Vapourisable Product and Method of Manufacture

Description

This disclosure concerns vapourisable and/or inhalable products for consumption by users and methods of production associated with the provision of such products in capsule form.

BACKGROUND OF THE INVENTION

A prior art hookah 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 a vapour, which is then inhaled through a hose.

The inventor has found numerous problems with prior art capsules. The capsules typically contain a shisha or Mu'assel product, which comprises a mixture of tobacco, molasses and glycerol. The shisha product is sticky, syrupy or otherwise viscous and during transit or storage of the capsule, the shisha may agglomerate. This reduces the effective surface area of the shisha, thereby reducing the amount and/or quality of vapour produced. For example, the product in the middle of the agglomeration may fail to reach sufficient temperature to produce vapour and/or the vapour may be unable to permeate through the high-density product.

Uneven heating of the product or vapour production may provide a reduced smoking experience of the user due to the inconsistency of vapour produced. It may also lead to portions of the shisha product either becoming burnt or not sufficiently heated at all, thus either compromising taste or wasting product.

Additionally, overtime, the volatile ingredients in the shisha product may vaporise and escape from the capsule. This alters and/or diminishes the flavour profile, resulting in an unsatisfactory smoking experience. Similarly, one or more components in the shisha product may oxidise, altering the flavour thereof. The capsule may leak liquid components of the product, thus wasting some of the product and making the capsule difficult to handle.

It is an aim of the present invention to overcome or ameliorate one or more of the above problems.

STATEMENT OF INVENTION

According to a first aspect of the invention, there is provided: a method of filling a capsule for a hookah pipe with a consumable product, the consumable product comprising a mixture of a solid and liquid component, the method comprising: de-agglomerating or rarefying the consumable product mixture; filling the capsule with a predetermined amount of the consumable product, and sealing the capsule with the consumable product mixture therein.

The capsule may comprise a disposable and/or non-reusable capsule. The capsule may be permanently sealed.

The consumable product contained within the capsule may comprise a pre-defined density of less than or equal to 1.8 g/ml; The smoking product contained within the capsule may comprise a pre-defined density of less than or equal to 1.2 g/ml; preferably, less than or equal to 0.8 g/ml.

The method may comprise levelling the product after filling the capsule. The product may be levelled to a position level with an edge or rim of the capsule (e.g. level with an opening of the capsule).

The product may be compacted after de-agglomeration to provide the pre-defined density. The method may comprise redistributing the product within the capsule before compaction thereof. Redistribution or levelling may provides a substantially uniform depth of product in the capsule.

The product may occupy substantially all of the internal volume of the capsule. The product may occupy at least 80% of the internal volume of the capsule; preferably, at least 90%.

The product may occupy a portion of the internal volume of the capsule. The product may occupy less than or equal to 80% of the internal volume of the capsule, e.g. less than or equal to 60% The product may occupy greater than or equal to 20%; preferably, greater than or equal to 30%. The product may occupy between 25% and 80% of the internal volume of the capsule, e.g. between 30% and 65%.

The capsule may comprise 2 g-40 g of the consumable product. The capsule may comprise greater than or equal to 4 g, 6 g or 8 g of the product. The capsule may comprise less than or equal to 35 g, 30 g, 25 g or 20 g of the product. The capsule may comprise 10-20 g or 20-30 g of the product.

In any examples herein, the density of the product may be defined relative to the volume of the product or relative to the internal volume of the capsule. The consumable product may or may not fill the capsule internal volume at the specified.

The product may comprise or consist of a consumable or vapourisable product, for example a smoking product. The product may comprise an active or volatile ingredient.

The capsule may comprise a metallic material. The capsule may be single use. The capsule may disposable. The capsule may comprise aluminium.

The method may comprise providing an inert atmosphere within the capsule. The internal volume within the capsule may be flushed/purged with an inert gas. The capsule may be flushed/purged with an inert gas before closure of the capsule.

The capsule may be closed using a closure/lid affixed thereto. The closure and/or capsule are mechanically deformed to retain the closure on the capsule and/or provide a seal therebetween. The closure and/or capsule may be plastically/permanently deformed.

The capsule may comprise an outwardly extending rim or flange, and the closure is deformed onto the rim/flange. The rim flange may comprise a stiffening element. The closure may be deformed onto/over the stiffening element. The stiffening element may comprise a bead or rolled/curled edge.

The closure and/or capsule may be crimped or curled to provide a seal therebetween.

The seal between the closure and capsule may be porous. The internal environment may be fluidly connected to the external/ambient environment.

The capsule may provided in a further package. The further package may be filled with an inert atmosphere. The capsule may be substantially devoid of the inert atmosphere.

The further package may comprise a blister package. The further package may comprise a flexible package (i.e. the package is not self-supporting). The further package may comprise a polymer. Each capsule may be provided in an individual, sealed blister pocket. The blister package may be closed via a lidding sheet. The lidding sheet may be heat-sealed to the blister pocket.

The further package may comprise a flow wrap package. The method may comprise creating package using a flow-wrap process. The method may comprise filling the package with an inert atmosphere during the flow wrap process. The capsule may be placed in the package during the flow wrapping process. The smoking product may be placed directly in the flow wrap package.

The method may comprise agitating the product sealed inside the capsule.

The product may comprise shisha or Mu'assel. The shisha product may comprise tobacco. The shisha product may comprise a tobacco substitute. The tobacco substitute may comprise an organic substate. The tobacco substitute may comprise cannabis, tea or hemp.

The product may comprise a sweetener (e.g. molasses). The product may comprise a mist-maker (e.g. glyercol). The product may comprise both a wet and dry component (e.g. a liquid and solid component).

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

The product may comprise one or more inert bead.

According to a further aspect, there is provided: a capsule for a hookah pipe having a consumable or vapourisable product comprising: a predetermined amount of the product; where the product contained within the capsule comprises a pre-defined density of density of less than or equal to 1.8 g/ml.

The product may comprise a dry product. The density of the smoking product may be between 0.05 g/ml and 0.4 g/ml. The density of the product may be between 0.05 g/ml and 0.3 g/ml.

The vapourisable product may comprise a wet product. The wet product may comprise a liquid or viscous material. The wet product may comprise a dry product bound or wetted by a liquid/viscous product. The density of the smoking product is between 0.2 g/ml and 0.9 g/ml. The density of the smoking product is between 0.3 g/ml and 0.8 g/ml.

The capsule may comprise an agitator configured to agitate the smoking product within the capsule.

The agitator may comprises one of more of: a shape memory alloy; an explosive material; a gas releasing material; rotatable blade; or pneumatic device. The agitator may comprise a handle or actuator. The handle or actuator may be accessible from outside the capsule.

The hookah pipe may comprise a conventional hookah pipe (e.g. heated using coal or the like). The hookah pipe may comprise an electronically heated hookah pipe.

According to a further aspect, there is provided: a capsule for a smoking product comprising: an agitator configured to agitate the smoking product within the capsule.

According to a further aspect of the invention, there is provided: a capsule for a vapourisable product comprising: an end wall connected to a side wall to define a cavity to receive a smoking product; the end wall comprising a plurality of apertures therein to allow air to pass through the smoking product in use, where the total area effectively occupied by apertures is at least 1% of the total area of end wall.

Preferably, the total area effectively occupied apertures is at least 5% of the total area of end wall.

The capsule may comprise first and second end walls spaced by the side wall, and the first and/or second end walls comprise apertures.

Any optional or preferable features described in relation to any one aspect of the invention may be applied to any further aspect, wherever practicable.

DETAILED DESCRIPTION

Practicable embodiments of the disclosure are described below in further detail, by way of example only, with reference to the accompanying drawings, of which:

FIG. 1 shows a schematic view of a filling process;

FIG. 2 shows a schematic side view of a filling step;

FIG. 3 shows a schematic side view of a levelling step;

FIG. 4 shows a schematic side view of a compacting step;

FIG. 5A shows a first schematic side view of a compacted product;

FIG. 5B shows a second schematic side view of a compacted product;

FIG. 5C shows a third schematic side view of a compacted product;

FIG. 6A shows a schematic side view of a product comprising beads;

FIG. 6B shows a schematic side view of a product comprising beads and a compacted product;

FIG. 7 shows a schematic view of a packaging process;

FIG. 8 shows a schematic side view of a first gas filling process;

FIG. 9 shows a schematic side view of a second gas filling process;

FIG. 10 shows a schematic side view of a third gas filling process;

FIG. 11 shows a schematic side view of a fourth gas filling process;

FIG. 12 shows a schematic side view of a crimping apparatus;

FIGS. 13 and 14 shows a schematic side view of a first crimping process;

FIGS. 15 and 16 shows a schematic side view of a second crimping process;

FIGS. 17 and 18 shows a schematic side view of a third crimping process;

FIG. 19 shows a schematic view of a flow wrap package;

FIG. 20 shows a schematic side view of a first package gas filling process;

FIG. 21 shows a schematic front view of a first package gas filling process;

FIG. 22 shows a schematic side view of a second package gas filling process;

FIG. 23 shows a schematic side view of a blister package;

FIG. 24 shows a schematic view of a first agitation mechanism;

FIG. 25 shows a schematic view of a second agitation mechanism;

FIG. 26 shows a schematic view of a third agitation mechanism;

FIG. 27 shows a schematic view of a fourth agitation mechanism;

FIG. 28 shows a perspective view of a capsule;

FIG. 29 shows a sectional side view of a capsule.

Referring a to FIG. 1, a capsule filling process is described. In a first step 2, the vapourisable product is manufactured. The manufacture may be conventional and will not be described in detail. The vaporisable or consumable product is described herein as a smoking product, although it will be appreciated that the product may not be consumed by combustion. Preferably the product undergoes controlled heating such that it does not ignite in use.

The smoking product comprises a “mist-maker”. The mist-maker is configured to create a cloud when vapourised. The mist-maker comprises a volatile material configured to provide a light-scattering cloud in a vaporised state. The mist-maker comprises a polyol. The polyol may comprises one of 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 comprise a “sugar alcohol” (hydrogenated sugar).

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

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

In some embodiments, the sweeteners comprise artificial sweeteners. The artificial sweeteners may comprise one or more of: sodium, calcium or ammonium saccharin salts; dihydrochalcones; rebaudiosides; mogrosides; glycyrrhizin; dipotassium glycyrrhizin; glycyrrhizic acid ammonium salt; L-aspartyl-L-phenylalanine methyl ester (aspartame); the sodium or potassium salt of 3,4-dihydro-6-methyl-1,2,3-oxathiazine-4-one-2,2-dioxide (Acesulfame-K); extracts of Stevia rebaudiana (Stevioside); extracts of Richardella dulcifica (Miracle Berry); orextracts of Dioscoreophyllum cumminsii (Serendipity Berry).

It can be appreciated that any of the above sweeteners may be combined with any of the other above sweeteners or classes of sweeteners.

The product comprises a flavouring. The flavouring may comprise, inter alia, one or more of: mint; such as peppermint and spearmint; chocolate; liquorice; citrus and other fruit flavours; gamma octalactone; vanillin; ethyl vanillin; or breath freshener flavours. The above-described sweeteners may comprise an example of a flavouring but typically both a sweetener and a further flavouring are provided.

The flavouring may comprise spice flavours, for example, one or more of: cinnamon; methyl salicylate; linalool; bergamot oil; geranium oil; lemon oil; or ginger oil. The flavouring may comprise plant extracts or essential oils. The flavouring may comprise a food-based flavouring, for example, one or of: apple flavouring; blueberry flavouring; coconut flavouring; grape flavouring; guava flavouring; pomegranate flavouring; or lemon flavouring etc. The flavouring may comprise a fruit or plant flavour. The flavouring may comprise one or more of: an acid; an alcohol; an ester; an aldehyde; a ketone; or a pyrazine.

The product, e.g. the flavouring thereof, may comprise a stimulant. The stimulant has a stimulatory effect on the central nervous system and may induce alertness in a subject. The stimulant may comprise one or more: caffeine (1,3,7-trimethylxanthine); taurine (2-aminoethanesulfonic acid); theobromine (3,7-dimethylxanthine); or their derivatives.

In some embodiments, the stimulant is provided by a plant-based extract forming part of the flavouring. The plant extract may comprise one or more of: coffee; black tea; green tea; matcha; mate; kola nut; cocoa; ginseng; guarana; or a cannabinoid such as tetrahydrocannabinol (THC) or cannabidiol (CBD). In other embodiments, the stimulant may comprise an additive provided in addition to the flavouring. For example, a coffee flavouring may be enhanced with additional caffeine.

The product may comprise Cannabis or Cannabis derived products. The cannabis product may comprise a part of a cannabis plants, for example, one or more of: bud; flowers; fruits; leaves; stems; kief; oil. The cannabis may be raw or processed. [Do we want to keep specific cannabis formulation for new patent?]

The product may comprise a colourant. The colourant may provide a coloured product 30 and/or smoke. The colourant comprises a food, pharmaceutical or cosmetic safe colourant. The colourant comprises a water-soluble colourant. The colourant comprises a plant based colourant, for example, one or more of: beet juice; brazilwood; caramel; carminic acid; litmus; logwood; orchil; or saffron. In some embodiments, the colourant comprises an artificial colourant.

In a specific embodiment, the smoking product comprises a shisha or Mu'assel. The shisha comprises tobacco. The tobacco may be shredded or otherwise particulated. The tobacco is mixed with a sweetener (e.g. molasses) and a mist-maker (e.g. glyercol). The shisha is thus provided as a viscous, semi-solid. In some embodiments, the shisha may be tobacco free. The shisha may comprise a nicotine additive and/or substitute. The shisha may comprise a tobacco substitute. The tobacco substitute may comprise an organic substate.

In some embodiments, the smoking product may be provided on an inert substrate. The substrate comprises an inert or food safe material. The inert material is configured to not to melt, combust, decompose or otherwise deteriorate when exposed to heat. For example, the inert material is temperature stable to at least 200° C.; at least 250° C.; or at least 300° C.

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; foamed glass; or aluminosilicate glass.

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 minerals); 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.

In some embodiments, the inert material comprises a stone/rock material (i.e. a natural substance containing 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; or the like.

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

In some embodiments, the inert materials comprises one or more of: activated carbon powder; graphite powder; graphene; carbon fibre or the like.

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

In some embodiments, the inter filler may comprise a sand or granules (e.g. a crushed or fine particulate). 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 has a grainy/sandy consistency and does not form suspensions in the air in the manner of finer particulates such as powders and dust. This may reduce the health risks associated with fine powders.

In a specific embodiment, the substate comprises: stone; glass; ceramic; pumice or sand.

The product may be provided on the surface of the substrate (e.g. provides a coating on the substrate). The substrate may there provide a core. The coating may cover substantially the whole surface of the substrate, thus maximising the surface area of the product. The coating may comprise a uniform thickness across the surface of substrate. The substrate may comprise rounded/spherical shape. The product and the substrate thus define a bead like arrangement.

In some embodiments, the smoking product may be provided as plurality of particles. The particles may be granular and/or powdery. The particles may be sticky or otherwise prone to agglomeration.

It can be appreciated that the smoking product comprises is generally viscous. The smoking product may comprise a viscous liquid, a semi-solid, a liquid-solid mixture, fluent solid and or combinations thereof. The smoking product is generally fluent. The smoking product may comprise a viscosity greater than or equal to 10 Pa·s; preferably, greater than or equal to 100 Pa·s; preferably, greater than or equal to 1000 Pa·s

The product may then be transported to capsule filling location. During manufacture, transport and/or storage, the smoking product may agglomerate or settle. Additionally, or alternatively, the product may fractionate. For example, the liquid/viscous components of the shisha product may separate from the solid components. Thus, in a second step 4, the product is deagglomerated and/or homogenised. De-agglomeration comprises any suitable process to aerate, rarify, fluff or otherwise reduce the density of the product.

Deagglomeration/homogenisation may be performed using any suitable means agitation means. In some embodiments, the product is agitated using a mechanical means. The mechanical means may comprise an agitator or stirrer. The agitator/stirrer may comprise one or more of: a rod; a blade; a paddle; screw; whisk; propeller; wire shredder; or the like. The agitator/stirrer may be rotatable or otherwise movable.

In some embodiments, the product is deagglomerated using a pneumatic means. For example, product is exposed to one or more jets of high-pressure air.

In some embodiments, the product is deagglomerated is performed via a dynamic process (i.e. the product as a whole is moved). This process may comprise one or more of: tumbling; shaking; tossing; vibrating; or the like.

In some embodiments, one or more components of smoking product may be provided to the filling location separately. Thus, the deagglomeration/homogenisation step may be used as part of manufacturing process to mix the components together. For example, the dry components. Such as the tobacco, and the wet components, such the glycerol/molasses, are provided separately and first mixed at the filling location.

Deagglomeration is performed until the product comprises desired a mechanical and/or compositional consistency or homogeneity. Deagglomeration may be performed until the product has reached a certain density. The density of the deagglomerated/rarefied product 14 may less than or equal to 2.5 g/ml; preferably less than or equal to 2 g/ml; preferably less than or equal to 1.5 g/ml; preferably less than or equal to 1.2 g/ml; preferably less than or equal to 1 g/ml; preferably less than or equal to 0.8 g/ml; preferably less than or equal to 0.7 g/ml; preferably less than or equal to 0.5 g/ml. The density of the deagglomerated/rarefied product 14 may be at least 0.05 g/ml; preferably at least 0.1 g/ml; preferably at least 0.2 g/ml; preferably at least 0.3 g/ml; preferably at least 0.4 g/ml. The density of the deagglomerated/rarefied 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 a specific embodiment, the density be may be 0.45 g/ml or 0.62 g/ml.

In the next step 6, a capsule is filled with the product. The product is divided into a number of portions of a predetermined weight/volume. Each of the portions is filled into a respective capsule. Each portion of product may comprise a mass of less than or equal to equal to 200 g; preferably, less than or equal to 100 g; preferably, less than or equal to 50 g; preferably, less than or equal to 40 g; preferably, less than or equal to 30 g; preferably, less than or equal to 20 g. Each portion of product may comprise a mass of greater than or equal to 1 g; preferably, greater than or equal to 1.5 g. Each portion of product may comprise a mass between 1 g and 30 g; preferably, between 1.5 g and 20 g.

The portions may be weighed/measure using any suitable means. The portions may be weighed/measure using a multihead weighing machine. The weighing machine may comprise dimpled and/or perforated contact surfaces.

The product may be cooled and/or frozen before/during the filling process. The product may be processed in a low humidity environment. This makes handling of the sticky shisha product easier. Vibrations may be applied to the weighing machine and/or to the capsules during filling to reduce sticking of the product to the capsule or machine.

The capsule 12 filled with product 14 is shown in FIG. 2. The capsule 12 comprises a frustoconical shape (i.e. is trapezoidal in profile). The capsule 12 is chamfered or tapered toward a base portion thereof.

The capsule 12 comprises a heat-resistant material. The capsule comprises a thermally conductive material to allow heat pass thereinto. The capsule 12 comprises a metallic material. The metallic material may comprise aluminium. The capsule 12 may comprise a deformable/malleable material. The capsule may be formed and/or stamped from a sheet material. The material may comprises a thickness less than or equal to 0.5 mm; preferably, less than or equal to 0.3 mm; less than or equal to 0.2 mm

During the filling step 6, the product 14 may be unevenly distributed within the capsule 12 (i.e. as a natural result of the filling process). In the example shown in FIG. 2, the product 14 is piled higher in a central area 16 thereof. Therefore, in a next step 8, the product 14 is levelled/uniformly distributed.

Levelling may be performed using any suitable means. In some embodiments, the product is levelled using a mechanical means. The mechanical means may comprise a doctor blade or scraper. The blade/scraper is movable over the top edge 18 of the capsule 12, thus spreading the contents thereof. Such an embodiment may be beneficial where the volume of the product portion 14 is near or the same as the volume of the capsule 12.

In some embodiments, the product is levelled using a pneumatic means. For example, product is exposed to one or more jets of high-pressure air.

In some embodiments, the product is levelled is performed via a dynamic process. This process may comprise one or more of: shaking and/or vibrating. Such an embodiment may be beneficial where the volume of the product portion 14 is significantly less than the volume of the capsule 12 and/or where the product 14 comprises a fluent solid.

After the levelling step 8, the product 14 is uniformly distributed within the capsule 12 (i.e. the depth of product 14 is uniform across the width of capsule 12), as shown in FIG. 3. It can be appreciated that some degree of unevenness in the distribution of the product 14 may be tolerated. For example, the depth of the product 14 within the capsule may be acceptable if the maximum/minimum depth is within ±20% of the mean depth, preferably within ±10%. In some embodiments, the capsule 12 may be completely filled with product 12 (i.e. up to the opening thereof). The product 14 is therefore level with the upper edge of the capsule. This may be beneficial where the product is sold by volume and/or where the product has a consistent density.

An inspection means may be provided to ensure adequate levelling. The inspection means may comprise a range finding (i.e. length measuring) means. The range finder may scan over the product 14 within the capsule 12 thus determining a variation in depth of the product. Such a scan be performed as the capsule 12 passes under the range finder on a conveyor. In other embodiments, an optical sensor and an image processor may use captured photos to determine depth and/or uniformity of the product (e.g. using photogrammetry).

In some embodiments, the product 14 may be too sparsely distributed (i.e. the density is too low) to provide an optimal experience. For example, the effective surface area of the product 14 may be too high, thus providing a too intense experience. Therefore, in a next step 10, the product 14 is compacted.

As shown in FIG. 4, compaction is provided by a compaction device 20. The compaction device 20 compacts the product 14 to a predetermined depth 22. Given the weight of the product 14 in each capsule 12 is known, the density of the product 14 may be determined. The density of the compacted product 14 may less than or equal to 2 g/ml, preferably, less than or equal to 1 g/ml, preferably, less than or equal to 0.8 g/ml; preferably, less than or equal to 0.5 g/ml; preferably, less than or equal to 0.4 g/ml. The density of the compacted product 14 may be at least 0.1 g/ml; preferably, at least 0.15 g/ml; preferably, at least 0.2 g/ml.

It can be appreciated that a given density for a product will result in a given airflow/pressure drop when air flows through the capsule. Therefore, the density of the product may be modified until the pressure drop through the capsule is less than or equal to 5 kPa; preferably, less than or equal to 4 kPa; preferably, less than or equal to 3 kPa; preferably, less than or equal to 2.5 kPa. The pressure drop through the capsule is greater than or equal to 0.3 kPa; preferably, greater than or equal to 0.5 kPa; preferably, greater than or equal to 1 kPa.

The compaction device 20 is configured to be received within the capsule 12. The compaction device 20 may comprise a similar/complementary shape to the capsule 12, thus providing a plug like arrangement. The compaction device comprises a close fit with the capsule 12. The compaction device 20 is shaped according to the depth 22 in which the compaction device 20 is inserted. The compaction device 20 extends across the complete width of the capsule. The compaction device 20 thus extends across the complete area of the upper surface 24 of the product (i.e. occupies the cross-section of the capsule 12). This ensures compaction is applied evenly across the surface 24 of the product, and thus the density of the compacted product 14 is uniform. The close fit of the compaction device 20 and the capsule 12 ensure no product 14 leaks between the edges of the compaction device 20 and the side walls 26 of the capsule 12.

The compacted product 14 is shown in isolation within the capsule 12 in FIG. 5. It can be seen that the product 14 only occupies a portion of the internal volume of the capsule. Thus, a cavity 28 is provided between the product 14 and the upper edge/rim 30 of the capsule. The cavity 28 allows the flow of air into the capsule 12 during use thereof. This allows more uniform heating of the product 14 and flow of vaporised smoking product from the capsule 12.

The capsule 12 may comprise an internal volume of less than or equal to 200 ml; preferably, less than or equal to 100 ml; preferably, less than or equal to 50 ml; preferably, less than or equal to 40 ml; preferably, less than or equal to 30 ml. The capsule 12 may comprise an internal volume of greater than or equal to 5 ml; preferably, greater than or equal to 10 ml. The capsule 12 may comprises an internal volume between 5 ml and 50 ml; preferably, between 10 ml and 30 ml. In a specific embodiment, the capsule comprises a volume of 15 ml or 22.5 ml.

The product 14 may occupy less than or equal to 90% of the internal volume of the capsule 12; preferably, less than or equal to 70%; preferably, less than or equal to 66%; preferably, less than or equal to 60%; preferably, less than or equal to 55%. The product 14 may occupy greater than or equal to 10% of the internal volume of the capsule 12; preferably, greater than or equal to 20%; preferably, greater than or equal to 30%. The product 14 may occupy between 25% and 80% of the internal volume of the capsule; preferably, between 30% and 65%. In specific embodiments, the product 14 occupies 55% or 40% of the internal volume of the capsule 12.

In the embodiment shown in FIG. 5A, the depth 22 of the product 14 is substantially uniform across the width of the capsule 12. The product 14 may therefore be flat. The product 14 be cylindrical/puck shaped.

In the embodiment shown in FIG. 5b, the base 32 of the capsule 12 comprises a recess 34. The recess 34 extends toward the upper edge 30 of the capsule 12. The recess 34 therefore extends into the capsule 12. The recess 34 is curvate/arcuate. The base 32 of the capsule 12 is therefore domed. The recess 34 comprises a plurality of apertures 36 extending through the wall 36 of the base 32. The apertures allow air/vapour to through the capsule 12 in use (i.e. to provide unidirectional airflow). The surface 24 of the product 14 remains substantially flat. The depth 22 of the product 14 therefore varies to accommodate the recess 34.

In the embodiment shown in FIG. 5C, the height of the product 14 remains substantially constant. Thus, the product 14 comprises a domed shape corresponding to the recess 34. This aids with uniform heating of the product 14. The compaction device 20 comprises a recess to create the domed product shape. The compaction device 20 thus conforms to the inner shape of the capsule 12. It can be appreciated that such an arrangement can be provided any shape of capsule and/or base 32 thereof.

In the embodiment shown in FIG. 6A, a substrate 37 is provided. The substrate 37 is provided in a layered arrangement. The substrate 37 is provided adjacent the base 32 of the capsule 12. The substrate may overlie and/or at least partially occlude one or more apertures/perforations in the base 32.

The substrate 37 may comprise the inert material as previously described. The substrate 37 comprises a particulate. The substate 37 comprises a bead or the like. The beads are aligned to form a layer arrangement. In some embodiments, the substrate 37 may comprise a smoking product. The smoking product may be provided as a coating and/or layer on the substrate 37.

As shown in FIG. 6B, the smoking product 14 may be compacted onto the substrate 37. The substrate 37 is therefore 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 the beads and the capsule 12. In the embodiment in FIG. 6B, a gap 39 is provided between the smoking product 14 and the capsule base 32. This provides an air pathway for the vapourised smoke. This may also prevent smoking product egressing through the perforations in the base 32. The substrate 37 may therefore provide a partial barrier and/or buffer between the smoking product 14 and the capsule wall. In other embodiments, the smoking product 2 may complete envelope the substrate 37.

In some embodiments, the compaction step may not be performed. For example, if during the agglomeration step, the density of the product is controlled to a desirable value, then the capsule 12 may be filled without compaction. In some embodiments, the capsule 12 is filled and merely levelled. The product 30 may therefore occupy substantially the full volume of the capsule. For example, the product may occupy at least 70% of the internal volume of the capsule; preferably, at least 80%; preferably, at least 90%; preferably, at least 95%. Complete or nearly complete filling of the capsule 12 prevents the product moving any significant degree, thereby preventing agglomeration thereof. In other embodiments, the capsule 12 may be partially filled as previously described.

In such embodiments, it can be appreciated that the density of the product with the capsule 12 will be substantially the same as the deagglomerated/rarefied product 14 as described above.

In some embodiments, the non-compacted smoking product may only partially fill the capsule, as described above.

Examples of specific capsule of compact or non-compacted filling regimes are provided below:

Example 1: Complete Fill

	Composition 1	Composition 2

Weight (g)	2	4.4	6	8	10	14	16
Density (g/ml)	0.1	0.2	0.25	0.35	0.4	0.6	0.7

Example 2: 55% Volume Fill

	Composition 1	Composition 2

Weight (g)	2	4.4	6	8	10	14	16
Density (g/ml)	0.15	0.3	0.45	0.6	0.75	1	1.2

Example 3: 40% Volume Fill

	Composition 1	Composition 2

Weight (g)	2	4.4	6	8	10	14	16
Density (g/ml)	0.2	0.5	0.7	0.9	1.1	1.6	1.8

Composition 1 may comprise a “dry” formulation. The dry formulation may comprise shredded, powdered or otherwise particulated material. The density thereof is relatively lower accordingly. The material may comprise an organic or plant material. For example, the material may comprise one or more of: tobacco; tea; cannabis; hemp; and/or their derivatives.

In some embodiments, the dry formulation may comprise a density of between 0.05 g/ml and 0.3 g/ml (e.g. when completely filled). In some embodiments, the dry formulation may comprise a density of between 0.1 g/ml and 0.6 g/ml (e.g. when 55% filled). In some embodiments, the dry formulation may comprise a density of between 0.2 g/ml and 0.9 g/ml (e.g. when 40% filled).

The dry formulation may comprise a weight between 1 g and 10 g; preferably, between 1.5 g and 9 g.

Composition 1 may comprise a “wet” formulation. The wet formulation comprise a liquid, viscous solid, or wetting material. The wet formulation may be fluent, viscous or sticky. The wet formulation may include the material of the dry formulation. The viscous/liquid component of the formulation binds or wets the dry material. The density is relatively higher accordingly. The dry and wet product may provide a matric or homogenous mixture. The wet formulation may comprise the shisha formulation previously described.

In some embodiments, the wet formulation may comprise a density of between 0.3 g/ml and 0.9 g/ml (e.g. when completely filled). In some embodiments, the wet formulation may comprise a density of between 0.5 g/ml and 1.4 g/ml (e.g. when 55% filled). In some embodiments, the dry formulation may comprise a density of between 0.8 g/ml and 2 g/ml (e.g. when 40% filled).

The wet formulation may comprise a weight between 5 g and 20 g; preferably, between 7 g and 18 g.

Once the capsule 12 has been filled, the capsule 12 is packaged ready for transport and/or sale. The process is described in FIG. 7. In a first step 38, the capsule 12 (i.e. the internal volume thereof) is filled with an inert gas. The inert gas helps to prevent undesired oxidation and/or contamination of the product 14. This provides an improved smoking experience for the user. In the present embodiment, the inert gas comprises nitrogen. However, the inert gas may comprise any suitable inert gas, for example, one or more of: carbon dioxide; helium; argon; neon; or other Noble gases.

The capsule 12 comprises a low oxygen or substantially oxygen free environment. The environment may comprise less than or equal to 15% oxygen by volume; preferably, less than or equal to 10%; preferably, less than or equal to 5%; preferably, less than or equal to 1%; preferably, less than or equal to 0.5%;

The capsule 12 may filled with the inert gas via a number of methods. In a first example shown in FIG. 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. part way about the upper rim 30 thereof). The unsealed portion provides a gap 44. The lance 40 can be inserted into the gap 44 for fluid communication with the internal volume of the capsule 12.

The inert gas is injected into the capsule 12. Typically, enough gas is injected to displace the oxygen within the capsule (i.e. the inert gas purges or flushes the oxygen). The gap 44 may therefore by wider than the lance 40 to allow the displaced air to escape. The inert gas is thus applied in excess. The volume of gas injected is therefore much greater than the internal volume of the capsule 12. The gas may be injected at high pressure and/or a high flow rate to prevent equilibration of the oxygen partial pressure.

Once the oxygen pressure/volume reaches a predetermined level, the lance 40 may be removed. The lance 40 may comprise an oxygen sensor to determine oxygen levels within the capsule 12. In other embodiments, the lance 40 is removed after a predetermined period of time or volume of inert gas injected. Typically, these values will pre-calibrated according to the capsule 12 or lance 40 size/volume etc.

After removal of the lance 40, the gap 44 is sealed. The inert atmosphere of the capsule 12 is thus preserved. In some embodiments, the closure/capsule wall surrounding the gap 44 is mechanically deformed (e.g. crimped or crushed) to seal the gap 44. In some embodiments, the gap 44 is plugged (e.g. via an inert or solder etc). In some embodiments, the gap 44 is sealed with adhesive or the like. It can be appreciated the exact means of sealing the gap 44 is not pertinent to the invention, and suitable means may be used. Sealing of the gap 44 is performed shortly after and/or during removal of the lance 40. Typically, sealing occurs less than 5 seconds from removal, preferably, less than 2 seconds.

The closure 42 and/or capsule 12 may be shaped to provide the gap 44 (i.e. a channel is formed therein). The channel may then be crushed/filled during sealing. In other embodiments, the gap 44 may be provided by the flexion of the closure 42 and/or 12. The closure 42 may therefore fully engage the capsule 12 when the lance 40 is removed. In some embodiments, the closure 42 and/or capsule 12 is provided with an aperture in a wall thereof. In some embodiments, the closure 42 and/or capsule 12 may be pierced or other penetrated by the lance 40. The aperture/piercing may then be sealed once the lance 40 is removed

A second example is shown in FIG. 9. In this embodiment, the closure 42 comprises a plurality of apertures or perforations 46 therein. The apertures 46 allow air to pass into the capsule 12 during use thereof. The inert gas may be blown or otherwise forced into the capsule 12 via the apertures 46 as previously described. A lance 40 may be used. The apertures 46 may only be partially covered, thus allowing the purged air to escape.

Once purging is complete, a seal 48 is applied to the closure 42. The seal 48 is configured seal the apertures 46 in the closure 42. The seal 48 is typically removed by the user before use of the capsule 12. The seal 48 may comprise a flexible material. The seal 48 comprises a peelable adhesive to allowable removal from the closure 42. The seal 48 is applied less than 5 seconds completion of purging, preferably, less than 2 seconds.

Such an arrangement may be provided in any of the described embodiments. The perforations 46 allow to pass into the into the capsule 12. The seal 48 and the closure 42 may be provided as a single unit. The single unit may then be attached to the capsule 12. The seal 48 is removed by the user before use to expose the perforations 46. A similar seal may be provided on the base 32 of the capsule. The seal may cover a plurality of apertures/perforations on the base 32. This allows airflow through the capsule 12.

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 sealing of the closure 42 is performed within the inert atmosphere 50, thus trapping the inert gas within the capsule 12. Such an arrangement allows greater control of the oxygen levels within the atmosphere and does not require complex mechanism for withdrawal of a lance etc. The inert atmosphere 50 may further allow the product 14 to “out-gas”, thus removing oxygen contained therein. An inlet 54 may provide a source of inert gas. The atmosphere 50 may be replaced and/or recirculated to ensure oxygen removal. In some embodiments, oxygen scrubbers or like may be used.

As shown in FIG. 11, the capsule 12 may be supported on a conveyor 56. The conveyor 56 may move the capsule 12 in/out of the containment vessel 52, thus providing a continuous process. Doorways 58 are provided within the containment vessel 52 to allow entering/exiting of the capsule 12. In the present embodiment, the doorways 58 comprise an air curtain 60. The air curtain 60 comprises a curtain of high-pressure gas. The high-pressure gas provides a partial barrier to gas movement between the interior and exterior of the containment vessel 52. This helps to maintain the inert atmosphere 50 within the containment vessel 52. The air curtain 60 may be configured to emit the inert gas.

In other embodiments, the inert gas may be provided at a positive pressure (i.e. an over-pressure), thus maintaining an inert atmosphere.

A sealing mechanism 62 configured to secure the closure 42 to the capsule 12 or otherwise provide sealing thereof is provided within the containment vessel 52. The sealing mechanism 62 may comprise one or more actuator configured to move the sealing mechanism 62 into engagement with the capsule 12 and/or provide sealing thereof.

In some embodiments, the inert gas may be placed in the 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 make handling of the inert gas easier. The solid/liquid may then evaporate/sublimate to provide an inert gas.

In some embodiments, the capsule 12 may be purged/flushed in a substantially open state. The capsule 12 may then be sealed quickly to reduce inert gas loss.

In some embodiments, the capsule 12 may comprise an oxygen absorbing material. The oxygen absorbing material may comprise an oxygen scavenger. The oxygen absorbing material may comprise a food safe material. The oxygen absorbing material may comprise ferrous powder. The ferrous power may comprise iron powder. An accelerant may be provided. The accelerant may comprise a halide, for example, a chloride. The oxygen absorbing material may comprise one or more: ascorbate; pyrogallic acid; or an organic cobalt complex.

The oxygen absorbing material may be provided in a package (e.g. a sachet) contained within the capsule 12. The package is air-permeable, thus allowing scavenging of the oxygen. In some embodiments, the oxygen absorbing material may coated and/or incorporated into the capsule walls and/or closure. The oxygen absorbing material may be high temperature resistant (e.g. does not burn or decompose at high temperature). The oxygen absorbing material therefore does not affect the smoking experience. In some embodiments, the user may remove the oxygen absorbing material from the capsule 12 before use thereof.

In some embodiments, a vacuum or partial vacuum is provided within the capsule 12.

The sealing process is shown in closer detail in FIGS. 12-16. In the present embodiment, the capsule 12 is sealed via mechanical (e.g. plastic) deformation of the capsule 12 and/or the closure 42. The closure 42 is crimped onto the capsule 12.

The sealing mechanism 62 is shown in detail in FIG. 12. The sealing mechanism 62 comprises a forming tool 64 configured engage the capsule/closure. The forming tool 64 is mounted to an actuator (not shown) configured to move the forming tool 64 in/out of engagement with the capsule 12. The forming tool 62 is configured to conform to the shape of a rim 30 and/or the side wall 26. The face 66 may therefore provide a close fit with the side walls 26 of the capsule when engaged therewith (see FIG. 14). The forming tool 64 may be annular. The forming tool 64 may therefore be corresponding in shape to a circular rim 30 of the capsule 12. The forming tool 64 is divided into a number of discrete portions about the circumferential direction. The forming tool 64 thus provides a collet like arrangement. The portions are movable apart from each other.

An actuator (not shown) may move the portions in a lateral direction 68. The collet is thus radially expandable. A second actuator (not shown) may move the forming tool 64 toward/away from the capsule 12 in an axial direction 70. However, it can be appreciated that a single actuator may provide lateral and axial movement (e.g. a single actuator moving in the diagonal direction). In some embodiments, the portions of the forming tool are pivotally connected, thus lateral and/or axial movement I provided by a pivoting/swinging motion. It can be appreciated that the exact form of the actuators is not pertinent to the invention at hand.

The capsule 12 may held in mandrel 72. The mandrel 72 may prevent deformation or collapse of the capsule 12 during the sealing process. The mandrel may engage the side walls 26 of the capsule 12.

As shown in FIG. 13, the rim 30 of the capsule 12 comprises a stiffening element 74. The stiffening element 74 is configured to increase the structural rigidity of the rim 30 to prevent deformation thereof. In present embodiment, stiffening element 74 comprises a curled/rolled edge of the side wall 26 of the capsule. The stiffening element 74 therefore comprises an integral portion of the capsule 12. Rolling of the side wall 26 may be provided by conventional means. The stiffening element 74 extends outwardly from the rim 30.

In some embodiments, the stiffening element 74 is spaced from the side wall 26 of the capsule. The stiffening element 74 may be spaced via a rim/flange. The closure 42 may sit in the rim/flange in use.

As shown in FIG. 14, the capsule closure 42 is mechanically deformed onto the capsule 12 to provide retention thereof. An edge portion 76 of the closure 42 is deformed over the stiffening element 74. This deforms the edge portion 76 over the side walls 26/rim 30 of the capsule 12. The edge portion 76 may comprise a flange. lip or rim etc. The edge portion 76 therefore extends out of the plane of the body of the closure 42 (e.g. at right angles thereto).

The forming tool 64 comprises a die or engagement surface configured to deform the closure 42 to the appropriate shape. The forming tool 64 typically comprises a shape corresponding to the shape of the stiffening element 74 and/or the side wall 26 adjacent thereto. This deforms the closure 42 to provide a close fit with the stiffening element 74. In the present example, the forming tool 64 comprises a U-shape engagement face 80.

It can be appreciated the stiffening element 74 shown in FIG. 13 is merely exemplary and the stiffening element 74 may take any form, for example: a thickened side wall portion; a flange/ring; studs; fasteners; ridges, grooves; band; roughened surface or the like. It can 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 or the like). The portions may be spaced about the circumference/periphery of the capsule 12.

The closure 42 may be engage the capsule 12 about the entire periphery thereof (i.e. to 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 portion 76 may only be deformed at one or more discrete position. In some embodiments, the edge portion 76 may be provided as one or more of discrete tabs.

In the embodiments shown in FIGS. 15 and 16, the closure 42 is retained by curling thereof. The rim 30 of the capsule 12 comprises a flange 74. The flange 74 extends laterally outward from the rim 30. The edge portion 76 of the closure 42 is configured to overlie the flange 74. A die 64 is moved into engagement with the flange 74 and edge portion 76.

As shown in FIG. 16, as the die 64 is moved toward the capsule 12, the flange 74 and edge portion 76 are curled over one another. This retains the closure 42 on the capsule 12, whilst proving a tight seal therebetween. The die 64 typically comprises a curved surface 80 to ensure effective curling of the closure 42/flange 74.

In the embodiment shown in FIGS. 17 and 18, the edge portion 76 of the closure 42 is configured to overlie the flange 74 on the capsule 12. The forming tool 64 is moved down the side wall 26 of the capsule 12. The forming tool 64 engages the edge portion 76 and the flange 74, bending them toward the side walls 26 of the capsule 12.

As shown in FIG. 18, the flange 74 and the edge portion 76 are pressed flat against the side wall 26 of the capsule. Such an arrangement may be provided about remainder of the rim 30. Due to the chamfered side walls 26 of the capsule 12, the closure 42 is retained on the capsule 12. The forming tool 64 comprises a chamfered/tapered face 66. The chamfer may correspond in shape to tapered shape of the capsule 12.

The forming tool 64 moves in a lateral and axial direction relative to the capsule 12 (i.e. moves in a diagonal direction). In some embodiments, movement in the lateral and axial directions is provided in two discrete steps. For example, the forming tool moves in a downward axial direction 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.

In some embodiments, the forming tool 64 is pivotable/rotatable into engagement with the capsule 12. For example, the forming tool 64 is pivotally mounted at an upper end thereof. Such an arrangement ensures the flange/edge portion are bent in the correct direction by providing by lateral and axial movement. It can be appreciated that such an arrangement may be provided in all or any of the described embodiments.

Where 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 from the others. The independently operable forming tool 64 may then seal the capsule 12 once the lance 40 has been removed.

In some embodiments, the stiffening element 74 (e.g. flange or curled lip) may not be provided. This may be provided where the side walls 26 are of sufficient thickness to prevent buckling during sealing. The closure 42 may directly engage the side walls 26 of the capsule 12.

In some embodiments, a portion of the capsule 12 may be configured to be deformed over the closure 42. For example, the flange 74 may be deformed over the upper surface of the capsule. In some embodiments, an intermediate piece may be used in the crimping process. For example, a ring may be deformed over the flange/edge portion (i.e. to provide a clamp like arrangement)

In some embodiments, the capsule 12 is sealed using a welding technique. The welding technique may comprise resistance welding. For example, a welding seam may be provided between the flange 74 and the edge portion 76. Where capsule/closure materials are suitable, heating sealing may be used.

In some embodiments, sealing may be provided by one or more of: adhesive; one or more fastener; interference fit; staking; or riveting. However, it can be appreciated that mechanical deformation techniques are preferred as they a simple to performed, can maintain a good seal and are stable at high temperatures.

In some embodiments, a seal may be provided over the seal or partial seal between the capsule 12 and the closure 42. For example, a polymer strip may be overlaid the seal between the capsule 12 and the closure 42. The strip may be heat-sealed or heat-shrink onto the capsule 12/closure 42

It can be appreciated that some of the above techniques may provide a substantially gas-tight or liquid-tight seal between the capsule 12 and the closure 42. The capsule 12 as a whole is therefore gas-tight. This prevents egress of the inert gas and/or ingress of oxygen. Where the 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 viscous fluid.

In the next stage 82, the sealed capsule 12 is packaged. In the present embodiments, the capsule 12 is packaged using a “flow-wrap” method. The package 84 is shown in FIG. 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 elongate strip. The elongate strip may be provided in a roll or drum. The plastic film is folded about a lateral direction to define an elongate tube. The edges of the film are sealed to define an axial seam 86. The capsule 12 is then placed within the tube. Lateral seams 88 are provided across the package 84 to provide an individually packaged capsule 12. The general aspects of the flow-wrap process are known and will not be described further.

The flow-wrap process produces a semicontinuous strip of capsule packages 84. The strip is then divided by cutting across the lateral seam 88 as indicated at 90. This forms a plurality of individual packages. In some embodiments, the packages 84 may be provided in a strip form. The user may then access each package as required. In some embodiments, the lateral seam 88 may be frangible. A plurality of perforations or scores etc. may be provided in the lateral seam 88. The strip and/or individual packages 84 may be provided in a further container, for example, for transportation.

During the packaging process, the package 84 is filled with an inert gas. This helps to further reduced oxidation and/or other contamination of the product 14. This may also help to further reduce oxygen content within the capsule 12, as the oxygen may diffuse therefrom. The inert gas may comprise any gas as previously described.

The packaging process is shown in detail in FIG. 17. The package 84 is shown in a partially assembled stage. The axial seam 86 (not shown) and several lateral seams 86 have been created, thus encapsulating a capsule 12a in a first package 84a. A second capsule 12b is provided in a partially sealed package 84b (i.e. only the axial seam 86 and a single lateral seam 86 are provided). A lance 90 is inserted into the open end 91 of the package 84. The lance 90 is configured to purge/flush the package 84 with an inert gas as previously described.

Once the package has been flushed, the package is sealed. A sealing mechanism 92 is used to provide the lateral seam 86. The sealing mechanism 92 comprises a heated head 94 configured to engage the package to provide a heat seal (i.e. weld) thereon. A plurality of heads 94 are provided in an opposing arrangement. The heads 94 move together (e.g. in a clamping arrangement) to trap the package 84 therebetween. Typically, the heads 94 will dwell on the package 84 to ensure adequate sealing.

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

The package 84 may be partially formed before and/or during insertion of the lance 90. This helps to reduce the escape of the inert gas and/or re-entrance of oxygen. As shown in FIG. 18, the lateral seam 86 only extends partially across the package 84. A gap 96 is provided to allow 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.

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

In some embodiments, the sealing mechanism 92 comprises a plurality of 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 once the lance 90 is removed. The heads 94 may therefore comprise different lateral lengths.

The lance 40 may be mounted to actuator to allow withdrawal thereof from the package 84. In other embodiments, effective withdrawal is provided by advancement of the package 84 relative to the lance 40. The lance 40 may be therefore static/fixed. For example, the second sealing head may be provided downstream of the first sealing head 94 and of the lance 40. Therefore, where the lateral seam 88 is advanced passed the end of the lance 40, the second head engages the package 84, sealing the gap 96.

The gap 96 comprises sufficient width to provide a space between the lance 40 and the end of the lateral seam 88. This allows the purged gas to escape, allowing the flow of inert gas into the package. The lance 40 is inserted into the package into a sufficient depth (i.e. a distance past the lateral seal 88) such that the inert gas flows into the package and circulates therein.

In an alternative embodiment shown in FIG. 19, the inert gas is injected into the package 84 without a partial lateral seam 86 being formed. Gas 100 is continuously blown from an outlet 102 into the partially formed package 84. The inert gas inflates the tube formed by the vertical seam 86. The inert gas is maintained at a constant pressure. The sealing mechanism 92 forms the lateral seam 86 during the continued blowing (i.e. pinches the inflated tube), forming a sealed package and trapping the inert gas. This arrangement does not require withdrawal of a lance 40 or complicated sealing mechanism 92. However, as the inert gas is continually blown, inert gas may escape, wasting resources. In some embodiments, the package 84 may be held or sealed against the gas outlet 102 to prevent the escape of the inert gas.

Typically, the flow-wrap arrangement comprises a vertical flow-wrap arrangement. In this arrangement, the capsules 12 are filled into the package 84 under the action of gravity. However, the flow-wrap arrangement may be provided in any suitable orientation (e.g. a horizontal or angled arrangement). The capsule 12 may supported on a conveyor.

In some embodiments, the inert gas may be insert into the package 84 once completely sealed. For example, the lance 90 may be configured to pierce or otherwise penetrate package 84 to inject the inert gas. The piercing may then be sealed (e.g. using heating sealing) once the lance 90 is removed. In some embodiments, the package 84 comprises a unidirectional valve to allow filling thereof.

It can be appreciated where the capsule 12 is contained within the package 84, release of the product 14 and/or volatile elements thereof into the environment is prevented. Thus providing an inert capsule environment may not be required, and the capsule flushing step may be entirely optional. Additionally or alternatively, air-tight or liquid-tight sealing of the closure 42 on the capsule 12 may not be required.

In a further embodiment, the capsule 12 is contained within a blister package. Referring to FIG. 20, the capsule 12 is contained with a blister pocket 122. The pocket 122 is shaped similarly 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 in use. This allows space to receive an inert gas, as previously described. The pocket 122 may comprise a flexible or deformable material. The blister package allows the user to push out the capsule, reducing the manual handling required, and thus the user is less likely to contact viscous or sticky product.

A lidding sheet 126 is fixed over the pocket 122. The lidding sheet 126 comprises a tearable, rupturable or otherwise destructible material. Typically, the lidding sheet 126 comprise a foil, for example, aluminium foil. In other embodiments, the lidding sheet comprises a paper-based material or suitable polymer. The lidding sheet 126 may comprise lines of weakness or frangible portions.

The lidding sheet 126 may be attached using any suitable means, for example, one or more of: heat sealing; welding; adhesive; crimping/deformation; fasteners etc. The lidding sheet 126 and blister pockets 122 are joined via a seam 128. The seam 128 separates each individual pocket, thereby providing individually sealed blisters. The blisters packages may be separated by cutting along the seams 128.

In some embodiments, the smoking product 14 may be placed directly into the flow wrap package or the blister package. The capsule 12 may therefore be optional, and the user may place the product 14 into the bowl of a hookah pipe. However, it can be appreciated that this arrangement may be suboptimal, as the product may be crushed or compressed during transport/storage, thereby affecting the density thereof. In some embodiments, the packaging may be rigid to prevent compression of the smoking product 14. In some embodiments, the package may be over-inflated to provide a buffer or barrier for the product 14.

In some embodiments, the capsule 12 comprises an agitator. The agitator is configured to mix, churn or other agitate the product 14. This may help to create air pathways within the product to help air pass into then product 14 and to help the vapourised smoking product leave the solid mass. Provision of the agitator with the capsule 12 allows the end user to agitate the product, for example, which may have settled during storage/transportation.

In a first embodiment shown in FIG. 20, the agitator comprises a mechanical agitator 104. The agitator 104 comprises a one or more blades 106. The blades 106 are mounted to a base portion 108. The base portion 108 is rotatable, thereby allowing rotation of the blades 106. The blades 106 are generally upstanding (i.e. extend between the top/base of the capsule 12). The blades 106 thus extend through the product in use. The base portion 108 typically extends parallel to the base 32 of the capsule 12.

The agitator 104 is mounted to the capsule 12 via a rotatable joint/mount. The agitator 104 is therefore fixed/mounted to the capsule 12. The joint may comprise a bearing or the like. In the present embodiment, the agitator 104 is mounted to the base 32 of the capsule. However, it can be appreciated, the agitator 104 may be mounted in any suitable location, for example, the side walls 26 and/or closure 42.

The blades 106 are angled relative to the base portion 108. The blades 106 may be angled between 45 and 90 degrees relative to the base portion 108. The blades 106 thus extend in an axial and radial direction. In some embodiments, the blades 106 and the base portion may be substantially continuous. The blades 106/base portion 108 may be curved (e.g. to define a U or cup shape blade).

The blades 106 and/or base portion 108 comprises a wire or the like. For example, the blades 106 and/or base portion 108 comprise a width/thickness of less than 2 mm. This may provide sufficient agitation where the product 14 is inhomogeneous. In other embodiments, the blades 106 and/or base portion 108 may comprise a substantial thickness. The blades 106 and/or base portion 108 may therefore provide a paddle like arrangement.

A plurality of blades 106a,b may be provided. The plurality of blades may comprise one of more of:

• • different lengths;
  • different widths/thickness;
  • different angles relative to the base portion;
  • different shape/profile;
  • different radial position (i.e. relative to the axis of rotation).

The agitator 104 is operatively connected to an actuator 110 to effect rotation thereof. The actuator 110 may comprise a manual actuator. The actuator 110 may comprise a handle or grip 112 to provide actuation thereof. The actuator 110 may comprise a key or like. The key may be detachable.

In some embodiment, shown in FIG. 21, agitation of the product 14 is performed by a pneumatic means. The capsule 12 comprises an inlet 112 to allow ingress of a pneumatic gas (e.g. air) thereinto. A gas pump/compressor 114 is operatively connected to the inlet 112. The air pressure/air flow from the pump 114 is sufficient is agitate the product 14 to provide air pathways and/or mixing thereof.

In some embodiments, the pump 114 comprises a manual pump. The pump 114 may comprise a flexible diaphragm/bellows or the like. The user may therefore manually squeeze the pump 114. The pump 114 may comprise a unidirectional valve arrangement to provide reinflation of the diaphragm/bellows. In some embodiment, the volume of pump 114 may be sufficient to provide agitation and a valve arrangement is not required.

In some embodiments, the pump 114 may comprise a mechanical (e.g. electrical) pump. In some embodiments, the pump 114 may comprise a compressed gas reservoir. For example, the pump 114 may comprise a compressed gas canister.

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 aperture 118 in the capsule wall. The aperture 118 may be sealed by a removable seal. Alternatively, the pump 114 may expel air through the perforations formed in the base of the capsule 12.

In some embodiments, the capsule 12 and/or product 14 comprises 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 a change in temperature. The element 120 comprises a shape-memory alloy (SMA). The SMA is configured is configured to deform upon reaching a threshold (relaxation) temperature. As the capsule 12 is heated in use, the SMA element 120 changes shape, thus agitating the product 14. For example, the element 120 transforms from a linear shape to a curved/coiled shape at the relaxation temperature.

It can be appreciated that such an arrangement is merely exemplary, and any suitable configuration may be used. A plurality of elements 120 may be used. The elements 120 may be dispersed about the product 14. The elements 120 may comprise different shapes and/or sizes. The element 120 is substantially temperature stable and will not degrade at high temperatures (e.g. at 200-300° C.). This prevents the release of pollutants etc.

In some embodiments, the element 120 is configured to expand and/or explode upon application of heat. In the present embodiment, the element 120 comprises a corn (maize) kernel. The kernel explodes/expands upon application of heat, thus agitating the product 14. The exploded kernel may then combust/disintegrate with when the product 14 is likewise combusted/volatised. This may further add a flavouring to the product 14. It can be appreciated that that the element 120 may comprise any object configured to expand/explode explosively due to heating thereof.

In some embodiments, the capsule may comprise a material configured to release a gas. This 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 comprise bicarbonate of soda. The material may comprise an acid-alkali mixture configured to produce gas upon reaction thereof. The material may comprise a raising and/or foaming agent. It can be appreciated the element 120 may be comprise any suitable material configured to provide significant expansion upon application of heat.

In some embodiments, the agitator may comprise a conductive material. For example, the agitator may comprise ferrite or similar material. The agitator may provide an induction element, so that when subjected to an induction heating field, the agitator is heater. The pod is therefore heated from within.

The capsule 12 is shown in closer detail in FIGS. 28 and 29. The capsule 12 comprises a plurality of apertures 132 in the closure. Apertures 134 are provided in the base 32. The apertures 132, 134 allow air to pass through the capsule 12. The apertures may be provided by any suitable means, for example, one or more of: cut-outs; perforations; mesh; grille; or other porous surface.

The size and/or frequency of the apertures 132,134 are optimised to allow the optimal amount of air to pass through, without causing excessive leakage. The total area effectively occupied apertures is at least 1% of the total area of the lid/base; preferably, at least 3%; preferably, at least 5%; preferably, at least 7% The total area effectively occupied aperture less than or equal to 15% of the total area of the lid/base; preferably, less than or equal to 10%; preferably, less than or equal to 8%; preferably, less than or equal to 5%.

The apertures of the lid 42 and base 32 may comprise the same total effective area (i.e. the same amount of air flowing in the lid 32 may exit through the base 32). In other embodiment, the base 32 may comprise a smaller total effective area than the lid 42. This ensures leakage is not excessive. The total effective area of the apertures in the base 32 may less than or equal to 95% of the total effective area of the lid 42; preferably, less than or equal to 90%; preferably, less than or equal to 80%. The ratio of the total effective area of the apertures 132, 134 may scale with the total area of the base 32 and lid 42 (i.e. the aperture spacing/size is the same for the base 32 and lid 42).

In some embodiments, the apertures in the lid 42 and the base 32 may comprise the same respective sizes. In some embodiments, the apertures in the lid 42 and the base 32 may comprise different respective sizes. For example, the aperture 134 in the base may be of smaller size compared the apertures in the lid 42 to prevent excessive leakage.

The present arrangement ensures that the thermal and fluid dynamic properties of the smoking product provide a consistent and improved experience. The consistent and/or determined density helps to prevent undesirable agglomeration or fractionation of the smoking product. An included agitator may help to further prevent agglomeration. The inert gas ensures that the product remains fresh.

The provided densities and/or packing volumes help to ensure adequate airflow through the smoking product in use. This helps to ensure the pressure drop through the device is adequate accordingly, thus providing an optimal experience for the user. The optimised airflow also helps to ensure heat is able to penetrate into the smoking product, and the vaporised product is able to be entrained in the airflow passing through the smoking product.