An apparatus for manufacturing delivery systems

Abstract

An Apparatus for Manufacturing Delivery Systems The present invention relates to an apparatus for manufacturing delivery systems. The apparatus comprises a dosing system, a delivery system forming system, and a cutting system configured to cut a plurality of individual delivery systems from a web of delivery systems. The dosing system comprises a dosing drum comprising a recess to receive powder from a feeder mechanism. The dosing drum is configured to form an agglomeration of powder and place the agglomeration on a first web of sheet material. The delivery system forming system comprises a pair of delivery system forming oscillating beams comprising an upper oscillating beam and a lower oscillating beam configured to move between upstream and downstream positions, each comprising a plurality of sealing blocks, each which have at least one sealing profile. The upper and lower oscillating beams are configured to move into a sealing position at the upstream position and remain in the sealing position until the downstream position to seal first and second webs of sheet material around an agglomeration of powder to form a web of delivery systems.

Description

[0001] An Apparatus for Manufacturing Delivery Systems

[0002] Technical Field of the Invention

[0003] 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.

[0004] Background of the Invention

[0005] It is known to provide alternatives to combustible aerosol provision systems. Such systems are referred to as non-combustible aerosol provision systems and aerosol-free delivery systems. In such systems at least one substance is delivered to a user. In non-combustible aerosol provision systems an aerosol is generated from an aerosol-generating material without being combusted, whereas in aerosol-free delivery systems a substance is delivered without generating an aerosol It is known to provide the substance to be delivered in a delivery system. Some delivery 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.

[0006] Summary of the Invention

[0007] In a first aspect of the present invention, there is provided an apparatus for manufacturing delivery systems. The apparatus comprises a dosing system, the dosing system comprising a dosing drum comprising a recess located in its circumferential surface, the recess being configured to receive powder from a feeder mechanism, the dosing drum being configured to form an agglomeration of powder and place the agglomeration of powder on a first web of sheet material, and a delivery system forming system comprising a pair of delivery system forming oscillating beams comprising an upper oscillating beam and a lower oscillating beam configured to move between upstream and downstream positions, each of the oscillating beams comprising a plurality of sealing blocks each having at least one sealing profile, wherein the upper and lower oscillating beams are configured to move into a sealing position at the upstream position, in which each sealing profile extends around an agglomeration of powder, and remain in the sealing position until the downstream position along a conveyance path of the agglomeration of powder to seal first and second webs of sheet material around an agglomeration of powder to form a web ofdelivery systems, and a cutting system configured to cut a plurality of individual delivery systems from a web of delivery systems.

[0008] In some embodiments, each of the plurality of sealing blocks may be pre-loaded by a spring to provide consistent sealing pressure when the upper and lower oscillating beams are in the sealing position.

[0009] In some embodiments, the pre-loaded spring may be adjustable via a nut to vary the sealing pressure of each sealing block individually such that consistent pressure in the sealing position is obtainable.

[0010] In some embodiments, the upper and lower oscillating beams may be configured to provide a sealing force in the range of about 300 N to about 600 N per delivery system.

[0011] In some embodiments, the upper and lower oscillating beams may remain in the sealing position for in the range of about 300 ms to about 450 ms.

[0012] In some embodiments, each of the sealing profiles may be heated during use. In some embodiments, the surface temperature of each of the sealing profiles may be in the range of about 190 °C to about 200 °C.

[0013] In some embodiments, each sealing profile of each of the plurality of blocks may comprise a non-stick coating.

[0014] In some embodiments, the cutting system may comprise an oscillating cutter comprising an upper punch and a lower die configured to move between upstream and downstream positions along the conveyance path of a web of delivery systems, wherein the punch and die may be configured to move from a separated configuration at the upstream position to a cutting configuration along the conveyance path to cut individual delivery systems from a web of delivery systems.

[0015] In some embodiments, both the punch and the die may be moved towards one another when moved from their respective positions in the separated configuration to their respective positions in the cutting configuration.In some embodiments, the die may comprise a delivery system aperture extending therethrough, the delivery system aperture may be configured to allow a delivery system cut from a web of delivery systems to pass therethrough.

[0016] In some embodiments, the punch may comprise a nozzle configured to eject a jet of gas when in the cutting configuration to aid passage of a delivery system through the delivery system aperture.

[0017] In some embodiments, the apparatus may further comprise a pouch transport system configured to receive delivery systems from the cutting system.

[0018] In some embodiments, the pouch transport system may comprise a vacuum transport belt, the vacuum transport comprising a plurality of transport elements having a delivery system container coupled to a suction nozzle.

[0019] In some embodiments, a first vacuum transport belt may be located below the oscillating cutter and may be configured to such that the delivery system container moves synchronously along a part of the conveyance path from an upstream position to a downstream position with the die.

[0020] In some embodiments, the apparatus may further comprise a first inspection element configured to inspect a first side of a delivery system.

[0021] In some embodiments, a second vacuum transport belt may be located downstream of the first vacuum transport belt and may be configured receive delivery systems from the first vacuum transport belt via suction transfer.

[0022] In some embodiments, the apparatus may further comprise a second inspection element configured to inspect a second side of a delivery system.

[0023] In some embodiments, the apparatus may further comprise a rejection bin configured to receive delivery systems that fail inspection.

[0024] In some embodiments, the apparatus may further comprise a web stabilisation mechanism configured to prevent first and second webs of sheet material from stretching under tension and / or heat.In some embodiments, the web stabilisation mechanism may comprise a pair of upper endless belts configured to contact both edges of the first web and a pair of lower endless belts configured to contact both edges of the second web.

[0025] In some embodiments, the pairs of upper and lower endless belts may comprise a high friction surface or a plurality of high friction elements thereon.

[0026] In some embodiments, the pairs of upper and lower endless belts may be configured to compress the edges of first and second webs of sheet material therebetween.

[0027] In some embodiments, the pairs of upper and lower endless belts may be configured to move at the same speed as first and second webs of sheet material along a portion of the conveyance path.

[0028] In some embodiments, the delivery forming system may comprise a first web stabilisation mechanism. In some embodiments, the cutting system may comprise a second web stabilisation mechanism.

[0029] In some embodiments, the dosing drum may comprise a movable piston having a piston surface, the piston surface forming the bottom of the recess, wherein the movable piston may be configured to compress the powder received in the recess against a compression surface as the dosing drum rotates.

[0030] In some embodiments, the compression surface may be formed by a stationary curved wall.

[0031] In some embodiments, the piston may be configured to move from a starting position to a compressed position to reduce the volume of the recess in the range of about 40% to about 90%.

[0032] In some embodiments, the starting position of the piston may be adjustable.

[0033] In some embodiments, the starting position of the piston may be adjustable such that the volume of the recess in the starting position may be increased or reduced by up to 20%.

[0034] In some embodiments, the dosing drum may comprise an adjustment mechanism, the adjustment mechanism may comprise a telescopic piston shaft comprising first andsecond portions, and a cam comprising two diverging tracks, a first track coupled to a first portion of the telescopic piston shaft and a second track coupled to a second portion of the telescopic piston shaft.

[0035] In some embodiments, the piston may be configured to apply in the range of 80 N to 100 N of force on the powder receiving in the recess.

[0036] In some embodiments, the movable piston may be coupled to a dosing cam by a coupling, the coupling being located radially from the piston surface and on the centreline of the piston.

[0037] In some embodiments, the recess may be formed in an insert, wherein the insert may be removably locatable in an aperture located in the circumferential surface of the dosing drum.

[0038] In a second aspect of the present invention, there is provided a method for manufacturing a delivery system. The method comprises the steps of filing a recess in a dosing drum with powder to form an agglomeration of powder, placing the agglomeration of powder on a first web of sheet material, placing a second web of sheet material over the agglomeration of powder on the first web of material, transporting the agglomeration of powder and webs along part of the conveyance path between a pair of delivery system forming oscillating beams, heating profiles on the pair of delivery system forming oscillating beams to seal the agglomeration of powder within the webs to form a web of delivery systems, and cutting individual delivery systems from the web of delivery systems.

[0039] Brief Description of the Drawings

[0040] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0041] Fig. 1 shows a schematic perspective view of an apparatus for manufacturing delivery systems;

[0042] Fig. 2 shows an enlarged schematic perspective view of a feeder mechanism;

[0043] Fig. 3 shows an enlarged schematic perspective view of a portion of an apparatus for manufacturing a delivery system;

[0044] Fig. 4 shows an enlarged schematic front view of a dosing drum of an apparatus for manufacturing a delivery system;Figs. 5a-c show embodiments of the circumferential surface of the dosing drum;

[0045] Fig. 6 shows a perspective cross-section side view of a dosing system;

[0046] Fig. 7 shows a perspective schematic view of the dosing drum;

[0047] Fig. 8 shows a schematic side view of a delivery system forming system;

[0048] Fig. 9 shows a schematic perspective front view of the delivery system forming system;

[0049] Fig. 10 shows a schematic perspective view of a sealing block;

[0050] Fig. 11 shows a schematic perspective view of a cutting system;

[0051] Fig. 12 shows a schematic perspective view of a pouch transport system; and Fig. 13 shows a schematic perspective view of a web stabilisation mechanism.

[0052] Detailed Description of the Invention

[0053] As used herein, the term "delivery system" is intended to encompass systems that deliver at least one substance to a user, and includes:

[0054] 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

[0055] 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, article comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein at least one substance may or may not comprise nicotine.

[0056] According to the present discloses, 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.

[0057] In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.

[0058] 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.

[0059] 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 aerosolgenerating material and a solid aerosol-generating material. The solid aerosolgenerating material may comprise, for example, tobacco or a non-tobacco product.

[0060] 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.

[0061] 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.

[0062] In some embodiments, the non-combustible aerosol provision system, such as non-combustible 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 the power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.

[0063] 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.

[0064] 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, and 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.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.

[0065] 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 constituents, one or more flavours, one or more aerosol-former materials, and / or one or more other functional materials.

[0066] In some embodiments, the substance to be delivered comprises an active substance.

[0067] 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, touring, 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.

[0068] In one embodiment, the active substance is a legally permissible recreational drug.

[0069] In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.

[0070] The active substance may be CBD or a derivative thereof.

[0071] 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, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, Wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, Damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, 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 citrate c.v., Mentha piperita c.v., Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.

[0072] 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.

[0073] 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.

[0074] 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.

[0075] In some embodiments, the substance to be delivered comprises a flavour.

[0076] 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 (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, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit,papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, 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, 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, marjoram, 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.

[0077] 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.

[0078] 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, banillyl ethyl ether and a suitable cooling agent may be, but not limited to, eucolyptol, WS-3.

[0079] Aerosol-generating material is a material that is capable of generating aerosol, for example, when heated, irradiated or energized in any other way. Aerosol-generatingmaterial 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.

[0080] The aerosol-generating material may comprise on or more active substances and / or flavours, one or more aerosol-former materials, and optionally one or more other functional material.

[0081] 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.

[0082] The aerosol generating material may comprise or be in the form of an aerosolgenerating film. Ther 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. Ther aerosol-generating film may be substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free.

[0083] 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.

[0084] 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 aerosolgenerating material.

[0085] The aerosol-generating film may be discontinuous. For example, the aerosolgenerating film may comprise one or more discrete portions or regions of aerosolgenerating 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.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.

[0086] The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent.

[0087] The aerosol-generating material may comprise or be an "amorphous solid". In some embodiments, the aerosol-generating material 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%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid.

[0088] The amorphous solid may be substantially free from botanical material. The amorphous solid may be substantially tobacco free.

[0089] 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-Erythritol, ethyly vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, nezyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0090] 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.

[0091] 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. Ther aerosol-modifying agent may be free from filtration material.

[0092] As 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.

[0093] Referring now to Fig. 1, a schematic front view of an apparatus for manufacturing delivery systems 2 is shown. The apparatus 1 comprises a dosing system 3. The dosing system 3 comprises a dosing drum 5. The dosing drum 5 comprises a recess 11 located in its circumferential surface 12. The recess 11 may be configured to received powder 8 from a feeder mechanism 4. The dosing drum 5 is configured to form an agglomeration of powder 9 and place the agglomeration of powder 9 on a first web of sheet material 14.

[0094] The apparatus 1 further comprises a delivery system forming system 6. The delivery system forming system 6 comprises a pair of delivery systems forming oscillating beams 7. The pair of delivery system forming oscillating beams 7 comprise an upper oscillating beam 7a and a lower oscillating beam 7b. The upper and lower oscillating beams 7a, 7b are configured to move between upstream and downstream positions. Each of the oscillating beams 7a, 7b comprise a plurality of sealing blocks 15. Each sealing block 15 comprises at least one sealing profile 16.

[0095] The upper and lower oscillating beams 7, 7b are configured to move into a sealing position at the upstream position. In the sealing position, each sealing profile 16 extends around an agglomeration of powder 9. The upper and lower oscillating beams 7a, 7b remain in the sealing position until the downstream position along a conveyance path of the agglomeration of powder 9 to seal first and second webs ofsheet material 14, 19 around an agglomeration of powder 9 to form a web 20 of delivery systems 2.

[0096] The apparatus 1 further comprises a cutting system 13. The cutting system 13 is configured to cut a plurality of individual delivery systems 2 from a web 20 of delivery system 2.

[0097] In some embodiments, the delivery system 2 may be a pouch.

[0098] An agglomeration of powder may be a mass of powder that is collected together to form a specified shape. In some embodiments, the agglomeration of powder may be a mass of powder that is collected together and compressed into a specified or given shape. The agglomeration of powder may be an agglomeration of moist powder. That is, the agglomeration of powder may be an agglomeration or collection of powder with a moisture content. The powder may have a moisture content that can be augmented during the manufacturing process or in the packaging process by spraying water onto the delivery systems or into the package for the delivery systems.

[0099] Referring to Fig. 2, a schematic perspective view of a feeder mechanism 4 is shown. The feeder mechanism 4 may be formed by a hopper 24. The hopper 24 may be located directly above the dosing system 3. The feeder mechanism 4 may further comprise an agitation bar 31. The agitation bar 31 may be configured to vibrate to ensure that the powder 8 remains mobile and keeps flowing towards the bottom of the hopper 24 to be transferred to the dosing drum 5 to maximise filling of the recess 11 in the dosing drum 5. The hopper 24 may further comprise a level sensor 32. The level sensor 32 may be configured to indicate when the level of powder 8 in the hopper 24 is low.

[0100] The feeder mechanism 4 may further comprise an air conveyor 33. The air conveyor 33 may be configured to transport a charge of powder 8 from a bulk supply (not shown) to the apparatus 1 for manufacturing delivery systems 2. The air conveyor 33 may have its own control system. The air conveyor 33 may be configured to automatically shut off once its chamber is full.

[0101] The feeder mechanism 4 may further comprise an auger system 34. The auger system 34 may be configured to meter out the powder 8 at a low, consistent rate into the hopper 24. The auger system 34 may comprise a control system configured to indicate when the level of powder 8 therein is low.Referring now to Fig. 3, a schematic perspective view of a portion of the apparatus 1 for manufacturing a delivery system 2 is shown. As shown, the apparatus 1 may further comprise a first spindle 41 and a second spindle 42. The first spindle 41 may be configured to receive the first web of sheet material 14. The second spindle 42 may be configured to receive the second web of sheet material 19.

[0102] The first web of sheet material 14 may be provided in the form of a first bobbin 43. The first bobbin 43 of the first web of sheet material 14 may be received on the first spindle 41. The second web of sheet material 19 may be provided in the form of a second bobbin 44. The second bobbin 44 of the second web of sheet material 19 may be received on the second spindle 42.

[0103] The first and second webs of sheet material 14, 19 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.

[0104] The apparatus 1 for manufacturing delivery systems 2 may further comprise a first plurality of rollers 46 and a first tensioning arm 47. The first plurality of rollers 46 may be configured to guide the first web of sheet material 14 along a first web conveyance path. The first tensioning arm 47 may be configured to provide constant tension on the first web of sheet material 14. The apparatus 1 for manufacturing delivery systems 2 may further comprise a second plurality of rollers 48 and a second tensioning arm 49. The second plurality of rollers 48 may be configured to guide the second web of sheet material 19 along a second web conveyance path. The second tensioning arm 49 may be configured to provide constant tension on the second web of sheet material 19. A third tensioning arm may be provided for the waster web outfeed.

[0105] In some embodiments, the rollers 46, 48 may have a silicon coated circumferential surface. Thus, the rollers 46, 48 may have a high friction surface compared to known aluminium rollers. This may provide more control over the webs of sheet material 14, 19. As slip between the webs and the rollers is reduced, the webs are also less likely to be stretched or deformed.In some embodiments, the tensioning arms may be connected to a digital tension sensor. The digital tension sensor may feedback the tension value to a controller to aid with web control.

[0106] The first web of sheet material 14 may be guided along the first web conveyance path in order to form a lower web of the delivery system 2 manufactured by the apparatus 1. The second web of sheet material 19 may be guided along the second web conveyance path in order to form an upper web of the delivery system 2 manufactured by the apparatus 1.

[0107] Referring now to Fig. 4, there is shown an enlarged schematic front view of the dosing drum 5 of the apparatus 1 for manufacturing a delivery system 2. The dosing drum 5 may be generally cylindrical. The dosing drum 5 may be rotatable about a longitudinal axis A. The longitudinal axis A of the dosing drum 5 about which it rotates may coincide with the centre line of the dosing drum 5. The dosing drum 5 may comprise a circumferential surface 12.

[0108] The dosing drum 5 comprises the recess 11 located in its circumferential surface 12. The recess 11 may be configured to receive powder 8 from the feeder mechanism 4. The dosing drum 5 is also configured to form an agglomeration of powder 9 and place the agglomeration of powder 9 on the first web of sheet material 14. The recess 11 may comprise a leading edge 51. The leading edge 51 may be considered to be the part of the recess 11 furthest forward in the direction of rotation of the dosing drum 5. The recess 11 may comprise a trailing edge 52. The trailing edge 52 may be considered to be the part of the recess 11 furthest rearward in the direction of rotation of the dosing drum 5.

[0109] The recess 11 of the dosing drum 5 may extend from the circumferential surface 12 of the dosing drum 5 into the dosing drum 5. The recess 11 may be non-square in shape. That is, the recess 11 may have a generally circular, triangular, tear-drop, heart, diamond, or any other shape that is not square. The recess 11 may also be non-rectangular in shape. Non-square and non-rectangular shapes may include square and rectangular shapes with rounded corners. In some embodiments, the recess 11 may be generally square or rectangular.

[0110] The recess 11 of the dosing drum 5 may be formed as a right prism. That is, the cross-sectional area of the recess 11 may be constant throughout the depth of the recess 11, i.e. radial distance from the circumferential surface 12 of the dosing drum5. In some embodiments, the recess 11 of the dosing drum 5 may be formed from a shape other than a right prism. That is, the cross-sectional area of the recess 11 may vary or taper along its depth dimension. For example, the cross-sectional area of the recess 11 may taper or reduce with distance from the circumferential surface 12 of the dosing drum 5. Thus, a circular recess 11 formed as a right prism may form a cylindrical or disk-shaped agglomeration of powder 9 and a circular recess 11 formed with a taper may form a cone or truncated cone agglomeration of powder 9. The volume of the recess 11 may be in the range of about 200 mm3to about 800 mm3.

[0111] As the dosing drum 5 is rotated, the leading edge 51 of the recess 11 passes the feed mechanism 4. At this point, powder 8 stored in the feed mechanism 4 may begin to be transferred into the recess 11 of the dosing drum 5. As the dosing drum 5 continues to rotate more of the recess aligns with the feed mechanism 4 to facilitate the transfer of the powder 8 into the recess 11. The dosing drum 5 continues to rotate until the trailing edge 52 of the recess 11 is also aligned with the feed mechanism 4, which enables the whole of the recess 11 to be filled with powder 8.

[0112] As the dosing drum 5 continues to rotate, the leading edge 51 of the recess 11 moves past the feeder mechanism 4 and may come into contact with the scraping edge 27. The scraping edge 27 may push powder 8 backwards towards the trailing edge 52 of the recess 11 in order to ensure the recess 11 is completely filled. Any excess powder 8 that cannot be pushed into the recess 11 to fill the recess 11 is removed by relative motion of the dosing drum 5 relative to the scraping edge 27.

[0113] It will be appreciated that in some embodiments, there may be an instant where the whole recess 11 is aligned with the feed mechanism 4 so that powder can be deposited into the whole recess 11 at the same time. It will also be appreciated that in some embodiments, the leading edge 51 of the recess 11 may be out of alignment with the feed mechanism 4 before the trailing edge 52 of the recess 11 has come into alignment with the feed mechanism 4.

[0114] Referring now to Fig. 5a, it can be seen that in some embodiments, the dosing drum 5 may comprise a plurality of recesses 11. Fig. 5a shows the circumferential surface 12 of a dosing drum 5 stretched out into a 2D plane in order to better aid understanding of the following description. It will be appreciated that the 2D view in Fig. 5a could be curved around a central axis in order to form a circumferential surface 12 of a dosing drum 5.The plurality of recesses 11 may be spaced around the circumferential surface 51 of the dosing drum 5. The plurality of recesses 11 may be equidistantly spaced around the circumferential surface 51 of the dosing drum 5. Thus, the constant supply of powder 8 to the feed mechanism 4 may be constantly and evenly distributed. The pitch P between circumferentially spaced recesses 11 may be in the range of about 30 mm to about 50 mm. That is, the distance around the circumferential surface 51 of the dosing drum 5 between the leading edge 51 of one recess 11 and the leading edge 51 of the circumferentially adjacent, i.e. angularly spaced, recess 11 may be in the range of about 30 mm to about 50 mm. Furthermore, the gap G between adjacent circumferentially spaced recess 11 may be in the range of about 2 mm to about 15 mm. That is, the distance between the trailing edge 52 of one recess 11 and the leading edge 51 of a circumferentially adjacent recess 11, behind the one recess 11 when considering the rotation of the dosing drum 5, may be in the range of about 2 mm to about 15 mm. In some embodiments, the gap G may be less than 10 mm. In some embodiments, the gap may be in the range of about 5 mm to about 10 mm.

[0115] These parameters enable the maximum amount of recesses 11 to be used around the circumferential surface 51 of the dosing drum 5 of a given width, which helps to increase agglomeration of powder 9 output, whilst ensuring that the space between the agglomerations of powder 9 placed onto the first web of sheet material 14 are large enough for the apparatus 1 to be able to form a sufficient seal to create durable delivery systems 2. Thus, the minimum distance between adjacent recesses 11 may be about 2 mm. In some embodiments, the minimum distance between adjacent recesses 11 may be about 5 mm.

[0116] Referring now to Fig. 5b, it can be seen that in some embodiments, the dosing drum 5 may comprise a plurality of recesses 11 spaced across its width. As with Fig. 5a, Fig.

[0117] 5b shows the circumferential surface 12 of a dosing drum 5 stretched out into a 2D plane. The plurality of recesses 11 may be spaced across the width of the circumferential surface 12 of the dosing drum 11, i.e. in the direction of the longitudinal axis A. As the width of the dosing drum 5 extends transversely to the direction of travel of the recesses 11, the plurality of recesses 11 may be referred to as transversely spaced recesses 11. The plurality of recesses 11 extending across the width of the dosing drum 5 may be in addition to the plurality of circumferentially spaced recesses 11 to form an array of recesses 11, as shown in Fig. 5b, or as an alternative.The plurality of recesses 11 spaced across the width of the circumferential surface 12 of the dosing drum 11 may be aligned. That is, the leading edges 51 of the transversely spaced recesses 11 may be aligned such that they rotate past the same point in space simultaneously. Furthermore, the trailing edges 52 of the transversely spaced recesses 11 may be aligned such that they rotate past the same point in space simultaneously.

[0118] Therefore, the dosing drum 5 may comprise an array of recesses 11 arranged in columns of recesses 11 that extend circumferentially around the dosing drum 5 and rows which extend transversely across the circumferential surface 12 of the dosing drum 5. Thus, the dosing drum 5 may be able to place row after row of delivery systems 2 onto the first web of sheet material 14.

[0119] Referring now to Fig. 5c, it can be seen that in some embodiments, the dosing drum 5 may comprise a plurality of recesses 11 in the circumferential surface 12 of the dosing drum 5 that are tessellated. As with Figs. 5a and 5b, Fig. 5c shows the circumferential surface 12 of a dosing drum 5 stretched out into a 2D plane.

[0120] In the context of the present invention, the term 'tessellated' is used to mean that the plurality of recesses 11 fit together closely without large gaps. Thus, the available surface area of the circumferential surface 12 of the dosing drum 5 is used more efficiently in order to provide a greater number of the agglomerations of powder 9 to the first web of sheet material 14. This helps to maximise output for a given size of dosing drum 5.

[0121] The plurality of recesses 11 may be arranged such that each column of recesses 11 that are spaced circumferentially are offset from the adjacent columns of recesses 11. That is, the leading edge 51 of a recess 11 in one circumferentially extending column of recesses 11 may be offset in the circumferential direction from the leading edge 51 of a recess 11 in the adjacent circumferentially extending columns of recesses 11. In some embodiments, the leading edges 51 of recesses 11 in alternate circumferentially extending columns of recesses 11 may be circumferentially aligned, as shown in Fig.

[0122] 5c. The trailing edge 52 of a recess 11 in one circumferentially extending column of recesses 11 may be offset in the circumferential direction from the trailing edge 52 of a recess 11 in the adjacent circumferentially extending columns of recesses 11. In some embodiments, the trailing edges 52 of recesses 11 in alternate circumferentially extending columns of recesses 11 may be circumferentially aligned, as shown in Fig.

[0123] 5c.Furthermore, it will be appreciated that in alternative embodiments, a dosing drum 5 may comprise recesses 11 having a plurality of differently shaped volumes. That is, a single dosing drum 5 may comprise a plurality of recesses 11 formed by a first plurality of recesses and a second plurality of recesses. The first plurality of recesses and the second plurality of recesses may be different in terms of shape and / or volume.

[0124] For example, the first plurality of recesses may be the same shape as the second plurality of recesses but have a larger cross-sectional area. In some embodiments, the shape and cross-sectional area of the opening of the first plurality of recesses and the second plurality of recesses may be the same but the depth of one plurality of recesses may be larger than the other, or the volume of one may be tapered whilst the other is not. In other examples, the volumes of the first plurality of recesses and the second plurality of recesses may be the same but their shapes may be different. Alternatively, both the shapes and the volumes of the first and second plurality of recesses may be different.

[0125] It will be understood that in some embodiments, the first plurality of recesses may form adjacent columns of circumferentially spaced recesses on one side of the dosing drum 5 and the second plurality of recesses may form adjacent columns of circumferentially spaced recesses on the other side of the dosing drum 5.

[0126] Alternatively, the columns of first and second pluralities of recesses 11 may alternate in the transverse direction across the circumferential surface 12 of the dosing drum 5.

[0127] It will be understood that in some embodiments, the first plurality of recesses may form adjacent rows of transversely spaced recesses over one semi-circle of the circumferential surface 12 of the dosing drum 5 and the second plurality of recesses may form adjacent rows of transversely spaced recesses over the other semi-circle of the circumferential surface of the dosing drum 5. Alternatively, the rows of first and second pluralities of recesses 11 may alternate in the circumferential direction around the circumferential surface 12 of the dosing drum 5.

[0128] It will be appreciated that the dosing drum 5 may comprise more than two pluralities of recesses. The apparatus 1 may be configured to separate the two or more configurations of delivery system 2 formed at a later point in the process or the different configurations of delivery system 2 may be packaged in a container comprising an assortment of delivery systems 2.Referring back to Fig. 4, the apparatus 1 for manufacturing delivery systems 2 may further comprise a compression surface 55. The compression surface 55 may be located adjacent to a portion of the dosing drum 5. The compression surface 55 may be configured to apply pressure to one side of the powder 8 in the recess 11 of the dosing drum 5 in order to compact the powder 8 into an agglomeration of powder.

[0129] The compression surface 55 may be a stationary element. The stationary compression surface 56 may comprise a low-friction material, such as, for example, Teflon ®. The low-friction stationary surface 55 reduces the amount of friction between the powder 8 in the recess 11 of the dosing drum 5 and the compression surface 55 as the dosing drum 5 rotates. The compression surface 55 may be formed by a stationary curved wall. The geometry of the stationary curved compression surface 55 may be closely matched to the curvature of the circumferential surface 12 of the dosing drum 5.

[0130] In alternative embodiments, the compression surface 55 may be a movable element, such as, for example, but not limited to a conveyor belt 56 that moves with the dosing drum 5 so that there is no relative motion between the compression surface 55 and the powder 8 in the recess 11 of the dosing drum 5. The conveyor belt 56 may be formed from, for example, but not limited to a stainless-steel belt. The apparatus 1 may further comprise a support element 57. The support element 57 may be configured to support the stainless-steel belt against the compression load placed on the compression surface 55. The surface of the support element 57 may be formed from a low friction material. The conveyor belt 56 may be supported and moved by a plurality of rollers 58. At least one of the plurality of rollers 58 may be driven by a servomotor (not shown).

[0131] The dosing drum 5 may further comprise a moveable piston 61. The piston 61 may piston surface 62. In some embodiments, the piston surface 62 may form the bottom of the recess 11. In some embodiments, the piston surface 62 may act on a compression element 64, as shown in Fig. 5. The compression element 64 may be at least partially located in the recess 11 and may form the bottom of the recess 11. The compression element 64 may be coupled to the piston surface 62 of the moveable piston 61 in order to move radially to compress the powder 8 received in the recess 8 and then return to a starting position to receive more powder 8. The moveable piston 61 may be configured to compress the powder received in the recess 11 against the compression surface 55 as the dosing drum 5 rotates.In some embodiments, the piston surface 62 of the piston 61 or compression element 64 may be profiled. Thus, the profiled surface 62 of the piston 61 or compression element 64 may provide the cross-sectional area change over the depth of the recess 11. Thus, the profiled piston surface 62 may form a part of the side wall of the recess 11 as well as the bottom wall.

[0132] The moveable piston 61 may be driven by a rotary cam 63, as shown schematically in Fig. 4 or by a cam track 66 and coupling 75 as shown in Fig. 6. The rotary cam 63 or cam track 66 may have a profile that is optimised for the powder fill weight of each recess 11 and the predetermined compression ratio for the agglomeration of powder 9 of each of the different configurations of the delivery system 2.

[0133] Referring to Fig. 4, it can be seen that as the dosing drum 5 rotates, in the anticlockwise direction as shown, the recess 11 that has been filled with powder 8 by the feed mechanism 4 comes into alignment with the compression surface 55. When the whole of the recess 11 in the circumferential surface 12 of the dosing drum 5 is covered by the compression surface 55, the rotary cam 63 or cam track 66 causes the moveable position 61 to move radially outwards. This radial movement of the moveable piston 61 reduces the distance between the piston surface 62 and the compression surface 55. The reduction in distance means that the volume of the recess 11 is reduced and the powder 8 is compressed. The powder 8, which is loosely held together prior to compression, is then compressed and packed together more tightly to form an agglomeration of powder 9.

[0134] In some embodiments, the moveable piston 61 may be configured to move from a starting position to a compressed position to reduce the volume of the recess 11 by about 40 % to about 90 %. The moveable piston 61 may travel in the range of about 0.1 mm to about 6 mm in the radial direction. In some embodiments, the moveable piston 61 may be configured to apply in the range of about 80 Newtons (N) to about 100 Newtons of force on the powder 8 received in the recess 11 of the dosing drum 5.

[0135] Once the powder 8 in the recess 11 of the dosing drum 5 has been compacted to form an agglomeration of powder, the recess 11 may be rotated out of alignment with and beyond the compression surface 55. After this, as the dosing drum 5 continues to rotate, the moveable piston 61 may be configured to move further outwards in the radial direction in order to remove the agglomeration of powder 9 from the recess 11 in the dosing drum 5. Alternatively, the agglomeration of powder 9 may fall from the recess 11 in the dosing drum 5 under the force of gravity. The agglomeration ofpowder 9 is deposited by the dosing drum 5 onto the first web of sheet material 14 at a release point. The release point is typically the lowest point of the rotational path of the circumferential surface 12 of the dosing drum 5.

[0136] As the dosing drum 5 continues to rotate, the rotary cam 63 or cam track 66 allows for the moveable piston 61 to return to its original position in order to receive the next charge of powder 8 from the feed mechanism 4. The apparatus 1 may further comprise a vacuum station 65. The vacuum station 65 may be configured to remove any remining powder 8 from the recess 11 of the dosing drum 5. The vacuum station 65 may be located after the release point but before the feed mechanism 4 in the direction of rotation of the dosing drum 5.

[0137] In some embodiments, it will be appreciated that the apparatus 1 may comprise rollers that form a part of the first plurality of rollers 46 of the first web of sheet material 14 that are configured to pass the first web of sheet material between the dosing drum 5 and the compression surface 55. Therefore, the first web of sheet material 14 is located proximate to the agglomeration of powder 9 formed in the recess 11 of the dosing drum 5 at and before the release point. Thus, the agglomeration of powder 9 is less likely to break when it is deposited onto the first web of sheet material 14 and more of the powder 8 is likely to be retained on the first web of sheet material 14.

[0138] In some embodiments, as shown in Fig. 4, the first web of sheet material 14 may be passed underneath the dosing drum 5 in a tangential fashion in order to have the agglomeration of powder 9 deposited onto the first web of sheet material 14. After the agglomeration of powder is deposited onto the first web of sheet material 14, the agglomeration of powder is transported downstream in the apparatus 1, where the second plurality of rollers 48 substantially align the second web conveyance path with the first web conveyance path. In some embodiments, when the first and second web conveyance paths are aligned, the first and second webs of sheet material 14, 19 may be in contact or may be spaced by a distance in the range of about 0.5 mm to about 10 mm, depending on the thickness of the webs of sheet material.

[0139] Whilst some of the embodiments described herein, such as described above, mainly deal with unconnected first and second webs of sheet material on different conveyance paths, 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 angledfold 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. The fold may be performed by a folding apparatus or garniture (not shown) located downstream of the dosing drum 5.

[0140] Referring now to Fig. 6, a perspective cross-section side view of the dosing system 3 is shown. The piston 61 is shown in its starting position. The starting position is the position of the piston 61 when the recess 11 is in its vertically upward position. That is, the starting position is the position of the piston 61 when the recess 11 underneath the feeder mechanism 4 and ready to receive powder 8.

[0141] The starting position of the piston 61 may be adjustable. The starting position of the piston 61 may be adjustable such that the volume of the recess 11 in the starting position may be increased or reduced by up to 20%.

[0142] The dosing drum 5 may comprise an adjustment mechanism 71. The adjustment mechanism 71 may comprise a telescopic piston shaft 72. The telescopic piston shaft 72 may comprise a first portion 73 and a second portion 74. The first portion 73 may be coupled to the piston 61. The second portion 74 may be coupled to a cam track 66 by a coupling 75. The coupling 75 may be located radially from the piston surface 62. The coupling 75 may be located on the centreline of the piston 61. Therefore, when there is a compression force on the piston 61, no moments are generated on the coupling 75 and the cam track 66. As a result, the friction and wear on the coupling 75 and cam track 66 are reduced and seizure of the dosing system 3 due to excessive loads can be avoided.

[0143] The adjustment mechanism 71 may further comprise a cam 76. The cam 76 may comprise a housing 77. The housing 77 may extend generally parallel to the rotational axis A of the dosing drum 5. The cam 76 may comprise two tracks: a first track 78 and a second track 79. The first and second tracks 78, 79 may extend generally in the direction of the rotational axis A of the dosing drum 5. However, the first and second tracks 78, 79 may be divergent tracks. That is, the distance between the first and second tracks 78, 79 may increase with distance in the direction of the rotational axis A of the dosing drum 5.

[0144] The cam 76 may also comprise a piston accommodating aperture 81. The piston accommodating aperture 81 extends in the same direction as the telescopic piston shaft 72 and is configured to allow the piston shaft 72 to extend therethrough. Thepiston accommodating aperture 81 may extend in the direction of the rotational axis A over the same distance as the first and second tracks 78, 79.

[0145] The first track 78 of the cam 76 may be coupled to the first portion 73 of the telescopic piston shaft 72. The first portion 73 of the telescopic piston shaft 72 may comprise a first pin 83 that is configured to be located in the first track 78 of the cam 76. The second track 79 of the cam 76 may be coupled to the second portion 74 of the telescopic piston shaft 72. The second portion 74 of the telescopic piston shaft 72 may comprise a second pin 84 that is configured to be located in the second track 79 of the cam 76.

[0146] Thus, when the cam 76 is moved in a first direction parallel to the rotational axis A of the dosing drum 5, the distance between the first and second track 78, 79 at the location of the pins 73, 74 may increase. As a result, the first and second pins 73, 74 are moved apart. Thus, the starting position of the piston 61 is moved radially outwards, and the starting volume of the recess 11 in the dosing drum 5 is reduced.

[0147] When the cam 76 is moved in a second direction, opposite to the first direction, parallel to the rotational axis A of the dosing drum 5, the distance between the first and second track 78, 79 at the location of the pins 73, 74 may decrease. As a result, the first and second pins 73, 74 are moved towards each other in the vertical direction. Thus, the starting position of the piston 61 is moved radially inward, and the starting volume of the recess 11 in the dosing drum 5 may be increased.

[0148] In some embodiments, the cam 76 may be moveable in the radial direction. For example, the cam 76 may comprise a sliding arrangement 86 at one end. The sliding arrangement 86 may comprise a radially extending track 87 and a sliding bearing 88 coupled to the cam 76. The sliding arrangement 86 allows the piston 61 and cam 76 to move radially as the coupling 66 of the piston 61 moves along the cam track 66. The sliding arrangement 86 allows the piston 61 to move from its powder receiving position to its powder compression position and to its ejection position.

[0149] Thus, in embodiments where both tracks 78, 79 extend at an angle to the rotational axis A of the dosing drum 5, the cam 76 may move in the radial direction due to the fixed radial position of the second pin 74.In some embodiments, the second track 79 of the cam 76 may extend parallel to the longitudinal axis A of the dosing drum 5 and so the sliding arrangement 86 may be omitted.

[0150] It will be appreciated that the apparatus may comprise a piston 61 and adjustment mechanism 71 for each recess 11 or set of recesses 11. The plurality of adjustment mechanisms 71 may be connected together at a central hub 89, also shown in Fig. 7. An operator of the apparatus 1 to change the starting volume of all of the recesses 11 by changing the starting position of all of the pistons 61 at once. The apparatus 1 may be configured such that the starting position of the pistons 61 can be changed whilst the apparatus 1 is running.

[0151] Referring briefly to Fig. 7, a perspective schematic view of the dosing drum 5 is shown. In the embodiment shown in Fig. 7, the dosing drum 5 comprises a recess 11. The recess 11 may be formed in an insert 91. The insert 91 may be removably located in an aperture 92 located in the circumferential surface 12 of the dosing drum 5.

[0152] The aperture 92 may be, for example, but not limited to, circular in cross-section, i.e. cylindrical in volume. The insert 91 may be sized to fit within the aperture 92. The insert 91 may be removably fixed within the aperture 92. The insert 91 may be machined to a higher precision than recesses formed in the circumferential surface 12 of the dosing drum 5. Therefore, the volume of the recesses 11 in the insert 91 may be more consistent and result in a more consistent end product. In addition, if only of the recesses 11 in an insert 91 fails in some way, the whole dosing drum 5 does not need to be replaced and a single insert 91 can be replaced instead.

[0153] It will be appreciated that each insert 91 may comprise a plurality of recesses 11, as shown in Fig. 7.

[0154] Referring now to Fig. 8, Fig. 9, and Fig. 10, a schematic side view of the delivery system forming system 6, a schematic perspective view of the delivery system forming system 6 and a schematic perspective view of a sealing block 15 are shown.

[0155] In Fig. 8, the pair of delivery system forming oscillating beams 7 are shown in the sealing position in the downstream position. That is, the pair of delivery system forming oscillating beams 7 are in their configuration immediately before the upper and lower beams 7a, 7b move away from each other and return to the upstream position.Each of the plurality of sealing block 15 may be located vertically relative to a housing 101. Each of the plurality of sealing blocks 15 may be pre-loaded in order to provide a consistent pressure in the sealing position between the upper and lower beams 7a, 7b.

[0156] Referring to Fig. 9, each of the plurality of sealing block 15 may be pre-loaded by a spring 102. That is, each of the plurality of sealing blocks 15 may be pre-loaded by individual springs 102. Thus, the pressure of each of the plurality of sealing blocks 15 may be individually controlled. As a result, the sealing pressure applied along the webs of sheet material 14, 19 is uniform. In addition, any obstructions or misalignments in the apparatus 1 will only effect one set of sealing blocks 15 rather than all the sealing blocks on the upper and lower delivery system forming oscillating beams 7a, 7b.

[0157] The pre-loaded spring 102 may be adjustable via a nut 103. That is, each pre-loaded spring 102 may be adjustable via a nut 103 to vary the sealing pressure of each sealing block 15 individually. This enables a consistent pressure to be provided by each sealing block 15 when in the pair of delivery system forming oscillating beams 7 are in the sealing position.

[0158] The nut 103 may be located on a screw 104 that extends in a direction parallel to the direction of the sealing pressure. The spring 102 may be located around the screw 104 and between the nut 103 and the sealing block 15. By moving the nut 103 towards the sealing block 15, the load on the spring 102 may be increased which increases the force on the sealing block 15. Thus, the force of each spring 102 on each sealing block 15 can be tuned such that each sealing block 15 provides the same amount of pressure and the same quality seal on the webs of sheet material 14, 19.

[0159] In some embodiments, the upper and lower oscillating beams 7a, 7b may be configured to provide a sealing force in the range of about 300 N to about 600 N per delivery system. In some embodiments, the upper and lower oscillating beams 7a, 7b may be configured to provide a sealing force in the range of about 400 N to about 500 N per delivery system or about 500 N to about 600 N per delivery system. A sealing force in this range helps form consistent and uniform seals around the agglomerations of powder 9 between the first and second webs of sheet material 14, 19.Therefore, a sealing block 15 comprises two sealing profiles may be configured to provide a sealing force in the range of 300 N to 600 N per block. In some embodiments, the sealing force may be in the range of 200 N to 800 N.

[0160] In some embodiments, the upper and lower oscillating beams 7a, 7b may remain in the sealing position for in the range of about 300 ms to about 450 ms. That is, the upper and lower oscillating beams 7a, 7b may take in the range of about 300 ms to about 450 ms to move from the upstream position to the downstream position when the beams 7a, 7b are in the sealing position. A sealing time in this range helps to form consistent and uniform seals around the agglomerations of powder 9 between the first and second webs of sheet material 14, 19.

[0161] It will be appreciated that the sealing time may be affected by the length of the conveyance path between the upstream and downstream positions and the speed with which the oscillating beams 7a, 7b move between the upstream and downstream positions. Thus, depending on the speed and length of the delivery system forming system 6, the sealing time may be in the range of about 250 ms to about 1 s.

[0162] In some embodiments, the spring 102, nut 103, and screw 104 my all be located within the housing 101.

[0163] Referring to Fig. 10, each of the plurality of sealing block 15 may comprise at least one sealing profile 16. The sealing profile 16 may match the profile of the recess 11, as previously described. That is, the sealing profile 16 may be similar to the perimeter of the recess 11. However, the sealing profile 16 may be an enlargement of the perimeter of the recess 11 to ensure that the whole of the agglomeration of powder 9 is contained within the seal formed.

[0164] The sealing profile 16 may be non-square and non-rectangular in shape. That is, the sealing profile may have a generally circular, triangular, tear-drop, heart, diamond, or any other shape that is not square or rectangular. Non-square and non-rectangular shapes may include squares and rectangles with rounded corners. In some embodiments, the sealing profile 16 may be square or rectangular.

[0165] The sealing profile 16 may be formed by a hollow projection. The hollow projection may extend from an end face 105 of the sealing block 15. The hollow projection allows space to accommodate the agglomeration of powder 9 within the sealing profile 16 ofthe sealing blocks 15 on both the upper and lower beams 7a, 7b of the delivery system forming system 6.

[0166] The sealing profile 16 on the sealing block 15 of the upper beam 7a may be the same as the sealing profile 16 on the sealing block 15 of the lower beam 7b. The sealing profiles on the sealing blocks 15 on the upper and lower beams 7a, 7b of the pair of oscillating beams 7 may be mirror images of each other such that the two profiles come together in the sealing position on either side of the first and second webs of sheet material 14, 19 and around an agglomeration of powder 9.

[0167] Each sealing block 15 may comprise two sealing profiles 16, as shown in Fig. 9. The two sealing profiles 16 on the same sealing block 15 may be mirror images of each other, as shown in Fig. 10.

[0168] Each of the sealing profiles 16 may be heated during use. The surface temperature of each of the sealing profiles 16 may be in the range of about 150 °C to about 250 °C during use. The surface temperature of each of the sealing profiles 16 may be in the range of about 180 °C to about 220 °C during use. The surface temperature of each of the sealing profiles 16 may be in the range of about 190 °C to about 200 °C during use. The application of this temperature to the first and second webs of sheet material 14, 19 helps to form consistent and uniform seals around the agglomerations of powder 9 between the first and second webs of sheet material 14, 19.

[0169] It has been found that the combination of the above temperatures and sealing time beneficially provide consistent and uniform seals without requiring the higher temperatures of known apparatus. That is, it has been found that applying a lower temperature for a longer time provides a more consistent and uniform seal.

[0170] In some embodiments, each sealing profile 16 of each of the plurality of sealing blocks 15 may comprise a non-stick coating. The non-stick coating may be, for example, but not limited to, a Teflon ® coating. Advantageously, the Teflon ® coating may prevent the webs of sheet material 14, 19 from sticking to or leaving deposits on the sealing profiles 16.

[0171] It will be appreciated that the upper and lower beams 7a, 7b of the delivery system forming system 6 will have the same number of sealing blocks 15. However, the number of sealing blocks and their arrangement may be varied. For example, each of the upper and lower beams 7a, 7b may comprise 8 sealing blocks 15 arrangedlinearly. Each sealing block 15 may comprise one or two sealing profiles 16. The number of sealing blocks 15 arranged linearly in the conveyance direction may be between, for example, but not limited to, 4 and 16.

[0172] In another example, each of the upper and lower beams 7a, 7b may comprise 16 sealing blocks arranged in an 8x2 formation. Each sealing block 15 may comprise one sealing profile 16. The number of sealing blocks 15 arranged linearly in the conveyance direction may be between, for example, but not limited to, 4 and 16. The number of sealing blocks 15 arranged linearly in the direction transverse to the conveyance direction may be between, for example, but not limited to, 2 and 8. The arrangement of the sealing blocks 15 and sealing profiles 16 will be arranged to match the recess 11 formation in the dosing drum 5.

[0173] Referring now to Fig. 11, a schematic perspective view of the cutting system 13 is shown. The arrangement of the cutting system 13 is similar to the arrangement of the delivery system forming system 6. The cutting system 13 in Fig. 11 is shown in a maintenance position, in which an operator can work on the cutting system 13, in order to provide a clearer view of the components of the cutting system 13.

[0174] The cutting system 13 may comprise an oscillating cutter 111. The oscillating cutter 111 may comprise a punch 112 and a die 113. The punch 112 may form the upper portion of the oscillating cutter 111. The die 113 may form the lower portion of the oscillating cutter 111. The punch 112 and die 113 may be configured to move between upstream and downstream positions along the conveyance path of a web 20 of delivery systems 2. The punch 112 and die 113 may be configured to move from a separated configuration in the upstream position to a cutting configuration along the conveyance path to cut individual delivery systems 2 from a web 20 of delivery systems 2.

[0175] The punch 112 may comprise a plurality of cutting elements 114. The plurality of cutting elements 114 may extend transversely to the conveyance path. The die 113 may comprise a plurality of delivery system apertures 115. The plurality of delivery system apertures 115 may extend through the full thickness of the die 113 in a direction transverse to the conveyance path. Each delivery system aperture 115 may be configured to allow a delivery system 2 cut from a web 20 of delivery systems 2 to pass therethrough.When the oscillating cutter 111 is in its separated configuration, the cutting elements 114 may be located at a distance from the die 113 such that the web 20 of delivery systems 2 may be advanced through the cutting system 13 unobstructed.

[0176] The plurality of cutting elements 114 of the punch 112 may be configured to extend into the plurality of delivery system apertures 115 in the die 113 when the oscillating cutter 111 is in its cutting configuration. Both the punch 112 and the die 114 may be moved towards each other, and the conveyance path of the web 20, when moved from their respective positions on either side of the web 20 in the separated configuration to their respective positions in the cutting configuration.

[0177] The oscillating cutter 111 may be configured to provide a shear cut on the web 20 of delivery systems 2. Thus, the perimeter of the cutting elements 114 and delivery system apertures 115 may be substantially equal in shape and size. The perimeter of the cutting elements 114 and delivery system apertures 115 may be the same as the sealing profiles 16 of the sealing blocks 15 of the delivery system forming system 6. Each of the cutting elements 114 of the punch 112 may be formed by a solid punching element, i.e. non-hollow. The perimeter of the cutting elements 114 and the delivery system apertures 115 may be configured such that the cuts formed in the web 20 of delivery systems 2 are formed in the seal on the web 20 formed by the delivery system forming system 6.

[0178] The arrangement of the cutting elements 114 on the punch 112 and the apertures 115 on the die 113 may be configured to match the number and arrangement of sealing profiles 16 on the oscillating beams 7a, 7b and the recesses 11 in the dosing drum 5.

[0179] In some embodiments, the punch 112 may comprise a nozzle 117. Each cutting element 114 of the punch 112 may comprise its own nozzle 117. Each of the nozzles 117 may be configured to eject a jet of gas when in the oscillating cutter 111 is in the cutting configuration. The jet of gas may be configured to aid passage of a delivery system 2 cut from the web 20 of delivery systems 2 through the delivery system aperture 114.

[0180] As previously mentioned, the oscillating cutter 111 may be configured to provide a shear cut on the web 20 of delivery systems 2. The shear cut may be performed by arranging the outer edge of the cutting elements 114 of the punch 112 relative to the inner edge of the apertures 115 of the die 113. It has been determined by the inventors that the distance between the outer edge of the cutting elements 114 of thepunch 112 and the inner edge of the apertures 115 of the die 113 may be in the range of between about 10 microns and about 30 microns. In some embodiments, the distance between the outer edge of the cutting elements 114 of the punch 112 and the inner edge of the apertures 115 of the die 113 may be about 20 microns.

[0181] It will be appreciated that the optimal distance between the outer edge of the cutting elements 114 of the punch 112 and the inner edge of the apertures 115 of the die 113 will be dependent upon the thickness of web 20, i.e. the material that the web 20 is formed from.

[0182] It has been determined by the inventors that as the size of the gap approaches a distance of 10 microns, there is an increase in friction. This increase in friction may adversely affect the colour of the web 20 and may cause a build up of deposits on the cutting elements 114 and apertures 115. Thus, more force is required to perform the cut, which may have a detrimental effect on the oscillating cutter 111.

[0183] In addition, it has been determined that as the size of the gap approaches a distance of 30 microns, there is decrease in the quality of the peripheral edge of the delivery system 2 that is formed by the cut. That is, as the size of the gap approaches a distance of 30 microns, the edges of the delivery systems 2 become increasing frayed. This may provide a delivery system 2 with reduced aesthetic appeal to a consumer.

[0184] Furthermore, it has been determined by the inventors that the optimal cut edges of delivery systems 2 are provided when each of the plurality of cutting heads, i.e. punch 112 and die 113, provides in the range of about 110 N to about 120 N of feree. In some embodiments, the optimal cut edges of delivery systems 2 is provided when each of the plurality of cutting heads provides about 114.5 N of force.

[0185] In some embodiments, the oscillating cutter 111 may be provided with two rows of cutting heads, which extend transversely to the convey direction, wherein each row of cutting heads comprises 8 cutting heads. Therefore, the total number of cutting heads, i.e. punch 112 and die 113, may be 16. Thus, 16 delivery systems 2 may be cut from the web 20 in each cycle of the oscillating cutter 111. The total vertical cutting force may be in the range of about 1760 N to about 1920 N. In some embodiments, the total vertical cutting force may be about 1832 N. The total cutting force may be distributed uniformly over the oscillating cutter 111 so that each cutting head provides the same force to cut the web 20.In order to monitor the cutting force provided by the oscillating cutter 111 to the web 20, a motor of the oscillating cutter may be monitored. The motor may have a servocontroller that is monitored. That is, the oscillating cutter 111 may comprise a motor comprising a motor controller with a torque sensor integrated into the motor controller. The inventors have determined that the motor driving the punch 112 and die 113 towards each other has a peak torque in the range of about 8.2 Nm to about 9 Nm when performing the cut. The inventors have determined that to achieve the optimal cut edge of a delivery system, the motor may have a peak torque of about 8.6 Nm when performing the cut.

[0186] By knowing that a peak torque of about 8.6 Nm corresponds to ideal cutting conditions, i.e. able to provide a total cutting force of about 1832 N, the monitoring system of the motor can ensure that the motor of the oscillating cutter 111 reaches this torque on each cutting operation. It will be appreciated that the torque achieved in each cutting operations may indicate the state of the oscillating cutter 111 and the cuts formed in the web 20. For example, cutting operations where the torque does not reach the ideal peak torque indicates that not all delivery systems 2 were fully sheared from the web 20. Conversely, cutting operations where the torque overshoots the ideal peak torque indicate a jam, dulling blade, or deposit build up on the punch 112 or die 113 causing excessive resistance.

[0187] Thus, the motor torque may be used by a control system as a proxy for cutting force and active quality control of the delivery systems 2 cut from the web 20. The torque feedback approach allows the oscillating cutter to "self-check" and maintain optimal force automatically. The oscillating cutter 111 advantageously ensures that almost all of the motor's work goes into shearing the delivery systems 2 from the web 20 because the motor only has to move the punch 112 and die 113 vertically relative to the web 20. Thus, the vertical motion of the oscillating cutter 11 reduces material drag and prevents deformation of the delivery system 2 during cutting, which helps to retain their proper shape.

[0188] The web 20 may be formed from a material having a basis weight in the range of about 30 gsm to about 40 gsm, preferably about 34 gsm. The material forming the web 20 may have an MD elongation in the range of about 5% to about 15% and a CD elongation in the range of about 20% to about 50%.

[0189] Referring now to Fig. 12, the apparatus 1 may further comprise a pouch transport system 121. The pouch transport system 121 may be configured to receive deliverysystems from the cutting system 13. As shown in Fig. 10, the pouch transport system 121 may be located directly below the cutting system 13. Thus, the pouch transport system 121 may be configured to receive delivery systems 2 that have passed through the delivery system apertures 115 in the die 113 of the oscillating cutter 111.

[0190] The pouch transport system 121 may comprise a transport belt 122. The transport belt 122 may be a vacuum transport belt 112. That is, the transport belt 112 may be connected to a vacuum source (not shown). The vacuum transport belt 122 may comprise an endless belt 123 and a plurality of transport elements 124. The plurality of transport elements 124 may be located on the endless belt 123.

[0191] Each transport element 124 may comprise a base 125. The base 125 may be attached to the endless belt 123. Each transport element 124 may comprise a delivery system container 126 coupled to a suction nozzle 127. The suction nozzle 127 may be configured to be selectively connected to the vacuum source (not shown) dependent upon the suction nozzle's location around the transport belt 122.

[0192] Each delivery system container 126 may be configured to receive an individual delivery system 2. Each delivery system container 126 may be formed as a shallow bowl to receive a delivery system. Each transport element 124 may comprise a plurality of suction nozzles 127 to draw in and hold a delivery system 2 that falls from the cutting system 13. Each suction nozzle 127 may have an opening located in the bottom of a delivery system container 126.

[0193] The pouch delivery system 121 may comprise a first vacuum transport belt 121. The first vacuum transport belt 122 may be located below the oscillating cutter 111. The first vacuum transport belt 122 may be configured such that the delivery system containers 126 move synchronously along a part of the conveyance path from an upstream position to a downstream position with the die 113 of the oscillating cutter 111. Thus, delivery systems 2 cut from the web 20 in the cutting system 13 can be dropped directly into a delivery system container 126 of the first vacuum transport belt 121.

[0194] The number and arrangement of delivery system containers 126 may be chosen to match the output formation of delivery systems 2 from the cutting system 13 and output rate thereof so that each delivery system 2 is received in a delivery system container 126.The pouch delivery system may further comprise a first inspection element 128. The first inspection element 128 may be configured to inspect a first side 2a of a delivery system 2. The first inspection element 128 may be located above the first vacuum transport belt 122 to inspect delivery systems 2 held on the top of the first vacuum transport belt 128. The first inspection element 128 may be, for example, but not limited to, a camera.

[0195] The pouch transport system 121 may further comprise a second vacuum transport belt 132. The second transport belt 132 is essentially the same as the first vacuum transport belt 122 and so a detail description will be omitted. The second vacuum transport belt 132 may be located downstream of the first vacuum transport belt 122. The second vacuum transport belt 132 may be configured to receive delivery systems from the first vacuum transport belt 122 via suction transfer. That is, the second vacuum transport belt 132 may be configured to pick up a delivery system 2 from the first vacuum transfer belt 122 at a hand over point 139.

[0196] In order to for the second vacuum transfer belt 132 to pick up a delivery system from the first vacuum transfer belt 122, the suction nozzle 127 on the first vacuum transfer belt 122 may be disconnected from the vacuum source (not shown) and the suction nozzle 137 on the second vacuum transfer belt 132 may be connected to the vacuum source to suck the delivery system 2 out of the delivery system container 126 on the first vacuum transport belt 122 into the delivery system container 136 on the second vacuum transport belt 132.

[0197] The pouch delivery system may further comprise a second inspection element 138. The second inspection element 138 may be configured to inspect a second side 2b of a delivery system 2. The second inspection element 138 may be located below the second vacuum transport belt 132 to inspect delivery systems 2 held on the bottom of the second vacuum transport belt 138. The second inspection element 138 may be, for example, but not limited to, a camera.

[0198] In some embodiments, the apparatus 1 may further comprise a rejection bin 141. The rejection bin 141 may be configured to receive delivery systems 2 that fail inspection. Delivery systems 2 that pass inspection may be passed on to a packaging machine (not shown).

[0199] Referring now to Fig. 13, the apparatus 1 may further comprise a web stabilisation mechanism 151. The web stabilisation mechanism 151 may be configured to preventthe first and second webs of sheet material 14, 19 from stretching under tension. The web stabilisation mechanism 151 may be configured to prevent the first and second webs of sheet material 14, 19 from stretching under the application of heat.

[0200] As shown in Fig. 13, the web stabilisation mechanism 151 may comprise a pair of upper endless belts 152, 153. The pair of upper endless belts 152, 153 may be configured to contact both edges of the second web of sheet material 19. The pair of upper endless belts 152, 153 may be configured to contact the upper surface of the second web of sheet material 19.

[0201] The web stabilisation mechanism 151 may also comprise a pair of lower endless belts 154, 155. The pair of lower endless belts 154, 155 may be configured to contact both edges of the first web of sheet material 14. The pair of lower endless belts 155 may be configured to contact the lower surface of the first web of sheet material 14.

[0202] The pair of upper endless belts 152, 153 may be configured to be driven synchronously with the second web of sheet material 19 along the conveyance path by a set of rollers 156. The pair of lower endless belts 154, 155 may be configured to be driven synchronously with the first web of sheet material 14 along the conveyance path by a set of rollers 157. The first and second webs of sheet material 14, 19 may be moved at the same speed.

[0203] The rollers of the sets of rollers 156, 157 may be positioned such that the upper endless belts 152, 153 and lower endless belts 154, 155 force the first and second webs of sheet material 14, 19 into contact with each other. That is, the pairs of upper and lower endless belts 152, 153, 154, 155 may be configured to compress the edges of first and second webs of sheet material 14, 19 therebetween.

[0204] Each of the pairs of upper and lower endless belts 152, 153, 154, 155 may comprise a high friction surface 158. In some embodiments, each of the pairs of upper and lower endless belts 152, 153, 154, 155 may alternatively or additionally comprise a plurality of high friction elements 159 thereon. The high friction surface 158 and / or high friction elements 159 may be configured to prevent the webs of sheet material 14, 19 from slipping relative to the each other or the systems of the apparatus 1.

[0205] Referring briefly back to Fig. 8 and Fi. 9, it can be seen that the delivery system forming system 6 comprises a first web stabilisation mechanism 151. The first webstabilisation mechanism 151 may be configured to prevent the webs of sheet material 14, 19 from stretching under tension and heat.

[0206] Referring briefly back to Fig. 11, it can be seen that the cutting system 13 comprises a second web stabilisation mechanism 151. The second web stabilisation mechanism 151 may be configured to help maintain the web 20 of delivery systems 2 in sync with the oscillating cutter 111. The second web stabilisation mechanism 151 may also be configured to retain the off-cuts of the web 20 of delivery systems 2 once the delivery systems 2 have been cut therefrom. Thus, the cutting system 13 can safely remove and dispose of the excess web 20 without the excess web getting caught in the apparatus 1.

[0207] Although described in detail above in relation to each of the features of the apparatus 1 for manufacturing delivery systems 2, a method for manufacturing a delivery system, will now be described hereinafter.

[0208] The method comprises the steps of filing a recess 11 in a dosing drum 5 with powder 8 to form an agglomeration of powder 9. The method further comprises placing the agglomeration of powder 9 on a first web of sheet material 14, and placing a second web of sheet material 19 over the agglomeration of powder 9 on the first web of material 14. The method further comprises transporting the agglomeration of powder 9 and webs 14, 19 along part of the conveyance path between a pair of delivery system forming oscillating beams 7. The method further comprises heating sealing profiles 16 on the pair of delivery system forming oscillating beams 7 to seal the agglomeration of powder 9 within the webs 14, 19 to form a web 20 of delivery systems 2. The method further comprises cutting individual delivery systems 2 from the web 20 of delivery systems 2.

[0209] 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

- 39 - Claims1. An apparatus for manufacturing delivery systems, the apparatus comprising:a dosing system, the dosing system comprising a dosing drum comprising a recess located in its circumferential surface, the recess being configured to receive powder from a feeder mechanism;the dosing drum being configured to form an agglomeration of powder and place the agglomeration of powder on a first web of sheet material; anda delivery system forming system comprising a pair of delivery system forming oscillating beams comprising an upper oscillating beam and a lower oscillating beam configured to move between upstream and downstream positions, each of the oscillating beams comprising a plurality of sealing blocks each having at least one sealing profile,wherein the upper and lower oscillating beams are configured to move into a sealing position at the upstream position, in which each sealing profile extends around an agglomeration of powder, and remain in the sealing position until the downstream position along a conveyance path of the agglomeration of powder to seal first and second webs of sheet material around an agglomeration of powder to form a web of delivery systems; anda cutting system configured to cut a plurality of individual delivery systems from a web of delivery systems.

2. The apparatus according to claim 1, wherein each of the plurality of sealing blocks is pre-loaded by a spring to provide consistent sealing pressure when the upper and lower oscillating beams are in the sealing position.

3. The apparatus according to claim 2, wherein the pre-loaded spring is adjustable via a nut to vary the sealing pressure of each sealing block individually such that consistent pressure in the sealing position is obtainable.

4. The apparatus according to any one of the preceding claims, wherein the upper and lower oscillating beams are configured to provide a sealing force in the range of about 300 N to about 600 N per delivery system.

5. The apparatus according to any one of the preceding claims, wherein the upper and lower oscillating beams remain in the sealing position for in the range of about 300 ms to about 450 ms.- 40 - 6. The apparatus according to any one of the preceding claims, wherein each of the sealing profiles is heated during use.

7. The apparatus according to claim 6, wherein the surface temperature of each of the sealing profiles is in the range of about 190 °C to about 200 °C.

8. The apparatus according to any one of the preceding claims, wherein each sealing profile of each of the plurality of blocks comprise a non-stick coating.

9. The apparatus according to any one of the preceding claims, wherein the cutting system comprises an oscillating cutter comprising an upper punch and a lower die configured to move between upstream and downstream positions along the conveyance path of a web of delivery systems,wherein the punch and die are configured to move from a separated configuration at the upstream position to a cutting configuration along the conveyance path to cut individual delivery systems from a web of delivery systems.

10. The apparatus according to claim 9, wherein both the punch and the die are moved towards one another when moved from their respective positions in the separated configuration to their respective positions in the cutting configuration.

11. The apparatus according to claim 9 or claim 10, wherein the die comprises a delivery system aperture extending therethrough, the delivery system aperture being configured to allow a delivery system cut from a web of delivery systems to pass therethrough.

12. The apparatus according to claim 11, wherein the punch comprises a nozzle configured to eject a jet of gas when in the cutting configuration to aid passage of a delivery system through the delivery system aperture.

13. The apparatus according to any one of claim 9 to claim 12, further comprising a pouch transport system configured to receive delivery systems from the cutting system.

14. The apparatus according to claim 13, wherein the pouch transport system comprises a vacuum transport belt, the vacuum transport comprising a plurality of transport elements having a delivery system container coupled to a suction nozzle.- 41 - 15. The apparatus according to claim 14, wherein a first vacuum transport belt is located below the oscillating cutter and is configured to such that the delivery system container moves synchronously along a part of the conveyance path from an upstream position to a downstream position with the die.

16. The apparatus according to claim 15, further comprising a first inspection element configured to inspect a first side of a delivery system.

17. The apparatus according to claim 15 or claim 16, wherein a second vacuum transport belt is located downstream of the first vacuum transport belt and is configured receive delivery systems from the first vacuum transport belt via suction transfer.

18. The apparatus according to claim 17, further comprising a second inspection element configured to inspect a second side of a delivery system.

19. The apparatus according to claim 16 or claim 18, further comprising a rejection bin configured to receive delivery systems that fail inspection.

20. The apparatus according to any one of the preceding claims, further comprising a web stabilisation mechanism configured to prevent first and second webs of sheet material from stretching under tension and / or heat.

21. The apparatus according to claim 20, wherein the web stabilisation mechanism comprises a pair of upper endless belts configured to contact both edges of the first web and a pair of lower endless belts configured to contact both edges of the second web.

22. The apparatus according to claim 21, wherein the pairs of upper and lower endless belts comprise a high friction surface.

23. The apparatus according to claim 21 or claim 22, wherein the pairs of upper and lower endless belts are configured to compress the edges of first and second webs of sheet material therebetween.

24. The apparatus according to any one of claim 21 to claim 23, wherein the pairs of upper and lower endless belts are configured to move at the same speed as first and second webs of sheet material along a portion of the conveyance path.

25. The apparatus according to any one of claim 20 to claim 24, wherein the delivery forming system comprises a first web stabilisation mechanism.

26. The apparatus according to any one of claim 20 to claim 25, wherein the cutting system comprises a second web stabilisation mechanism.

27. The apparatus according to any one of the preceding claims, wherein the dosing drum comprises a movable piston having a piston surface, the piston surface forming the bottom of the recess, wherein the movable piston is configured to compress the powder received in the recess against a compression surface as the dosing drum rotates.

28. The apparatus according to claim 27, wherein the compression surface is formed by a stationary curved wall.

29. The apparatus according to claim 27 or claim 28, wherein the piston is configured to move from a starting position to a compressed position to reduce the volume of the recess in the range of about 40% to about 90%.

30. The apparatus according to claim 29, wherein the starting position of the piston is adjustable.

31. The apparatus according to claim 30, wherein the starting position of the piston is adjustable such that the volume of the recess in the starting position may be increased or reduced by up to 20%.

32. The apparatus according to claim 30 to claim 31, wherein the dosing drum comprises an adjustment mechanism, the adjustment mechanism comprises a telescopic piston shaft comprising first and second portions, and a cam comprising two diverging tracks, a first track coupled to a first portion of the telescopic piston shaft and a second track coupled to a second portion of the telescopic piston shaft.

33. The apparatus according to any one of claim 27 to claim 32, wherein the piston is configured to apply in the range of 80 N to 100 N of force on the powder receiving in the recess.

34. The apparatus according to any one of claim 27 to claim 33, wherein the movable piston is coupled to a dosing cam by a coupling, the coupling being located radially from the piston surface and on the centreline of the piston.

35. The apparatus according to any one of the preceding claims, wherein the recess is formed in an insert, wherein the insert is removably locatable in an aperture located in the circumferential surface of the dosing drum.

36. A method for manufacturing a delivery system, the method comprising the steps of:filing a recess in a dosing drum with powder to form an agglomeration of powder;placing the agglomeration of powder on a first web of sheet material; placing a second web of sheet material over the agglomeration of powder on the first web of material;transporting the agglomeration of powder and webs along part of the conveyance path between a pair of delivery system forming oscillating beams;heating profiles on the pair of delivery system forming oscillating beams to seal the agglomeration of powder within the webs to form a web of delivery systems; and cutting individual delivery systems from the web of delivery systems.

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