capsule

Abstract

The present invention relates to a capsule for a hookah device. The capsule includes a smoking product including at least one component configured to vaporize during heating of the smoking product in use, and a housing including a plurality of walls shaped to define an internal chamber containing the smoking product and defining at least one air passageway through which the vaporized component can exit the capsule in use. A support structure is provided within the housing, defining a surface area spaced from the plurality of walls within the internal chamber and on which the smoking product is at least partially disposed. The capsule, wherein the smoking product and support structure only partially occupy the internal chamber.

Description

[Technical field]

[0001] The present disclosure relates to a capsule containing a consumable for a water pipe such as a hookah device, and in particular to a capsule suitable for an electrically heated hookah device. [Background technology]

[0002] A prior art hookah device is disclosed in WO2015172224(A1). The hookah device includes a capsule (see Figs. 6 and 7) configured to receive a smoking product. The capsule is placed in a heating chamber where the smoking product (e.g., shisha tobacco) can be heated and vaporized. The vaporized product is drawn out of the hose by the user's inhalation through a water tank.

[0003] The capsules may be pre-packaged, for example, filled by the manufacturer and sold to the consumer in pre-filled form. The inventors have discovered that such a pre-filled arrangement presents a number of problems.

[0004] Smoking products are provided as a single mass. Therefore, the product has a small surface area per unit volume of the product. When heated, only a small portion of the product is available for vaporization. This results in a weak flavor and low smoke production.

[0005] Furthermore, a single mass may behave unpredictably during heating depending on the mass's location / orientation relative to the heat source and airflow through the capsule. Some areas may be significantly hotter / colder, resulting in variable user experience. It would be desirable to produce a more consistent user experience.

[0006] A larger specific surface area relative to ordinary tobacco / molasses generally means that a smaller mass of smoking product is contained in a given internal volume of the capsule, which translates into the capsule contents being consumed more quickly and therefore the need to replace the capsule more frequently.

[0007] Furthermore, during manufacturing, shipping, handling, and / or storage of pre-filled capsules, the product therein may "settle", resulting in the product clumping and / or separating into components (e.g., due to the "Brazil nut effect") resulting in undesirable / ununiform properties, which may lead to non-optimal performance of the smoking product during heating, resulting in a non-optimal experience for the user. Summary of the Invention [Problem to be solved by the invention]

[0008] It is an object of the present disclosure to overcome or ameliorate one or more of these problems. It is also envisaged as an additional or alternative object to provide a capsule that provides a predictable and / or consistent user experience. [Means for solving the problem]

[0009] According to one aspect of the present disclosure, there is provided a capsule for a water pipe comprising a smoking article including at least one component configured to vaporize during heating of the product, and a housing configured to contain the product and including at least one air passageway that allows the vaporized component to exit the capsule in use, wherein the capsule includes a support structure configured to at least partially separate or spread the smoking article within the housing.

[0010] The housing may include one or more inlet and / or outlet openings within the capsule, and the support structure may define an air passageway leading to the inlet and / or outlet openings.

[0011] According to a second aspect of the present disclosure, there is provided a capsule for a water pipe comprising a smoking product comprising at least one component configured to vaporize upon heating of the smoking product, a housing comprising a wall structure shaped to define an internal chamber containing the smoking product and configured to provide at least one air passageway to allow the vaporized component to exit the capsule in use, and one or more inert inclusions within the internal chamber.

[0012] The smoking article may be provided as a coating on one or more inert inclusions. The inclusions may be embedded in the smoking article. The inclusions may include beads.

[0013] According to a third aspect of the present disclosure, there is provided a capsule for a water pipe comprising a smoking product comprising at least one component configured to vaporize upon heating of the smoking product and divided into a plurality of discrete portions, and a housing including a wall structure shaped to define an internal chamber containing the discrete portions of the smoking product and configured to provide at least one air passageway, in use, to allow the vaporized component to exit the capsule, wherein the plurality of discrete portions are of different surface areas.

[0014] The discrete portions may be of different shapes / sizes and / or thicknesses of the smoking article.

[0015] According to a fourth aspect of the present disclosure, there is provided a capsule for a water pipe comprising a smoking product comprising at least one component configured to vaporize during heating of the smoking product, and a housing comprising a wall structure shaped to define an internal chamber containing the smoking product, wherein the smoking product comprises a viscous fluid, semi-solid, or paste material arranged to at least partially conform to a surface of the internal chamber, and the wall structure is configured to define at least one air passageway to allow the vaporized component to exit the capsule in use.

[0016] According to a fifth aspect of the present disclosure there is provided a water pipe including a capsule of any of the first, second, third or fourth aspects. The water pipe may include an electric heater for heating the capsule therein.

[0017] According to a further aspect of the present disclosure, there is provided a method of manufacturing a capsule for a water pipe, the method comprising providing a smoking product including at least one component configured to vaporize upon heating, forming a housing for the capsule having an internal chamber, providing a support structure for the internal chamber having a surface area configured to receive the smoking product, applying the smoking product to the surface area of ​​the support structure, and closing the support structure with the smoking product applied thereto with the housing.

[0018] Closing involves sealing the housing with the smoking article and support structure inside.

[0019] Typically, the smoking article and support structure only partially fill the internal chamber, such that the internal chamber is breathable during use. The smoking article may be applied to a surface area of ​​the support structure to maintain air passages within the capsule to allow vapour to escape from the capsule upon heating during use.

[0020] Optional features of any aspect of the invention are set out below and in the accompanying dependent claims, any of which may be applied to any aspect of the invention so far as is practical, and which may not, for reasons of brevity only, be repeated separately in each aspect.

[0021] Smoking products are generally consumable products: the support structure is not consumed or vaporized during heating during use.

[0022] The capsule may be a one-time, consumable and / or disposable capsule that can be inserted into the water pipe for heating during use and removed from the hookah after use.

[0023] The support structure may have greater strength and / or rigidity than the smoking article. The support structure may be substantially inert, for example at temperatures achieved during heating of the product in use.

[0024] The support structure may be at least partially covered by the smoking article. The majority, or substantially all, of the support structure may be covered by the smoking article.

[0025] The smoking product may be malleable and / or deformable. The smoking product may be comprised of a viscous liquid, semi-solid, and / or paste material. The smoking product may be amorphous and / or unable to support its own weight without deformation. The support structure may define the shape of the smoking product within the capsule.

[0026] Additionally or alternatively, the smoking product may be applied to the support structure in liquid, viscous liquid or semi-solid form, for example as a coating. The smoking product may be sticky / adhesive. The smoking product may or may not harden after being applied to the support structure.

[0027] The support structure and smoking product only partially fill the housing, e.g. its internal chamber (i.e. the fill / fill ratio is less than 1). A part of the internal chamber may be composed of a void, e.g. a void filled with gas / air. The support structure and / or smoking product may occupy 50% or less of the capsule internal volume, preferably 90% or less, preferably 80% or less, preferably 70% or less, preferably 60% or less, preferably 50% or less. The support structure and / or smoking product may occupy 20% or more of the capsule internal volume, preferably 30% or more, preferably 40% or more, preferably 50% or more. The support structure and / or smoking product may occupy between 20% and 90%, preferably between 30% and 80%, preferably between 40% and 70%, preferably between 50% and 60% of the capsule internal volume.

[0028] The smoking product (e.g., its components) may include a binder, a mist generating agent, and / or a flavoring. The smoking product may or may not include a thickening agent. The flavoring product may include a sweetener, and / or the smoking product may include multiple flavorings, at least one of which, for example, includes a sweetener. The binder may or may not be an absorbent binder.

[0029] The absorbent binder may include one or more of fumed silica, amorphous silica, or talc.The smoking product includes an inert, granular / powdered filler.

[0030] The smoking article may be configured to release flavourants and / or mist generating agents when heated (eg, the flavourants and / or mist generating agents may vaporize or otherwise become volatile / buoyant).

[0031] The smoking product may include colorants and / or stimulants. The stimulants may include any one or any combination of caffeine, taurine, theobromine, nicotine, and / or cannabinoids. The cannabinoids may include tetrahydrocannabinol (THC) or cannabidiol (CBD). The smoking product may include cannabis and / or its extracts and / or derivatives.

[0032] The smoking product may include a nicotine-containing product. The smoking product may include tobacco. The product may include a tobacco substitute (e.g., an organic substrate).

[0033] The product may include a shisha or muesl product. The product may include a tobacco product that includes a sugar liquid (e.g., molasses). The product may include glycerol or other mist generating agents. The product may include flavorings and / or other additives. The tobacco may be provided with other conventional materials that are adapted to vaporize during heating.

[0034] The smoking article may include a filler. The smoking article may include granules, for example granules of an inert material.

[0035] The smoking article may comprise a mixture or agglomerate of any combination of the above ingredients / components.

[0036] The capsule may comprise a first and second wall with an internal chamber between the first and second walls, wherein the first and second walls include at least one respective opening therein such that, in use, air passes through the respective opening and over a smoking article in the internal chamber.

[0037] The support structure may have greater strength than the smoking article.

[0038] The support structure may be shaped to maintain a desired distribution of the smoking articles within the interior chamber.

[0039] The support structure may span substantially the entire height and / or width dimension of the internal chamber. The support structure may have a height dimension that is half, 2 / 3, or 3 / 4 or more of the height of the internal chamber. The support structure may be shorter than the internal chamber to provide an open head volume within the capsule, for example, directly below the capsule lid or the ceiling of the internal chamber.

[0040] The support structure may form part of the wall structure of the capsule housing, where it may be integral thereto or affixed thereto.

[0041] The support structure may be loosely disposed within the internal chamber and / or movement of the support structure may be constrained by contact with a number of walls. The support structure may be constrained by filling the remainder of the capsule with smoking articles.

[0042] The support structure may include a divider / divider. The divider / divider may divide the internal volume of the chamber and / or the smoking products into a plurality of separate / spaced portions. The divider / divider may define an open air passage through the capsule, e.g., against obstruction such as a blocking of the air passage by the smoking products. The air passage may be centrally located and / or may lead to an outlet of the capsule. The support structure may define an annular internal chamber for containing the smoking products.

[0043] The divider may be configured to divide the internal chamber of the capsule into two or more compartments or cells configured to contain respective portions of the smoking article. The divider may provide a bowl / tray.

[0044] The partitions / cells may be of uniform shape / size. The partitions / cells may be of different shapes / sizes. The partitions / cells may be arranged in a tessellated fashion.

[0045] The support structure may be arranged to separate multiple layers of the smoking article. The layers may be provided horizontally and / or stacked in the height direction of the capsule. The layers may extend vertically. The layers may be parallel. The layers may be separated by further (i.e. non-product-constituting) layers. The further layers are breathable. The support structure may be undulated / corrugated.

[0046] The partition may extend radially (e.g. to provide multiple portions), the partition may only partially traverse the capsule (e.g. partially traverse the height / width of the capsule), the partition may extend between side walls of the capsule, the partition may extend between top / bottom walls of the capsule.

[0047] The support structure may at least partially contain / surround the smoking articles. The support structure may be comprised of a sheet material. The sheet may be flexible. The sheet material may be porous / breathable. A plurality of contained smoking articles may be provided within the capsule. The contained smoking articles may be loosely held within the capsule.

[0048] The support structure may provide a sachet / pouch / package. The support structure may provide a casing / wrapper. The product may be in a roll / coil within the support structure.

[0049] The support structure may be at least partially embedded or covered by the smoking article.

[0050] The support structure may include a hygroscopic material (eg powder / granules).

[0051] The support structure may include a plurality of elongate arms configured to extend into the smoking article to inhibit its movement. The arms may be parallel. The arms may include protrusions to provide an impediment to removal of the product. The protrusions may comprise bards and / or flanges. The arms may be breathable (e.g. porous or mesh). The arms may be hollow. The arms may provide an air passageway. The arms may be connected to a handle so as to be retractable. The arms may form part of a closure for the capsule.

[0052] The support structure is removable or removable from the capsule to leave an air flow path within the smoking article after removal therefrom.

[0053] The support structure is breathable (e.g., porous) and may include one or more of a mesh, a foam, a perforated sheet material, or a woven fabric.

[0054] The support structure may be a number of elements (e.g., inclusions) contained within the capsule. The elements may be beads. The elements may be porous. The elements may be loosely held within the smoking product and / or capsule (i.e., may flow therein). The elements may be inert. The elements may be coated, for example, with the smoking product or another flavourant.

[0055] The inclusions may be metallic and / or electrically conductive. The inclusions may provide an inductive heating element.

[0056] The smoking product may at least partially encapsulate the support structure, with the support structure providing a core over which the smoking product forms a coating.

[0057] The core may comprise an inert inorganic material. The core may be one or more of stone, glass, ceramic, or sand. The core may be a bead.

[0058] The coating may include an organic thickener. The coating may be substantially dry (e.g., non-tacky or viscous).

[0059] Multiple coated cores can be provided, with at least two coated cores separated or constrained by a further support structure.

[0060] The smoking product may be provided in a plurality of discrete portions, each of which may have a different effective surface area of ​​the smoking product. The discrete portions may have different sizes and / or shapes. The discrete portions may have cores of different shapes / sizes. The discrete portions may have coatings on the core of different shapes / thicknesses. The discrete portions may comprise smoking product particulates of different shapes / sizes. The discrete portions may be provided in compartments / cells of different shapes / sizes.

[0061] The smoking article may comprise portions having different cross-sectional areas or different volume to surface area ratios such that different portions of the smoking article are consumed at different rates during heating.

[0062] The overall proportion of vaporized smoking product produced by the capsule may remain within a predetermined range over a predetermined period of use (eg, the amount of vaporized smoking product remains substantially constant over time).

[0063] The ingredients of the smoking article may include one or more of a binder, a mist generating agent, or a flavouring.

[0064] The support structure may comprise a metal, which, when heated for example via the outer wall of the housing, may assist in thermal conduction within the capsule in use to promote a desired temperature profile throughout the capsule interior, an increased thermal contact area between the support structure and the smoking article may be beneficial in this regard.

[0065] Possible embodiments of the present disclosure are described in further detail below, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0066] [Figure 1] FIG. 1 is a perspective view of a capsule in association with a water pipe (e.g., a hookah pipe). [Diagram 2] FIG. 2 is a cross-sectional side view of the capsule. [Diagram 3] FIG. 2 is a top view of the capsule. [Figure 4A] FIG. 2 is a cross-sectional side view of a capsule including a first example of a separator. [Figure 4B] FIG. 13 is a cross-sectional side view of a capsule including an alternative to the first example separator. [Figure 5A] FIG. 13 is a cross-sectional top view of a capsule including a second example of a separator. [Figure 5B] FIG. 13 is a cross-sectional side view of a capsule including an alternative to the second example separator. [Figure 6] FIG. 13 is a cross-sectional top view of a capsule including a third example of a separator. [Figure 7] FIG. 13 is a cross-sectional top view of a capsule including a fourth example of a separator. [Figure 8] FIG. 13 is a cross-sectional top view of a capsule including a fifth example of a separator. [Figure 9] FIG. 13 is a cross-sectional top view of a capsule including a sixth example of a separator. [Figure 10] FIG. 13 is a cross-sectional top view of a capsule including a seventh example of a separator. [Figure 11] FIG. 13 is a cross-sectional top view of a capsule including an eighth example of a separator. [Figure 12] FIG. 2 is a cross-sectional side view of a capsule including a first example of a multi-layer separator. [Figure 13] FIG. 2 is a cross-sectional side view of a capsule including a second example of a multi-layer separator. [Figure 14] FIG. 2 is a perspective view of a first example of a flexible separator. [Figure 15] FIG. 2 is a cross-sectional top view of a capsule including a second example of a flexible separator. [Figure 16] FIG. 13 is a perspective view of a third example of a flexible separator. [Figure 17] FIG. 13 is a perspective view of a fourth example of a flexible separator. [Figure 18] FIG. 13 is a cross-sectional side view of a capsule including a fourth example of a flexible separator. [Figure 19] FIG. 2 is a cross-sectional side view of the enclosed product. [Figure 20] FIG. 2 is a cross-sectional top view of a capsule containing an enclosed product. [Figure 21] FIG. 2 is a cross-sectional side view of a capsule including a first example of a finger-like separator. [Figure 22] FIG. 2 is a cross-sectional top view of a capsule including a first example of a finger-like separator. [Diagram 23] FIG. 13 is a cross-sectional top view of a capsule including a second example of a finger-like separator. [Figure 24] 11A-11C are cross-sectional top views of capsules including second and third examples of finger-like separators. [Diagram 25] FIG. 1 is a cross-sectional view of an article coated on a substrate. [Figure 26] FIG. 2 is a cross-sectional side view of a capsule containing a coated substrate. [Figure 27] 1 is a first graph showing bead size distribution. [Figure 28] 2 is a second graph showing bead size distribution. [Figure 29] 1 is a graph showing smoking intensity curves for different bead sizes. [Diagram 30] FIG. 2 is a cross-sectional side view of a capsule containing a first example of a coated product. [Diagram 31] FIG. 2 is a cross-sectional side view of a capsule containing a second example of a coated product. [Diagram 32] FIG. 2 is a cross-sectional side view of a capsule containing a first example of an inclusion-containing product. [Diagram 33] FIG. 13 is a cross-sectional side view of a capsule containing a second example of an inclusion-containing product. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0067] Figure 1 shows an example of a water pipe 2, referred to herein as a hookah device, although it should be understood that the pipe may alternatively be referred to as a shisha pipe. The hookah device 2 in this embodiment is electrically heated and / or electronically controlled.

[0068] The hookah 2 includes a base 4, an electronics compartment 6, and a tank 8 for filling with a liquid coolant (eg, water). The device 2 can be supported by the wide base 4.

[0069] The electronics compartment 6 includes a lid 12 providing an opening thereto. The electronics compartment 6 is fitted with a heater 10 (shown diagrammatically) configured to receive a capsule 14 containing a smoking product. The heater heats the capsule 14 to vaporize or otherwise dissipate one or more components of the smoking product. The capsule 14 is provided with a number of openings 16 to allow the vaporized product to escape therefrom. The heater is controllable by electronics within the electronics compartment 6. A power switch 18 or the like may be provided.

[0070] The heater is connected to the tank 8 via a conduit 15 which passes through the electronics compartment 6. The vaporized smoking product then passes from the conduit 15 through the coolant in the tank 8 where it is cooled and / or filtered.

[0071] A suction hose 20 communicates with the tank 8 above the coolant level and includes a mouthpiece 22. The user can then inhale the vaporized product through the device 2 and through the hose 20. Such a system resembles a conventional non-powered shisha / hookah pipe. Air can be drawn through the heated capsule, with the vaporized product within the capsule being carried away by the airflow through the conduit.

[0072] It will be appreciated that the device 2 shown in Figure 1 is merely exemplary and any suitable such device may be used. In some embodiments, the electronics housing 6 may be located below the coolant tank 8 such that vaporized smoking product passes upwardly through the device 2 during use. The electronics housing 6 may thus form the base of the device 2. A conduit 15 may extend from the heater upwardly into the coolant to deliver vaporized product thereto.

[0073] Examples of suitable hookahs 2 and associated heaters 10 are described in previously published patent applications WO2017 / 080545(A1) and WO2015 / 172224(A1), and such details will not be repeated here for the sake of brevity.

[0074] 2, the capsule 14 comprises a top wall 24 and a bottom wall 26. The top wall 24 and the bottom wall 24, 26 are connected by a side wall 28, e.g., a continuous side wall. The top, bottom and side walls thus provide an enclosure / cavity for the smoking article 30.

[0075] A plurality of openings 16a, 16b are provided in each of the top wall 24 and bottom wall 26. During use, air 32 enters or passes through the smoking article 30 through the openings in the top wall 24. When heated during use, the air 32 entrains vaporized product 34 within the capsule 14 and exits through the openings in the bottom wall 26.

[0076] Such an arrangement provides a prepackaged or prefilled capsule. Although the openings 16a, 16b are shown in this example as spanning the entire width of the top and bottom walls 24, 26, it will be understood that the openings could be provided in only a portion of the top and / or bottom walls 24, 26, if desired, as shown in FIG.

[0077] It should be understood that the terms "top", "bottom" and "side" are used merely to aid in describing the capsule, and that the capsule can be in any suitable orientation when in use.

[0078] In some embodiments, the openings 16 may be provided in only one of the top wall 24 and the bottom wall 26. Thus, air enters and exits through the same openings 16. In some embodiments, the openings 16 may also be provided in the side walls 28.

[0079] In some embodiments, the device 2 is configured to puncture, perforate or otherwise open the capsule 14 to allow air to enter or exit. The capsule 14 can therefore be sealed before opening, which helps to preserve freshness. It is also possible to puncture the top wall with a suitable shape of the lid 12 and / or the bottom with the end of the smoke conduit 15. Thus, the opening does not have to be formed at the time of manufacture, but can be formed during use of the capsule.

[0080] The capsule 14 may include a seal to cover the opening 16. The seal is removed prior to use to expose the opening 16. The seal thus aids in maintaining freshness. The seal may be provided on the top / bottom / side surfaces as appropriate. The seal may be attached to the capsule 14 using a removable adhesive or the like.

[0081] In some instances, the entire capsule may be held in a sealed pouch or sleeve (with or without one or more seals covering the opening 16) to provide a retail product that allows the capsule to remain fresh for extended periods of time. The pouch may be filled with a gas (e.g., other than air), such as nitrogen. Thus, either the capsule or the pouch, or both, are filled with gas to facilitate preservation of the smoking product therein until use. Even if the capsule itself is filled with air, it has been found that filling the pouch with a suitable gas is sufficient in some cases, such as when the gas in the pouch and the air in the capsule mix over time, resulting in a low overall oxygen content in the pouch.

[0082] The top surface 24 may include a closure 35 (e.g., a lid) which allows the product 30 to be placed within the capsule 14. The opening 16a may or may not be provided in the lid 35. The closure 35 is then secured to the capsule (i.e., to the top of its sidewall 28) to retain the product 30 therein. The closure may be permanently secured to the capsule 14 to prevent the product 30 from being removed therefrom. For example, the closure 35 may be pressed or adhered to the capsule 14. The top of the sidewall may include a flange for this purpose.

[0083] In other embodiments, the closure 35 is removably connected to the capsule 14, thereby allowing a user to access the interior of the capsule 14 (i.e., to refill the capsule 14). The closure 35 can be connected to the capsule by a releasable connecting means, which can be one or more of an interference fit, a snap fit, threads, a removable latch or clip, a clamp, a hook-and-loop fastener, a press stud, a bayonet, and the like.

[0084] In this embodiment, the bottom surface 26 is integrally formed with the capsule 14 (i.e., integral with the sidewall 28). The opening 16b is thus formed in the capsule 14. In alternative embodiments, the bottom surface 26 may include a permanent / removable seal.

[0085] 1 to 3 has an upper wall 24 that is larger in planar area than a bottom wall 26, giving the capsule a tapered shape. The capsule 14 tapers toward the bottom wall 26. The capsule 14 therefore has a trapezoidal cross section (when viewed from the side).

[0086] As shown in Figure 3, the capsule 14 has a circular shape (when viewed from above). The capsule 14 is therefore frusto-conical in shape. However, it will be understood that the shape of the capsule 14 is merely exemplary and the capsule may have any suitable shape for the intended purpose. The capsule can be provided with different shapes to achieve the desired contact with the interior of the device 2, for example a shape that provides close and / or good thermal contact with the heater 10. For example, capsules that are oval or polygonal in plan are also applicable.

[0087] The capsule 14 comprises a heat-resistant material. The capsule 14 is therefore stable at the heating temperature of the device 2. The capsule 14 comprises a metallic material, for example aluminum. The metallic material ensures sufficient heat conduction to the capsule. In other embodiments, the capsule 14 may comprise a ceramic material.

[0088] Product 30 includes a chemically inert filler that does not melt or degrade at temperatures equal to or less than the temperatures at which tobacco or tobacco substitutes are typically heated in a water pipe, and thus the filler does not melt / burn / decompose at temperatures below 250°C, more preferably below 300°C, more preferably below 350°C, and more preferably below 400°C.

[0089] The presence of the filler may or may not impart a sparkly appearance to the product. The inert filler may include inorganic or mineral fillers.

[0090] In some embodiments, the inert material comprises a non-crystalline amorphous material, such as glass. Glass includes silica (SiO 2 The glass may include one or more of fused quartz (also known as fused silica or vitreous silica), soda-lime-silica glass, sodium borosilicate glass, lead oxide glass, foam glass, or aluminosilicate glass.

[0091] In some embodiments, the inert material comprises a mineral. For example, minerals include silica, limestone (calcium carbide), feldspar (tectosilicate mineral), gypsum, magnetite (Fe 3 O 4 ), chlorite ((Mg,Fe) 3 (Si,Al) 4 O 10 (OH) 2 (Mg,Fe) 3 (OH) 6 ), glauconite ((K,Na)(Fe 3+ ,Al,Mg) 2 (Si,Al) 4 O 10 (OH) 2 ), or alumina.

[0092] In some embodiments, the inert material includes stony / rock material (i.e., a naturally occurring substance that includes one or more minerals or mineraloids). For example, stony material may include one or more of granite, basalt, marble, quartz, pumice, obsidian, jet, biotite, etc.

[0093] In some embodiments, the inert material may include a ceramic. The ceramic may be semi-crystalline, vitrified, or amorphous. The ceramic may be clay and / or alumina based.

[0094] In some embodiments, the inert material comprises one or more of activated carbon powder, graphite powder, graphene, carbon fiber, and the like.

[0095] In some embodiments, the inert material may include an aggregate or composite of one or more inert materials. For example, the inert material may include a cementitious material or a mixture of a liquid phase material and a solid phase material (e.g., a granular material).

[0096] In some embodiments, the interfill may include sand or granules (e.g., crushed or fine particles). The sand may include particles of one or more of the materials listed above. The average particle size of the granules is such that the fill has a granular / sand-like consistency and does not become suspended particles in the air like fine particles such as powders or dust. This can reduce health risks associated with fine powders.

[0097] The granules may have an average diameter of less than 2 mm, preferably less than 1.5 mm, more preferably less than 1 mm. The granules may have an average diameter of between 0.0625 mm and 2 mm, preferably between 0.125 mm and 2 mm, more preferably between 0.25 mm and 1 mm.

[0098] The product 30 comprises an absorbent binder. The absorbent binder comprises a powdered material. The powdered material comprises fine particles. The particles may be finer than the inclusion particles. The absorbent binder thus has a high specific surface area. The absorbent binder particles may have an average diameter of less than 200 μm, preferably less than 100 μm, more preferably less than 80 μm. The absorbent binder particles may have an average diameter of between 2.5 μm and 100 μm, preferably between 5 μm and 60 μm.

[0099] Without being bound to any particular theory, it is believed that the absorbent binder stabilizes the product, presumably by binding the granules to the other components of the product and absorbing liquids that may be present in the paste-forming ingredients. The result is a blend that is free of fluid residues such as liquids or syrups, and is also heat resistant, in contrast to gels, which melt upon heating due to their inherently unstable structure.

[0100] The absorbent binder comprises an inorganic / mineral material. The absorbent binder may be silica. The absorbent binder may be "fumed silica". Fumed silica comprises a powder material also known as pyrogenic silica, which is made by fusing primary particles of amorphous silica into branched, chain-like, three-dimensional secondary beads that are then agglomerated into tertiary beads. The three-dimensional structure and large surface area of ​​fumed silica are believed to make it an excellent binder in paste formulations. Fumed silica has a density of 50 to 400 m 2 / g. In other embodiments, the silica comprises amorphous silica.

[0101] The binder may include one or more of talc powder, gypsum powder, or other inorganic or mineral powder.

[0102] The product 30 includes a mist generating agent configured to generate a visible cloud upon heating to simulate tobacco smoke. The mist generating agent includes a volatile material configured to provide a light scattering cloud in a vaporized state.

[0103] The mist generating agent includes a polyol. The polyol may include one or more of glycerin, 1,2-propylene glycol, 1,3-propylene glycol, 1,2-butylene glycol, 1,3-butylene glycol, 1,4-butylene glycol, 2,3-butylene glycol, 1,2,4-butanetriol, triethylene glycol, triacetin, mannitol, sorbitol, xylitol, inositol, isosorbide, polydextrose, or dianhydro-D-glucitol. The polyol may include a "sugar alcohol" (hydrogenated sugar).

[0104] The product 30 may include a sweetener. The sweetener may include a carbohydrate sweetener (e.g., a monosaccharide having 5 or 6 carbon atoms), such as one or more of arabinose, xylose, ribose, glucose, mannose, galactose, fructose, dextrose, or sorbose. The sweetener may include a disaccharide, such as one or more of sucrose, such as cane sugar or beet sugar, lactose, maltose, or cellobiose. The sweetener may include one or more polysaccharides, such as one or more of partially hydrolyzed starches or dextrins; polyols, such as sorbitol, mannitol, xylitol; and mixtures of one or more of the above sugars.

[0105] In some embodiments, the sweetener comprises high fructose corn syrup (also known as glucose-fructose isomerase and glucose-fructose syrup).

[0106] In some embodiments, the sweetener comprises an artificial sweetener, which may include one or more of sodium, calcium or ammonium saccharin salts, dihydrochalcones, rebaudiosides, mogrosides, glycyrrhizin, dipotassium glycyrrhizin, ammonium glycyrrhizinate, L-aspartyl-L-phenylalanine methyl ester (aspartame), sodium or potassium salt of 3,4-dihydro-6-methyl-1,2,3-oxathiazin-4-one-2,2-dioxide (acesulfame-K), stevioside (Stevia rebaudiana) extract, miracle berry (Richardella dulcifica) extract, or serendipity berry (Dioscoreophyllum cumminsii) extract.

[0107] It will be understood that any of the sweeteners described above may be combined with any of the other sweeteners or types of sweeteners described above.

[0108] The product 30 includes a flavoring agent, which may include one or more of mints such as peppermint or spearmint, chocolate, licorice, citrus or other fruit flavors, gamma-octalactone, vanillin, or a breath freshener flavor, among others. The aforementioned sweeteners may include one example of a flavoring agent, although it is common for both a sweetener and additional flavoring agents to be provided.

[0109] The flavoring may include one or more spice flavorings, such as cinnamon, methyl salicylate, linalool, bergamot oil, geranium oil, lemon oil, or ginger oil. The flavoring may include a plant extract or essential oil. The flavoring may include one or more food-based flavorings, such as apple flavoring, blueberry flavoring, coconut flavoring, grape flavoring, guava flavoring, pomegranate flavoring, or lemon flavoring. The flavoring may have a fruit or vegetable flavor. The flavoring may include one or more acids, alcohols, esters, aldehydes, ketones, or pyrazines.

[0110] The product 30 may include, for example, a flavoring thereof, a stimulant that may have a stimulating effect on the central nervous system and induce wakefulness in the subject, and may include one or more of caffeine (1,3,7-trimethylxanthine), taurine (2-aminoethanesulfonic acid), theobromine (3,7-dimethylxanthine), or derivatives thereof.

[0111] In some embodiments, the stimulant is provided by a plant-derived extract that forms part of the flavoring. The plant extract may include one or more of coffee, black tea, green tea, matcha, yerba mate, cola nut, cocoa, ginseng, guarana, or cannabinoids such as tetrahydrocannabinol (THC) or cannabidiol (CBD). In other embodiments, the stimulant may include an additive that is added in addition to the flavoring. For example, a coffee flavoring may be enhanced with the addition of caffeine.

[0112] The product 30 may include colorants. The colorants can provide a colored product 30 and / or smoke. Colorants include food, drug, or cosmetic safe colorants. Colorants include water-soluble colorants. Colorants include plant-derived colorants, such as one or more of beet juice, brazilwood, caramel, carminic acid, litmus, logwood, orthyl, or saffron. In some embodiments, the colorants include artificial colorants.

[0113] In some instances, one or more solvents may also be present, such as when one or more components are added to the mixture in the form of a liquid solution. If advantageous, for example to promote the formation of a uniform, homogeneous paste, a quantity of pure solvent or combination of solvents may be added during the formation of the mixture or during further steps such as kneading or manipulation into capsules.

[0114] The inert filler may comprise less than 25 wt% of the weight of the product 30, preferably less than 20 wt%, and more preferably less than 15 wt%. The inert filler may comprise between 5-25 wt% of the weight of the product 30, preferably between 5-15 wt%.

[0115] The absorbent binder may comprise less than 25 wt% of the weight of the product 30, preferably less than 20 wt%, and more preferably less than 15 wt%. The absorbent binder may comprise between 5-20 wt% of the weight of the product 30, preferably between 5-15 wt%.

[0116] The mist generating agent may comprise less than 80 wt%, preferably less than 70 wt%, and more preferably less than 60 wt% by weight of the product 30. The mist maker may comprise more than 20% or 30% by weight of the product, for example between 20-70 wt%, and more preferably between 40-60 wt% by weight of the product 30.

[0117] The sweetener may comprise less than 40 wt% by weight of the product 30, preferably less than 35 wt%. The sweetener may comprise between 15 wt% and 40 wt% by weight of the product 30, more preferably between 15 and 3 wt%.

[0118] The fragrance may comprise less than 20 wt% by weight of the product 30, preferably less than 15 wt%. The fragrance may comprise between 5-15 wt% by weight of the product 30, more preferably between 2-10 wt%.

[0119] The colorant may comprise less than 0.1 wt% of the weight of the product 30, preferably less than 0.05%. The colorant may comprise between 0.01-0.05 wt% of the weight of the product 30, more preferably between 0.01-0.03 wt%.

[0120] The composition of the product 30 can provide a paste-like smoking product. The product can thus be a semi-solid or highly viscous liquid. The paste can be dispensed into capsules to facilitate easy handling during manufacture or storage.

[0121] The paste may have a viscosity (at standard conditions) of more than 100 Pa·s or 300 Pa·s, preferably more than 500 Pa·s. The paste may have a viscosity between 100 and 3000 Pa·s, preferably between 500 and 2000 Pa·s.

[0122] Unlike conventional gel-based tobacco substitutes, the paste is heat resistant and will not melt or lose its shape when exposed to temperatures typically generated in water pipes. Thus, the paste is temperature stable. The paste will not melt when exposed to temperatures below 200°C or 250°C.

[0123] These attributes make the paste easier to handle and greatly reduce the volume of liquid that may be present during heating. Thus, a wide variety of water pipe heater jars or capsules can be used. The paste can also be free or substantially free of combustible materials, thus preventing the formation of toxic combustion products that normally result from burning combustible materials such as tobacco. Different colorants and flavorants can be included to obtain an assortment to suit the tastes of all types of consumers.

[0124] The particular composition of the paste offers many advantages. When heated to a temperature suitable for smoke production in a water pipe, the paste releases the mist generating agents, sweeteners, and flavorings in the smoke produced by the water pipe without dissolving. In some embodiments, when exposed to temperatures typical of a water pipe, the paste releases the mist generating agents, sweeteners, and flavorings and degrades into a dry residue rather than melting. If melting or partial melting of the paste occurs, it occurs only after the heat-induced release of the mist generating agents, sweeteners, and flavorings has begun. Without being bound to any particular theory, it is believed that the absorbent binder stabilizes the paste, possibly by binding the granules to the other components of the product and by absorbing liquids that may be present in the ingredients that form the paste. The result is a blend that is generally free of fluid residues such as liquids or syrups, and is also heat resistant. This is in contrast to gels, which melt upon heating due to their inherently more unstable structure.

[0125] In a second aspect, a method is provided for producing capsules containing such pasty smoking products for presentation to consumers, where the ingredients of the paste, including inert granules, absorbent binder, sweetener, and flavorant, are mixed together and then dispensed into capsules using a support structure of the type described herein to provide a paste of consistent shape / form.

[0126] In one embodiment, the ingredients are mixed at room temperature, although mild heating may be used if appropriate for good or rapid mixing. Excess solvent, which may give the paste a wet or syrupy feel, can be removed by standard methods such as airing. Advantageously, the paste can be stored in a soft, flexible packaging and dispensing pump, making it more convenient, less messy, and easier to construct than traditional gels.

[0127] An example of a paste is shown below.

[0128] Several pastes were formed by mixing the ingredients at room temperature in relative amounts within the following ranges: [Table 1]

[0129] The glycerin paste had a specific gravity of 1.2612 g / ml at 25°C, a maximum water content of 0.3%, and a minimum glycerin content of 99.7%. The fumed silica had a pH of 3.8–4.3 and a BET surface area of ​​175–225 m 2 It is characterized by a pH of 3.3-4.5, an acidity of up to 4 ml, a dry matter content of 76.8-77.4%, and a refractive index of 1.4774-1.4798 at 20°C. The fructose color was up to 20 on the ICUMSA (International Commission for Uniform Methods of Sugar Analysis) grading method. The fructose content of the aqueous solution was between 74.80 and 75.80 on the degree Brix (°Bx) scale.

[0130] Samples of each paste were tested by heating them in a water pipe to a temperature of approximately 300° C. In all cases, the paste maintained its shape and did not melt when heated, and when subjected to the intake of air released an aerosol containing fructose, glycerin and flavourings.

[0131] A sample of one of the pastes was then analyzed using the rotational viscometer of the rheometer. The composition of the test paste was as follows: [Table 2]

[0132] The rheometer was first validated using ASTM D15000 oil (41.1 °C), which was selected as a standard because it has a similar viscosity to the samples. On each day of analysis, the instrument setup was successfully validated using the standard oil and a 25 mm plate-plate configuration, with deviations from the established viscosity of the standard oil of less than 4%.

[0133] The viscosity of the paste samples was measured by shear rate sweep in a 25 mm plate-plate configuration with a 1 mm gap at 25.0 °C. The shear ramps were 10, 18.8, 32.6, 56.9, and 100 s, respectively. -1 The shear rate was 1.0 s. This analysis was performed in duplicate. The results are shown below. [Table 3]

[0134] The samples are shear thinning and non-Newtonian fluids, which causes the paste to flow more easily during application but become stationary after application.

[0135] Product 30 is substantially free of tobacco and / or nicotine, and therefore may provide a healthier alternative to conventional products.

[0136] In some embodiments, the product 30 is a product that contains nicotine (or a derivative thereof). The product 30 may also contain tobacco. The product may include a tobacco substitute (e.g., an organic matrix).

[0137] In some embodiments, the product 30 may include a traditional shisha or tobacco product (e.g., shisha or Mu'assel). The product 30 may be a tobacco product that includes sugar syrup (e.g., molasses). The product 30 may include glycerol or other mist generating agents. The product may include flavorings and / or other additives. The product may thus be a mixture of tobacco or other plant-derived smoking product and any other components previously described, providing the smoking product as a mixture of solid and liquid components, e.g., a wet mass.

[0138] The capsule 14 includes an internal structure for the smoking article, referred to herein as a separator or support structure, configured to at least partially divide, separate, space or maintain a desired surface area of ​​the smoking article. The separator may help control the distribution / uniformity of the smoking article within the capsule and / or allow for the division of the product into multiple, at least partially spaced or separated portions, which may provide one or more of several possible advantages. Preventing the product from clumping together, e.g. during handling or transport. Increases the specific surface area of ​​the product, thereby improving the quantity / quality of smoke produced during use. Adapting the volume to surface area ratio of the product in the capsule to achieve the desired intensity and / or duration of experience for the user when applying the heating regimen with an electric heater. · Providing air passages into / through the product to increase contact with the product.

[0139] In some embodiments, the support structure may confine the smoking article only partially within the capsule interior. The support structure may partially fill the capsule, for example filling an upper and / or lower portion of the capsule interior. The support structure may define air passages, for example to ensure adequate air flow and / or pressure drop through the capsule in use.

[0140] In some embodiments, the separator / support structure includes breathable members or spacing members that form air passageways therebetween. The breathable nature of the support structure can provide product separation and increased airflow within the capsule. Such a configuration can be beneficial when the product 30 includes a liquid or semi-liquid (e.g., a paste) and the breathable member acts as a substrate to distribute and / or separate the product 30.

[0141] In some embodiments, the breathable member comprises a mesh. The mesh may be woven or non-woven. The mesh may be metallic. Metallic mesh can be constructed of food-safe metals. The mesh may be a fine mesh (e.g., <1 mm) to prevent particle penetration. Alternatively, the mesh may be a coarse mesh (e.g., >1 mm) to increase flow through the capsule 14.

[0142] In some embodiments, the breathable member comprises a foam. The foam may be a porous foam and / or an open-cell foam. The foam may be composed of a high temperature (e.g., above 200° C.) resistant material. The foam may be composed of an inorganic foam, such as one or more of a porous glass (e.g., pumice), a porous ceramic, and a porous mineral (e.g., zeolite).

[0143] The foam may comprise a rigid / hard material. In alternative embodiments, the foam may be flexible or deformable / pliable.

[0144] In some embodiments, the breathable member may include a paper-based material. The paper-based material may include parchment paper, baking paper, etc. The paper-based material may include card, cardboard, etc.

[0145] Breathability may be provided by the inherent properties of the breathable member material (e.g., mesh or foam). Alternatively, if the breathable member material is non-permeable or has low permeability (e.g., paper), openings, grooves, depressions, etc. may be provided to enhance air permeability. For example, a paper-based material may include a plurality of perforations (e.g., arranged in an array).

[0146] In some embodiments, the permeability of an inherently breathable material can be enhanced / modified by providing openings, grooves, depressions, and the like.

[0147] The breathable member may be configured to burn, decompose, or otherwise degrade during heating of the capsule, which may improve air flow or product flow during use of the capsule, or the breathable member may not degrade during use and remain substantially intact even after use.

[0148] A first example of a breathable / porous member 36 is shown in Figure 4A. In a specific example, the breathable member 36 comprises a mesh. The breathable member 36 extends along the bottom surface 26 and sidewall 28 of the capsule 14. The breathable member 36 thus provides a bowl or basket-like arrangement. The breathable member 36 may substantially conform to the shape of the capsule 14 (i.e., extend across the entire height / width of the capsule 14).

[0149] The product 30 may simply rest on the breathable member 36. If the product 30 is of a more liquid or semi-solid composition, the product may spread at least partially onto the breathable member 36. The product 30 may thus at least partially cover and / or penetrate the breathable member (e.g., filling gaps in the mesh).

[0150] The breathable member 36 may be loosely held in the capsule 14. Movement of the breathable member 36 can be prevented by sealing it against the capsule wall. Alternatively, the breathable member 36 is fixed.

[0151] In some embodiments, there may be no bottom of the breathable member 36. The breathable member 36 may thus be a frustoconical ring.

[0152] The capsule 14 includes a divider 38 configured to divide the product 30 into separate portions 30a, 30b and / or increase its surface area. The divider 38 extends from the bottom surface 26 towards the top surface 24. The divider 38 may extend substantially the entire height of the capsule 14. In this manner, the product 30 is divided into discrete portions 30a, 30b. The divider may thus provide a baffle or the like.

[0153] The breathable member 36 and / or the divider 38 have a substantial thickness. The breathable member 36 and / or the divider 38 therefore provide a fluid passageway through / into the product, thus allowing increased airflow within the capsule 14.

[0154] In Fig. 4B an alternative example is shown in which the support structure defines a central flow passage 37 through the interior of the capsule, for example towards the capsule outlet or between the inlet and the outlet. The support structure can define an enclosure for the smoking article that is annular in shape. In this example, the partition 38A itself can be annular, for example separating the central flow passage from the outer space of the smoking article. The partition 38A can be porous or not in this example, since the desired flow through the capsule is ensured by the flow passage 37 rather than requiring flow through the wall of the support structure. The base of the support structure can be present or absent, for example since the partition is formed by the molded inner wall of the capsule. Thus, the side walls and floor of the capsule can be integral with the partition 38A, for example the partition can be an extension of the base / floor of the capsule.

[0155] In the example of Figure 4B, the partition wall 38A terminates a distance below the top surface 24 of the capsule. This allows some head space to allow air to enter the capsule interior and mix with the gas / vapor within the capsule before exiting the capsule through the flow passage 37.

[0156] In various embodiments, the capsule 14 may include multiple compartments. In the embodiment shown in Figures 5A and 5B, multiple compartments 38 are provided to define multiple compartments 40a-40f for containing respective products 30 therein.

[0157] The dividers 38 extend radially (i.e. from a central point in FIG. 5A). The dividers 38 thus provide a spoke-like arrangement. The compartments are therefore sector-shaped. Any number of dividers 38 may be provided to divide the capsule 14 into any number of portions. For example, 110 dividers may be provided to provide between 2 and 10 portions. The dividers help to prevent the smoking products within the capsule from congregating into a single mass within the capsule.

[0158] In the example of FIG. 5B, the radial partition 38 terminates in an annular partition wall 38 that defines a flow passage 37 through the capsule.

[0159] A third example of a support structure or breathable member 36 is shown in Figure 6. In this example, the dividers 38 are provided in a parallel arrangement. The dividers 38 thus define a plurality of elongated compartments 40. The dividers 38 may be equally spaced apart. In other embodiments, the dividers 38 may be arranged such that each compartment 40 is of equal volume.

[0160] A fourth example is shown in Figure 7. In this example, the dividers 38 are arranged in a grid. The dividers 38 thus define a number of cells 42. The number of dividers 38 in one direction (e.g. left to right) may be different from the number of dividers in a second orthogonal direction (e.g. up and down the page). This can provide elongated cells. In other embodiments, the cells 42 may be equally divided (e.g. to provide square cells or cells with a more uniform area).

[0161] In some embodiments, the cells 42 may be substantially the same shape / dimension. For example, the cells 42 may be arranged in a hexagonal array, as shown in Figure 8. Each cell 42 may thus comprise a hexagonal shape.

[0162] In some embodiments, the cells 42 may be of different shapes / sizes. For example, as shown in Figure 9, the cells include triangular cells 42a and arcuate cells 42b.

[0163] In some embodiments, the cells 42 may be random and / or irregularly shaped.

[0164] In some embodiments, the dividers 38 only partially extend laterally through the capsule (i.e. only partially extend between the capsule side walls 28). The dividers 38 therefore only partially divide the smoking article 30. For example, as shown in FIG. 10, a plurality of dividers 38 extend radially inward from the capsule side walls 28. The dividers thus provide a cross-hair like arrangement. A central divider 38A may or may not be provided in different embodiments.

[0165] In some embodiments, the dividers or support members may be arranged in a configuration / pattern that has rotational symmetry about the axis / center of the capsule.

[0166] In some embodiments, the partial divider 38 may be spaced apart from the sidewall 28. In some embodiments, multiple partial dividers 38 may be combined. For example, multiple dividers 38 may be spaced apart from the sidewall 28 (e.g., in the center of the capsule 14) to provide an X-shaped divider.

[0167] In some embodiments, the partition 38 may only extend partially along the height of the capsule 14 (i.e. only partially between the top and bottom surfaces 24, 26). As shown in Fig. 11, the partition 38 does not extend the entire distance to the top and bottom surfaces 24, 26. The partition 38 may thus be fixed directly to the capsule wall 28. Thus, a gap 44 is provided between the partition and the top / bottom surface respectively. Such an arrangement may be beneficial if some spreading of the product 30 is required during smoking (e.g. if the product 30 is liquid / semi-solid).

[0168] 9 shows a gap 44 between the partition 36 and the top / bottom surfaces, respectively, it will be appreciated that the gap 44 may be between only one of the top surface 24 or bottom surface 26 and the partition 36. The spacing from the top or bottom of the top surface 24 and / or bottom surface 26 of the capsule can provide a plenum / manifold zone for mixing of gases / vapors in use.

[0169] In some embodiments, the partition 38 may extend only a portion of the height of the capsule 14 at selected portions. Thus, the gap 44 may be provided in one or more discrete portions. Such an arrangement may provide a "window" that allows a selected amount of product to flow within the capsule 14. The gap 44 may be located adjacent to and / or at a distance from the top / bottom surfaces.

[0170] In some embodiments, the dividers 38, 38A may be air impermeable (i.e., continuous) in shape. The dividers 38 thus function to divide the product 30 into separate portions. The impermeable dividers 38 may be arranged in substantially the same manner as the permeable dividers described thus far.

[0171] The impermeable partition 38 may be integrally formed with the capsule 14. This may be beneficial when the capsule 14 is a moldable material (such as plastic) or a malleable material (such as aluminum or other metal).

[0172] In alternative embodiments, the impermeable divider 38 may be comprised of a discontinuous member. The impermeable divider 38 may be secured to the capsule using a suitable technique (e.g., welding or adhesives). In some embodiments, the divider 36, 46 may be retained in the capsule 14 by an interference fit or a tight / friction fit. In any of the embodiments of Figures 4-10, the divider may be provided by an insert member 36 or may be attached to the capsule wall as a structural part of the capsule body.

[0173] In some embodiments, the non-permeable divider 38 may be loosely held within the capsule 14, although a tight fit with the capsule 14 / product 30 ensures that the divider 38 is held in place. The divider 38 is removable. The divider 38 may be removable before or after use for recycling or refilling. The divider 38 may be attached to a lid or the like for convenient removal. When the insert 36 is removable from or loosely inserted within the capsule interior, it may be referred to as a cage-like inert for the capsule.

[0174] As shown in FIG. 12, the breathable member 36 can extend across the capsule (i.e., between the side walls 28). In a specific embodiment, the breathable member 38 comprises a foam, gauze, wool-like material, or the like. The product 30 is placed on top of the breathable member 36. A further breathable member 38 may then be placed on top of the product 30. The product 30 is thus sandwiched between multiple breathable members 36, 38. This procedure is repeated to provide a layered arrangement, which alternates between products 30 and breathable members 38 (e.g., forming a lasagna-like arrangement). The layers may be substantially parallel.

[0175] The layers may be parallel to the top surface 24 and / or bottom surface 26. Air can therefore penetrate vertically through the layers 36.

[0176] The top and / or bottom of the layered arrangement may comprise a breathable member 36. This may prevent the product from leaking out of the capsule 14.

[0177] 13, in some embodiments of the layered arrangement, the product 30 can be supported on a carrier 46. The carrier 46 in turn rests on / supports the breathable member 38. This arrangement can provide a number of advantages. · It can assist with inserting the product into the capsule 14 during production. Separating products, increasing their surface area and / or preventing settling. -Prevents the product from being crushed by upper layers.

[0178] The carrier 46 is comprised of an undulated / corrugated sheet. The undulations thus define a number of compartments 48 for the products 30. Thus, the carrier 46 divides the products 30. In a specific example, the carrier comprises a paper-based material.

[0179] In some embodiments, the carrier 46 can include a tray-like arrangement (i.e., including a base and side walls) such that the product can be contained within the tray. The tray can include one or more dividers to divide the tray into multiple compartments.

[0180] In some embodiments, the carrier 46 may comprise a plate or sheet-like (ie, substantially flat) arrangement.

[0181] In some embodiments, one or more layers of product 30 may be separated by spacers. Spacers may include posts, pedestals, spires, columns, tables, etc. Product 30 may be provided in a tiered structure.

[0182] As shown in Figure 14, the breathable member 36 may be a flexible sheet 48. The flexible sheet 48 may include a plurality of perforations 50 or the like to allow air to flow. The flexible sheet 48 may be an elongated strip. The product 30 is deposited onto the flexible sheet 48. The flexible sheet 48 is shaped to provide a separator / support for the product.

[0183] The perforations may have dimensions (e.g. diameter / width) of 0.2mm to 5mm, preferably 0.2mm to 2mm, preferably 0.2mm to 1mm, preferably 0.5mm to 1mm. The perforations may have dimensions of 0.2mm or more, preferably 0.5mm or more. The perforations may have dimensions of 5mm or less, preferably 2mm or less. The perforations may be spaced 5mm or more apart, preferably 100mm or more apart.

[0184] The product may be deposited in a linear fashion on flexible sheet 28 (as shown in FIG. 15). In some embodiments, the product may be provided in a wavy fashion (e.g., in a zigzag pattern) across the surface of flexible sheet 28.

[0185] In some embodiments, product 20 may be provided as a layer over part or the entire surface of flexible sheet 28. Product 30 may thus provide a covering or partial covering. The covering may be provided on one or both sides of flexible sheet 28. In instances where product 20 is applied as a layer or partial layer, the product may have a layer depth of between 1 and 10 mm, for example 1 and 5 mm.

[0186] A first embodiment of a flexible sheet arrangement is shown in Figure 15. The flexible sheet 48 is rolled onto itself into a spiral shape. The product 30 is thus spiralled in this way (i.e. in concentric spirals). This arrangement provides a "Swiss roll" type arrangement. The spiral arrangement is then placed within the capsule 14. The spiral arrangement is positioned such that the side edges 52 of the sheet surface face the top and bottom surfaces 24 and 26, respectively, of the capsule 14. This allows air to flow across the flexible sheet 48 during use.

[0187] 15, flexible sheet 48 is loosely rolled, which allows gaps 54 between the rolled layers. Gaps 54 may increase airflow therethrough. In other embodiments, flexible sheet 38 may be tightly rolled, with adjacent layers contacting each other.

[0188] Although a single helical arrangement is shown, it will be appreciated that any number of individual helices may be provided.

[0189] In some embodiments, flexible sheet 48 is configured to at least partially encase products to provide individual packets or the like.

[0190] A first embodiment is shown in Figure 16. Flexible sheet 48 comprises a hollow cylinder. Product 30 is placed within the hollow cylinder. This arrangement forms a pellet or "cannoli" like arrangement. The cylinder has an open end 56, so that the product is only partially enclosed and allows air to pass through.

[0191] A plurality of pellets are provided within each capsule 14. The cylindrical sheet thus acts as a separator for the individual portions of product 30.

[0192] In some embodiments, the flexible sheet 48 may be cone-shaped, with the product 48 provided inside the cone in a "cream horn" like arrangement.

[0193] A second embodiment is shown in Figures 17 and 18. As shown in Figure 18, the product 30 is sandwiched between two portions of flexible sheets 48a, 48b. The portions 48a, 48b are sealed at their respective edges 58 to form a pouch 60 or the like. The product 30 is fully packaged to provide a "ravioli" like arrangement. Multiple pouches can be provided in the capsule 14. Gaps naturally form between the pouches to allow air flow.

[0194] Flexible sheets 48a, 48b can be configured to accommodate the depth of product 30. For example, one or both of sheets 48a, 48b can include a recess 62 or pocket to accommodate product 30. In other embodiments, the flexibility / stretchability or folding of sheet 48 accommodates product 30.

[0195] In some embodiments, the sheet portions 48a, 48b are formed from separate sheets 48. The sheets 48a, 48b are then joined together to enclose the product 30. Multiple product portions may be provided on the sheet 48a in a spaced apart arrangement. A second sheet 48b is placed over the first sheet 48a to enclose the multiple products. Individual pouches are then formed by cutting between the portions.

[0196] In other embodiments, the sheet portions 48a, 48b may be formed from a single piece of material (i.e., by folding over on itself), it being understood that such an arrangement may be utilized to provide multiple products as previously described herein.

[0197] 18 is square / cubic in shape, it will be appreciated that the pouch 60 may be any suitable shape. For example, the pouch 60 may be a circle / sphere / cylinder, or a triangle / pyramid (e.g., a square pyramid).

[0198] In one embodiment, the product 30 is encased within a casing 62 in a "sausage" like arrangement. The casing 62 completely surrounds or encases the product, as shown in Figure 19. The casing 62 thus acts as a separator.

[0199] As shown in Figure 20, the wrapped product 30 is elongated. For example, the wrapped product has a length to width ratio greater than 5, preferably greater than 10. Such an arrangement increases its surface area. The casing 62 may include a seal 64 at one or both ends. The seal 64 may be provided by any suitable means, such as, for example, by using a heat seal, adhesive, ties, or fasteners. In some embodiments, both ends of the casing 62 may be left open.

[0200] The casing 62 is flexible. The enclosed products are curved or otherwise deformed to fit inside the capsule. The flexibility of the casing 62 may be provided by the casing 62 being thin or by its elastic / compliant nature. As shown in FIG. 20, multiple enclosed goods 30 are provided within a single capsule. Encapsulated Products.

[0201] In some embodiments, the casing 62 is made of a mesh. In some embodiments, the casing 62 is made of a membrane that is permeable to air or liquid.

[0202] In some embodiments, the capsule 14 includes an impaction member that extends into the product 30 and serves to reduce the flow of the product 30 upon impact therewith.

[0203] A first example is shown in Figure 21. The impact member 64 comprises a number of "fingers" 66. The fingers 66 comprise elongated rods or pins or the like. The fingers 50 are parallel to one another. The fingers 66 are attached to a base 68. As shown in Figure 23, the fingers 66 are spaced apart with respect to the base 68 (i.e. with respect to a two-dimensional plane). The fingers 66 thus extend across the product 30.

[0204] The fingers 66 have a circular cross-section, although it will be appreciated that the fingers 66 may have any suitable shape, such as, for example, a triangular, square, or hexagonal shape. The fingers 66 may be solid or hollow.

[0205] The fingers 66 are arranged in a hexagonal array, which provides a uniform distribution of the fingers 66. Again, it will be appreciated that this arrangement is merely exemplary and the fingers 66 may be spaced in any suitable arrangement, such as, for example, a square array, or a random array.

[0206] In some embodiments, the fingers 66 may be provided only on selected portions of the capsule 14 / product 30. This may be done if only certain portions of the product 30 are desired to be prone to settling. In some embodiments, the size and / or spacing of the fingers 66 may vary throughout the capsule 14.

[0207] The impact member 64 is configured to be removable from the capsule 14. Thus, when the fingers 66 are withdrawn from the product interior 30, they leave behind grooves, which may increase airflow within the capsule 14. The fingers 66 are shaped / sized / spaced to be insertable into openings in the top surface 24 and / or bottom surface 26. Thus, when the impact member 64 is removed, the openings in the top surface 24 and / or bottom surface 26 are exposed.

[0208] The base 68 is sealed to the top surface 24 and / or bottom surface 26. The impact member 64 may thus provide a lid / seal for the capsule 14, thereby preserving the freshness of the product 30. The base 14 may be sealed to the capsule using any suitable means, such as, for example, an adhesive.

[0209] The impact member 64 may include a handle 70 to aid in removal from the capsule 14. In other embodiments, usage may involve simply pulling the end of the base 68 away from the capsule. Alternatively, a pull tab or the like may be provided.

[0210] In some embodiments, one or more of the fingers 66 include an agitator 72 thereon. Thus, as the finger 66 is withdrawn, the agitator 72 engages and redistributes / disturbs the product 30.

[0211] In a first example, shown in Fig. 21, the stirrer 72a comprises a flange or the like. The flange may be a substantially flat plate. In a second example, the stirrer 72b is a hook (e.g. in the form of a chevron or an arrowhead). The stirrer 72b may be provided at the end of the finger 66. The stirrer 72 is thus movable over the entire height of the capsule 14 when the finger 66 is withdrawn. In some embodiments, multiple stirrers 72 may be provided on each finger 66.

[0212] In an alternative embodiment, the impact members 64 / fingers 66 may be fixed (ie, non-removable) to the capsule.

[0213] A second example of an impingement member is shown in Figure 23. In this example, the fingers 66 are substantially hollow. The fingers 66 are aligned with openings in the top surface 24. The fingers 66 therefore provide an air passage (e.g. a chimney or flue) into / through the capsule 14 and / or product 30. The air passage is thus the same as the flow passage 37 of Figures 4B and 5B described above. Such an arrangement therefore provides impingement and improves air flow.

[0214] The fingers 66 are substantially D-shaped / semi-circular. In alternative embodiments, the fingers 66 may take any suitable shape.

[0215] A first example of fingers 66a is shown on the left side of Figure 24. In this example, fingers 66a extend only part way between top surface 24 and bottom surface 26. Thus, ends 74 of fingers 66a remain within product 30 during use.

[0216] The fingers 66a are sized such that the product cannot fit inside the fingers.

[0217] A second example of fingers 66b is shown on the right side of Figure 24. In this embodiment, fingers 66b extend the entire length between top surface 24 and bottom surface 26. Fingers 56b have a breathable surface (e.g., provided by perforations / mesh). The perforations / mesh are sized such that product 30 enters fingers 66b. Fingers 66b thus provide an air passageway extending through product 30.

[0218] In some embodiments, the product 30 is provided on a porous / permeable or substantially air impermeable substrate. The substrate is comprised of an inert material or a food-safe material. The inert material is configured not to melt, burn, decompose or otherwise degrade when exposed to heat. For example, the inert material is stable to temperatures of at least 200° C., at least 300° C., or at least 350° C. The inert material may include any of the "inert filler" materials or "elements" as previously described herein. In specific embodiments, the substrate includes stone, glass, ceramic, pumice, or sand.

[0219] A first embodiment of a substrate is shown in Figure 26. The product 30 is provided on the surface of the substrate 76. Thus, the product 30 provides a coating on the substrate 76. The substrate 76 provides a core. The coating 30 covers substantially the entire surface of the substrate 76, thus maximizing the surface area of ​​the product 30. The coating 30 comprises a uniform thickness across the surface of the substrate 76. In alternative embodiments, the coating 30 only partially covers the surface of the substrate 76 and / or the thickness of the coating 30 may vary.

[0220] The coating 30 may be of a composition similar to the "paste" previously described. An absorbent binder may aid in bonding the coating 30 to the substrate 76.

[0221] In some embodiments, the coating 30 may not include any particulate inert filler material.

[0222] In some embodiments, the coating 30 may include a thickening agent. The thickening agent may include a gel-forming agent. The gel-forming agent may form a gel in the aqueous mixture at room temperature. The thickening agent may increase the viscosity of the coating layer and provide a glossy appearance. The thickening agent may include one or more polysaccharides (e.g., starch, gum, or pectin). The starch may include one or more of arrowroot, corn starch, potato starch, sago, tapioca, or derivatives thereof. The gum may include microbial gums and / or vegetable gums, such as one or more of alginate gum, guar gum, locust bean gum, gum arabic, or xanthan gum. The thickening agent may include one or more of a protein thickener, such as one or more of collagen, egg white, or gelatin. The thickening agent may include one or more of a sugar polymer, such as one or more of agar, carboxymethylcellulose, pectin, or carrageenan.

[0223] It will be understood that the composition of the coating 30 may be used in any embodiment as described herein. Conversely, a paste composition may be used to coat the substrate 76. For the avoidance of doubt, the coating 30 and / or paste may include any suitable combination of inert fillers, absorbent binders, mist generating agents, sweeteners, flavoring agents, or thickening agents.

[0224] Substrate 76 comprises a round / spherical shape. Product 30 and substrate 76 thus define a bead 78-like arrangement. However, it will be understood that substrate 78 may comprise any suitable shape, such as, for example, a cube or pyramid. In some embodiments, substrate 76 may be in the shape of a plate, disk, or puck. In some embodiments, substrate 76 may be in the shape of an elongated rod or diamond. In some embodiments, substrate 76 is ovoid. In some embodiments, substrate 76 may be in the shape of a ring (i.e., toroidal). In some embodiments, substrate 76 comprises one or more of the above shapes.

[0225] The substrate / core 76 may have an average diameter between 0.5 mm and 20 mm, preferably between 1 mm and 15 mm, more preferably between 2 mm and 15 mm, more preferably between 2 mm and 10 mm, and most preferably between 3 mm and 10 mm.

[0226] Substrate 76 may be greater than 30 wt%, preferably greater than 40 wt%, of the weight of beads 78. Substrate 76 may be between 30 wt% and 70 wt%, preferably between 40 wt% and 60 wt% of the weight of beads 78.

[0227] The beads 78 may contain about 1.5-2 wt% thickening agent, about 6-9 wt% mist generating agent, about 14-18 wt% carbohydrate sweetener, about 2-5 wt% flavoring, and about 0.0 wt% coloring. If the coating is made of components of an aqueous mixture, the amount of water in the coating is about 6-8 wt% of the total weight of the capsule.

[0228] This composition can provide a "dry" product. The coating 30 is therefore not sticky or syrupy, thereby ensuring that the beads 78 do not stick to one another. The coating 30 can be lubricious (e.g., the coating provides a lubricious shell). The beads 78 can be free-flowing within the capsule 14. The beads 78 can be easy to handle by the user or when filling the capsule 14.

[0229] The method of making the beads 78 involves forming a coating mixture containing the perfume and applying it to the core beads to form a precursor to the coating layer. An absorbent binder is then added to convert the precursor into a coating layer that encapsulates the core beads.

[0230] First, ingredients including flavors, mist generating agents, sweeteners, and thickeners are dissolved or suspended in a solvent to form a coating mixture. In some embodiments, one or more ingredients, such as flavors, may be introduced at a later stage of the process rather than as a component of the coating mixture. The selection of a suitable solvent depends, among other things, on the need to form a homogenous mixture having the appropriate viscosity and other desired attributes when the solvent is combined with the other ingredients. In some embodiments, the solvent is either water alone or in combination with a water-soluble solvent such as methanol, ethanol, isopropanol, glycol ether solvents, and combinations thereof.

[0231] The coating mixture may also include additives such as colorants and stimulants. Certain additives may be used to aid in the dispersion of other ingredients in the solvent, among other purposes.

[0232] Once prepared, the coating mixture is applied to the core beads. In one exemplary embodiment, a batch of core beads is placed in a spray coater pan that rotates in an orbital motion. The rotational motion causes the beads to roll in the pan. During the orbital tumbling of the beads, the coating mixture is added, forming a coating layer precursor on the surface of the beads. The coating mixture may be introduced by spraying, which allows for quicker and more uniform distribution than simply introducing it as a liquid.

[0233] After a sufficient amount of the coating mixture has been added, the absorbent binder is introduced. If the absorbent binder is a powdery material, it can be fed into the coating machine while the pan is rotating, sprinkling the absorbent binder onto the beads. The rotation can be continued until the applied absorbent binder is uniformly distributed and the particles are covered with a homogeneous coating. The beads are then dried, for example by blowing air through the pan to evaporate at least a portion of the solvent in the coating layer precursor. This produces dry, smooth-feeling beads without liquid or viscous residue on their surface. If desired, one or more ingredients, such as perfume, can be added at this stage rather than as a component of the coating mixture.

[0234] In some cases, it may be beneficial to divide the coating mixture into two or more portions: The first portion is bound to the absorbent binder on the bead surface as described above to form the first layer of the encapsulation layer.

[0235] A second portion is then applied to form a second layer over the first layer, and the process may continue by applying one additional portion until the encapsulation layer reaches the desired thickness.

[0236] In this embodiment, the substrate 76 has a substantially smooth surface 80. In some embodiments, the surface 80 may be roughened, which may promote bonding with the coating 70. In some embodiments, the surface 80 may be contoured / complex to increase the surface area of ​​the substrate 76.

[0237] Although specific examples of suitable coatings for the substrates (e.g., beads / elements) are described above, the coating may include only some of the coating materials described. For example, the coating may include a flavor coating, and the capsule may include other types of smoking materials apart from the coating.

[0238] As shown in FIG. 26, a plurality of beads 78 are provided in the capsule 14. The beads are stacked to provide gaps 82 between them. The arrangement of the beads thus provides air passages and aids in the dispersion of the product 30. The capsule 14 may be partially filled, thus providing free space 84 within the capsule. The beads 78 are loosely held within the capsule (i.e., free-flowing). This allows the user to shake the capsule 14 prior to use to facilitate dispersion of the beads 78. The beads 78 may occupy no more than 80% of the capsule interior volume, preferably no more than 70%, and more preferably no more than 60%.

[0239] In some embodiments, multiple beads 78 may be configured with different dimensions (e.g., different diameters or volumes), such as at least one bead 78 having a first dimension and at least one bead 78 having a second, different dimension, etc.

[0240] In some embodiments, the sizes of the different beads 78 are selected from a finite set of discrete sizes (i.e. from a predefined list of sizes). For example, a first set of beads may be 1 mm in diameter, a second set 2 mm, and a third set 3 mm. An example of such a distribution is shown in Figure 27. The discrete / quantified bead sizes thus produce multiple discrete peaks 86 in the distribution curve.

[0241] The number of beads 78 in each peak 86 (i.e., discrete bead sizes) may vary between different discrete bead sizes (i.e., resulting in different peak 86 heights). In alternative embodiments, the number of beads 78 in each peak 86 may be substantially constant. The distribution of bead sizes is thus substantially uniform.

[0242] In an alternative embodiment, the different sizes of beads 78 are distributed continuously. As shown in Figure 28, the bead sizes may thus form a continuous distribution curve 88. The bead sizes may be within a predetermined size range 90.

[0243] The number of beads may vary across the bead size distribution, resulting in a non-uniform curve 88a. In some embodiments, the bead size distribution may be a Poisson, normal, or Weibull distribution. The number of beads may increase towards the middle of the bead size distribution.

[0244] In some embodiments, the size distribution forms a substantially uniform curve 88b (the number of beads 78 at each different size is the same), which can be achieved by providing random bead sizes.

[0245] It will be understood that the graphs shown in Figures 27 and 28 are merely examples and are intended to aid in the explanation of the present disclosure.

[0246] The distribution of bead 78 sizes can be tailored to create optimal smoking conditions. For example, small bead sizes provide a larger surface area for the product 30, thus increasing the smoke strength (i.e., density of the volatile product). However, this also increases the rate of product depletion, resulting in a lower strength product towards the end of use. Additionally, small bead sizes have a lower thermal inertia, thus shortening the time it takes for the beads to reach the temperature required for the coating to become volatile. Thus, small beads are fast acting.

[0247] Conversely, larger beads provide a lower intensity smoke, but at a reduced rate of depletion compared to smaller beads. Furthermore, the thermal inertia of the beads increases the time it takes to reach the temperature at which the coating becomes volatile. The larger beads are therefore slow acting. Thus, combining beads 78 of different sizes ensures that the intensity of the smoke produced by the capsule remains at least partially constant. This configuration is shown diagrammatically in FIG. 29.

[0248] A smoke intensity curve 92a over time is shown for a small bead 78. Curve 92a includes a high intensity peak 94a, however, which increases and / or decreases in intensity rapidly over time. A second smoke intensity curve 92b is shown for a medium sized bead 78. Curve 92b includes a medium intensity peak 94b and a medium increase and / or decrease in intensity. A third smoke intensity curve 92c is shown for a large sized bead 78. Curve 92c includes a low intensity peak 94 and a slow increase and / or decrease in intensity. It can be seen that each of the peak intensities 94a-94c are spaced apart in time.

[0249] The resulting intensity curve 96 represents the sum of curves 92a to 92c. During an initial phase 98a, the capsule 14 and its contents begin to heat up, resulting in an increase in intensity. During an intermediate phase 98b, the resulting intensity remains substantially constant due to the contribution of different intensities from the different sized beads 78. The intermediate phase 98b thus provides the user with a consistent and balanced experience. As the small and medium sized beads 78 are consumed and the large sized beads 78 begin to be consumed, the resulting curve 98 enters a terminal phase 98c, where the intensity decreases. At this point, the user may stop using the device 2 and / or replace the capsule 14.

[0250] By adjusting the distribution of the size of the beads 78, the intermediate stage 98b can provide a consistent smoke intensity 96. Although the smoke intensity of the intermediate stage 98b is shown as substantially constant in FIG. 30, it will be understood that the intensity 96 can be configured to be within a certain tolerance range. The tolerance range can vary depending on the sensitivity of the user to the particular product 30 used. For example, a product with a high fragrance intensity may be able to tolerate a significant reduction in the intensity 96 because the fragrance intensity experienced by the user may be "saturated" even at low smoke intensities 96. The intensity 96 of the intermediate stage 98b can be configured to be within 50% of the average intensity 96 of the intermediate stage 98b, preferably within ±40%, more preferably within ±20%, and more preferably within ±10%.

[0251] In some embodiments, the size distribution of the beads 78 can be altered to change the user's experience. For example, providing a relatively large number of small beads 78 can create a "strong" experience for the user. Conversely, providing a relatively large number of large beads 78 can create a "soft" experience for the user.

[0252] In some embodiments, the plurality of beads 78 may be of different shapes. For example, at least one bead 78 is of a first shape and at least one bead is of a second, different shape, etc. This provides a distribution of the effective surface area of ​​the beads 78 and therefore may have the same / similar effect as varying the dimensions of the beads 78. The shape distribution of the bands 78 can thus be adjusted to provide a modified or consistent user experience as described herein above. The different shapes may further modify the air passage through the capsule 14.

[0253] Although different shapes / sizes of product 30 have been described in terms of beads 78, it will be understood that such configurations may be provided when product 30 is provided in separate portions. For example, configurations that may be provided in any of the embodiments described herein are described herein, specifically as follows: The compartments 40, 44 / cells 42 may be of different shapes / sizes or contain different amounts of product 30 therein. The amount of product 30 and / or the spacing of breathable layers 36 (e.g., FIGS. 13 and 14) The amount of product disposed on the flexible sheet 48 along its length The size / shape of the portion contained within the flexible sheet 48 (e.g., the shape / size of a cylinder (FIG. 17), pouch 60, or casing 62) and / or the size / shape of the product 30 contained therein

[0254] In some embodiments, the smoking article 30 may be provided in separate portions without the use of discrete separators, etc. This is possible when the smoking article is solid or semi-solid.

[0255] A first example is shown in Figure 30. The capsule 14 is made up of a number of discrete / individual product portions 100. The portions 100 may be loosely contained within the capsule (e.g., free-flowing therein). The shape shown in Figure 30 is substantially spherical / ovoid, but may be any suitable shape. The portions 100 may provide pellets, etc.

[0256] A second example is shown in Figure 31. The portion 100 is substantially flat / elongated. The portion may be a sheet, plate, strip, or foil etc.

[0257] The portions 100 can be configured in different sizes, shapes, and / or orientations to provide a consistent user experience (as described with reference to beads 78). Free space 102 is provided within capsule 14 to allow the user to disperse portions 100 prior to use.

[0258] The parts 100 have a coating to prevent adjacent parts 100 from sticking or coalescing. The coating can reduce the tackiness of the outer surface of the parts 100. The coating can be a powder. The coating thus acts as an effective separator. The coating can be anhydrous and / or hygroscopic (absorbs water) material. The coating can include an anti-caking agent.

[0259] The coating may include a food-based material, which may be one or more of a flour (wheat or corn), a sugar (e.g., powdered sugar), or a starch (e.g., potato starch).

[0260] The coating may include an inert material. The coating may include one or more of sand, calcium carbonate, zeolite, or granular / powdered minerals. The coating may include fine-grained material (e.g., less than 0.50 mm, alternatively less than 0.25 mm).

[0261] In some embodiments, part 100 may be at least partially dried, hardened or cured to reduce the tackiness of its outer surface. A coating may be applied to beads 78 to prevent them from sticking.

[0262] In some embodiments, the product 30 may include one or more inclusions therein that may help disperse the product 30 and / or provide air passages through the product 30.

[0263] A first embodiment is shown in Figure 32. The inclusions 86 are freely dispersed within the product 30. When the capsule 14 is moved, the inclusions 86 also move freely within the product 30 / capsule 14, dispersing the product. This may result in the product being dispersed, for example, during transportation of the capsule 14 or when the user shakes the capsule 14 prior to use. It will be appreciated that such an arrangement may be beneficial where the product 30 is homogenous / liquid / semi-solid, but may also be beneficial where the product is provided as individual portions (e.g. to separate beads 78).

[0264] The inclusions 78 can be composed of the same materials as the inert fillers previously described herein. In a specific example, the inclusions 78 can include stone or rock material. The inclusions 78 can include glass beads.

[0265] In some embodiments, the inclusions 78 include a metallic material. The metallic material may increase the effective thermal conductivity of the smoking article, thereby ensuring more uniform heating. The metallic material may even act as a dielectric (when exposed to a changing magnetic / electric field) to provide heating of the smoking article. The metallic material may be iron. The metallic material may be ferrite (Fe 2 O 3 The metallic material may be aluminum.

[0266] In some embodiments, the inclusions 78 comprise one or more of a flake, wire, sponge, or wool-like configuration.

[0267] The inclusions 78 may be greater than 3 mm, 4 mm, or 5 mm in diameter, potentially greater than 8 mm or 10 mm in diameter. Although the inclusions 78 shown in Figure 33 are spherical, the inclusions 78 may be any suitable shape, such as ovoid or polyhedral.

[0268] In a specific embodiment, the product 30 includes a shisha / tobacco product. The inclusions 78 are inert beads. The beads may provide air passages and / or disrupt the tobacco / shisha. In some embodiments, the beads may be embedded and / or dispersed within the shisha product.

[0269] In some embodiments, the beads may be provided in one or more layers. The layers may be provided at the base of the capsule. The shisha / smoking product may be placed on top of the beads. In some embodiments, one or more layers of beads may be placed on top of the shisha product. In some embodiments, alternating layers of beads and shisha products may be provided in a layered arrangement. The smoking product and / or layered arrangement may be compressed and / or otherwise compacted to mix / disperse the beads within the shisha product.

[0270] The ratio (by volume or mass) of ingredients 78 to product 30 may be 1:0.2-5, preferably 1:0.3-3, preferably 1:0.5-2, preferably 1:0.7-1.5.

[0271] As shown in Figure 33, the inclusions 86 can be breathable. In some embodiments, the inclusions 86 can be a mesh and / or a porous structure (e.g., a foam or pumice-like material).

[0272] The inclusions may passively distribute the product within the capsule in a desired form for use. Additionally or alternatively, the capsule may be agitated immediately prior to use to encourage the inclusions to redistribute the product within the capsule in preparation for use. The inclusions 86 may thus serve to provide a more rigid structure within the product to produce a desired distribution of the product within the capsule.

[0273] The support structure may provide one or more air passages and / or voids within the smoking article, thereby increasing air penetration and / or smoke emission. In general, the support structure and / or smoking product may only partially fill the housing, e.g., the internal chamber thereof. A portion of the internal chamber may be void, e.g., a void filled with gas / air. The support structure and / or smoking product may occupy 90% or less of the capsule's internal volume, preferably 80% or less, preferably 70% or less, preferably 60% or less, preferably 50% or less, preferably 40% or less. The support structure and / or smoking product may occupy 20% or more of the capsule's internal volume, preferably 30% or more, preferably 40% or more, more preferably 50% or more. The support structure and / or smoking product may occupy between 20% and 90%, preferably between 30% and 80%, preferably between 40% and 70% of the capsule's internal volume.

[0274] Any of the above embodiments, or specific features thereof, may be combined with any other embodiment disclosed or claimed herein, except where mutually exclusive. For example, the smoking article described in conjunction with the examples of Figures 25-33 may be provided in combination with any of the support structures described in any of Figures 4-8.

[0275] In any embodiment of the present invention, the product within the capsule may be a liquid, a viscous liquid, a semi-solid / paste, or a soft / spreadable solid. However, the product is generally deformable to an extent that it requires mechanical support or controlled deformation to assume a desired surface profile or shape during use. The product may be applied to the capsule or support structure as a flowable liquid, a viscous liquid, or a paste, but may be allowed to harden, for example, on the support structure within the capsule, to provide a more rigid product in situ. In some examples, the product comprises a tobacco component mixed with other viscous materials.

[0276] Although the capsule has been described for use with an electronic hookah device, it will be appreciated that the capsule can be used with any suitable conventional hookah or water pipe.

Claims

1. A capsule for a hookah device, comprising: a smoking product including at least one component configured to vaporize during heating of the smoking product in use; a housing including a plurality of walls formed to define an internal chamber containing the smoking article, the housing defining at least one air passageway which, in use, allows the vaporized components to exit the capsule; a support structure within the housing including one or more partitions extending radially inward from a sidewall of the capsule; Equipped with the smoking article and support structure only partially occupy the interior chamber; the support structure comprises a metal which assists in thermal conduction within the capsule in use; capsule.

2. the capsule comprises a first wall and a second wall, the interior chamber being between the first wall and the second wall; 2. The capsule of claim 1, wherein the first wall and the second wall include at least one respective opening therein, such that, in use, air passes through each of the openings and over the smoking article in the internal chamber.

3. 3. A capsule according to claim 1 or claim 2, wherein the support structure has greater mechanical strength than the smoking product.

4. 3. The capsule of claim 1 or claim 2, wherein the support structure is shaped to maintain a desired distribution of the smoking products within the internal chamber.

5. 3. The capsule of claim 1 or claim 2, wherein the support structure substantially spans a height and / or width dimension of the internal chamber.

6. A capsule as described in claim 1 or claim 2, wherein the one or more partitions extend only partially between the side walls of the capsule.

7. the divider is configured to divide the interior chamber of the capsule into two or more compartments or cells; 3. The capsule of claim 1 or claim 2, wherein the divider defines an annular interior chamber for containing the smoking article and a central air passage extending therethrough.

8. A capsule as described in claim 1 or claim 2, wherein the support structure is at least partially embedded or covered by the smoking product.

9. The capsule of claim 1 or claim 2, wherein the support structure is breathable and includes one or more of a mesh, a foam, a perforated sheet material, or a woven fabric.

10. 3. The capsule of claim 1 or claim 2, wherein the one or more partitions are shaped to define an air passage in the shape of a flow passage through the internal chamber, whereby the one or more partitions prevent intrusion of the smoking product into the flow passage.

11. The capsule of claim 1, further comprising a plurality of discrete elements or beads within the capsule.

12. 12. The capsule of claim 11, wherein the smoking product at least partially encapsulates the discrete elements, each of the discrete elements providing a core, and the smoking product forms a coating over the core.

13. 13. The capsule of claim 12, wherein the core comprises an inert inorganic material that is one or more of stone, glass, ceramic, or sand.

14. 13. The capsule of claim 12, wherein the coating comprises an organic thickener, the coating is dry, or both.

15. The capsule of claim 11, wherein at least two of the discrete elements are separated or restrained by the support structure.

16. the smoking article is provided in a plurality of discrete portions, each of the discrete portions having a different effective surface area of ​​the smoking article; 3. The capsule of claim 1 or claim 2, wherein the smoking article comprises portions having different cross-sectional areas or different volume to surface area ratios, and wherein the different portions of the smoking article are consumed at different rates during heating.

17. 17. The capsule of claim 16, wherein the overall percentage of vaporized smoking product produced by the capsule remains within a predetermined range over a predetermined period of use.

18. 3. The capsule of claim 1 or claim 2, wherein the ingredients of the smoking product include a binder, a mist generating agent, and a flavoring agent.

19. 20. The capsule of claim 18, wherein the smoking product includes an absorbent binder that is one or more of fumed silica, amorphous silica, or talc.

20. The smoking product comprises a viscous liquid or semi-solid; 3. A capsule according to claim 1 or claim 2, wherein the smoking product comprises either or both an inert particulate filler material.

21. A water pipe comprising a capsule according to claim 1 or 2.

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