Vaporizable products and methods for producing same

Abstract

A method of filling a water pipe capsule with a consumable product is disclosed. The consumable product comprises a mixture of solid and liquid components arranged to be vaporizable upon use. The consumable mixture is deagglomerated or de-densified for insertion into the capsule. The capsule is filled with a predetermined amount of consumable product and sealed with the consumable mixture therein. The consumable product may be compressed or compacted within the capsule or may be substantially filled into the capsule to achieve a predetermined density. Related capsule products for use in water pipes are disclosed.

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates to vaporizable and / or inhalable products for ingestion by a user, as well as manufacturing methods related to providing such products in capsule form. [Background technology]

[0002] A prior art Hooker device is shown in WO 2017 / 080545. The device comprises a heating chamber configured to receive a capsule containing a smoking product. The capsule is heated using the heating chamber to produce vapor, which is then inhaled through a hose.

[0003] The inventors have identified a number of problems with prior art capsules. The capsules typically contain a shisha or muesli product, which includes a mixture of tobacco, molasses, and glycerol. Shisha products can be sticky, syrupy, or otherwise viscous, and the shisha can clump together during transportation or storage of the capsule. This reduces the effective surface area of the shisha, reducing the quantity and / or quality of vapor produced. For example, the clumped product may not be able to reach a sufficient temperature to generate vapor, and / or the vapor may not be able to penetrate the dense product.

[0004] Inconsistent product heating and vapor production can result in a poor smoking experience for users due to inconsistent vapor production, and can also result in parts of the shisha product being burnt or not heated enough, resulting in a poor flavor or rendering the product unusable.

[0005] Additionally, over time, volatile components of the shisha product may evaporate and escape from the capsule, resulting in a change and / or degradation of flavor and an unsatisfactory smoking experience. Similarly, one or more components in the shisha product may oxidize, resulting in a change in flavor. Liquid components of the product may also leak from the capsule, resulting in partial product waste and making the capsule difficult to handle.

[0006] It is an object of the present invention to overcome or ameliorate one or more of the problems set forth above. Summary of the Invention

[0007] According to a first aspect of the present invention, there is provided a method of filling a capsule for a hookah pipe with consumables, the consumables comprising a mixture of solid and liquid components, the method comprising: deagglomerating or de-densifying the mixture of consumables; filling a capsule with a predetermined amount of consumables; and sealing the capsule containing the mixture of consumables.

[0008] The capsules may include disposable and / or non-reusable capsules. The capsules may be permanently sealed.

[0009] The consumable contained within the capsule may have a predefined density of 1.8 g / mL or less. The smoking product contained within the capsule may have a predefined density of 1.2 g / mL or less, preferably 0.8 g / mL or less.

[0010] The method may include leveling the product after filling the capsule. The product may be leveled at the same level as the edge or rim of the capsule (e.g., level with the opening of the capsule).

[0011] The product may be compressed after deagglomeration to provide a predefined density. The method may include redispersing the product within the capsule prior to compression. Redispersing or leveling may provide a substantially uniform depth of product within the capsule.

[0012] The product may occupy substantially all of the internal volume of the capsule. The product may occupy 80% or more of the internal volume of the capsule, preferably 90% or more.

[0013] The product may occupy a portion of the capsule's internal volume. The product may occupy 80% or less of the capsule's internal volume, for example, 60% or less. The product may occupy 20% or more, preferably 30% or more. The product may occupy 25% to 80% of the capsule's internal volume, for example, 30% to 65%.

[0014] The capsules may contain 2g to 40g of consumable product. The capsules may contain 4g or more, 6g or more, or 8g or more of product. The capsules may contain 35g or less, 30g or less, 25g or less, or 20g or less of product. The capsules may contain 10-20g or 20-30g of product.

[0015] In any example herein, the density of the product may be specified relative to the volume of the product or relative to the internal volume of the capsule. The consumable may or may not fill the internal volume of the capsule by a specified amount.

[0016] The product may comprise or consist of a consumable or vaporizable product, such as a smoking product. The product may comprise an active ingredient or a volatile ingredient.

[0017] The capsule may comprise a metallic material. The capsule may be for one-time use. The capsule may be disposable. The capsule may comprise aluminium.

[0018] The method may include providing an inert atmosphere within the capsule. The internal volume within the capsule may be flushed / purged with an inert gas. Prior to sealing the capsule, the capsule may be flushed / purged with an inert gas.

[0019] The capsule may be sealed with a closure / lid attached thereto. The closure and / or capsule may be mechanically deformed to hold the closure on the capsule and / or provide a seal between the closure and the capsule. The closure and / or capsule may be plastically / permanently deformed.

[0020] The capsule may have an outwardly extending rim or flange and the closure may be deformed over the rim / flange. The rim flange may have a reinforcing element. The closure may be deformed over / over the reinforcing element. The reinforcing element may have a bead or a rolled / bent edge.

[0021] The closure and / or capsule may be crimped or rolled to provide a seal between the closure and capsule.

[0022] The seal between the closure and the capsule may be porous. The internal environment may be in fluid communication with the external / ambient environment.

[0023] The capsules may be provided in a separate package, which may be filled with an inert atmosphere, or the capsules may be substantially free of an inert atmosphere.

[0024] The separate packaging may comprise a blister pack. The separate packaging may comprise a flexible packaging (i.e., the packaging is not self-supporting). The separate packaging may comprise a polymer. Each capsule may be provided in an individual sealed blister pocket. The blister pack may be sealed via a lid sheet. The lid sheet may be heat-sealed to the blister pocket.

[0025] The separate package may comprise a flow wrap package. The method may include creating the package using a flow wrap process. The method may include filling the package with an inert atmosphere during the flow wrap process. The capsule may be placed within the package during the flow wrap process. The smoking article may be placed directly into the flow wrap package.

[0026] The method may include agitating the product sealed within the capsule.

[0027] The product may comprise shisha or muesl. The shisha product may comprise tobacco. The shisha product may comprise a tobacco substitute. The tobacco substitute may comprise an organic substitute. The tobacco substitute may comprise cannabis, tea, or hemp.

[0028] The product may include a sweetener (e.g., molasses). The product may include a mist maker (e.g., glyercol). The product may include both wet and dry ingredients (e.g., liquid and solid ingredients).

[0029] The product may comprise a liquid. The product may comprise a viscous and / or semi-solid substance. The product may comprise a syrup. The product may comprise a sticky material.

[0030] The product may also include one or more inert beads.

[0031] According to a further aspect, there is provided a capsule for a hookah pipe having a consumable or vaporizable product, the capsule containing a predetermined amount of the product, the product contained within the capsule having a predefined density of 1.8 g / mL or less.

[0032] The product may comprise a dry product. The density of the smoking product may be between 0.05g / mL and 0.4g / mL. The density of the product may be between 0.05g / mL and 0.3g / mL.

[0033] The vaporizable product may include a wet product. The wet product may include a liquid or viscous substance. The wet product may include a dry product bound or wetted by a liquid / viscous product. The smoking product has a density of 0.2 g / mL to 0.9 g / mL. The smoking product has a density of 0.3 g / mL to 0.8 g / mL.

[0034] The capsule may include an agitator configured to agitate the smoking article within the capsule.

[0035] The agitator may include one or more of a shape memory alloy, a burstable material, a gas-releasing material, a rotatable blade, or a pneumatic device. The agitator may include a handle or actuator. The handle or actuator may be accessible from the exterior of the capsule.

[0036] The hookah pipe may comprise a conventional hookah pipe (e.g., heated using coal, etc.) The hookah pipe may comprise an electrically heated hookah pipe.

[0037] According to a further aspect, there is provided a capsule for a smoking article, the capsule including an agitator configured to agitate the smoking article within the capsule.

[0038] According to a further aspect of the present invention, there is provided a capsule for a vaporizable product, comprising an end wall connected to a side wall defining a cavity for receiving a smoking product, the end wall having a plurality of openings to allow air to pass through the smoking product in use, the total area effectively occupied by the openings being at least 1% of the total area of the end wall.

[0039] Preferably, the total area effectively occupied by the openings is at least 5% of the total area of the end wall.

[0040] The capsule may have first and second end walls spaced apart by a side wall, the first and / or second end walls comprising an opening.

[0041] Optional or preferred features described in relation to one aspect of the invention may, to the extent possible, be applied to any further aspects.

[0042] Specific embodiments of the present disclosure will now be described by way of detailed examples with reference to the accompanying drawings. [Brief explanation of the drawings]

[0043] [Figure 1] Figure 1 shows a schematic diagram of the filling process. [Figure 2] FIG. 2 shows a schematic side view of the filling process. [Figure 3] FIG. 3 shows a schematic side view of the leveling process. [Figure 4] FIG. 4 shows a schematic side view of the compression process. [Figure 5A] FIG. 5A shows a first schematic side view of the compressed product. [Figure 5B] FIG. 5B shows a second schematic side view of the compressed product. [Figure 5C] FIG. 5C shows a third schematic side view of the compressed product. [Figure 6A] FIG. 6A shows a schematic side view of a product containing beads. [Figure 6B] FIG. 6B shows a schematic side view of a product including beads and a compressed product. [Figure 7] Figure 7 shows a schematic diagram of the packaging process. [Figure 8] FIG. 8 shows a schematic side view of the first gas filling process. [Figure 9] FIG. 9 shows a schematic side view of the second gas filling process. [Figure 10] FIG. 10 shows a schematic side view of the third gas filling process. [Figure 11] FIG. 11 shows a schematic side view of the fourth gas filling process. [Figure 12] FIG. 12 shows a schematic side view of the crimping device. [Figure 13] FIG. 13 shows a schematic side view of the first crimping process. [Figure 14] FIG. 14 shows a schematic side view of the first crimping process. [Figure 15] FIG. 15 shows a schematic side view of the second crimping process. [Figure 16] FIG. 16 shows a schematic side view of the second crimping process. [Figure 17] FIG. 17 shows a schematic side view of the third crimping process. [Figure 18] FIG. 18 shows a schematic side view of the third crimping process. [Figure 19]FIG. 19 shows a schematic diagram of flow wrap packaging. [Figure 20] FIG. 20 shows a schematic side view of the first packaging gas filling process. [Figure 21] FIG. 21 shows a schematic front view of the first packaging gas filling process. [Figure 22] FIG. 22 shows a schematic side view of the second packaging gas filling process. [Figure 23] FIG. 23 shows a schematic side view of a blister pack. [Figure 24] FIG. 24 shows a schematic diagram of the first stirring mechanism. [Figure 25] FIG. 25 shows a schematic diagram of the second stirring mechanism. [Figure 26] FIG. 26 shows a schematic diagram of a third stirring mechanism. [Figure 27] FIG. 27 shows a schematic diagram of a fourth stirring mechanism. [Figure 28] FIG. 28 shows a perspective view of the capsule. [Figure 29] FIG. 29 shows a cross-sectional side view of the capsule. DETAILED DESCRIPTION OF THE INVENTION

[0044] The capsule filling process will now be described with reference to Figure 1. In a first step 2, a vaporizable product is produced. The production can be conventional and will not be described in detail. Although the vaporizable product or consumable is described herein as a smoking product, it will be understood that the product need not be consumed by combustion. Preferably, the heating of the product is controlled so that it does not ignite when used.

[0045] The smoking product includes a "mist maker." The mist maker is configured to produce smoke when vaporized. The mist maker includes a volatile material configured to provide light-scattering smoke in its vaporized state. The mist maker 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).

[0046] The product may include a sweetener. The sweetener may include one or more carbohydrate sweeteners (e.g., monosaccharides of 5 or 6 carbon atoms), such as arabinose, xylose, ribose, glucose, mannose, galactose, fructose, dextrose, or sorbose. The sweetener may include one or more disaccharides, such as sucrose, lactose, maltose, or cellobiose, such as cane sugar or beet sugar. The sweetener may include one or more polysaccharides, such as partially hydrolyzed starch or dextrin, polyols, such as sorbitol, mannitol, or xylitol, and mixtures of one or more of the above sugars. The sweetener may include a complex sugar / carbohydrate mixture (e.g., a natural sugar product). The sweetener may include one or more of molasses, invert syrup, corn (maize) syrup, maple syrup, golden syrup, trickle, etc.

[0047] In some embodiments, the sweetener comprises high fructose corn syrup (also known as glucose and fructose isoglucose and glucose and fructose syrup).

[0048] 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 glycyrrhizinate, 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), extract of Stevia rebaudiana (stevioside), extract of Richardella dulcifica (miracle berry), or extract of Dioscoreophyllum cumminsii (serendipity berry).

[0049] It will be appreciated that any of the above sweeteners may be combined with any of the other sweeteners or classes of sweeteners described above.

[0050] The product contains a flavoring agent, which may include one or more of mints, such as peppermint and spearmint, chocolate, licorice, citrus and other fruit flavors, gamma octalactone, vanillin, ethyl vanillin, or breath freshening flavors, among others. The aforementioned sweeteners may be an example of a flavoring agent, although typically both a sweetener and a flavoring agent are also provided.

[0051] The flavoring agent may include one or more of spice flavoring agents, such as cinnamon, methyl salicylate, linalool, bergamot oil, geranium oil, lemon oil, or ginger oil. The flavoring agent may include a plant extract or essential oil. The flavoring agent may include one or more of food-based flavoring agents, such as apple flavoring, blueberry flavoring, coconut flavoring, grape flavoring, guava flavoring, pomegranate flavoring, or lemon flavoring. The flavoring agent may include a fruit or plant flavor. The flavoring agent may include one or more of an acid, an alcohol, an ester, an aldehyde, a ketone, or a pyrazine.

[0052] The product may contain a stimulant, for example in its flavoring. The stimulant may have a stimulating effect on the central nervous system and induce alertness in the user. The stimulant may include one or more of caffeine (1,3,7-trimethylxanthine), taurine (2-aminoethanesulfonic acid), theobromine (3,7-dimethylxanthine), or derivatives thereof.

[0053] 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 provided in addition to the flavoring. For example, a coffee flavoring may be enhanced with the addition of caffeine.

[0054] The product may contain cannabis or a cannabis-derived product. The cannabis product may contain one or more parts of the cannabis plant, such as buds, flowers, fruit, leaves, stems, kief, or oil. The cannabis may be raw or processed. [Leave specific cannabis preparations for new patents?]

[0055] The product may include a colorant. The colorant may provide a colored product 30 and / or smoke. The colorant may include a food, drug, or cosmetic safe colorant. The colorant may include a water-soluble colorant. The colorant may include one or more of plant-derived colorants, such as beet juice, Brazilwood, caramel, carminic acid, litmus, logwood, orthol, or saffron. In some embodiments, the colorant includes an artificial colorant.

[0056] In particular embodiments, the smoking product comprises a shisha or muesli. Shisha comprises tobacco. The tobacco may be shredded or micronized. The tobacco is mixed with a sweetener (e.g., molasses) and a mist maker (e.g., glycol). Thus, the shisha is provided as a viscous semi-solid. In some embodiments, the shisha may be tobacco-free. The shisha may comprise nicotine additives and / or substitutes. The shisha may comprise a tobacco substitute. The tobacco substitute may comprise an organic substitute.

[0057] In some embodiments, the smoking article may be provided on an inert substrate. The substrate may comprise an inert material or a food-safe material. The inert material is configured to not melt, burn, decompose, or otherwise deteriorate upon exposure to heat. For example, the inert material may be temperature stable up to 200°C or higher, 250°C or higher, or 300°C or higher.

[0058] The inert substrate may comprise an inorganic or mineral material. In some embodiments, the inert material comprises a non-crystalline amorphous material such as glass. The glass may comprise a silica (SiO2)-based glass. The glass may comprise 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.

[0059] In some embodiments, the inert material comprises a mineral. For example, the mineral may comprise one or more of silica, limestone (calcium carbonate), feldspar (tectosilicate mineral), gypsum, magnetite (Fe3O4), chlorite ((Mg,Fe)3(Si,Al)4O10(OH)2·(Mg,Fe)3(OH)6), glauconite ((K,Na)(Fe3+,Al,Mg)2(Si,Al)4O10(OH)2), or alumina.

[0060] In some embodiments, the inert material comprises stone / rock material (i.e., a naturally occurring substance comprising one or more minerals or mineraloids). For example, the stone material may comprise one or more of granite, basalt, marble, quartz, pumice, obsidian, jet, biotite, etc.

[0061] 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.

[0062] In some embodiments, the inert material comprises one or more of activated carbon powder, graphite powder, graphene, carbon fiber, and the like.

[0063] 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).

[0064] In some embodiments, the interfiller may comprise sand or granules (e.g., crushed or fine particles). The sand may comprise particles of one or more of the above materials. The average particle size of the granules is such that the filler remains granular / sand-like and does not form airborne particles like particulates such as powders or dust. This may reduce the health risks associated with fine powders.

[0065] In particular embodiments, the substrate comprises stone, glass, ceramic, pumice, or sand.

[0066] The product may be provided on the surface of a substrate (e.g., providing a coating on the substrate). The substrate may provide a core. The coating may cover substantially the entire surface of the substrate, thereby maximizing the surface area of the product. The coating may be of uniform thickness across the entire surface of the substrate. The substrate may be rounded / spherical in shape. Thus, the product and substrate define a bead-like arrangement.

[0067] In some embodiments, the smoking product may be provided as a plurality of particles. The particles may be in granular and / or powder form. The particles may be sticky or clumpy.

[0068] It will be appreciated that smoking products are generally viscous. Smoking products may comprise a viscous liquid, a semi-solid, a mixture of liquid and solid, a flowable solid, or a combination thereof. Smoking products are generally flowable. Smoking products may have a viscosity of 10 Pa·s or greater, preferably 100 Pa·s or greater, and preferably 1000 Pa·s or greater.

[0069] The product may then be transported to a capsule filling location. During production, transportation, and / or storage, the smoking product may agglomerate or settle. Additionally or alternatively, the product may fragment. For example, the liquid / viscous components of a shisha product may separate from the solid components. Therefore, in a second step 4, the product is deagglomerated and / or homogenized. Deagglomeration includes any suitable process that deflates, breaks down, fluffs, or otherwise reduces the density of the product.

[0070] Deagglomeration / homogenization may be accomplished using any suitable agitation means. In some embodiments, the product is agitated using mechanical means. The mechanical means may include an agitator or stirrer. The agitator / stirrer may comprise one or more of a rod, blade, paddle, screw, whisk, propeller, wire shredder, etc. The agitator / stirrer may be rotatable or otherwise movable.

[0071] In some embodiments, the product is deagglomerated using pneumatic means, for example, by exposing the product to one or more jets of high-pressure air.

[0072] In some embodiments, deagglomeration of the product is accomplished via a dynamic process (i.e., the entire product is moved), which may include one or more of tumbling, shaking, tossing, vibrating, etc.

[0073] In some embodiments, one or more components of the smoking product may be provided separately to the loading station. Thus, a deagglomeration / homogenization step may be used as part of the manufacturing process to mix the components, e.g., dry components. For example, dry components, such as tobacco, and wet components, such as glycerin / molasses, may be provided separately and only mixed at the loading station.

[0074] Deagglomeration is performed until the product has a desired mechanical and / or compositional consistency or homogeneity. Deagglomeration may also be performed until the product reaches a certain density. The density of the deagglomerated / densified product 14 may be 2.5 g / mL or less, preferably 2 g / mL or less, preferably 1.5 g / mL or less, preferably 1.2 g / mL or less, preferably 1 g / mL or less, preferably 0.8 g / mL or less, preferably 0.7 g / mL or less, and preferably 0.5 g / mL or less. The density of the deagglomerated / densified product 14 may be 0.05 g / mL or more, preferably 0.1 g / mL or more, preferably 0.2 g / mL or more, preferably 0.3 g / mL or more, and preferably 0.4 g / mL or more. The density of the deagglomerated / densified product 14 may be between 0.05 g / mL and 2 g / mL, preferably between 0.1 g / mL and 0.1.8 g / mL, preferably between 0.2 g / mL and 0.9 g / mL, preferably between 0.3 g / mL and 0.8 g / mL, preferably between 0.35 g / mL and 0.75 g / mL, preferably between 0.4 g / mL and 0.7 g / mL. In specific embodiments, the density may be 0.45 g / mL or 0.62 g / mL.

[0075] In the next step 6, capsules are filled with the product. The product is divided into portions of predetermined weight / volume. Each portion is filled into a respective capsule. Each portion of the product may have a mass of 200g or less, preferably 100g or less, preferably 50g or less, preferably 40g or less, preferably 30g or less, preferably 20g. Each portion of the product may have a mass of 1g or more, preferably 1.5g or more. Each portion of the product may have a mass between 1g and 30g, preferably between 1.5g and 20g.

[0076] Each portion may be weighed / measured using any suitable means. Each portion may be weighed / measured using a multi-head weigher. The weigher may have a dimpled and / or perforated contact surface.

[0077] The product may be cooled and / or frozen before / during the filling process. The product may be processed in a low humidity environment, which makes handling sticky shisha products easier. The weighing machine and / or capsules may be vibrated during filling to reduce product adhesion to the capsule or machine.

[0078] A capsule 12 filled with product 14 is shown in Figure 2. The capsule 12 has a cone shape (i.e., a trapezoidal outer shape) and is chamfered or tapered towards its base.

[0079] The capsule 12 comprises a heat resistant material. The capsule comprises a thermally conductive material that conducts heat. The capsule 12 comprises a metallic material. The metallic material may comprise aluminum. The capsule 12 may comprise a deformable / ductile material. The capsule may be formed and / or stamped from a sheet of material. The material may be 0.5 mm or less in thickness, preferably 0.3 mm or less, and more preferably 0.2 mm or less.

[0080] During filling step 6, the product 14 may become unevenly distributed within the capsule 12 (i.e., as a natural result of the filling process). In the example shown in Figure 2, the product 14 is piled higher in its central region 16. Therefore, in the next step 8, the product 14 is leveled / evenly distributed.

[0081] Leveling may be accomplished using any suitable means. In some embodiments, the product is leveled using mechanical means. The mechanical means may comprise a doctor blade or scraper. The blade / scraper can be moved along the top edge 18 of the capsule 12, thereby spreading the contents. Such an embodiment may be beneficial when the volume of the product portion 14 is close to or the same as the volume of the capsule 12.

[0082] In some embodiments, the product is leveled using pneumatic means, for example, by subjecting the product to one or more blasts of high-pressure air.

[0083] In some embodiments, the product is leveled using a dynamic process, which may include one or more of shaking and / or vibrating. Such an embodiment may be beneficial when the volume of the product portion 14 is significantly smaller than the volume of the capsule 12 and / or when the product 14 comprises a flowable solid.

[0084] After leveling step 8, as shown in FIG. 3, the product 14 is uniformly distributed within the capsule 12 (i.e., the depth of the product 14 is uniform across the width of the capsule 12). It will be appreciated that some non-uniformity in the distribution of the product 14 may be tolerated. For example, the depth of the product 14 within the capsule may be acceptable as long as the maximum / minimum depth is within ±20%, preferably ±10%, of the average depth. In some embodiments, the capsule 12 may be completely filled with the product 12 (i.e., up to its opening). Thus, the product 14 is flush with the top edge of the capsule. This may be beneficial when the product is sold by weight and / or when the product has a consistent density.

[0085] Inspection means may be provided to ensure proper leveling. The inspection means may comprise distance (i.e., length) measuring means. The distance meter may scan the product 14 within the capsule 12 to determine the variation in product depth. Such scanning may be performed as the capsule 12 passes under the distance meter on the conveyor. In other embodiments, optical sensors and image processing devices may use photographs taken (e.g., using photogrammetry) to determine the depth and / or uniformity of the product.

[0086] In some embodiments, the product 14 may be too sparsely dispersed (i.e., too sparsely packed) to provide an optimal application experience. For example, if the effective surface area of the product 14 is too large, the application experience may be too intense. Therefore, in the next step 10, the product 14 is compressed.

[0087] As shown in Figure 4, compression is performed by a compression device 20. The compression device 20 compresses the product 14 to a predetermined depth 22. Knowing the weight of the product 14 in each capsule 12, it is possible to determine the density of the product 14. The density of the compressed product 14 may be 2 g / mL or less, preferably 1 g / mL or less, preferably 0.8 g / mL or less, preferably 0.5 g / mL or less, and preferably 0.4 g / mL or less. The density of the compressed product 14 may be 0.1 g / mL or more, preferably 0.15 g / mL or more, and preferably 0.2 g / mL or more.

[0088] It will be appreciated that a given density of the product will result in a given airflow / pressure drop as the air passes through the capsule. Thus, the density of the product can be varied until the pressure drop through the capsule is 5 kPa or less, preferably 4 kPa or less, preferably 3 kPa or less, preferably 2.5 kPa or less. The pressure drop through the capsule is 0.3 kPa or more, preferably 0.5 kPa or more, preferably 1 kPa or more.

[0089] The compression device 20 is configured to be received within the capsule 12. The compression device 20 may be of a similar / complementary shape to the capsule 12, thus providing a plug-like arrangement. The compression device is a tight fit with the capsule 12. The compression device 20 is shaped according to the depth 22 to which the compression device 20 is inserted. The compression device 20 extends across the entire width of the capsule. Thus, the compression device 20 extends across the entire area of the top surface 24 of the product (i.e., occupies the cross-section of the capsule 12). This ensures that compression is applied evenly across the entire surface 24 of the product, resulting in a uniform density of the compressed product 14. The tight fit between the compression device 20 and the capsule 12 prevents leakage of the product 14 between the edge of the compression device 20 and the sidewall 26 of the capsule 12.

[0090] Figure 5 shows the product 14 in isolation compressed within the capsule 12. It can be seen that the product 14 occupies only a portion of the capsule's internal volume. Thus, a cavity 28 is provided between the product 14 and the upper edge / rim 30 of the capsule. The cavity 28 allows air to flow into the capsule 12 during use, which allows for more uniform heating of the product 14 and the flow of vaporized smoking product from the capsule 12.

[0091] The capsule 12 may have an internal volume of 200 mL or less, preferably 100 mL or less, preferably 50 mL or less, preferably 40 mL or less, preferably 30 mL or less. The capsule 12 may have an internal volume of 5 mL or more, preferably 10 mL or more. The capsule 12 may have an internal volume of 5 mL to 50 mL, preferably 10 mL to 30 mL. In specific embodiments, the capsule has a volume of 15 mL or 22.5 mL.

[0092] Product 14 may occupy 90% or less of the internal volume of capsule 12, preferably 70% or less, preferably 66% or less, preferably 60% or less, and preferably 55% or less. Product 14 may occupy 10% or more of the internal volume of capsule 12, preferably 20% or more, and preferably 30% or more. Product 14 may occupy 25% to 80% of the internal volume of capsule 12, preferably 30% to 65%. In specific embodiments, product 14 occupies 55% or 40% of the internal volume of capsule 12.

[0093] In the embodiment shown in Figure 5A, the depth 22 of the product 14 is substantially uniform across the width of the capsule 12. Thus, the product 14 may be flat. The product 14 is cylindrical / puck-shaped.

[0094] In the embodiment shown in FIG. 5B, the base 32 of the capsule 12 includes a recess 34. The recess 34 extends toward the top edge 30 of the capsule 12. Thus, the recess 34 extends inwardly of the capsule 12. The recess 34 is curved / arcuate. Thus, the base 32 of the capsule 12 is dome-shaped. The recess 34 includes a plurality of openings 36 extending through the wall 36 of the base 32. The openings allow air / vapor to pass through the capsule 12 during use (i.e., provide unidirectional airflow). The surface 24 of the product 14 is substantially flat. Thus, the depth 22 of the product 14 varies to accommodate the recess 34.

[0095] In the embodiment shown in Figure 5C, the height of the product 14 remains substantially constant. Thus, the product 14 is dome-shaped, corresponding to the depression 34. This aids in uniform heating of the product 14. The compression device 20 is provided with a depression to form the dome-shaped product shape. In this way, the compression device 20 conforms to the internal shape of the capsule 12. It will be appreciated that such an arrangement can be provided where the capsule and / or its base 32 have any shape.

[0096] In the embodiment shown in Figure 6A, a substrate 37 is provided. The substrate 37 is provided in a layer. The substrate 37 is provided adjacent to the base 32 of the capsule 12. The substrate may cover and / or at least partially block one or more openings / perforations in the base 32.

[0097] Substrate 37 may comprise an inert material as previously described. Substrate 37 may comprise particulates. Substrate 37 may comprise beads, etc. The beads may be arranged to form a layer arrangement. In some embodiments, substrate 37 may comprise a smoking article. The smoking article may be provided as a coating and / or layer on substrate 37.

[0098] As shown in FIG. 6B , the smoking article 14 may be compressed onto the substrate 37. Thus, the substrate 37 is at least partially embedded within the product 14. The product 14 may fill at least some of the space between the beads 37 and / or between the beads and the capsule 12. In the embodiment of FIG. 6B , a gap 39 is provided between the smoking article 14 and the capsule base 32. This provides an air passage for vaporized smoke. This may also prevent the smoking article from escaping through the perforations in the base 32. Thus, the substrate 37 may provide a partial barrier and / or cushion between the smoking article 14 and the capsule wall. In other embodiments, the smoking article 2 may completely encase the substrate 37.

[0099] In some embodiments, a compaction step may not be performed. For example, if the density of the product is controlled to a desired value during the agglomeration step, the capsule 12 may be filled without compaction. In some embodiments, the capsule 12 is simply filled and leveled. Thus, the product 30 may occupy substantially the entire volume of the capsule. For example, the product may occupy 70% or more of the capsule's internal volume, preferably 80% or more, preferably 90% or more, and preferably 95% or more. Filling or nearly filling the capsule 12 completely prevents the product from significantly shifting, thereby preventing agglomeration. In other embodiments, the capsule 12 may be partially filled as described above.

[0100] In such an embodiment, it will be appreciated that the density of the product using the capsules 12 will be substantially the same as the de-agglomerated / de-densified product 14 as described above.

[0101] In some embodiments, the non-compressed smoking article may only partially fill the capsule, as described above.

[0102] Specific examples of capsules, either compressed or non-compressed, are shown below.

[0103] [Table 1]

[0104] [Table 2]

[0105] [Table 3]

[0106] Composition 1 may include a "dry" formulation. A dry formulation may include shredded, powdered, or otherwise granulated material. Accordingly, the density is relatively low. The material may include organic or plant material. For example, the material may include one or more of tobacco, tea, cannabis, hemp, and / or derivatives thereof.

[0107] In some embodiments, the dry formulation may have a density of 0.05 g / mL to 0.3 g / mL (e.g., when fully loaded). In some embodiments, the dry formulation may have a density of 0.1 g / mL to 0.6 g / mL (e.g., when 55% loaded). In some embodiments, the dry formulation may have a density of 0.2 g / mL to 0.9 g / mL (e.g., when 40% loaded).

[0108] The dry formulation may weigh between 1 g and 10 g, preferably between 1.5 g and 9 g.

[0109] Composition 1 may include a "wet" formulation. The wet formulation may include a liquid, a viscous solid, or a moist material. The wet formulation may be flowable, viscous, or sticky. The wet formulation may include ingredients from a dry formulation. The viscous / liquid component of the formulation binds or moistens the dry material, resulting in a correspondingly higher density. The dry and wet formulations may provide a matrix or homogeneous mixture. The wet formulation may include the shisha formulations described above.

[0110] In some embodiments, the wet formulation may have a density of 0.3 g / mL to 0.9 g / mL (e.g., when fully loaded). In some embodiments, the wet formulation may have a density of 0.5 g / mL to 1.4 g / mL (e.g., when 55% loaded). In some embodiments, the dry formulation may have a density of 0.8 g / mL to 2 g / mL (e.g., when 40% loaded).

[0111] The wet formulation may have a weight of 5 g to 20 g, preferably 7 g to 18 g.

[0112] Once the capsule 12 is filled, it is packaged for transport and / or sale. The process is illustrated in Figure 7. In a first step 38, the capsule 12 (i.e., its internal volume) is filled with an inert gas. The inert gas helps prevent undesirable oxidation and / or contamination of the product 14, thereby providing a superior smoking experience for the user. In this embodiment, the inert gas comprises nitrogen. However, the inert gas may comprise any suitable inert gas, such as one or more of carbon dioxide, helium, argon, neon, or other noble gases.

[0113] The capsule 12 includes a low-oxygen or substantially oxygen-free environment. The environment may include 15% or less by volume of oxygen, preferably 10% or less by volume, preferably 5% or less by volume, preferably 1% or less by volume, preferably 0.5% or less by volume.

[0114] The capsule 12 may be filled with an inert gas by several methods. In a first example, shown in Figure 8, the gas is injected into the capsule 12. The gas may be injected via a needle or lance 40. The capsule 12 is partially sealed via a closure 42 (i.e., a portion of its upper rim 30). The unsealed portion is a gap 44. The lance 40 can be inserted into the gap 44 so as to be in fluid communication with the interior volume of the capsule 12.

[0115] An inert gas is injected into the capsule 12. Typically, a sufficient amount of gas is injected to displace the oxygen in the capsule (i.e., the inert gas purges or flushes out the oxygen). Therefore, the gap 44 may be wider than the lance 40 to allow the displaced air to escape. Thus, the inert gas is injected in excess. Therefore, the volume of gas injected is significantly greater than the internal volume of the capsule 12. The gas may be injected at a high pressure and / or a high flow rate to prevent oxygen partial pressure equilibration.

[0116] Once the oxygen pressure / volume reaches a predetermined level, the lance 40 may be removed. The lance 40 may include an oxygen sensor to determine the oxygen level within the capsule 12. In other embodiments, the lance 40 is removed after a predetermined time or volume of inert gas has been injected. Typically, these values are pre-calibrated depending on the size / volume of the capsule 12 or lance 40, etc.

[0117] After removal of lance 40, gap 44 is sealed. The inert atmosphere of capsule 12 is thus maintained. In some embodiments, the closure / capsule wall surrounding gap 44 is mechanically deformed (e.g., crimped or crushed) to seal gap 44. In some embodiments, gap 44 is plugged (e.g., with a passivating agent or solder, etc.). In some embodiments, gap 44 is sealed with an adhesive, etc. It will be appreciated that the exact means of sealing gap 44 is not relevant to the present invention and any suitable means may be used. Sealing of gap 44 occurs immediately after and / or during removal of lance 40. Typically, sealing occurs in less than 5 seconds, preferably less than 2 seconds, of removal.

[0118] The closure 42 and / or capsule 12 may be formed to provide a gap 44 (i.e., a passageway is formed therein). The passageway may then be crushed / filled during sealing. In other embodiments, the gap 44 may be provided by flexing of the closure 42 and / or 12. Thus, the closure 42 may be fully engaged with the capsule 12 when the lance 40 is removed. In some embodiments, the closure 42 and / or capsule 12 is provided with an opening in its wall. In some embodiments, the closure 42 and / or capsule 12 may be perforated or pierced by the lance 40. The opening / perforation may be sealed once the lance 40 is removed.

[0119] A second example is shown in Figure 9. In this embodiment, the closure 42 includes a plurality of openings or perforations 46. The openings 46 allow air to pass into the capsule 12 during use. An inert gas may be blown or otherwise forced into the capsule 12 through the openings 46, as previously described. A lance 40 may also be used. The openings 46 may be only partially covered, thereby allowing the purged air to escape.

[0120] Once purging is complete, a seal 48 is applied to the closure 42. The seal 48 is configured to seal the opening 46 in the closure 42. The seal 48 is typically removed by the user prior to use of the capsule 12. The seal 48 may comprise a flexible material. The seal 48 comprises a releasable adhesive that allows it to be peeled from the closure 42. The seal 48 is applied less than five seconds, preferably less than two seconds, after purging is complete.

[0121] Such an arrangement may be provided in any of the described embodiments. Perforations 46 allow passage into capsule 12. Seal 48 and closure 42 may be provided as a single unit, which may then be attached to capsule 12. Seal 48 is peeled away by the user prior to use, exposing perforations 46. A similar seal may be provided on base 32 of the capsule. The seal may cover multiple openings / perforations on base 32, which allows airflow through capsule 12.

[0122] In a third example, shown in FIGS. 10 and 11, the capsule 12 is sealed in an inert atmosphere 50. The inert atmosphere 50 may be provided within a containment vessel 52. The closure 42 is sealed within the inert atmosphere 50, thereby trapping the inert gas within the capsule 12. This arrangement allows for greater control of the oxygen level within the atmosphere and does not require complex mechanisms such as lance withdrawal. The inert atmosphere 50 may also "degas" the product 14 to remove any oxygen contained therein. An inlet 54 may provide the inert gas. The atmosphere 50 may be purged and / or recirculated to ensure oxygen removal. In some embodiments, an oxygen scrubber or the like may be used.

[0123] As shown in FIG. 11 , the capsules 12 may be supported on a conveyor 56. The conveyor 56 can move the capsules 12 in and out of the containment vessel 52, thereby providing a continuous process. A doorway 58 is provided within the containment vessel 52 to allow the capsules 12 to enter and exit. In this embodiment, the doorway 58 includes an air curtain 60. The air curtain 60 includes a curtain of pressurized gas. The pressurized gas partially blocks gas transfer between the interior and exterior of the containment vessel 52. This helps maintain the inert atmosphere 50 within the containment vessel 52. The air curtain 60 may be configured to release the inert gas.

[0124] In other embodiments, the inert gas may be supplied at a positive pressure (ie, overpressure), thus maintaining an inert atmosphere.

[0125] A sealing mechanism 62 configured to secure the closure 42 to the capsule 12 or otherwise provide a seal is provided within the containment vessel 52. The sealing mechanism 62 may include one or more actuators configured to move the sealing mechanism 62 into engagement with the capsule 12 and / or to provide a seal.

[0126] In some embodiments, the inert gas may be disposed within capsule 12 in a liquid and / or solid state. For example, solid carbon dioxide (dry ice) and / or liquid nitrogen may be used. This may facilitate handling of the inert gas. The solid / liquid may then be evaporated / sublimated to provide the inert gas.

[0127] In some embodiments, the capsule 12 may be purged / flushed substantially open, after which the capsule 12 may be quickly sealed to reduce loss of inert gas.

[0128] In some embodiments, the capsule 12 may include an oxygen absorbing material. The oxygen absorbing material may include an oxygen scavenger. The oxygen absorbing material may include a food-safe material. The oxygen absorbing material may include ferrous powder. The ferrous powder may be iron powder. A promoter may be provided. The promoter may include a halide, for example, a chloride. The oxygen absorbing material may include one or more of ascorbate, pyrophosphate, or an organic cobalt complex.

[0129] The oxygen absorbing material may be provided as a package (e.g., a pouch) contained within the capsule 12. The package may be air permeable, thereby allowing for the removal of oxygen. In some embodiments, the oxygen absorbing material may be coated on and / or incorporated into the capsule wall and / or closure. The oxygen absorbing material may be high temperature resistant (e.g., not combustible or decompose at high temperatures). Thus, the oxygen absorbing material does not affect the smoking experience. In some embodiments, the user may remove the oxygen absorbing material from the capsule 12 prior to use.

[0130] In some embodiments, a vacuum or partial vacuum is provided within capsule 12 .

[0131] The sealing process is shown in more detail in Figures 12 to 16. In this embodiment, the capsule 12 is sealed by mechanical (e.g., plastic) deformation of the capsule 12 and / or the closure 42. The closure 42 is crimped onto the capsule 12.

[0132] The sealing mechanism 62 is shown in detail in FIG. 12. The sealing mechanism 62 comprises a forming tool 64 configured to engage the capsule / closure. The forming tool 64 is attached to an actuator (not shown) configured to move the forming tool 64 into and out of engagement with the capsule 12. The forming tool 62 is configured to conform to the shape of the rim 30 and / or sidewall 26. Thus, the surface 66 can provide a tight fit with the capsule sidewall 26 when engaged (see FIG. 14). The forming tool 64 can be annular. Thus, the forming tool 64 can be shaped to correspond to the circular rim 30 of the capsule 12. The forming tool 64 is divided into several circumferentially discrete sections. Thus, the forming tool 64 provides a collet-like arrangement, with each section movable away from the other sections.

[0133] An actuator (not shown) may move each portion laterally 68. Thus, the collet is radially expandable. A second actuator (not shown) may move the forming tool 64 axially 70 toward / away from the capsule 12. However, it will be appreciated that a single actuator may provide both lateral and axial movement (e.g., a single actuator moving diagonally). In some embodiments, each portion of the forming tool is pivotally connected, such that lateral and / or axial movement 1 is provided by a pivoting / swivel action. It will be appreciated that the exact form of the actuator is not relevant to the present invention.

[0134] The capsule 12 may be held in a mandrel 72. The mandrel 72 may prevent deformation or collapse of the capsule 12 during the sealing process. The mandrel may engage the sidewall 26 of the capsule 12.

[0135] As shown in Figure 13, the rim 30 of the capsule 12 includes a reinforcing element 74. The reinforcing element 74 is configured to increase the structural rigidity of the rim 30 and prevent deformation thereof. In this embodiment, the reinforcing element 74 is configured by bending / rolling the edge of the side wall 26 of the capsule. Thus, the reinforcing element 74 comprises an integral part of the capsule 12. The rolling of the side wall 26 can be accomplished by conventional means. The reinforcing element 74 extends outwardly from the rim 30.

[0136] In some embodiments, the reinforcing element 74 is spaced from the capsule sidewall 26. The reinforcing element 74 may be spaced through a rim / flange. The closure 42 may fit within the rim / flange in use.

[0137] 14, the capsule closure 42 is mechanically deformed onto the capsule 12 to retain the capsule. An edge 76 of the closure 42 is deformed over the reinforcing element 74, which causes the edge 76 to be deformed over the sidewall 26 / rim 30 of the capsule 12. The edge 76 may comprise a flange, lip, rim, or the like. Thus, the edge 76 extends outward from (e.g., perpendicular to) the plane of the body of the closure 42.

[0138] Forming tool 64 includes a die or engagement surface configured to deform closure 42 into the appropriate shape. Forming tool 64 typically includes a shape corresponding to the shape of reinforcement element 74 and / or adjacent sidewall 26, thereby deforming closure 42 to provide a tight fit with reinforcement element 74. In this example, forming tool 64 includes a U-shaped engagement surface 80.

[0139] It will be appreciated that the reinforcing element 74 shown in FIG. 13 is merely exemplary, and that the reinforcing element 74 may take any form, such as, for example, a thickened sidewall portion, a flange / ring, a stud, a fastener, a ridge, a groove, a band, a roughened surface, etc. It will be appreciated that any suitable protrusion or protruding member on the capsule 12 may be suitable for retaining the closure 42 thereon. The protrusion may extend around the circumference / periphery of the capsule 12 (i.e., continuously). Alternatively, the protrusion may be provided as one or more discrete portions (e.g., as detents, etc.), which may be spaced apart around the circumference / periphery of the capsule 12.

[0140] The closure 42 may engage the capsule 12 around the entire periphery (i.e., form a continuous seal). In other embodiments, the closure 42 may engage the capsule 12 at one or more discrete points. The seal therebetween may be discontinuous / intermittent. For example, the edge 76 may deform only at one or more discrete locations. In some embodiments, the edge 76 may be provided as one or more discrete tabs.

[0141] 15 and 16, the closure 42 is retained by its wrapping. The rim 30 of the capsule 12 includes a flange 74. The flange 74 extends laterally outward from the rim 30. An edge 76 of the closure 42 is configured to overlap the flange 74. The die 64 moves to engage the flange 74 and the edge 76.

[0142] 16, as the die 64 moves toward the capsule 12, the flange 74 and edge 76 curl toward each other, ensuring a tight seal while retaining the closure 42 on the capsule 12. The die 64 typically includes a curved surface 80 to ensure effective curling of the closure 42 / flange 74.

[0143] 17 and 18, edge 76 of closure 42 is configured to overlap flange 74 of capsule 12. Forming tool 64 moves along sidewall 26 of capsule 12. Forming tool 64 engages edge 76 and flange 74, bending them toward sidewall 26 of capsule 12.

[0144] 18, the flange 74 and edge 76 press flat against the side wall 26 of the capsule. Such an arrangement may be provided for the remainder of the rim 30. The chamfered side wall 26 of the capsule 12 holds the closure 42 to the capsule 12. The forming tool 64 includes a chamfered / tapered surface 66. The chamfer may correspond to the tapered shape of the capsule 12.

[0145] The forming tool 64 moves laterally and axially (i.e., diagonally) relative to the capsule 12. In some embodiments, the lateral and axial movements are provided in two separate steps. For example, the forming tool moves axially downward in a first step to partially bend the flange 74 / outer portion 76, and in a second step moves laterally toward the capsule 12 to flatten the flange 74 / outer portion 76 against the capsule 12.

[0146] In some embodiments, the forming tool 64 is pivotable / rotatable to engage the capsule 12. For example, the forming tool 64 is pivotally mounted at its upper end. Such an arrangement provides lateral and axial movement to ensure that the flange / edge is bent in the correct direction. It will be understood that such an arrangement may be provided in all or any of the described embodiments.

[0147] When a lance 40 is used to fill the capsule 12 with an inert gas, one of the forming tools 64 may be configured to seal the capsule 12 independently of the other. The independently operable forming tool 64 may seal the capsule 12 when the lance 40 is removed.

[0148] In some embodiments, the reinforcing element 74 (e.g., a flange or rolled lip) may not be provided. This may be accommodated if the side wall 26 has a sufficient thickness to prevent buckling during sealing. The closure 42 may be directly engaged with the side wall 26 of the capsule 12.

[0149] In some embodiments, a portion of capsule 12 may be configured to deform over closure 42. For example, flange 74 may be deformed over the top surface of the capsule. In some embodiments, an interposer may be used in the crimping process. For example, a ring may be deformed over the flange / edge (i.e., to provide a clamping arrangement).

[0150] In some embodiments, the capsule 12 is sealed using a welding technique, which may include resistance welding. For example, a weld seam may be provided between the flange 74 and the edge 76. Heat sealing may also be used if the capsule / seal material is suitable.

[0151] In some embodiments, the seal may be provided by one or more of an adhesive, one or more fasteners, an interference fit, a crimp, or a rivet, however, it will be appreciated that mechanical deformation techniques are preferred due to their ease of application, ability to maintain a good seal, and stability at high temperatures.

[0152] In some embodiments, a seal may be provided over the seal or partial seal between capsule 12 and closure 42. For example, a polymer strip may be overlaid over the seal between capsule 12 and closure 42. The strip may be heat sealed or heat shrunk to capsule 12 / closure 42.

[0153] It will be appreciated that some of the above techniques may provide a substantially airtight or liquid-tight seal between the capsule 12 and the closure 42. Thus, the capsule 12 is generally airtight. This prevents the release of inert gases and / or the ingress of oxygen. If an inert atmosphere is not required, only a partial barrier between the closure 42 and the capsule 12 is required. Thus, the seal between the capsule 12 and the closure 42 need only be sufficient to prevent significant egress of the viscous fluid.

[0154] In the next step 82, the sealed capsules 12 are packaged. In this embodiment, the capsules 12 are packaged using a "flow wrap" method. Package 84 is shown in Figure 16. The package comprises a flexible / deformable material. Typically, the material comprises a plastic film (e.g., a heat-sealable plastic). The material is provided in an elongated strip. The elongated strip may be provided on a roll or drum. The plastic film is folded transversely to form an elongated tube. The edges of the film are sealed, forming an axial seam 86. The capsules 12 are then placed within the tube. A transverse seam 88 is provided across the package 84, and the capsules 12 are individually packaged. The general aspects of the flow wrap process are known and will not be described further.

[0155] The flow wrap process produces a semi-continuous strip of capsule packaging 84. The strip is then divided by cutting across the transverse seam 88, as shown at 90, to form a plurality of individual packages. In some embodiments, packaging 84 may be provided in strip form. The user can then use each package as needed. In some embodiments, transverse seam 88 may be frangible. The transverse seam 88 may be provided with a plurality of perforations, score lines, or the like. The strip and / or individual packages 84 may be provided in additional containers, for example, for shipping.

[0156] During the packaging process, the package 84 is filled with an inert gas, which helps to further reduce oxidation and / or other contamination of the product 14. It may also help to further reduce the oxygen content within the capsule 12, as oxygen can dissipate therefrom. The inert gas may include any of the gases described above.

[0157] The packaging process is shown in detail in Figure 17. Package 84 is shown in a partially assembled stage. An axial seam 86 (not shown) and several transverse seams 86 have been formed, enclosing capsule 12a within first package 84a. A second capsule 12b is provided within partially sealed package 84b (i.e., only an axial seam 86 and a single transverse seam 86 are provided). A lance 90 is inserted into open end 91 of package 84. Lance 90 is configured to purge / flush package 84 with an inert gas, as previously described.

[0158] Once the package is flashed, it is sealed. A sealing mechanism 92 is used to create the transverse seam 86. The sealing mechanism 92 includes heated heads 94 configured to engage the package and provide a heat seal (i.e., a weld) thereon. A plurality of heads 94 are provided in an opposing arrangement. The heads 94 move together to sandwich the package 84 therebetween (e.g., in a clamping arrangement). Typically, the heads 94 remain on top of the package 84 to ensure proper sealing.

[0159] The packaging strip is then advanced and a new capsule 12 is placed into the partially sealed package 84 and the process is repeated.

[0160] The package 84 may be partially formed before and / or during insertion of the lance 90. This helps reduce inert gas release and / or oxygen re-entry. As shown in FIG. 18, the transverse seam 86 extends only partially across the package 84. A gap 96 is provided to allow for insertion of the lance 90. The gap 96 may be provided adjacent a lateral side 98 of the package. Once flushing is complete, the gap 96 is sealed.

[0161] In some embodiments, the sealing mechanism 92 may be configured to move laterally across the package 84 to sequentially form seals. For example, the sealing mechanism may include a heated wheel or roller configured to move across the package 84. The sealing mechanism 92 moves a first distance to form the partial transverse seam 88, and then, once the lance 90 is removed, moves a second distance to seal the gap 96. It will be appreciated that a similar effect can be achieved by moving the package 84 laterally relative to the sealing mechanism 92.

[0162] In some embodiments, the sealing mechanism 92 includes multiple independently actuatable heads 94. A first head 94 is configured to form the partial seam 88, and a second head is configured to seal the gap 96 when the lance 90 is removed. Thus, the heads 94 may be configured with different lateral lengths.

[0163] The lance 40 may be attached to an actuator to allow extraction from the package 84. In other embodiments, extraction is effected by advancing the package 84 relative to the lance 40. Thus, the lance 40 may be stationary / fixed. For example, a second sealing head may be provided downstream of the first sealing head 94 and the lance 40. Thus, once the transverse seam 88 has advanced past the end of the lance 40, the second head engages the package 84 and seals the gap 96.

[0164] The gap 96 is wide enough to provide space between the lance 40 and the end of the transverse seam 88, allowing the purged gas to escape and the inert gas to enter the package. The lance 40 is inserted into the package to a sufficient depth (i.e., a distance beyond the transverse seam 88) to allow the inert gas to enter and circulate within the package.

[0165] In an alternative embodiment shown in FIG. 19 , inert gas is injected into the package 84 without forming a partial transverse seam 86. Gas 100 is continuously blown into the partially formed package 84 through an exhaust port 102. The inert gas inflates the tube formed by the longitudinal seam 86. The inert gas is maintained at a constant pressure. A sealing mechanism 92 forms the transverse seam 86 (i.e., pinches the inflated tube) as the blowing continues, forming a sealed package and trapping the inert gas. This arrangement eliminates the need for the extraction of the lance 40 or the complex sealing mechanism 92. However, because the inert gas is continuously blown, there is a possibility that the inert gas will be released, wasting resources. In some embodiments, the package 84 may be held or sealed against the gas exhaust port 102 to prevent the release of the inert gas.

[0166] Typically, the flow wrap arrangement comprises a vertical flow wrap arrangement, in which the capsules 12 are filled into the package 84 by gravity. However, the flow wrap arrangement may be provided in any suitable orientation (e.g., horizontal or angled arrangement). The capsules 12 may be supported on a conveyor.

[0167] In some embodiments, the inert gas may be inserted into the package 84 once it is fully sealed. For example, the lance 90 may be configured to pierce or otherwise penetrate the package 84 to inject the inert gas. The penetration may then be sealed (e.g., using heat sealing) once the lance 90 is removed. In some embodiments, the package 84 includes a one-way valve to allow filling thereof.

[0168] It will be appreciated that when capsule 12 is contained within packaging 84, release of product 14 and / or its volatile components into the environment is prevented. Therefore, providing an inert capsule environment may not be necessary, and the capsule flushing step may be entirely optional. Additionally or alternatively, an airtight or liquid-tight seal of closure 42 on capsule 12 may not be necessary.

[0169] In a further embodiment, the capsule 12 is contained within a blister package. Referring to FIG. 20 , the capsule 12 is contained within a blister pocket 122. The pocket 122 is similar in shape to the capsule 12. However, the pocket 122 is larger than the capsule 14, thereby leaving a gap 124 between the capsule 14 and the walls of the pocket 122 during use. This provides space for containing an inert gas, as previously described. The pocket 122 may comprise a flexible or deformable material. Blister packaging allows the user to push the capsule out, reducing the amount of manual effort required and, as a result, reducing the likelihood of the user coming into contact with a sticky or tacky product.

[0170] A lid sheet 126 is secured over the pocket 122. The lid sheet 126 comprises a tearable, rupturable, or other destructible material. Typically, the lid sheet 126 comprises foil, such as aluminum foil. In other embodiments, the lid sheet comprises a paper-based material or a suitable polymer. The lid sheet 126 may include a breakable line or frangible portion.

[0171] The lid sheet 126 may be attached using any suitable means, such as, for example, heat sealing, welding, adhesive, crimping / deforming, fasteners, etc. The lid sheet 126 and the blister pockets 122 are joined via seams 128. The seams 128 separate each pocket, sealing the blisters individually. The blister packs may be separated by cutting along the seams 128.

[0172] In some embodiments, the smoking article 14 may be placed directly into a flow-wrap package or blister package. Thus, the capsule 12 is optional, and the user may place the product 14 into the tray of a hookah pipe. However, it will be appreciated that this arrangement may not be optimal, as the product may be crushed or compressed during shipping / storage, thereby affecting its density. In some embodiments, the packaging may be rigid to prevent compression of the smoking article 14. In some embodiments, the packaging may be over-inflated to provide a cushion or barrier for the product 14.

[0173] In some embodiments, capsule 12 includes an agitator. The agitator is configured to mix, stir, or otherwise agitate product 14. This can create air passages within the product, aid in the passage of air through product 14, and help separate vaporized smoking product from a solid mass. Providing an agitator in conjunction with capsule 12 allows the end user to agitate product that may settle during storage / transport, for example.

[0174] In a first embodiment, shown in Figure 20, the agitator comprises a mechanical agitator 104. The agitator 104 comprises one or more blades 106. The blades 106 are attached to a base 108. The base 108 is rotatable, thereby allowing the blades 106 to rotate. The blades 106 are generally upright (i.e., extending between the top / base of the capsule 12). Thus, the blades 106 extend through the product during use. The base 108 typically extends parallel to the base 32 of the capsule 12.

[0175] The agitator 104 is attached to the capsule 12 via a rotatable joint / mount. Thus, the agitator 104 is fixed / mounted to the capsule 12. The joint may comprise a bearing or the like. In this embodiment, the agitator 104 is attached to the base 32 of the capsule. However, it will be appreciated that the agitator 104 may be attached to any suitable location, such as, for example, the side wall 26 and / or the closure 42.

[0176] The blades 106 are angled relative to the base 108. The blades 106 may be angled between 45 degrees and 90 degrees relative to the base 108. Thus, the blades 106 extend axially and radially. In some embodiments, the blades 106 and the base may be substantially contiguous. The blades 106 / base 108 may be curved (e.g., to define a U-shaped or cup-shaped blade).

[0177] The blades 106 and / or the bottom portion 108 may comprise wires or the like. For example, the blades 106 and / or the bottom portion 108 may be less than 2 mm in width / thickness. This may provide sufficient agitation if the product 14 is uneven. In other embodiments, the blades 106 and / or the bottom portion 108 may have a substantial thickness. Thus, the blades 106 and / or the bottom portion 108 may provide a paddle-like arrangement.

[0178] A plurality of blades 106a, b may be provided. Different lengths, Different widths / thicknesses, Different angles to the bottom, Different shapes / profiles, Different radial positions (i.e. relative to the axis of rotation) The device may be provided with one or more of the following.

[0179] The agitator 104 is operatively connected to an actuator 110 to effect its rotation. The actuator 110 may comprise a manual actuator. The actuator 110 may comprise a handle or grip 112 for actuation thereof. The actuator 110 may comprise a key or the like. The key may be removable.

[0180] In some embodiments shown in Figure 21, agitation of the product 14 is accomplished by pneumatic means. The capsule 12 includes an inlet 112 that allows the entry of pneumatic gas (e.g., air). A gas pump / compressor 114 is operatively connected to the inlet 112. The air pressure / air flow from the pump 114 is sufficient to agitate the product 14 and provide air passage and / or mixing.

[0181] In some embodiments, the pump 114 comprises a manual pump. The pump 114 may comprise a flexible diaphragm / bellows or the like, so that a user may manually squeeze the pump 114. The pump 114 may comprise a one-way valve arrangement to re-inflate the diaphragm / bellows. In some embodiments, the volume of the pump 114 is sufficient for agitation, and no valve arrangement is necessary.

[0182] In some embodiments, pump 114 may comprise a mechanical (e.g., electric) pump. In some embodiments, pump 114 may comprise a compressed gas reservoir. For example, pump 114 may comprise a compressed gas cylinder.

[0183] The pump 114, or a portion thereof, may be configured to be insertable into the capsule 12. For example, a nozzle 116 may be insertable into the capsule 12. The nozzle 116 may be receivable within an opening 118 in the capsule wall. The opening 118 may be sealed by a removable seal. Alternatively, the pump 114 may expel air through a perforation formed in the base of the capsule 12.

[0184] In some embodiments, the capsule 12 and / or product 14 includes an element 120 configured to change shape in response to a change in temperature. In a first embodiment, shown in FIG. 22, the element 120 is configured to deform in response to a change in temperature. The element 120 comprises a shape memory alloy (SMA). The SMA is configured to deform when a threshold (relaxation) temperature is reached. When the capsule 12 is heated during use, the SMA element 120 changes shape, thereby agitating the product 14. For example, the element 120 deforms from a straight shape to a curved / coiled shape at the relaxation temperature.

[0185] It will be appreciated that such an arrangement is merely exemplary and that any suitable configuration may be used. Multiple elements 120 may be used. The elements 120 may be dispersed throughout the product 14. The elements 120 may have different shapes and / or sizes. The elements 120 are substantially temperature stable and do not degrade even at high temperatures (e.g., 200-300°C). This prevents the release of contaminants and the like.

[0186] In some embodiments, element 120 is configured to expand and / or burst upon heating. In this embodiment, element 120 comprises corn (maize) kernels. The kernels burst / expand upon application of heat, stirring product 14. The burst kernels may burn / disintegrate with product 14 as it burns / volatilizes, which may add additional flavor to product 14. It will be appreciated that element 120 may comprise any object configured to expand / burst upon heating.

[0187] In some embodiments, the capsule may include a material configured to release a gas, which may increase the porosity of the product 14. The gas may be produced by combustion and / or decomposition of the material. For example, the material may include sodium bicarbonate. The material may include an acid-alkali mixture configured to produce a gas upon reaction. The material may include a foaming agent and / or effervescent agent. It will be appreciated that the element 120 may include any suitable material configured to significantly expand upon heating.

[0188] In some embodiments, the agitator may comprise an electrically conductive material. For example, the agitator may comprise ferrite or a similar material. The agitator may provide an inductive element such that the agitator becomes a heater when exposed to an induction heating field. Thus, the pod is heated from the inside.

[0189] The capsule 12 is shown in detail in Figures 28 and 29. The capsule 12 includes a plurality of openings 132 in the closure. An opening 134 is provided in the base 32. The openings 132, 134 allow air to pass through the capsule 12. The openings may be formed by any suitable means, such as one or more of notches, perforations, a mesh, a grid, or other porous surface.

[0190] The size and / or density of the openings 132, 134 are optimized to allow an optimal amount of air to pass through without causing excessive leakage. The total area effectively occupied by the openings is 1% or more of the total lid / base area, preferably 3% or more, preferably 5% or more, preferably 7% or more. The total area effectively occupied by the openings is 15% or less of the total lid / base area, preferably 10% or less, preferably 8% or less, preferably 5% or less.

[0191] The openings in the lid 42 and the base 32 may have the same total effective area (i.e., the same amount of air entering the lid 32 may exit through the base 32). In other embodiments, the base 32 may have a smaller total effective area than the lid 42. This prevents excessive leakage. The total effective area of the openings in the base 32 may be 95% or less of the total effective area of the lid 42, preferably 90% or less, and preferably 80% or less. The percentage of the total effective area of the openings 132, 134 may be proportional to the total area of the base 32 and the lid 42 (i.e., the spacing / size of the openings is the same as the base 32 and the lid 42).

[0192] In some embodiments, the openings in the lid 42 and the base 32 may be the same size. In some embodiments, the openings in the lid 42 and the base 32 may be different sizes. For example, the opening 134 in the base may be smaller than the opening in the lid 42 to prevent excessive leakage.

[0193] This arrangement ensures that the thermal and hydrodynamic properties of the smoking product provide a consistently superior experience. A consistent and / or determined density helps prevent undesirable clumping or separation of ingredients in the smoking product. An attached agitator can further help prevent clumping. The inert gas maintains product freshness.

[0194] The density and / or fill provided helps ensure adequate airflow through the smoking article during use, which in turn ensures an appropriate pressure drop through the device, providing an optimal user experience. Optimized airflow aids in the transfer of heat to the smoking article and ensures that vaporized product is carried along in the airflow past the smoking article.

Claims

1. A method for filling a water pipe capsule with a consumable, wherein the consumable comprises a mixture of a solid component and a liquid component arranged to be vaporizable upon use, and the method is: De-aggregating or reducing the density of the mixture of the aforementioned consumables, Filling the capsule with a predetermined amount of the consumable, This includes sealing the capsule containing the mixture of the consumables, The method wherein the consumable contained in the capsule has a predetermined density of 1.8 g / mL or less.

2. The method according to claim 1, wherein the consumable contained in the capsule includes tobacco or a non-tobacco shisha product having a predetermined density of 1.2 g / mL or less.

3. The method according to claim 1 or 2, comprising leveling the consumable after filling the capsule, leveling the consumable at the same height as the edge or rim of the capsule, and / or leveling so that the consumable is of substantially uniform depth.

4. The method according to claim 1 or 2, wherein the consumable is compressed after deagglomeration in order to provide the predetermined density.

5. The method according to claim 4, comprising redispersing the consumables within the capsule before compression.

6. The method according to claim 1 or 2, wherein the product accounts for at least 80%, preferably at least 90%, of the internal volume of the capsule.

7. This includes providing an inert atmosphere inside the capsule, The method according to claim 1 or claim 2, wherein the internal volume inside the capsule is flushed / purged with an inert gas before sealing the capsule.

8. The method according to claim 1 or 2, wherein the capsule comprises a metal material and is sealed using an attached sealing device.

9. The method according to claim 8, wherein the capsule comprises an outwardly extending rim or flange, and the capsule is mechanically deformed on the rim / flange to hold the sealant on the capsule and / or to provide a seal between the sealant and the capsule.

10. The method according to claim 1 or 2, wherein the seal between the sealing device and the capsule is porous, and the capsule is provided in separate packaging filled with an inert atmosphere.

11. The method according to claim 10, wherein the capsule is substantially shielded from the inert atmosphere when inserted into the separate packaging.

12. The method according to claim 1 or claim 2, comprising stirring the consumable sealed inside the capsule.

13. A capsule for a hooker pipe having a consumable part arranged to vaporize when used, Equipped with a predetermined amount of deagglomerated or dedensified consumables, The capsule contains the consumables having a predetermined density of 1.8 g / mL or less.

14. The capsule according to claim 13, wherein the density of the consumable is 0.05 g / mL to 0.4 g / mL or 0.2 g / mL to 0.9 g / mL.

15. It has end walls connected to side walls that define a cavity for receiving consumables, The end wall has a plurality of openings to allow air to pass through the consumables during use. The capsule according to claim 13 or 14, wherein the total area effectively occupied by the opening is at least 5% of the total area of ​​the end wall.

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