seal 9 on the web of sheet material 5 to form a sealed deliveiy system 10 on the web of sheet material 5, and cutting individual delivery systems from the web of sheet material 5.

[0139] Referring finally to Figs. 7a to 7g, there is shown examples of non-square and non- rectangular delivery systems 2. Each of the exemplary delivery systems 2 comprises a first web of sheet material and a second web of sheet material sealed together around the periphery and defining a cavity therebetween. Powder 8 for delivering a substance is located in the cavity. Each delivery system 2 is non-square and non-rectangular in shape. In some embodiments, each of the corners of the delivery system 2 are rounded. Thus, the pillow shaped delivery system 2 is not considered rectangular because it has rounded corners. In some embodiments, the pouch delivery systems are any shaped except for square with pointed corners, square with rounded corners, rectangular with square corners, or rectangular with rounded corners.

[0140] As explained previously, the shape of the delivery system 2 is defined by the outline of the continuous peripheral seal. The continuous peripheral seal is formed by the two seals discussed herein. Thus, the shape of the delivery system 2 is defined by its cross- sectional shape at the seal between the webs of sheet material. Thus, it will be understood that a delivery system may be flattened and would form a non-square and non-rectangular shape. In some embodiments, the powder 8 may occupy in the range of about 60 % to about 95 % of the volume of the cavity. In some embodiments, the powder 8 may have a moisture content in the range of about 18 % to about 50 %.

[0141] The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and / or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc, other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.”

Claims

Claims1. An apparatus for manufacturing delivery systems, the apparatus comprising: a first pair of profiled rollers configured to form a first seal on a web of sheet material to form a partially formed delivery system on the web of sheet material; a powder insertion device configured to insert powder into a partially formed delivery system of the web of sheet material; and a second pair of profiled rollers configured to form a second seal on a web of sheet material to form a sealed delivery system on the web of sheet material.

2. The apparatus according to claim 1, wherein the first pair of rollers comprises a first roller and a second roller, wherein the first roller comprises a first profile configured to form a first seal to close a first end of a delivery system. 3- The apparatus according to claim 2, wherein the first profile is heated to form the first seal on the web of sheet material.

4. The apparatus according to claim 2 or claim 3, wherein the second roller comprises a second profile which matches the shape of the first profile on the first roller.

5. The apparatus according to claim 4, wherein the second profile is heated to form the first seal on the web of sheet material.

6. The apparatus according to any one of claim 2 to claim 5, wherein the first profile is non-linear.

7. The apparatus according to any one of claim 2 to claim 6, wherein the first roller has a first profile that forms a part of a non-square and non-rectangular contour.

8. The apparatus according to claim 6 or claim 7, wherein the first profile comprises a first part and a second part that extend substantially circumferentially about the first roller.

9. The apparatus according to claim 8, wherein the first profile comprises a third part and a fourth part located between the first and second parts, the third and fourth parts extending such that they are non-parallel. io. The apparatus according to claim 8, wherein the first profile comprises an intermediate part that is non-linear. n. The apparatus according to any one of claim 2 to claim io, wherein the first profile and / or the second profile is raised from the circumferential surface of the first roller and / or the second roller.

12. The apparatus according to claim n, wherein the first profile and / or the second profile is raised in the range of about 0.2 mm to about 5 mm.

13. The apparatus according to any one of the preceding claims, wherein the second pair of rollers comprises a first roller and a second roller, wherein the first roller comprises a first profile configured to form a second seal to close a second end of a delivery system.

14. The apparatus according to claim 13, wherein the first profile is heated to form the first seal on the web of sheet material.

15. The apparatus according to claim 13 or claim 14, wherein the second roller comprises a second profile which matches the shape of the first profile on the first roller.

16. The apparatus according to claim 15, wherein the second profile is heated to form the second seal on the web of sheet material.

17. The apparatus according to any one of claim 12 to claim 15, wherein the first profile is non-linear.

18. The apparatus according to any one of claim 13 to claim 17, wherein the first roller has a first profile that forms a part of a non-square and non-rectangular contour.19- The apparatus according to claim 17 or claim 18, wherein the first profile comprises a first part and a second part, wherein the first and second parts extend such that they are non-parallel.

20. The apparatus according to any one of claim 13 to claim 19, wherein the first profile and / or the second profile is raised from the circumferential surface of the first roller and / or the second roller.

21. The apparatus according to claim 19, wherein the first profile and / or the second profile is raised in the range of about 0.2 mm to about 5 mm.

22. The apparatus according to any one of claim 2 to claim 21, wherein the first profile on the first pair of profiled rollers and the first profile on the second pair of profiled rollers form a non-square and non-rectangular contour when they form first and second seals on the web of sheet material.

23. The apparatus according to any one of the preceding claims, further comprising a cutting apparatus configured to cut individual delivery systems from a web of sealed delivery systems.

24. The apparatus according to 23, wherein the cutting apparatus comprises a pair of cutting drums.

25. The apparatus according to claim 24, wherein the pair of cutting drums comprise a first cutting drum and a second cutting drum, the first cutting drum comprising a plurality of cutting knives.

26. The apparatus according to claim 25, wherein any one of the plurality of cutting knives is configured to make a cut in the web of delivery systems to separate a downstream end of a delivery system from the web of sheet material.

27. The apparatus according to claim 25, wherein the plurality of cutting knives are shaped to cut through the web of deliveiy systems through the first and second seals.

28. The apparatus according to any one of the preceding claims, wherein the powder insertion device comprising a powder storage container, a dosingcompartment, and a pneumatic nozzle configured to blow powder into the partially formed delivery system.

29. The apparatus according to any one of the preceding claims, further comprising a tube forming wheel configured to fold a web of sheet material into a tubular web of sheet material.

30. The apparatus according to claim 29, wherein the tube forming wheel is heated to form a seal line along the tubular web of sheet material.

31. The apparatus according to any one of claim 1 to claim 28, further comprising a first feed path for a first web of sheet material and a second feed path for a second web of sheet material, the first and second feed paths aligning at or before the first pair of roller drums.

32. The apparatus according to claim 31, further comprising a crimping roller configured to form longitudinal seals between the first and second webs of sheet material.

33. A method of forming a delivery system, the method comprising: providing a web of sheet material; forming a first seal on the web of sheet material to create a partially formed delivery system on the web of sheet material; inserting powder into the partially formed delivery system; forming a second seal on the web of sheet material to form a sealed delivery system on the web of sheet material such that the powder is surrounded by a continuous seal; and cutting individual delivery systems from the web of sheet material.

34. A delivery system comprising: a first web of sheet material and a second web of sheet material sealed together around the periphery to define a cavity therebetween; wherein the seal is a continuous seal around the periphery of the delivery system; and powder for delivering a substance located in the cavity.35- The delivery system according to claim 34, wherein the delivery system is nonsquare and non-rectangular in shape.

36. The delivery system according to claim 34 or claim 35, wherein the powder occupies in the range of about 60 % to about 95 % of the volume of the cavity.

37. The delivery system according to any one of claim 34 to claim 36, wherein the powder has a moisture content in the range of about 18 % to about 50 %.

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