EP4701936A2 - An apparatus for manufacturing delivery systems - Google Patents

Abstract

The present invention relates to an apparatus for manufacturing delivery systems. The present invention also relates to a method of manufacturing a delivery system. The apparatus comprises a first pair of jaws and a web transporter. The first pair of jaws comprise a first jaw and a second jaw. The first and second jaws are moveable from an open position, in which the first and second jaws are out of contact with each other, and a closed position, in which the first and second jaws are pressed together. The web transporter is configured to transport first and second webs of sheet material between the first and second jaws along a conveyance path. Each of the first and second jaws comprises at least one forming segment. The at least one forming segment comprises a frame portion configured to form a first seal between the first and second webs of sheet material together.

Description

An Apparatus for Manufacturing Delivery Systems

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

Background of the Invention It is known to provide alternatives to combustible aerosol provision systems. Such systems are referred to a non-combustible aerosol provision systems and aerosol-free delivery systems. In such systems at least one substance is delivered to a user. In noncombustible aerosol provision systems an aerosol is generated from an aerosolgenerating material, whereas in aerosol-free delivery systems a substance is delivered without generating an aerosol. It is also known to provide the substance to be delivered in a delivery system. Some deliver 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. Summary of the Invention

In a first aspect of the present invention, there is provided an apparatus for manufacturing delivery systems. The apparatus comprises a first pair of jaws comprising a first jaw and a second jaw, the first and second jaws being moveable from an open position, in which the first and second jaws are out of contact with each other, and a closed position, in which the first and second jaws are pressed together, a web transporter configured to transport first and second webs of sheet material between the first and second jaws along a conveyance path; each of the first and second jaws comprising at least one forming segment, the at least one forming segment comprising a frame portion configured to form a first seal between the first and second webs of sheet material together.

In some embodiments, the pair of jaws may be rotatable between the open position and the second position. In some embodiments, the frame portion may be heated and configured to seal together the first and second web of sheet material to form a partially closed delivery system. In some embodiments, the frame portion may comprise a recess therein which determines the shape of the delivery system, and an aperture extending through a side wall of the frame portion.

In some embodiments, the apparatus may further comprise a powder insertion tube located between the first and second j aws when the first and second j aws are in the closed position, the powder insertion tube being configured to insert powder into the cavity between the first and second webs of sheet material.

In some embodiments, the powder insertion tube may be moveable between a first position, in which the powder insertion tube can deliver powder into the cavity between the first and second webs of sheet material, and a second position, in which the powder insertion tube is unable to deliver powder into the cavity.

In some embodiments, the recess in the frame portion may be non-square in shape.

In some embodiments, each of the first pair of jaws may comprise a plurality of delivery system forming segments.

In some embodiments, the apparatus may further comprise a second pair of jaws comprising a first j aw and a second j aw, the first and second j aws may be moveable from an open position, in which the first and second jaws are out of contact with each other, and a closed position, in which the first and second jaws are pressed together, each of the first and second jaws may comprise at least one delivery system closing segment configured to seal closed the unsealed portion of the web of sheet material.

In some embodiments, each of the delivery system forming segments may further comprise a delivery system closing segment configured to seal closed the unsealed portion of the delivery system once the powder insertion tube is removed. In some embodiments, the delivery system closing segment may be heated and configured to seal together the first and second web of sheet material to form a partially closed delivery system. In some embodiments, the apparatus may be configured to suspend motion of the first and second webs of sheet material between the first pair of jaws such that the first seal can be formed.

In some embodiments, the first pair of jaws may be moveable together with the first and second webs of sheet material along the conveyance path.

In a second aspect of the present invention, there is provided a method of forming a delivery system. The method comprises the steps of: providing a first and second web of sheet material; advancing the webs of sheet material along a conveyance path between the first pair of j aws; inserting powder into the cavity between the first and second webs of sheet material; and closing the first pair of jaws to form a first seal between the first and second webs of sheet material to form a partially closed delivery system; opening the first pair of jaws; and transporting the at least partially closed delivery systems along the conveyance path.

In some embodiments, the method may further comprise the steps of: inserting a powder insertion tube between the first and second web of sheet material to delivery the powder into the cavity between the first and second webs of sheet material; removing the powder insertion tube from the partially closed delivery system; forming a second seal to close the delivery system; and transporting the closed delivery system along the conveyance path.

In some embodiments, the step of forming the second seal may be performed before opening the first pair of jaws.

In some embodiments, the method may further comprise the step of transporting the partially closed delivery systems along the conveyance path and wherein the step of forming the second seal is performed thereafter by a second pair of jaws. In a third aspect of the present invention, there is provided a delivery system. The delivery system comprises a first web of sheet material and a second web of sheet material sealed together around the periphery to define a cavity therebetween; wherein the seal is a continuous seal around the peripheiy of the delivery system; and powder for delivering a substance located in the cavity. In some embodiments, the delivery system may be non-square and non-rectangular in shape.

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

In some embodiments, the powder may have a moisture content of in the range of about 18 % to about 50 %.

Brief Description of the Drawings

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

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

Fig. 2 shows a web of delivery systems with a first seal formed;

Fig. 3 shows a web of delivery systems with a second seal formed; and

Fig. 4a to 4g show exemplary embodiments of delivery systesm manufactured by the apparatus.

Detailed Description of the Invention

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

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

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

In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.

In some embodiments, the non-combustible aerosol provision system is an aerosolgenerating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

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

Typically, the non-combustible aerosol provision system may comprise a non- combustible aerosol provision device and a consumable for use with the non- combustible aerosol provision device.

In some embodiments, the disclosure relates to consumables comprising aerosolgenerating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure. In some embodiments, the non-combustible aerosol provision system, such as a noncombustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source. 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.

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

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

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

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

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

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

As noted herein, the active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes. The active substance may be CBD or a derivative thereof

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

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.

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

In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel. In some embodiments, the substance to be delivered comprises a flavour.

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

In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not alimited to eucolyptol, WS-3. Aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or semi-solid (such as a gel) which may or may not contain an active substance and/or flavourants. The aerosol-generating material may comprise one or more active substances and/ or flavours, one or more aerosol-former materials, and optionally one or more other functional material.

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

The aerosol-generating material may comprise or be in the form of an aerosolgenerating film. The aerosol-generating film may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. The aerosol-generating film may be substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free.

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.

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

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

The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosolgenerating film.

The sluriy may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or The aerosol-generating material may comprise or be an “amorphous solid”. In some embodiments, the aerosol-generating materiel comprises an aerosol-generating film that is an amorphous solid. The amorphous solid may be a “monolithic solid”. The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the amorphous solid may, for example, comprise from about 50wt%, 6owt% or owt% of amorphous solid, to about 90wt%, 95wt% or ioowt% of amorphous solid. The amorphous solid may be substantially free from botanical material. The amorphous solid may be substantially tobacco free.

The aerosol-former material may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol-former material may comprise one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Eiythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauiyl acetate, lauric acid, myristic acid, and propylene carbonate.

The one or more other functional materials may comprise one or more of a pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants. An aerosol -modifying agent is a substance that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol. The aerosol-modifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent

The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent may be in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material. An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol.

In some embodiments, the aerosol generator is configured to cause an aerosol to be generated from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

Referring now to Fig. 1, there is shown a schematic perspective view of an apparatus 1 for manufacturing a delivery system 2, shown in Fig. 3. The apparatus 1 comprises a first pair of jaws 3. The first pair of jaws 3 comprises a first jaw 4 and a second jaw 5. The first and second jaws 4, 5 movable from an open position, in which the first and second jaws 4, 5 are out of contact with each other, and a closed position, in which the first and second jaws 4, 5 pressed together.

The apparatus 1 further comprises a web transporter 6. The web transporter 6 is configured to transport first and second webs of sheets material 7, 8 between the first and second jaws 4, 5 along a conveyance path. Each of the first and second jaws 4, 5 comprise at least one delivery system forming segment 9, 10. The least one delivery system forming segment 9 of the first jaw 4 comprises a frame portion 11. The at least one delivery system forming segment 10 of the second jaw 5 comprises a frame portion 12. The frame portions 11, 12 are configured to form a first seal 13, shown in Fig. 2 between the first and second webs of sheet material 7, 8.

In some embodiments, the pair of jaws 3 maybe rotatable between the open position and the closed position. In the open position, the first jaw 4 and the second jaw 5 may be spaced such that first and second webs of sheet material 7, 8 may be moved relative to the first jaw 4 and the second jaw 5. The closed position maybe referred to as the second position, the open position being the first position. In the second position, the first j aw 4 and the second j aw 5 maybe located proximity to each other such that first and second webs of sheet material 7, 8 are immovable relative to the first jaw 4 and the second jaw 5. In this closed position, said jaws 4, 5 maybe pressed together. However the first j aw 4 and the second j aw 5 may be prevented from contacting one another by the presence of the first and second webs of sheets material 7, 8. In some embodiments, the web transporter 6 may comprise a plurality of web rollers. However, it will be appreciated that any form of web transporter 6 may be used, such as, for example, but not limited to, a conveyor.

The webs 7, 8 of sheet material 5 may be formed from a material, such as, for example, but not limited to, fleece, film, non-woven webs, or foil with a binder layer, or any other material that may be sealed via the application of heat or ultrasound . Whilst the embodiments described herein mainly deal with unconnected first and second webs of sheet material, it will be appreciated that in some embodiments the first and second webs of sheet material may correspond to upper and lower or first and second portions of a single web of sheet material that are connected by a fold. The fold may be an angled fold within the web of sheet material along a fold line or a curved portion of the web where the web has been bent over on itself.

The apparatus 1 may be configured to suspend motion of the first and second webs of sheet material 7, 9 between the first pair of jaws 3 so that the first seal 13 can be formed. Alternatively, the apparatus 1 maybe configured such that the first pair of jaws 3 may be movable together with the first and second webs of sheet material 7, 8 along a portion of the conveyance path.

Each of the at least one delivery system forming segments 9, 10 may comprise an arm 14, 15. The arm 13, 14 may extend from a portion of the frame portions 11 , 12. That is, the arm 14 of the at least one delivery system forming segment 9 of the first jaw 4 may extend from a portion of the frame portion 11. The arm 15 of the at least one delivery system forming segment 10 of the second jaw 5 may extend from a portion of the frame portion 12. The arms 14, 15 may be elongate. The end of the arms 14, 15 distal to the frame portions 11, 12 may comprise a hinge element 16, 17. Thus, rotation of the delivery system forming segments 9, 10 of the first jaw 4 and the second jaw 5 maybe driven by rotation of the hinge element 16, 17.

The frame portions 11, 12 of the first jaw 4 and the second jaw 5 may each comprise a pressing surface 21, 22. The pressing surfaces 21, 22 may face each other. That is, the pressing surface 21, 22 may be brought into close proximity when they are in the second position. The frame portions n, 12 may be heated. The frame portions 11, 12 may be heated to a temperature in the range of about 160 degrees Celsius to about 220 degrees Celsius. The heated frame portions 11, 12 may be configured to seal together the first and second webs of sheet material. 7, 8 to form a partially closed delivery system 23. In some embodiments, only the pressing surfaces 21, 22 of the frame portions 11, 12 may be heated. The partially closed delivery system 23 may be sealed substantially all the way around its periphery. In the present embodiment, frame portion 11, 12 of the delivery system forming segments 9, 10 have generally rectangular form. That is, the outer edges of the frame portions 11, 12 may extend so as to form a rectangular outline. As shown in Figure 1, the frame portions 11, 12 comprise two sets of opposing side walls 24, 25. The first set of opposing side walls 24 may form the major sides of the frame portions 11, 12. That is, the first set of opposing side walls 24 may form the sides of the frame portions 11, 12 that extend in the longitudinal direction. The first set of opposing side walls 24 may comprise a first wall 26 and a second wall 27. The first wall 26 and the second wall 27 may extend substantially parallel to each other. The arms 14, 15 may extend from the second wall 27. The first wall 26 may be arranged such that it is opposite to the second wall 27.

The second set of opposing side walls 25 may form the minor sides of the frame portions 11, 12. That is, the second set of opposing side walls 25 may form the sides of the frame portions 11, 12 that extend in the transverse direction. The second set of opposing side walls 25 may comprise a first wall 28 and a second wall 29.

The frame portions 11, 12 may comprise a recess 31, 32 therein. The recesses 31, 32 may determine the shape of the delivery system 2 formed by the apparatus 1. In some embodiments, the recess 31, 32 may extend completely through the thickness of the frame portions 11, 12. In some embodiments, the recesses 31, 32 may extend partially through the thickness of the frame portions 11, 12. The recess 31, 32 may extend partially through the thickness of the frame portions 11, 12 such that the recesses 31, 32 face one another to form a delivery system defining volume when the first and second jaws 4, 5 are in the second position. The recesses 31, 32 in the frame portions 11, 12 may be non- square in shape. The recesses 31, 32 may be defined by the inner edges of the first and second pairs of opposing walls 24, 25 of the frame portions 11, 12. The inner edges of the first and second pairs of opposing walls 24, 25 of the frame portions 11, 12 may define the same shape. The shape defined by the first and second pairs of opposing walls 24, 25 of the frame portions 11, 12 may be different to the shape defined by the outer edges of the frame portions 11, 12.

In some embodiments, the recesses 31, 32 may be circular, triangular, diamond- shaped, pillow-shaped, pentagonal, hexagonal, or any other non-square shape. That is, the inner edges 31, 32 of the first and second pairs of opposing walls 24, 25 of the frame portions 11, 12 may define a circular, triangular, diamond-shaped, pillow-shaped, pentagonal, hexagonal, or any other non-square shape interior hollow. The frame portions 11, 12 may further comprise an aperture 34, 35. The apertures 34, 35 may extend from the outside of the frame portions 11, 12 to the recesses 31, 32 in the frame portions 11, 12. The apertures 34, 35 may extend from the pressing surfaces 21, 22 of the frame portions 11, 12 partially through the thickness of the frame portions 11, 12. The apertures 34, 35 on the first and second jaws 4, 5 may be aligned such they face one another to form a powder insertion aperture, as will be explained in more detail hereinafter.

The aperture 34 in the frame portion 11 of the first jaw 4 may be located in the first wall 26. The aperture 35 in the frame portion 12 of the second jaw 5 may be located in the first wall 28. Thus, when the first and second jaws 4, 5 may moved into the second position, the apertures 34, 35 coincide to form the powder insertion aperture. The aperture 34 in the first jaw 4 may be, for example, but not limited to, a half cylinder. The aperture 35 in the second 5 may be, for example, but not limited to, a half-cylinder. Thus, the powder insertion aperture may be generally cylindrical.

The apertures 34, 35 form a break in the peripheral pressing surfaces 21, 22 of the frame portions 11, 12. Thus, the apertures 34, 35 allow a gap 37, see Fig. 2, to be formed in the first seal 13 formed on the first and second webs of sheet material 7, 8. The apparatus 1 for manufacturing delivery systems 2 may further comprise a powder insertion tube 41. The powder insertion tube 41 may be located in a position between the first and second jaws 4, 5 of the first pair of jaws 3 when the first pair of jaws 3 is in its closed position. In some embodiments, the powder insertion tube 41 may be located midway between the first and second jaws 4, 5 such that each jaw 4, 5. Therefore, each jaw 4, 5 moves the same distance, in opposite motions, from the open position to the closed position.

In some embodiments, the powder insertion tube 41 may be a hollow cylindrical tube. However, it will be appreciated that the cross-sectional shape of the powder insertion tube 41 may be any shape as long as it matches the shape of the powder insertion aperture formed by the apertures 34, 35 in the frame portions 11, 12 in the first and second jaws 4, 5 when they are in the closed position.

The powder insertion tube 41 may be moveable between a first position and a second position. In the first position, the powder insertion tube 41 may be configured to deliver powder into the delivery system defining volume. That is, in the first position, the powder insertion tube 41 may be configured to deliver powder into the cavity between the first and second webs of sheet material 7, 8. In the second position, the powder insertion tube 41 may be configured to be unable to delivery powder into the delivery system defining volume. That is, in the second position, the powder insertion tube 41 may be configured to be unable to deliver powder into the cavity between the first and second webs of sheet material 7, 8.

In the first position, the powder insertion tube 41 may extend completely through the powder insertion aperture formed by the apertures 34, 35 when the first pair of jaws 3 are in the closed position. In some embodiments, when the powder insertion tube 41 is in the first position, the powder insertion tube 41 may protrude into the delivery system defining volume formed by the recesses 31, 32 in the frame portions 11, 12 when the first and second jaws 4, 5 are in the closed position. The powder insertion tube 41 may be formed from a heat resistant material. The powder insertion tube 41 may be capable of maintaining its integrity at temperatures of up to at least 220 degrees Celsius.

The powder insertion tube 41 may be configured to insert powder into the delivery system defining volume formed by the recesses 31, 32 in the frame portions 11, 12 of the first and second jaws 4, 5. Thus, when the first and second webs of sheet material 7, 8 are located between the first pair of jaws 3 in the closed position, the powder insertion tube 41 may be configured to insert powder into a cavity between the first and second webs of sheet material 7, 8.

The powder insertion tube 41 may be connected to a powder feed mechanism (not shown). The powder feed mechanism may be configured to measure out a dose of powder. The powder feed mechanism may also be configured to deliver the powder to the delivery system defining volume. The deliveiy mechanism of the powder feed mechanism may be, for example, but not limited to, a pneumatic nozzle. In the second position, the powder insertion tube 41 may be withdrawn from the location in which the powder insertion aperture is formed when the first and second jaws 4, 5 of the first pair of jaw 3 are in the closed position. The powder insertion tube 41 may be moved between the first position and the second position by translational motion. That is, the powder insertion tube 41 may be moved between the first position and the second position by motion in a direction parallel to the longitudinal axis of the powder insertion tube 41.

As shown in Fig. 1, the first jaw 4 and the second jaw 5 may comprise a plurality of delivery system forming segments 9, 10. Each of the delivery system forming segments 9, 10 may be configured as described above and so a detailed description will be omitted herein.

The plurality of delivery system forming segments 9, 10 may be aligned consecutively in the longitudinal direction. That is, the adjacent delivery system forming segments 9, 10 may be aligned such that the first wall 28 of the second pair of opposing side walls 25 of one delivery system forming segment 9, 10 contacts, or is at least in close proximity to, the second wall 29 of the second pair of opposing side walls 25 of the adjacent delivery system forming segment 9, 10. The adjacent delivery system forming segments 9 may be aligned such that the first wall 26 of the first pair of opposing side walls 24 of each deliveiy system forming segment 9 on the first jaw 4 are coaxial. The adjacent delivery system forming segments 9 may be aligned such that the second wall 27 of the first pair of opposing side walls 24 of each delivery system forming segment 9 on the first jaw 4 are coaxial. The adjacent delivery system forming segments 10 may be aligned such that the first wall 26 of the first pair of opposing side walls 24 of each delivery system forming segment 10 on the second jaw 5 are coaxial. The adjacent delivery system forming segments to may be aligned such that the second wall 27 of the first pair of opposing side walls 24 of each delivery system forming segment 10 on the second jaw 5 are coaxial. In some embodiments, the recesses 31, 32 in each of the plurality of delivery system forming segments 9, 10 are identical. However, it will be appreciated that in some embodiments, the recesses 31, 32 in adjacent delivery system forming segments 9, 10 may be different. For example, the first pair of jaws 3 may comprise one delivery system forming segment 9, 10 having circular recesses 31, 32 and an adjacent delivery system forming segment 9, 10 having diamond shaped recesses 31, 32.

The apparatus 1 for manufacturing delivery systems 2 may further comprise a second pair of jaws 51. The second pair of jaws 51 may comprise a first jaw 52 and a second jaw 53. The second pair of jaws 51 may be moveable from an open position to a closed position. That is, the first and second jaws 52, 53 may be movable from an open position to a closed position.

In the open position, the first jaw 52 and the second jaw 53 maybe spaced such that first and second webs of sheet material 7, 8 may be moved relative to the first jaw 52 and the second jaw 53. The closed position may be referred to as the open position. In the second position, the first jaw 52 and the second jaw 53 maybe located proximity to each other such that first and second webs of sheet material 7, 8 are immovable relative to the first jaw 52 and the second jaw 53. In this closed position, said jaws 52, 53 may be pressed together. However the first jaw 52 and the second jaw 53 may be prevented from contacting one another by the presence of the first and second webs of sheet material 7, 8.

Each of the first and second jaws 52, 53 of the second pair of jaws 51 may comprise at least one delivery system closing segment 55, 56. The delivery system closing segments 55, 56 may be configured to seal closed the unsealed portion of the first and second webs of sheet material 7, 8. The at least one delivery system closing segment 55 of the first jaw 52 may comprise a delivery system sealing element 57. The at least one delivery system closing segment 56 of the second jaw 53 may comprise a delivery system sealing element 58. The delivery system sealing elements 57, 58 of the first and second jaws 52, 53 may be configured to form a second seal 59, shown in Fig. 3, on the first and second webs of sheet material 7, 8 to form a fully sealed delivery system 2. That is, when the first and second jaws 52, 53 are moved into the closed position, the delivery system sealing elements 57, 58 may be configured to be brought into close proximity.

The delivery system sealing elements 57, 58 may each comprise a pressing surface 61, 62. The pressing surfaces 61, 62 may face each other. That is, the pressing surfaces 61, 62 may be brought into close proximity when they are in the second position. The delivery system sealing elements 57, 58, and therefore the pressing surfaces 61, 62, may be dimensioned such that they only contact the first and second webs of sheet material 7, 8 in the area where there is a gap 37 in the first seal 13, i.e. where the apertures 34, 35 in the frame portions 11, 12 of the first pair of jaws 3 were when the first seal 13 was formed.

The delivery system closing segments 55, 56 may be heated. The deliveiy system closing segments 55, 56 may be heated to a temperature in the range of about 160 degrees Celsius to a about 220 degrees Celsius. The heated delivery system closing segments 55, 56 may be configured to seal together the unsealed peripheral portions of the first and second webs of sheet material. 7, 8 to form a partially closed delivery system 23. In some embodiments, only the pressing surfaces 61, 62 of the deliveiy system closing segments 55, 56 may be heated. The closed delivery system 2 may be sealed substantially all the way around its periphery. In some embodiments, the delivery system closing segments 55, 56 of the second pair of jaws 51 may only comprise the delivery system sealing elements 57, 58 and arms 63, 64 directly contacted to the delivery system sealing elements 57, 58. The arms 63, 64 may be elongate and may be shaped so as to avoid contact with the first and second webs of sheet material 7, 8 except for with the delivery system sealing elements 57, 58 when the second pair of jaws 51 is in the closed position. The end of the arms 63, 64 distal to the delivery system sealing elements 57, 58 may comprise a hinge element 65, 66. Thus, rotation of the delivery system closing segments 55, 56 of the first jaw 52 and the second jaw 53 may be driven by rotating the hinge elements 65, 66. However, it will be appreciated that in some embodiments, such as the embodiment shown in Fig. 1, the delivery system closing segments 55, 56 may comprise frame portions 67, 68. The frame portions 67, 68 of the delivery system closing segments 55, 56 of the second pair of jaws 51 are similar to the frame portions 11, 12 described above in relation to the first pair of jaws 3 and so a detailed description thereof will be omitted herein.

In the present embodiment, frame portions 67, 68 of the delivery system closing segments 55, 56 have generally rectangular form. That is, the outer edges of the frame portions 67, 68 may extend so as to form a rectangular outline. As shown in Figure 1, the frame portions 67, 68 comprise two sets of opposing side walls 71, 72.

The first set of opposing side walls 71 may form the major sides of the frame portions 67, 68. That is, the first set of opposing side walls 71 may form the sides of the frame portions 67, 68 that extend in the longitudinal direction. The first set of opposing side walls 71 may comprise a first wall 73 and a second wall 74. The first wall 73 and the second wall 74 may extend substantially parallel to each other. The arms 63, 64 may extend from the second wall 74. The first wall 73 may be arranged such that it is opposite to the second wall 74.

The second set of opposing side walls 72 may form the minor sides of the frame portions 67, 68. That is, the second set of opposing side walls 72 may form the sides of the frame portions 67, 68 that extend in the transverse direction. The second set of opposing side walls 72 may comprise a first wall 75 and a second wall 76.

The frame portions 67, 68 may comprise a recess 77, 78 therein. The recesses 77, 78 may be sized such that the frame portions 67, 68 apart from the deliveiy system sealing elements 57, 58 do not contact, or at least substantially compress, the partially sealed delivery system 23. That is, the recesses 77, 78 of the second pair of jaws 51 may define a delivery system receiving volume 81 that is greater than the delivery system defining volume in the first pair of jaws 3.

Alternatively, the delivery system receiving volume 81 may be the same volume as the delivery system defining volume. In some embodiments, the pressing surfaces 61, 62 may extend around the whole of the frame portions 67, 68 such that the second seal 59 seals the gap 37 in the first seal 13 closed and further seals the first seal 13. It will be appreciated that in an alternative embodiment the apparatus i may not comprise the second pair of jaws 51. Instead, each of the delivery system forming segments 9, 10 of the first pair of jaws 3 may further comprise a delivery system closing segment 55, 56. The delivery system closing segments 55, 56 may be movable between open and closed positions to form the second seal 59 once the powder insertion tube 41 has been moved from its first position to its second position. In some embodiments, the delivery system closing segments 55, 56 may be located adjacent to the outer edge of the first wall 26 of the first pair of opposing side walls 24 of the frame portions 11, 12 of the first and second jaws 4, 5. The deliveiy system closing segments 55, 56 may be moved from the open position to the closed position whilst the first and second jaws 4, 5 are in the closed position.

In some embodiments, the opposing surfaces of the first and/or second pairs of jaws 3, 51 may comprise a coating. That is, surfaces of the first pair of jaws 3 ot the second pair of jaws 51 that are brought together to form a seal in a webs of sheet material 7, 8 may comprise a coating. In some embodiments, the pressing surfaces 21, 22, 61, 62 of the frame portions 11, 12 and the pouch sealing elements 57, 58 of the first and second pairs of jaws 3, 51 may comprise a coating. The coating may be, for example, but not limited to Teflon ® or a similar material.

The non-stick coating may prevent the parts of the material forming the webs of sheet material 7, 8 or loose powder, or any adhesive used on the web, from sticking to the coated surfaces of the pairs of jaws 3, 51. Thus, the apparatus 1 may run continuously for a shift without having to be stopped to be cleaned.

With reference to Fig. 1, a method of forming a deliveiy system 2 will now be described. First, the apparatus 1 is provided with first and second webs of sheet material 7, 8. The first pair of jaws 3 are positioned in their open position. The powder insertion tube 41 may be positioned in either its first position or its second position.

The first and second webs of sheet material 7, 8 are advanced along the first and second conveyance paths into the space between the first jaw 4 and the second jaw 5. The first and second webs of sheet material 7, 8 are positioned within the first pair of jaws 3 such that there is a gap 37 between them large enough for the powder insertion tube 41 to be inserted in between them. In some embodiments, the first and second webs of sheet material 7, 8 may be advanced into the first pair of jaws 3 such that they are positioned either side of the powder insertion tube 41. In some embodiments, the first and second webs of sheet material 7, 8 may be inserted in between the first jaw 4 and the second jaw 5 and then the powder insertion tube 41 may be moved into the first position in between the first and second webs of sheet material 7, 8.

In some embodiments, the first and second webs of sheet material 7, 8 may have their motion suspended once they have been advanced into their position between the first and second jaws 4, 5 of the first pair of jaws 3 such that the first seal 13 can be formed.

In an alternative embodiment, the first and second webs of sheet material 7, 8 may not have their motion suspended, and instead the first and second pairs of jaws may be supported by a conveying means. The conveying means may be configured to convey the first and second pairs of jaws in motion at the same speed as the first and second webs of sheet material 7, 8 such that the seal 13 can be formed without requiring suspension of the motion of the first and second webs of sheet material 7, 8. The conveying means may then return the first and second pairs of jaws to an initial location once the seal 13 has been formed.

In some embodiments, such as the suspended motion embodiment described above, the first and second jaws 3, 4 may then be moved from the open position to the closed position. In the closed position, the first and second jaws 3, 4 may clamp down of the first and second webs of sheet material 7, 8 to compress the first and second webs of sheet material 7, 8 together. In the closed position, the first and second jaws 3, 4 may also form the powder insertion aperture around the powder insertion tube 41. That is, the first and second jaws 4, 5 may close around the powder insertion tube 41.

At least the pressing surfaces 21, 22 of the delivery system forming segments 9, 10 of the first and second jaws 4, 5 may be heated to form the first seal 13 on the first and second webs of sheet material 7, 8. It will be appreciated that the pressing surfaces 21, 22 may have been pre-heated and held at the required temperature before the first and second webs of sheet material 7, 8 were placed in between the first pair of jaws 3. Once the first pair of jaws 3 have been moved into the closed position and the first seal is beginning to be formed, powder may be inserted into the cavity between the first and second webs of sheet material 7, 8. The powder may be blown into the cavity through the powder insertion tube 41 in the powder insertion aperture formed by the apertures 34, 35 in the delivery system forming segments 9, 10. After the first seal 13 has been formed by the first pair of jaws 3 and the powder has been inserted into the cavity between the first and second webs of sheet material 7, 8, the first and second jaws 4, 5 may be moved from the closed position to the open position. Furthermore, the powder insertion tube 41 may be moved from its first position to its second position such that it is no longer located between the first and second webs of sheet material 7, 8. At this stage the apparatus 1 has created at least one partially sealed delivery system 23.

The first and second webs of sheet material 7, 8 that are sealed together by the first seal 13 may then be transported along the conveyance path. In the present embodiment, the partially sealed delivery system 23 formed by the first and second webs of sheet material 7, 8 are advanced into the space between the second pair of jaws 51 in the open position. The first and second webs of sheet material 7, 8 may have their motion suspended once they have been advanced into their position between the first and second jaws 52, 53 of the second pair of jaws 51 such that the second seal 59 can be formed.

The first and second jaws 52, 53 may then be moved from the open position to the closed position. In the closed position, the at least the delivery system sealing elements 57, 58 may clamp down of the first and second webs of sheet material 7, 8 to compress the portion of first and second webs of sheet material 7, 8 that did not form a part of the first seal 13 together to form the second seal to form a fully sealed delivery system 2.

The second pair of jaws 51 may then be moved from the closed position to the open position and the web of sealed delivery systems can be transported to a cutting apparatus (not shown) to separate the web of sealed delivery systems into individual delivery systems.

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

Referring finally to Figs. 4a to 4g, there is shown examples of non-square and non- rectangular delivery systems 2. Each of the exemplary delivery systems 2 comprises a first web of sheet material 7 and a second web of sheet material 8 sealed together around the peripheiy and defining a cavity therebetween. Powder for delivering a substance is located in the cavity. Each delivery system 2 is non-square and non- rectangular in shape. In some embodiments, each of the corners of the delivery system 2 are rounded. Thus, the pillow shaped deliveiy system 2 is not considered rectangular because it has rounded corners. In some embodiments, the pouch deliveiy systems are any shaped except for square with pointed corners, square with rounded corners, rectangular with square corners, or rectangular with rounded corners.

As explained previously, the shape of the delivery system 2 is defined by the outline of the continuous peripheral seal. In the present invention, the continuous seal is formed by the two seals formed. Thus, the shape of the deliveiy system 2 is defined by its cross- sectional shape at the seal between the webs of sheet material. Thus, it will be understood that a delivery system may be flattened and would form a non-square and non-rectangular shape.

In some embodiments, the powder may occupy in the range of about 60 % to about 95 % of the volume of the cavity. In some embodiments, the powder 8 may have a moisture content in the range of about 18 % to about 50 %.

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

Claims

1. An apparatus for manufacturing delivery systems, the apparatus comprising: a first pair of jaws comprising a first jaw and a second jaw, the first and second jaws being moveable from an open position, in which the first and second jaws are out of contact with each other, and a closed position, in which the first and second jaws are pressed together, a web transporter configured to transport first and second webs of sheet material between the first and second jaws along a conveyance path; each of the first and second jaws comprising at least one delivery system forming segment, the at least one delivery system forming segment comprising a frame portion configured to form a first seal between the first and second webs of sheet material together.

2. The apparatus according to claim 1, wherein the pair of jaws are rotatable between the open position and the second position.

3. The apparatus according to claim 1 or claim 2, wherein the frame portion is heated and configured to seal together the first and second web of sheet material to form a partially closed delivery system.

4. The apparatus according to any one of the preceding claims, wherein the frame portion comprises a recess therein which determines the shape of the deliveiy system delivery system, and an aperture extending through a side wall of the frame portion.

5. The apparatus according to claim 4, further comprising a powder insertion tube located between the first and second jaws when the first and second jaws are in the closed position, the powder insertion tube being configured to insert powder into the cavity between the first and second webs of sheet material.

6. The apparatus according to claim 5, wherein the powder insertion tube is moveable between a first position, in which the powder insertion tube can deliver powder into the cavity between the first and second webs of sheet material, and a second position, in which the powder insertion tube is unable to deliver powder into the cavity.

7. The apparatus according to any one of claim 4 to claim 6, wherein the recess in the frame portion in non-square in shape.

8. The apparatus according to any one of the preceding claims, wherein each of the first and second j aws comprise a plurality of deliveiy system forming segments.

9. The apparatus according to any one of the preceding claims, further comprising a second pair of jaws comprising a first jaw and a second jaw, the first and second jaws being moveable from an open position, in which the first and second jaws are out of contact with each other, and a closed position, in which the first and second jaws are pressed together, each of the first and second jaws comprising at least one deliveiy system closing segment configured to seal closed the unsealed portion of the web of sheet material.

10. The apparatus according to any one of claim 1 to claim 8, wherein each of the delivery system forming segments further comprise a delivery system closing segment configured to seal closed the unsealed portion of the delivery system once the powder insertion tube is removed.

11. The apparatus according to claim 9 or claim 10, wherein the delivery system closing segment is heated and configured to seal together the first and second web of sheet material to form a partially closed delivery system.

12. The apparatus according to any one of the preceding claims, wherein the apparatus is configured to suspend motion of the first and second webs of sheet material between the first pair of jaws such that the first seal can be formed.

13. The apparatus according to any one of claim 1 to claim 11, wherein the first pair of jaws is moveable together with the first and second webs of sheet material along the conveyance path.

14. A method of forming a delivery system, the method comprising the steps of: providing a first and second web of sheet material; advancing the webs of sheet material along a conveyance path between the first pair of jaws; inserting powder into the cavity between the first and second webs of sheet material; and closing the first pair of jaws to form a first seal between the first and second webs of sheet material to form a partially closed deliveiy system; opening the first pair of jaws; transporting the at least partially closed deliveiy system along the conveyance path.

15. The method according to claim 14, further comprising the steps of: inserting a powder insertion tube between the first and second web of sheet material to delivery the powder into the cavity between the first and second webs of sheet material; removing the powder insertion tube from the partially closed delivery system; forming a second seal to close the delivery system; and transporting the closed delivery system along the conveyance path.

16. The method according to claim 15, wherein forming the second seal is performed before opening the first pair of jaws.

17. The method according to claim 15, further comprising the step of transporting the partially closed delivery system along the conveyance path and wherein the step of forming the second seal is performed thereafter by a second pair of jaws.

18. A delivery system comprising: a first web of sheet material and a second web of sheet material sealed together around the periphery to define a cavity therebetween; wherein the seal is a continuous seal around the periphery of the delivery system; and powder for delivering a substance located in the cavity.

19. The delivery system according to claim 18, wherein the delivery system is nonsquare and non-rectangular in shape.

20. The delivery system according to claim 18 or claim 19, wherein the powder occupies in the range of about 60 % to about 95 % of the volume of the cavity.

21. The delivery system according to any one of claim 18 to claim 20, wherein the powder has a moisture content in the range of about 18 % to about 50 %.