WO2024028596A2

WO2024028596A2 - An apparatus for manufacturing a component for use in a delivery system

Info

Publication number: WO2024028596A2
Application number: PCT/GB2023/052037
Authority: WO
Inventors: Andrei GRISHCHENKO; Junior KABIRAT; Rosa GALATI
Original assignee: Nicoventures Trading Limited
Priority date: 2022-08-01
Filing date: 2023-08-01
Publication date: 2024-02-08
Also published as: GB202211187D0; WO2024028596A3

Abstract

An apparatus for manufacturing a component that comprises a crimped sheet of material is disclosed. The component is for use in delivery systems. The apparatus comprises a crimping unit configured to crimp a sheet of material; a gathering unit, downstream of the crimping unit, configured to gather the sheet of material that has been crimped by the crimping unit to form a continuous rod of material; and a device located between the crimping unit and the gathering unit. The device is configured to shape the crimped sheet of material prior to said crimped sheet of material being gathered by the gathering unit. A method of manufacturing a component that comprises a crimped sheet of material, the component being for use in a delivery system, a device for use in an apparatus for manufacturing a component that comprises a crimped sheet of material, the component being for use in a delivery system, a component for use in a delivery system and a delivery system are also disclosed. Furthermore, a pack is also disclosed. The pack comprises a plurality of delivery systems, each delivery system comprising a component formed from a crimped sheet of material. The percentage pressure drop standard deviation in the components of the plurality of delivery systems in the pack is less than 10%.

Description

An apparatus for manufacturing a component for use in a delivery system

Technical Field The present disclosure relates to a pair of rollers for use in an apparatus for manufacturing a component that comprises a crimped sheet of material, the component being for use in a delivery system. Additionally, the present disclosure relates to an apparatus for manufacturing a component that comprises a crimped sheet of material, the component being for use in a delivery system. A method of manufacturing a component for use in a delivery system, a component for use in a delivery system and a delivery system are also disclosed.

Background

It is known to form components for delivery systems, such as combustible and non- combustible aerosol provision devices, from a crimped sheet of material. A sheet of material, with which to form said component, is usually fed through a pair of crimping rollers which are configured to impart crimps in the sheet of material. The crimped sheet of material is then fed through a garniture which gathers and wraps the crimped sheet of material into a continuous rod of material. The continuous rod of material can then be cut to from said components.

Summary

According to the present disclosure, there is provided an apparatus for manufacturing a component that comprises a crimped sheet of material, the component being for use in delivery systems, the apparatus comprising: a crimping unit configured to crimp a sheet of material; a gathering unit, downstream of the crimping unit, configured to gather the sheet of material that has been crimped by the crimping unit to form a continuous rod of material; and a device located between the crimping unit and the gathering unit, said device being configured to shape the crimped sheet of material prior to said crimped sheet of material being gathered by the gathering unit.

The device may comprise a pair of rollers configured to shape the crimped sheet of material as the crimped sheet of material is fed therebetween. The apparatus may comprise a gap between the pair of rollers through which the crimped sheet of material is fed.

The device maybe configured such that the distance between the pair of rollers is adjustable to alter the size of the gap.

Each roller of the pair of rollers may comprise a longitudinal axis, the pair of rollers maybe positioned such that their respective axes are parallel to each other. Each roller of the pair of rollers may comprise a plurality of ridges spaced from one another along the length of the roller, and which may extend around the circumference of the roller.

Each roller of the pair of rollers may comprise a plurality of grooves located between each of the plurality of ridges, and which may extend around the circumference of the roller.

The pair of rollers maybe orientated such that a ridge of one roller is in alignment with a corresponding groove of the other roller.

The pair of rollers maybe configured to shape the crimped sheet of material such that the profile of the crimped sheet of material varies in a direction along the width of said crimped sheet of material. The pair of rollers may be configured to shape the crimped sheet of material such that a plurality of peaks and troughs are formed along the width of the crimped sheet of material.

The plurality of peaks and troughs in the crimped sheet of material may form a substantially sinusoidal wave in the crimped sheet of material.

The pair of rollers maybe configured to be heated.

The apparatus may comprise a feeding unit configured to feed the sheet of material along a conveyance path. The apparatus may comprises a wrapping unit configured to wrap the continuous rod of material in a wrapper.

The apparatus may comprise a cutting unit configured to cut the continuous wrapped rod of material into discrete wrapped rods of material.

According to another aspect of the present disclosure, there is provided a method of manufacturing a component that comprises a crimped sheet of material, the component being for use in a delivery system, the method comprising: providing a sheet of material; crimping the sheet of material by feeding said sheet of material through a crimping unit; gathering the sheet of material that has been crimped by the crimping unit to form a continuous rod of material by feeding said crimped sheet of material through a gathering unit; shaping the crimped sheet of material, prior to gathering the crimped sheet of material, by feeding said crimped sheet of material through a device configured to shape the crimped sheet of material; and forming a component for use with a delivery system from said crimped sheet of material.

The device may comprise a pair of rollers and shaping the crimped sheet of material may comprise feeding said crimped sheet of material therebetween.

The method may comprise forming a gap between the pair of rollers through which the crimped sheet of material is fed.

The method may comprise adjusting the distance between the pair of rollers to alter the size of the gap.

Each roller of the pair of rollers may comprise a longitudinal axis and wherein the method may comprise positioning the pair of rollers such that their respective axes are parallel to each other.

Each roller of the pair of rollers may comprise a plurality of ridges, spaced from one another along the length of the roller, and which may extend around the circumference of the roller, and a plurality of grooves located between each of the plurality of ridges, and which may extend around the circumference of the roller, wherein the method may comprise orientating the pair of rollers such that a ridge of one roller is in alignment with a corresponding groove of the other roller. Shaping the crimped sheet of material may comprise shaping the crimped sheet of material in a direction along the width of said crimped sheet of material. Shaping the crimped sheet of material may comprise forming a plurality of peaks and troughs along the width of the crimped sheet of material.

The plurality of peaks and troughs may form a substantially sinusoidal wave in the crimped sheet of material.

The method may comprise heating the pair of rollers prior to the sheet of material being fed through the pair of rollers.

The method may comprise feeding the sheet of material along a conveyance path.

The method may comprise wrapping the continuous rod of material in a wrapper.

The method may comprise cutting the wrapped continuous rod of material to from discrete wrapped rods of material.

According to another aspect of the present disclosure, there is provided a device for use in an apparatus for manufacturing a component that comprises a crimped sheet of material, the component being for use in a delivery system, wherein the device configured to shape the crimped sheet of material prior to said crimped sheet of material being gathered by a gathering unit.

The device may comprise a pair of rollers configured to shape the crimped sheet of material as said crimped sheet of material is fed therebetween. The device may comprise a gap between the pair of rollers through which the crimped sheet of material is fed.

The device is may be configured such that the distance between the pair of rollers is adjustable to alter the size of the gap. Each roller of the pair of rollers may comprise a longitudinal axis, the pair of rollers maybe positioned such that their respective axes are parallel to each other.

Each roller of the pair of rollers may comprise a plurality of ridges spaced from one another along the length of the roller, and which may extend around the circumference of the roller.

Each roller of the pair of rollers may comprise a plurality of grooves located between each of the plurality of ridges and which may extend around the circumference of the roller.

The pair of rollers maybe orientated such that a ridge of one roller is in alignment with a corresponding groove of the other roller. The pair of rollers may be configured to shape the crimped sheet of material in a direction along the width of said crimped sheet of material.

The pair of rollers maybe configured to shape the crimped sheet of material such that a plurality of peaks and troughs are formed along the width of the crimped sheet of material.

The plurality of peaks and troughs in the crimped sheet of material may form a substantially sinusoidal wave in the crimped sheet of material. The pair of rollers may be configured to be heated.

According to another aspect of the present disclosure, there is provided a component, for use in a delivery system, formed by the apparatus according to the present disclosure and/or the method according to the present disclosure.

According to another aspect of the present disclosure, there is provided a delivery system comprising the component according to the present disclosure.

According to another aspect of the present disclosure, there is provided a pack comprising a plurality of delivery systems, each delivery system comprising a component formed from a crimped sheet of material, wherein the percentage pressure drop standard deviation in the components of the plurality of delivery systems in the pack is less than 10%.

The component may be formed by the apparatus and/ or the method according to the present disclosure.

The pressure drop standard deviation of the components in the delivery systems in the pack maybe less than i mmWG. The pack may comprise at least to delivery systems.

Each component may have a length of around 12 mm.

Each component may be a filter component.

Brief description of the drawings

Embodiments of the invention will now be described, by way of example only, with reference to accompanying drawings, in which: Figure 1 is a schematic diagram of an embodiment of an apparatus for manufacturing a component for use in a delivery system;

Figure 2 is a side elevation partial cross-sectional view of an embodiment of a device for use in the apparatus of Figure 1;

Figure 3 is a table displaying data obtained from a pressure drop test; Figure 4 is an isometric view of an alternative device for use in the apparatus of Figure 1; and

Figure 5 is a flow diagram of an embodiment of a method of manufacturing a component for use in a delivery system. Detailed description

As used herein, the term “delivery system” is intended to encompass systems that deliver at least one substance to a user, and includes: combustible aerosol provision systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material); and 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.

According to the present disclosure, a “combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is combusted or burned during use in order to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a combustible aerosol provision system, such as a system selected from the group consisting of a cigarette, a cigarillo and a cigar. In some embodiments, the disclosure relates to a component for use in a combustible aerosol provision system, such as a filter, a filter rod, a filter segment, a tobacco rod, a spill, an aerosol-modifying agent release component such as a capsule, a thread, or a bead, or a paper such as a plug wrap, a tipping paper or a cigarette paper. 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 non-combustible aerosol provision system, such as a non- combustible 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 disclosure relates to a component for use in a non- combustible aerosol provision system, such as a filter, a filter rod, a filter segment, a tobacco rod, a spill, an aerosol-modifying agent release component such as a capsule, a thread, or a bead, or a paper such as a plug wrap, a tipping paper or a cigarette paper. Figure i illustrates a schematic diagram of an embodiment of an apparatus i for manufacturing a component that comprises a crimped sheet of material, the component being for use in a delivery system. In the present example, the component is a filtration component. However, it should be recognised that in alternative embodiments the component may have a different configuration.

The apparatus 1 comprises a crimping unit 2, which receives a sheet of material 3 and is configured to crimp said sheet of material 3 to from a crimped sheet of material 3a. The crimping unit 2 comprises a pair of crimping rollers 4 through which the sheet of material 3 is fed. The pair of crimping rollers 4 are configured to form a series of crimps along the width of the sheet of material 3 which extend in a direction along the length of the crimped sheet of material 3a.

Downstream of the crimping unit 2, the apparatus 1 comprises a gathering unit 6, configured to gather the crimped sheet of material 3a to form a continuous rod of material 7. The term “downstream” refers to the direction of travel of the sheet of material 3 as the sheet of material is fed towards the gathering unit 6. The gathering unit 6 may comprise a funnel or cone (not shown) that is configured to gather the crimped sheet of material 3a to form the continuous rod of material 7.

Additionally, the apparatus 1 comprises a device 5 located between the crimping unit 2 and the gathering unit 6. The device 5 is configured to shape the crimped sheet of material 3a prior to the crimped sheet of material 3a being gathered by the gathering apparatus 6. In the present example, the device 5 comprises a pair of rollers 8 configured to shape the crimped sheet of material 3a as the crimped sheet of material 3a is fed therebetween. The structure of the pair of rollers 8 is described below in relation to Figure 2.

In a conventional apparatus for forming a component for use in a delivery system from a crimped sheet of material, the sheet of material is gathered immediately after crimping of the sheet of material. In this situation, the gathering of the crimped sheet of material is completely random which results in non-uniform components. For example, when the crimped sheet of material is gathered, a higher percentage of the crimps may be gathered into one area of the component compared to another area which will inevitably comprise a lower percentage of crimps. In other words, the density of the crimped sheet of material in one area of the formed component may be different to another area of the component. This can lead to issues or a lack of performance when a user draws on a delivery system comprising the formed component. Presently, the crimped sheet of material is fed through the device 5 prior to being gathered by the gathering unit 6. The device 5 is configured to shape the crimped sheet of material 3a prior to gathering such that the gathering, and hence the uniformity of the formed components, can be controlled. The apparatus may comprise a feeding unit 9 which receives a supply of a sheet of material 3 and is configured to supply said sheet of material 3 along a conveyance path A. In the present example, the sheet of material 3 is formed from a fibrous material, such as paper. However, it is to be appreciated that in alternative embodiments, the sheet of material 3 maybe formed from a different material. For example, in some embodiments the sheet of material is a non-woven sheet of material, such as lyocell or viscose.

The feeding unit 9 comprises a receiving mechanism 10 which receives a supply of a sheet of material 3. In the present example, the receiving mechanism 10 is configured to receive a bobbin 11 of a paper material. The bobbin 11 supplies a continuous sheet of paper material along the conveyance path A. In an alternative embodiment (not shown) the feeding unit 9 supplies individual sheets of paper material along the conveyance path A. The sheet of material 3 may be fed along the conveyance path A by any suitable mechanism, for example, a plurality of rollers.

The apparatus 1 may comprise a wrapping unit 12, downstream of the gathering unit 6, configured to wrap the continuous rod of material 7 in a wrapper and to form a continuous wrapped rod of material 7a. The wrapping unit 12 comprises a garniture (not shown) that is configured to receive the continuous rod of material 7 and wrap the continuous rod of material 7 in a wrapper. The wrapper may be fed as a continuous web through the garniture on a garniture belt (not shown) that is configured to wrap around the continuous rod of material 7 as the belt, wrapper and crimped sheet of material 3a pass through a narrowing cone or tongue of the garniture. The wrapper may then be secured in position using adhesive that is applied or pre-applied to an edge of the wrapper. It should be recognised that in alternative embodiments the wrapping unit 12 may be of an alternate configuration, for example, comprising a wrapping drum that wraps the wrapper about the continuous rod of material 7. In the example of Figure 1, the crimped sheet of material 3a is gathered by the gathering unit 6 and then the continuous rod of material 7 is passed to the wrapping unit 12. However, in an alternative embodiment (not shown), a combined gathering and wrapping unit gathers the crimped sheet of material 3a into a continuous rod of material 7 and wraps the continuous rod of material 7 in a wrapper. For instance, the crimped sheet of material 3a could be fed into a garniture that gathers the crimped sheet of material 3a into a continuous rod of material 7 and simultaneously wraps the continuous rod of material 7 in a wrapper.

Additionally, the apparatus 1 may comprise a cutting unit 13 that is downstream of the wrapping unit 12 and is configured to cut the continuous wrapped rod of material 7a into discrete rods of wrapped material 7b. In some embodiments, the discrete rods produced by the cutting unit 13, commonly known as base rods, have a total length of around 96 mm. Each base rod is then cut into eight 12 mm rods that each form a component for use in a delivery system.

In some embodiments, the apparatus 1 comprises the crimping unit 2, the device 5 and the gathering unit 6 only.

The structure of the pair of rollers 8 of the device 5 will now be described in relation to Figure 2 which illustrates a side elevation partial cross-sectional view of the device 5 according to the present disclosure along the line X-X.

As seen in Figure 2, there is a gap between the pair of rollers 8 through which the crimped sheet of material 3a is fed. The device 5 is configured such that the distance between the pair of rollers 8 is adjustable to alter the size of the gap. If the distance between the pair of rollers 8 is reduced, the effect of the gap on the shaping of the crimped sheet of material 3a passing through the gap is increased. Alternatively, if the distance between the pair of rollers 8 is increased, the effect of the gap on the shaping of the crimped sheet of material 3a passing through the gap is reduced. It is to be appreciated that the distance between the pair of rollers 8 is less than the height of the crimps formed in the crimped sheet of material 3a otherwise the crimped sheet of material 3a would not be shaped by the pair rollers 8.

Each roller of the pair of rollers 8 comprises a longitudinal axis A-A about which the pair of rollers 8 rotate. The pair of rollers 8 are positioned such that their respective axes are parallel to each other. Each roller of the pair of rollers comprises a plurality of ridges 14 spaced from one another along the length of each roller, and which extend around the circumference of the roller. Furthermore, each roller of the pair of rollers 8 comprises a plurality of grooves 15 located between each of the plurality of ridges 14, and which extend around the circumference of the roller. The combination of said ridges 13 and grooves 14 is configured to shape the crimped sheet of material 3a as the crimped sheet of material 3a is fed through the gap. In other words, the pair of rollers 8 are configured to shape the crimped sheet of material 3a such that the crimps in the continuous rod of material 7, and therefore the resulting component, are uniformly distributed.

As explained above, the pair of crimping rollers 4 of the crimping unit 2 are configured to generate a plurality of crimps along the width of the sheet of material 3 and which extend longitudinally in a direction along the length of the sheet of material 3. By feeding the crimped sheet of material 3a through the pair of rollers 8 prior to gathering of the crimped sheet of material 3a, the uniformity of the crimps in the continuous rod of material 7, and therefore the resulting components, is controlled since the pair of rollers 8 are configured to shape the crimped sheet of material 3a such that a random gathering of the crimped sheet of material 3a is prevented. This may result in a more uniform density of the material in the formed component in any given cross section of said component.

Each roller of the pair of rollers 8 is configured to rotate about its own longitudinal axis A-A. In the present example, the pair of rollers 8 are configured to rotate due to friction with the crimped sheet of material 3a as the crimped sheet of material 3a is fed along the conveyance path A. However, it is to be appreciated that in other embodiments, one or both of the pair of rollers 8 may be driven by an external device such as a motor.

The pair of rollers 8 are orientated such that each ridge 14 of one roller is in alignment with a corresponding groove 15 of the other roller. In other words, the pair of rollers 8 are orientated in relation to each other such that the pair of rollers 8 mesh together. It is to be appreciated that the space between the pair of rollers 8 shown in Figure 2 (i.e. the gap) is exaggerated so that the structure of the pair of rollers 8 can be seen more clearly. In the example shown in Figure 2, each roller comprises three ridges 14 and two grooves 15. However, it should be recognised that in alternative embodiments, each roller may comprise any number of ridges and grooves along the length of each roller.

The pair of rollers 8 are configured to shape the crimped sheet of material 3a such that the profile of the crimped sheet of material varies in a direction along the width of the crimped sheet of material 3a. In particular, the pair of rollers 8 are configured to shape the crimped sheet of material 3a such that a plurality of peaks and troughs are formed along the width of the crimped sheet of material 3a. In particular, the plurality of peaks and troughs in the crimped sheet of material 3a form a substantially sinusoidal wave in the crimped sheet of material 3a such that the profile of the crimped sheet of material 3a is shaped without creases or folds in a continuously undulating manner. In other words, the plurality of peaks and troughs in the crimped sheet of material 3a provide the crimped sheet of material 3a with a corrugated form. It has been found that shaping the crimped sheet of material 3a in this manner prior to gathering of the crimped sheet of material 3a improves the uniformity of the gathered sheet of material 3a in the continuous rod of material 7.

Figure 3 is a data table displaying the results of a pressure drop test executed by the inventors in relation to the 96 mm base rods produced by the cutting unit 13 of the apparatus 1. As used herein, pressure drop is expressed with the units of pressure ‘mmWG’ or ‘mm of water gauge’ and is measured in accordance with ISO 6565:2002 and under the test conditions as defined in ISO 3402:1999.

The table shows the results of the test when using the apparatus 1 with and without the pair of rollers 8. As seen in Figure 3 the pressure drop standard deviation in the base rods was reduced in each test by the addition of the pair of rollers 8 to the apparatus 1. For example, in test 1 the pressure drop standard deviation was reduced from 13.8 mmWG to 7.6 mmWG, in test 2 the pressure drop standard deviation was reduced from 10.5 mmWG to 7.1 mmWG and in test 3 the pressure drop standard deviation was reduced from 20.7 mmWG to 9 mmWG. A lower pressure drop standard deviation in the base rods produced by the apparatus indicates increased uniformity in the base rods which results in a better uniformity of delivery systems containing components formed from said base rods.

As explained above, the 96 mm base rods are further cut to produce eight 12 mm components for use in delivery systems. A pack may be produced comprising a plurality of delivery systems each containing a component formed by the base rod. In some embodiments, the pack comprises at least ten delivery systems. Therefore, based on the data displayed in Figure 3, the pressure drop standard deviation in the components of the delivery systems in a pack is less than 10 mmWG, 5 mmWG or 1 mmWG.

Furthermore, as shown in Figure 3, the percentage standard deviation, calculated as the pressure drop standard deviation as a percentage of the mean pressure drop, was reduced in each test by the addition of the pair of rollers 8 to the apparatus 1. For example, in test 1 the percentage standard deviation was reduced from 9.09% to 5.01%, in test 2 the percentage standard deviation was reduced from 6.24% to 4.14% and in test 3 the percentage standard deviation was reduced from 9.64% to 4.33%. Thus, it can be said that the percentage standard deviation in the components of the delivery systems in a pack is less than 10%, 5% or 1%. Additionally, the pair of rollers 8 may be configured to be heated. Heating of the pair of rollers 8 may improve the shaping of the crimped sheet of material 3a as the sheet of material 3a is fed through the pair of rollers 8.

Figure 4 illustrates an alternative device for use with the apparatus of Figure 1. The device 5 comprises a pre-folding unit 16 comprising at least one groove 17 in a curved outer surface 18 of the pre-folding unit 16. In this example, the curved outer surface 18 is the curved outer wall of a solid frusto-conical, single piece component 19. However, it is to be appreciated that in some embodiments, the component is cylindrical in shape with a constant diameter. The component 19 comprises an upstream end U which is configured to face the direction of the incoming crimped sheet of material 3a and a downstream end D, opposite the upstream end. The upstream end is the larger diameter end of the frustum-cone. In the illustrated example, the component 19 comprises seven grooves 17 that each follow a linear path about the outer surface 18 of the component 19, though any number of grooves may be adopted as required. Additionally, in some embodiments, each groove 17 follows a helical path about the outer surface 18 of the component 19. As grooves with a helical structure are longer compared to grooves with a linear structure, providing the pre-folding unit 16 with helical grooves results in a larger amount of material being present per unit length within the formed continuous rod of material. In embodiments where the formed rods are used as filter components in aerosol delivery systems, this results in better filtration. In operation, the crimped sheet of material 3a is drawn over the upstream end U the component 19 and into the funnel/cone of the gathering unit 6. An inlet to the funnel/cone has a diameter equal to or less than the diameter of the downstream end D of the component 19 so that the crimped sheet of material 3a is drawn tightly over its curved surface 18 and into the grooves 17, causing the crimped sheet of material 3a to adopt the profile of the grooves. In this way the crimped sheet of material 3a is pre folded as the crimped sheet of material 3a remains in the shape imparted by the grooves 17 as it leaves the component 19.

In some embodiments, the pre-folding unit 16 additionally comprises a plurality of rods (not shown) extending in proximity to the component 19, and in particular, extending into, and in a direction along, the grooves 17. In this arrangement, the plurality of rods are configured to force the crimped sheet of material 3a into the grooves such that the shape of the grooves 17 is better imparted into the crimped sheet of material 3a. Furthermore, the position of the rods relative to the grooves maybe adjustable such that the pushing force provided by the rods onto the crimped sheet of material can be reduced or increased. Additionally, in other embodiments, the pre-folding unit 16 may comprise an outer member (not shown) surrounding the component 19 which directs the crimped sheet of material 3a into the grooves 17. For example, in some embodiments the outer member maybe a constant diameter funnel or conical/frusto- conical shape.

In some embodiments, which do not form part of the present invention, the pre-folding unit as described above can also be used with non-crimped sheets of material (i.e. sheets of material which have not undergone a crimping process) in a substantially similar way. For example, a non-crimped sheet of material can be drawn tightly over the curved outer surface and grooves, causing the non-crimped sheet of material to adopt the profile of the grooves. In this way a non-crimped sheet of material is prefolded as the non-crimped sheet of material remains in the shape imparted by the grooves as it leaves the pre-folding unit. Figure 5 illustrates a flow diagram of an embodiment of a method of manufacturing a component that comprises a crimped sheet of material, the component being for use in a delivery system. The method comprises a first step Si of providing a sheet of material, which may also include feeding the sheet of material along a conveyance path, followed by a second step S2 of crimping the sheet of material by feeding said sheet of material through a crimping unit. Next, the method comprises a third step S3 of shaping the crimped sheet of material by feeding said crimped sheet of material through a device configured to shape the crimped sheet of material, and a fourth step S4 of gathering the crimped sheet of material to form a continuous rod of material by feeding said crimped sheet of material through a gathering unit. Additionally, the method comprises a fifth step S5 comprising forming a component for use with a delivery system from said crimped sheet of material.

The step S3 of shaping the crimped sheet of material may comprise feeding the crimped sheet of material through a pair of rollers. Additionally, the step S3 may comprise forming a gap between the pair of rollers through which the crimped sheet of material is fed. Furthermore, the step S3 may comprise adjusting the distance between the pair of rollers to alter the size of the gap. Therefore, the extent to which the crimped sheet of material is shaped by the pair of rollers can be controlled as described above. Each roller of the pair of rollers comprises a longitudinal axis and the method step S3 may comprise positioning the pair of rollers such that their respective axes are parallel to each other. As described above, each roller of the pair of rollers comprises a plurality of ridges, spaced from one another along the length of the roller, and which extend around the circumference of the roller, and a plurality of grooves located between each of the plurality of ridges, and which extend around the circumference of the roller. The method step S3 may comprise orientating the pair of rollers such that a ridge of one roller is in alignment with a corresponding groove of the other roller.

The shaping of the crimped sheet of material in step S3 may comprise shaping the crimped sheet of material in a direction along the width of said crimped sheet of material. Additionally, step S3 may comprise forming a plurality of peaks and troughs along the width of the crimped sheet of material. The plurality of peaks and troughs form a substantially sinusoidal wave in the crimped sheet of material. The method may comprise heating the pair of rollers prior to the sheet of material being fed through the pair of rollers. The method may comprise a sixth step S6 of wrapping the continuous rod of material in a wrapper once the crimped sheet of material has been gathered. It is be appreciated that the wrapping step may occur simultaneously with the gathering step. Finally, the method may comprise a seventh step S7 of cutting the wrapped continuous rod of material to form discrete wrapped rods of material.

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

1. An apparatus for manufacturing a component that comprises a crimped sheet of material, the component being for use in delivery systems, the apparatus comprising: a crimping unit configured to crimp a sheet of material; a gathering unit, downstream of the crimping unit, configured to gather the sheet of material that has been crimped by the crimping unit to form a continuous rod of material; and a device located between the crimping unit and the gathering unit, said device being configured to shape the crimped sheet of material prior to said crimped sheet of material being gathered by the gathering unit.

2. An apparatus according to claim i, wherein the device comprises a pair of rollers configured to shape the crimped sheet of material as the crimped sheet of material is fed therebetween.

3. An apparatus according to claim 2, comprising a gap between the pair of rollers through which the crimped sheet of material is fed. 4. An apparatus according to claim 3, wherein the device is configured such that the distance between the pair of rollers is adjustable to alter the size of the gap.

5. An apparatus according to any of claims 2 to 4, wherein each roller of the pair of rollers comprises a longitudinal axis, the pair of rollers being positioned such that their respective axes are parallel to each other.

6. An apparatus according to any of claims 2 to 5, wherein each roller of the pair of rollers comprises a plurality of ridges spaced from one another along the length of the roller, and which extend around the circumference of the roller.

7. An apparatus according to claim 6, wherein each roller of the pair of rollers comprises a plurality of grooves located between each of the plurality of ridges, and which extend around the circumference of the roller.

8. An apparatus according to claim 7, wherein the pair of rollers are orientated such that a ridge of one roller is in alignment with a corresponding groove of the other roller. . An apparatus according to any of claims 2 to 8, wherein the pair of rollers are configured to shape the crimped sheet of material such that the profile of the crimped sheet of material varies in a direction along the width of said crimped sheet of material.

10. An apparatus according to any of claims 2 to 9, wherein the pair of rollers are configured to shape the crimped sheet of material such that a plurality of peaks and troughs are formed along the width of the crimped sheet of material.

11. An apparatus according to claim 10, wherein the plurality of peaks and troughs in the crimped sheet of material form a substantially sinusoidal wave in the crimped sheet of material.

12. An apparatus according to any of claims 2 to 11, wherein the pair of rollers are configured to be heated. 13. An apparatus according to any preceding claim, wherein the apparatus comprises a feeding unit configured to feed the sheet of material along a conveyance path.

14. An apparatus according to any preceding claim, wherein the apparatus comprises a wrapping unit configured to wrap the continuous rod of material in a wrapper.

15. An apparatus according to claim 11, wherein the apparatus comprises a cutting unit configured to cut the continuous wrapped rod of material into discrete wrapped rods of material.

16. A method of manufacturing a component that comprises a crimped sheet of material, the component being for use in a deliveiy system, the method comprising: providing a sheet of material; crimping the sheet of material by feeding said sheet of material through a crimping unit; gathering the sheet of material that has been crimped by the crimping unit to form a continuous rod of material by feeding said crimped sheet of material through a gathering unit; shaping the crimped sheet of material, prior to gathering the crimped sheet of material, by feeding said crimped sheet of material through a device configured to shape the crimped sheet of material; and forming a component for use with a delivery system from said crimped sheet of material. 17. A method according to claim 16, wherein the device comprises a pair of rollers and shaping the crimped sheet of material comprises feeding said crimped sheet of material therebetween.

18. A method according to claim 17, comprising forming a gap between the pair of rollers through which the crimped sheet of material is fed.

19. A method according to claim 18, comprising adjusting the distance between the pair of rollers to alter the size of the gap. 20. A method according to any of claims 16 to 19, wherein each roller of the pair of rollers comprises a longitudinal axis and wherein the method comprises positioning the pair of rollers such that their respective axes are parallel to each other.

21. A method according to any of claims 16 to 20, wherein each roller of the pair of rollers comprises a plurality of ridges, spaced from one another along the length of the roller, and which extend around the circumference of the roller, and a plurality of grooves located between each of the plurality of ridges, and which extend around the circumference of the roller, wherein the method comprises orientating the pair of rollers such that a ridge of one roller is in alignment with a corresponding groove of the other roller.

22. A method according to any of claims 16 to 21, wherein shaping the crimped sheet of material comprises shaping the crimped sheet of material in a direction along the width of said crimped sheet of material.

23. A method according to any of claims 16 to 22, wherein shaping the crimped sheet of material comprises forming a plurality of peaks and troughs along the width of the crimped sheet of material. 24. A method according to claim 23, wherein the plurality of peaks and troughs form a substantially sinusoidal wave in the crimped sheet of material.

25. A method according to any of claims 16 to 24, comprising heating the pair of rollers prior to the sheet of material being fed through the pair of rollers.

26. A method according to any of claims 16 to 25, comprising feeding the sheet of material along a conveyance path.

27. A method according to any of claims 16 to 26, comprising wrapping the continuous rod of material in a wrapper.

28. A method according to claim 23, comprising cutting the wrapped continuous rod of material to from discrete wrapped rods of material. 29. A device for use in an apparatus for manufacturing a component that comprises a crimped sheet of material, the component being for use in a delivery system, wherein the device configured to shape the crimped sheet of material prior to said crimped sheet of material being gathered by a gathering unit. 30. A device according to claim 29, wherein the device comprises a pair of rollers configured to shape the crimped sheet of material as said crimped sheet of material is fed therebetween.

31. A device according to claim 30, comprising a gap between the pair of rollers through which the crimped sheet of material is fed.

32. A device according to claim 31, wherein the device is configured such that the distance between the pair of rollers is adjustable to alter the size of the gap. 33- A device according to any of claims 30 to 32, wherein each roller of the pair of rollers comprises a longitudinal axis, the pair of rollers being positioned such that their respective axes are parallel to each other. 34. A device according to any of claims 30 to 33, wherein each roller of the pair of rollers comprises a plurality of ridges spaced from one another along the length of the roller, and which extend around the circumference of the roller.

35. A device according to claim 34, wherein each roller of the pair of rollers comprises a plurality of grooves located between each of the plurality of ridges and which extend around the circumference of the roller.

36. A device according to claim 35, wherein the pair of rollers are orientated such that a ridge of one roller is in alignment with a corresponding groove of the other roller.

37. A device according to any of claims 30 to 36, wherein the pair of rollers are configured to shape the crimped sheet of material in a direction along the width of said crimped sheet of material. 38. A device according to any of claims 30 to 37, wherein the pair of rollers are configured to shape the crimped sheet of material such that a plurality of peaks and troughs are formed along the width of the crimped sheet of material.

39. A device according to claim 38, wherein the plurality of peaks and troughs in the crimped sheet of material form a substantially sinusoidal wave in the crimped sheet of material.

40. A device according to any of claims 30 to 39, wherein the pair of rollers are configured to be heated.

41. A component, for use in a delivery system, formed by the apparatus according to any of claims 1 to 15 and/or the method according to any of claims 16 to 28.

42. A delivery system comprising the component according to claim 41. 43- A pack comprising a plurality of delivery systems, each delivery system comprising a component formed from a crimped sheet of material, wherein the percentage pressure drop standard deviation in the components of the plurality of delivery systems in the pack is less than 10%.

44. A pack according to claim 43, wherein the component is formed by the apparatus according to any of claims 1 to 15 and/or the method according to any of claims 16 to 28. 45. A pack according to claim 43 or 44, wherein the pressure drop standard deviation of the components in the delivery systems in the pack is less than 1 mmWG.

46. A pack according to any of claims 43 to 45, wherein the pack comprises at least ten delivery systems.

47. A pack according to any of claims 43 to 46, wherein each component has a length of around 12 mm.

48. A pack according to any of claims 43 to 47, wherein each component is a filter component.