Heat-not-burn devices and flavor carriers

Abstract

A flavor carrier for an aerosol generating device includes an outer shell extending in a longitudinal direction, an inner shell extending in the longitudinal direction, and a flavor chamber between the outer shell and the inner shell. The outer shell includes at least one outer shell perforation defined in a wall of the outer shell. The inner shell includes at least one inner shell perforation defined in a wall of the inner shell. The flavor chamber is configured to contain a flavor material.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Application No. 16 / 375,191, filed on April 4, 2019, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates to containers, heat not burn (HNB) aerosol generating devices, and methods of generating aerosols without involving substantial pyrolysis of an aerosol-forming substrate. Background Art

[0004] Some electronic devices are configured to heat plant material to a temperature sufficient to release plant material components while maintaining the temperature below the ignition point of the plant material to avoid any large amount of pyrolysis of the plant material. Such devices may be referred to as aerosol generating devices (e.g., heat-not-burn aerosol generating devices), and the heated plant material may be tobacco. In some cases, the plant material may be introduced directly into the heating chamber of the aerosol generating device. In other cases, the plant material may be prepackaged in a separate container to facilitate insertion into and removal from the aerosol generating device. Summary of the invention

[0005] At least one example embodiment relates to a flavor carrier for an aerosol generating device.

[0006] In at least one example embodiment, a flavor carrier for an aerosol generating device includes an outer housing extending in a longitudinal direction, an inner housing extending in the longitudinal direction, and a flavor chamber between the outer housing and the inner housing. The outer housing includes at least one outer housing perforation defined in a wall of the outer housing. The inner housing is coaxial with the outer housing. The inner housing includes at least one inner housing perforation defined in a wall of the inner housing. The flavor chamber is configured to contain a flavor material.

[0007] In at least one example embodiment, the adapter is located at an end of the flavor carrier. The adapter is configured to secure the flavor carrier within the aerosol generating device. The adapter defines a channel therein. The channel is in fluid communication with an air passageway defined in the inner housing. The adapter is formed of at least one of a polymer and a metal, the adapter being substantially impermeable to the aerosol.

[0008] In at least one example embodiment, the flavor carrier further comprises a gasket located at the second end of the flavor carrier. The gasket is substantially impermeable to the aerosol. The gasket is formed of at least one of a polymer and a metal.

[0009] In at least one example embodiment, the outer diameter of the outer housing ranges from about 3.0 mm to about 10.0 mm or from about 3.0 mm to about 5.0 mm. The outer diameter of the inner housing ranges from about 1.0 mm to about 3.0 mm.

[0010] In at least one example embodiment, the flavor material includes at least one of a plant material, a gel, a film, and flavor beads.

[0011] In at least one example embodiment, at least one of the outer shell wall and the inner shell wall has a thickness ranging from about 0.5 mm to about 1.5 mm. At least one of the outer shell wall and the inner shell wall is formed of at least one of paper, fabric, metal and polymer.

[0012] At least one example embodiment relates to an aerosol generating device.

[0013] In at least one example embodiment, an aerosol generating device includes: a plant material, a heating element configured to heat the plant material, and a flavor carrier. The flavor carrier includes: an outer shell extending in a longitudinal direction, an inner shell extending in the longitudinal direction, and a flavor chamber between the outer shell and the inner shell. The outer shell includes: at least one outer shell perforation defined in a wall of the outer shell. The inner shell is coaxial with the outer shell. The inner shell includes at least one inner shell perforation defined in a wall of the inner shell. The flavor chamber is configured to contain a flavor material. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] When reviewing the detailed description in conjunction with the accompanying drawings, the various features and advantages of the non-limiting embodiments of the present invention may become more apparent. The accompanying drawings are provided for illustrative purposes only, and the drawings should not be construed as limiting the scope of the claims. Unless explicitly noted, the accompanying drawings should not be considered to be drawn to scale. For clarity, the various dimensions of the accompanying drawings may be exaggerated.

[0015] Figure 1 is a schematic diagram of an aerosol generating device according to an example embodiment.

[0016] Figure 2 According to at least one example embodiment Figure 1 Cross-sectional view of a flavor carrier and mouthpiece of an aerosol generating device.

[0017] Figure 3 is a perspective view of a flavor carrier of an aerosol generating device according to at least one example embodiment.

[0018] Figure 4 is a perspective view of a flavor carrier of an aerosol generating device according to at least one example embodiment.

[0019] Figure 5is a perspective view of a flavor carrier of an aerosol generating device according to at least one example embodiment.

[0020] Figure 6 is a perspective view of a flavor carrier of an aerosol generating device according to at least one example embodiment.

[0021] Figure 7 is a perspective view of a flavor carrier of an aerosol generating device according to at least one example embodiment.

[0022] Figure 8 is a perspective view of a flavor carrier of an aerosol generating device according to at least one example embodiment.

[0023] Fig. 9 is a perspective view of a flavor carrier of an aerosol generating device according to at least one example embodiment.

[0024] Fig.10 is a perspective view of a flavor carrier of an aerosol generating device according to at least one example embodiment.

[0025] Fig.12 According to at least one example embodiment Figure 1 A cross-sectional view of the flavor cartridge along line XI-XI.

[0026] Fig.12 is a cross-sectional view of a flavor cartridge along line XI-XI according to at least one example embodiment.

[0027] Fig.13 is a perspective view of a flavor cartridge according to at least one example embodiment.

[0028] Fig.14 is a schematic diagram illustrating airflow through an aerosol generating device including a flavor carrier according to at least one example embodiment. DETAILED DESCRIPTION

[0029] Some detailed example embodiments are disclosed herein. However, the specific structural and functional details disclosed herein are only representative for the purpose of describing the example embodiments. However, the example embodiments may be implemented in many alternative forms and should not be construed as being limited to the example embodiments set forth herein.

[0030] Therefore, although the example embodiments are capable of various modifications and alternative forms, example embodiments thereof are illustrated by the embodiments in the drawings and described in detail herein. However, it should be understood that there is no intention to limit the example embodiments to the specific forms disclosed, but on the contrary, the example embodiments cover all modifications, equivalents and alternative forms thereof. Throughout the description of the drawings, the same reference numerals represent the same elements.

[0031] It should be understood that when an element or layer is referred to as being "on another element or layer," "connected to another element or layer," "coupled to another element or layer," "attached to another element or layer," "adjacent to another element or layer," or "covering another element or layer," the element or layer may be directly located on the other element or layer, directly connected to, coupled to, attached to, adjacent to, or covering the other element or layer, or there may be intermediate elements or layers. In contrast, when an element is referred to as being "directly located on another element or layer," "directly connected to another element or layer," "directly coupled to another element or layer," there are no intermediate elements or layers. Throughout the specification, the same reference numerals represent the same elements. As used herein, the term "and / or" includes any and all combinations or subcombinations of one or more of the listed associated items.

[0032] It should be understood that, although the terms first, second, third, etc. can be used in this article to describe different elements, regions, layers and / or parts, these elements, regions, layers and / or parts should not be limited by these terms. These terms are only used to distinguish one element, region, layer or part from another region, layer or part. Therefore, the first element, component, region, layer or part discussed below can be referred to as the second element, region, layer or part without departing from the teaching of the exemplary embodiment.

[0033] For ease of description, spatially related terms (e.g., "below," "below," "down," "above," and "on," etc.) may be used herein to describe the relationship of one element or feature to another element or feature shown in the accompanying drawings. It should be understood that, in addition to the orientation depicted in the accompanying drawings, spatially related terms are intended to include different orientations of the device in use or operation. For example, if the device in the accompanying drawings is flipped, an element described as "below other elements or features" or "below other elements or features" will be oriented to "above other elements or features." Therefore, the term "below" can include orientations above and below. The device can be oriented in other ways (rotated 90 degrees or in other orientations), and the spatially related descriptors used herein should be interpreted accordingly.

[0034] The terms used herein are only for the purpose of describing different example embodiments and are not intended to limit the example embodiments. As used herein, the singular forms "a", "an", and "said" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It should be further understood that when used in this specification, the terms "comprise", "comprises", "includes", and / or "comprising" indicate the presence of stated features, wholes, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, wholes, steps, operations, elements, components, and / or groups thereof.

[0035] When the words “about” and “substantially” are used in relation to numerical values, unless expressly defined otherwise, it is intended that the relevant numerical values ​​include a tolerance of ±10% around the stated numerical values.

[0036] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by those skilled in the art to which the example embodiments belong. It should be further understood that, unless explicitly defined herein, terms (including those defined in commonly used dictionaries) should be interpreted as having a meaning consistent with their meaning in the context of the relevant technical field and should not be interpreted in an idealized or overly formal sense.

[0037] Figure 1 is a schematic diagram of an aerosol generating device according to an example embodiment.

[0038] See also Figure 1 , an aerosol generating device 1000 (e.g., a heat-not-burn aerosol generating device) may include a mouthpiece 1015 and a device body 1025. A power source 1035 and a control circuit 1045 may be disposed within the device body 1025 of the aerosol generating device 1000. The aerosol generating device 1000 is configured to receive a container 1020, which may include a plant material, such as tobacco, as described in U.S. Patent Application No. 16 / 252,951, filed on January 21, 2019, entitled “CAPSULES, HEAT-NOT-BURNG (HNB) AEROSOL-GENERATING DEVICES, AND METHODS OF GENERATING AN AEROSOL,” the entire contents of which are incorporated herein by reference.

[0039] As discussed herein, an aerosol-forming substrate is a material or combination of materials that can be converted into an aerosol. An aerosol relates to a substance produced or output by the disclosed, claimed devices and their equivalents. The material may include a compound (e.g., nicotine), wherein an aerosol including the compound is produced when the material is heated. The heating may be below the combustion temperature to produce an aerosol without involving a large amount of pyrolysis of the aerosol-forming substrate or a large amount of production of combustion byproducts (if any). Therefore, in example embodiments, pyrolysis does not occur during the heating and the resulting aerosol production. In other cases, there may be some pyrolysis and combustion byproducts, but the extent may be relatively small and / or only incidental.

[0040] The aerosol-forming substrate can be a fibrous material. For example, the fibrous material can be a plant material. The fibrous material is configured to release a compound when heated. The compound can be a naturally occurring component of the fibrous material. For example, the fibrous material can be a plant material such as tobacco, and the released compound can be nicotine. The term "tobacco" includes: any tobacco plant material, including tobacco leaves, plugs, reconstituted tobacco, compressed tobacco, molded tobacco or powdered tobacco, and a combination from one or more tobacco plants, for example, Nicotiana tabacum and Nicotiana sabdariffa.

[0041] In some example embodiments, tobacco material can comprise the material from any member of Nicotiana. In addition, tobacco material can comprise the mixture of two or more different tobacco varieties. The example of operable tobacco material of suitable type includes but is not limited to, flue-cured tobacco, burley tobacco, black tobacco, Maryland tobacco, Japanese tobacco, rare tobacco, special tobacco and mixture thereof etc. Tobacco material can provide in any suitable form, and this form includes but is not limited to, tobacco sheet, processed tobacco material (for example volume expansion or puffed tobacco), processed tobacco stem (for example cut roll or cut puffed stem), reconstituted tobacco material and mixture thereof etc. In some example embodiments, tobacco material is the form of dry tobacco substance basically. In addition, in some cases, tobacco material can be mixed and / or combined with at least one in propylene glycol, glycerine, its sub-combination or its combination.

[0042] The compound may also be a naturally occurring component of a medicinal plant having a medically acceptable therapeutic effect.

[0043] Alternatively, the compound can be a non-naturally occurring additive that is subsequently introduced into the fiber material. In this case, the fiber material can include at least one of cotton, polyethylene, polyester, rayon, or a combination thereof, etc. (e.g., in the form of gauze). In another case, the fiber material can be a cellulosic material, and the introduced compound can be nicotine and / or a flavoring agent through a plant extract (e.g., a tobacco extract).

[0044] In at least one example embodiment, the aerosol generating device 1000 may further include a first electrode 1055a, a second electrode 1055b, a third electrode 1055c, and a fourth electrode 1055d, which are configured to be in electrical contact with the container 1020. In at least one example embodiment, the first electrode 1055a and the third electrode 1055c may be in electrical contact with the first heater 110a, while the second electrode 1055b and the fourth electrode 1055d may be in electrical contact with the second heater 110b. However, in non-limiting embodiments involving a container having only one heater, it should be understood that the first electrode 1055a and the third electrode 1055c (or the second electrode 1055b and the fourth electrode 1055d) may be omitted.

[0045] When the container 1020 is inserted into the aerosol generating device 1000, the control circuit 1045 can instruct the power supply 1035 to supply current to the first electrode 1055a, the second electrode 1055b, the third electrode 1055c and / or the fourth electrode 1055d. The current supply from the power supply 1035 can be in response to manual operation (e.g., button activation) or automatic operation (e.g., inhalation activation). As a result of the current, the container 1020 can be heated to generate an aerosol. Additional details of the container 1020 and the aerosol generating device 1000 (including the mouthpiece 1015, the device body 1025, the power supply 1035, the control circuit 1045, the first electrode 1055a, the second electrode 1055b, the third electrode 1055c and the fourth electrode 1055d) can be found in U.S. application Ser. No. 15 / 845,501, filed on Dec. 18, 2017, entitled “VAPORIZING DEVICES AND METHODS FOR DELIVERING A COMPOUND USING THE SAME,” Atty. Dkt. No. 24000DM-000012-US, the disclosure of which is incorporated herein by reference in its entirety.

[0046] In at least one example embodiment, Figure 1As shown, the aerosol generating device 1000 may also include a flavor carrier 760. The flavor carrier 760 may include: an outer shell 765 extending in the longitudinal direction; an inner shell 780 extending in the longitudinal direction; and a flavor chamber 790 between the outer shell 765 and the inner shell 780. The outer shell 765 and / or the inner shell 780 are generally cylindrical. In other exemplary embodiments, the cross-section of the outer shell 765 and / or the inner shell 780 may be generally oval, rectangular, square, triangular, polygonal, and / or may have any other cross-sectional shape. In some exemplary embodiments, the cross-section of the outer shell 765 may generally have the same shape as the cross-section of the inner shell 780. In some exemplary embodiments, the cross-section of the outer shell 765 may have a different shape from the cross-section of the inner shell 780. The outer shell 765 includes at least one outer shell perforation 770 defined in a wall 775 of the outer shell 765. In at least one exemplary embodiment, the inner shell 780 may be coaxial with the outer shell 765. In other example embodiments, the inner housing 780 is not coaxial with the outer housing 765. In some example embodiments, the inner housing 780 is within the outer housing 765. In some example embodiments, at least a portion of the inner housing 780 is within at least a portion of the outer housing 765. In some example embodiments, the cross-sectional area of ​​the inner housing 780 is less than the cross-sectional area of ​​the outer housing 765. In some example embodiments, the cross-section of the inner housing 780 is generally circular, while the cross-section of the outer housing 765 is generally circular, and the cross-sectional diameter of the inner housing 780 is less than the cross-sectional diameter of the outer housing 765. Other arrangements or variations may be used in other example embodiments. The inner housing 780 includes at least one inner housing perforation 785 defined in a wall 792 of the inner housing 780. The flavor chamber 790 is configured to contain a flavor material 795.

[0047] In at least one example embodiment, the adapter 797 is located at the end of the flavor carrier 760. The adapter 797 is configured to secure the flavor carrier 760 within the device body 1025 of the aerosol generating device 1000. The adapter 797 may be an annular body that fits tightly around the outer surface of the outer housing 765 of the flavor carrier 760. The adapter 797 is sized to provide a friction fit between the outer housing 765 of the flavor carrier 760 and the inner surface 700 of the device body 1025 of the aerosol generating device 1000.

[0048] In at least one example embodiment, the adapter 797 is formed of one or more materials including polymers, metals, subcombinations thereof, or combinations thereof. The adapter 797 is substantially impermeable to the aerosol, so that the aerosol is forced to flow through the flavor carrier 760, where the aroma and / or flavor from the flavor material 795 is eluted into the aerosol.

[0049] In at least one example embodiment, the outer housing 765 of the flavor carrier 760 is a hollow cylinder having an outer diameter ranging from about 3.0 mm to about 10.0 mm (e.g., about 3.0 mm to about 5.0 mm, about 3.5 mm to about 4.5 mm, or about 3.75 mm to about 4.25 mm, etc.). In other example embodiments, the outer housing 765 of the flavor carrier 760 is a hollow cylinder having an outer diameter less than about 3.0 mm or greater than about 10.0 mm.

[0050] In at least one example embodiment, the inner housing 780 is a hollow cylinder having an outer diameter ranging from about 1.0 mm to about 3.0 mm (e.g., about 1.5 mm to about 2.5 mm, about 1.75 mm to about 2.25 mm, etc.). In other example embodiments, the inner housing 780 of the flavor carrier 760 is a hollow cylinder having an outer diameter less than about 1.0 mm or greater than about 3.0 mm. The diameters of the inner housing 780 and the outer housing 765 can be selected to provide a desired volume of the flavor chamber 790 defined between the inner housing 780 and the outer housing 765.

[0051] In at least one example embodiment, the wall 775 of the outer shell 765 and the wall 792 of the inner shell 780 or each has a thickness ranging from about 0.5 mm to about 1.5 mm (e.g., about 0.75 mm to about 1.25 mm). In some example embodiments, the thickness of the wall 775 and / or the wall 792 is less than about 0.5 mm or greater than about 1.5 mm. In some example embodiments, the wall 775 of the outer shell 765 and the wall 792 of the inner shell 780 or both are formed of one or more materials, including paper, fabric, metal, polymer, and / or any other suitable material.

[0052] In at least one example embodiment, flavor material 795 comprises plant material, gel, film, flavor tablet, powder, compressed powder disk, flavor beads and / or any other flavor material. In some example embodiments, plant material can comprise tobacco plant material and / or other plant material. In other example embodiments, plant material can comprise non-tobacco plant material, such as tea, herbs, etc.

[0053] In some example embodiments, flavor material 795 may include a gel. The gel may include a polymer, one or more flavorants, and / or plant materials suspended in the gel.

[0054] In other example embodiments, the flavor material 795 may include a film. The film may be formed of at least one polymer and one or more flavoring agents. The film or films may be in the flavor chamber 790, wrapped around the inner housing 780 and / or provided in a tube form such that the tube is inserted into the flavor chamber 790 around the inner housing 780. In some examples, the film may be water soluble and / or may decompose when exposed to heat such that the film decomposes when the aerosol passes through the flavor chamber 790. In other examples, the film may be porous. Other types of films may be used.

[0055] In some example embodiments, the flavor material 795 includes flavor beads that include at least one polymer and at least one flavoring agent. The flavor beads may include an outer shell that wraps around an inner core. The inner core and / or the outer shell may contain menthol or other volatile flavoring agents. For example, the inner core may contain a mint flavor, such as peppermint, spearmint, or any other flavor.

[0056] In at least one example embodiment, the flavor beads may each have a diameter ranging from about 0.5 mm to about 5 mm (e.g., about 1 mm to about 4 mm, about 2 mm to about 3 mm, etc.). In other example embodiments, the flavor beads may each have a diameter less than about 0.5 mm or greater than about 5 mm. The flavor beads may be manufactured and / or include features of the flavor beads and / or flavor containers disclosed in U.S. Pat. No. 7,878,962, issued Feb. 1, 2011 to Karles et al. and U.S. Pat. No. 7,578,298, issued Aug. 25, 2009 to Karles et al., the entire contents of which are incorporated herein by reference.

[0057] In at least one example embodiment, flavor material 795 is in the form of paper impregnated and / or coated with one or more flavorants.

[0058] In some example embodiments, when flavor material 795 is a film or paper, the film or paper may be shredded before being placed into flavor chamber 790. In some example embodiments, the shredded film or paper may be mixed with at least one plant material and / or with flavor beads.

[0059] In at least one example embodiment, the flavor material 795 may be coated with a second material that includes at least one polymer and / or flavorant. The flavorant of the coating may be the same flavorant incorporated into the flavor material 795 below the coating, or the flavorant of the coating may be a different flavorant than the flavorant in the underlying flavor material 795. In at least one example embodiment, the flavor material 795 includes a cellulosic material containing one or more flavorants.

[0060] In at least one example embodiment, the flavorant is a volatile flavorant. In at least one example embodiment, the flavorant can be any flavorant commonly used in food, candy, or other oral products. Example flavorants include, but are not limited to, berry flavors, such as pomegranate, acai, raspberry, blueberry, strawberry, boysenberry, cranberry, and the like. Other example flavorants include, but are not limited to, any natural or synthetic flavor or aroma, such as menthol, peppermint, spearmint, wintergreen, bourbon, scotch, whiskey, cognac, hydrangea, lavender, chocolate, licorice, citrus and other fruit flavors, such as apple, peach, pear, cherry, plum, orange, lime, grape, and grapefruit, gamma-octalactone, vanillin, ethyl vanillin, breath freshener flavors, butter, rum, coconut, almond, pecan, walnut, hazelnut, French vanilla, macadamia, sugar cane, maple, black currant, caramel, banana, malt, espresso, kalua, white chocolate, spice flavors such as cinnamon, cloves, coriander, basil, oregano, garlic, mustard, nutmeg, rosemary, thyme, tarragon, dill, sage, star anise and fennel, methyl salicylate, linalool, jasmine, coffee, olive oil, sesame oil, sunflower oil, bergamot oil, geranium oil, lemon oil, ginger oil, balsamic vinegar, rice wine vinegar, red wine vinegar, etc. The flavor material 795 may include one or more flavoring agents.

[0061] In at least one example embodiment, flavor material 795 includes a polymer, and the polymer is a water-soluble or water-insoluble polymer. The polymer can be natural or synthetic. The polymer can be a hydrocolloid. Other example polymers include, but are not limited to, starch, dextrin, gum arabic, guar gum, chitosan, cellulose, polyvinyl alcohol, polylactic acid, gelatin, soy protein, whey protein, etc.

[0062] Figure 2 is a cross-sectional view of a flavor carrier and a mouthpiece of an aerosol generating device according to at least one example embodiment.

[0063] In at least one example embodiment, the flavor carrier 760 and the mouthpiece 800 may be joined together such that the adapter 797 surrounds a portion of the flavor carrier 760 and the mouthpiece 800 mates with an end of the adapter 797 .

[0064] In at least one example embodiment, mouthpiece 800 is formed of materials including plastic, metal, wood, and / or other suitable materials. In at least one example embodiment, mouthpiece 800 is formed of at least one plastic material, such as polyethylene or polypropylene. Mouthpiece 800 may be rounded and may not include any sharp edges. In other examples, the cross-section of mouthpiece 800 may be generally rectangular, oval, square, triangular, polygonal, and / or may have any other cross-sectional shape. In some example embodiments, mouthpiece 800 may include sharp edges. In some examples, the surface of mouthpiece 800 may be generally smooth.

[0065] The adapter 797 is generally U-shaped and cylindrical so that the flavor carrier 760 nests within the adapter 797. The bottom wall 910 of the adapter 797 defines a channel 900 that guides the aerosol into the flavor carrier 760 when the flavor carrier 760 and the adapter 797 are engaged with the device body 1025 of the aerosol generating device 1000. The adapter 797 also includes a flange portion 920 that engages with the device body 1025 of the aerosol generating device 1000. Thus, Figure 2 The flavor carrier 765 can be retrofitted with the aerosol generating device 1000 by removing the existing mouthpiece and inserting the adapter 797 into the housing of the aerosol generating device 1000 .

[0066] Figure 3 is a perspective view of a flavor carrier of an aerosol generating device according to at least one example embodiment.

[0067] In at least one example embodiment, Figure 3 As shown, the flavor carrier 760 is generally Figure 1 and Figure 275, except that the perforations 785 in the wall 792 of the inner shell 780 are aligned with the perforations 770 in the wall 775 of the outer shell 765. The perforations 785 and the perforations 770 can be arranged in a row. In other example embodiments, the perforations 785 in the wall 792 of the inner shell 780 are not aligned with the perforations 770 in the wall 775 of the outer shell 765. In some example embodiments, the wall 792 and / or the wall 775 can each include 1 to about 20 rows of perforations 770, 785 (e.g., about 2 to about 18, about 4 to about 16, about 6 to about 14, about 8 to about 12, or about 10 to about 12). In some example embodiments, the wall 792 and / or the wall 775 can each include more than 20 rows. In some example embodiments, each column of perforations 770, 785 in the wall 792 and / or the wall 775 may include 1 to about 20 perforations 770, 785 (e.g., about 2 to about 18, about 4 to about 16, about 6 to about 14, about 8 to about 12, or about 10 to about 12). In some example embodiments, each column of perforations 770, 785 in the wall 792 and / or the wall 775 may include more than 20 perforations. The perforations 770, 785 may be the same or different sizes. In some example embodiments, the perforations 770, 785 may be generally circular, or may be triangular, rectangular, oval, square, polygonal, or may have any other shape. The size and / or shape of the perforations 770 may be the same or different from the perforations 785. In some example embodiments, the perforations 770, 785 at the first end of the flavor carrier 760 may be larger than the perforations 770, 785 at the second end of the flavor carrier 760. In at least one example embodiment, the perforations 770, 785 at the center of the flavor carrier 760 may be larger or smaller than the perforations 770, 785 at the ends of the flavor carrier. In at least one example embodiment, each perforation 770, 785 has substantially the same diameter (e.g., about 0.1 mm in diameter to about 5.0 mm in diameter).

[0068] Figure 4 is a perspective view of a flavor carrier of an aerosol generating device according to at least one example embodiment.

[0069] In at least one example embodiment, Figure 4 As shown, the flavor carrier 760 is generally Figure 1 and Figure 2100, except that the adapter 797 is in the form of a cover 1100 that is placed over the end of the flavor carrier 760. The cover 1100 also defines a passage 1110 therein. The aerosol is introduced into the inner housing 780, then passes through the perforations 785 in the wall 792 of the inner housing 780 and into the flavor chamber 790. The aerosol can then flow out of the flavor chamber 790 via the perforations 770 in the wall 775 of the outer housing 765.

[0070] Figure 5 is a perspective view of a flavor carrier of an aerosol generating device according to at least one example embodiment.

[0071] In at least one example embodiment, Figure 5 As shown, the flavor carrier 760 is generally Figure 1 and Figure 2 , except that the flavor carrier 760 further includes a gasket 1200 at the second end of the flavor carrier 760. The gasket 1200 is substantially impermeable to the aerosol so as to force the aerosol to pass through the perforations 770 in the wall 775 of the outer shell 765 of the flavor carrier 760. The gasket 1200 is formed of one or more materials, including polymers, metals, or combinations thereof and / or other suitable materials. In at least one example embodiment, the gasket 1200 is formed of one or more materials, including food grade GRAS (generally recognized as safe) materials.

[0072] Figure 6 is a perspective view of a flavor carrier of an aerosol generating device according to at least one example embodiment.

[0073] In at least one example embodiment, Figure 6 As shown, the mouthpiece 800 fits around the end of the flavor carrier 760.

[0074] Figure 7 is a perspective view of an outer housing of a flavor carrier according to at least one example embodiment.

[0075] In at least one example embodiment, the perforations 770 of the outer shell 765 are elongated and extend parallel to the longitudinal direction of the flavor carrier 760. As shown, the perforations 770 are generally rectangular in shape. In at least one example embodiment, the perforations 785 of the inner shell 780 (not shown) may be similar in shape, size, and / or pattern to the flavor carrier 760. Figure 7 The perforations 770 shown in FIG. 785 may be the same or different than the perforations 770 shown in FIG. The perforations 785 may be aligned with the perforations 770 and may be approximately the same size. In other example embodiments, the perforations 785 may have different sizes and / or may not be aligned with the perforations 770.

[0076] Figure 8is a perspective view of a flavor carrier of an aerosol generating device according to at least one example embodiment.

[0077] In at least one example embodiment, the perforations 770 of the outer shell 765 are elongated and extend perpendicularly to the longitudinal direction of the flavor carrier 760 .

[0078] In an exemplary embodiment, the perforations 785 of the inner housing 780 (not shown) may be similar to those of the inner housing 780 in terms of shape, size and / or pattern. Figure 8 The perforations 770 shown in FIG. 785 may be the same or different than the perforations 770 shown in FIG. The perforations 785 may be aligned with the perforations 770 and may be approximately the same size. In other example embodiments, the perforations 785 may have different sizes and / or may not be aligned with the perforations 770.

[0079] Fig. 9 is a perspective view of a flavor carrier of an aerosol generating device according to at least one example embodiment.

[0080] In at least one example embodiment, Fig. 9 As shown, the perforations 770 of the outer shell 765 are generally circular or oval in shape and are arranged in uniform rows and / or columns along the outer shell 765.

[0081] In an exemplary embodiment, the perforations 785 of the inner housing 780 (not shown) may be similar to those of the inner housing 780 in terms of shape, size and / or pattern. Fig. 9 The perforations 770 shown in FIG. 785 may be the same or different than the perforations 770 shown in FIG. The perforations 785 may be aligned with the perforations 770 and may be approximately the same size. In other example embodiments, the perforations 785 may have different sizes and / or may not be aligned with the perforations 770.

[0082] Fig.10 is a perspective view of a flavor carrier of an aerosol generating device according to at least one example embodiment.

[0083] In at least one example embodiment, Fig.10 As shown, the flavor carrier 760 is generally Figure 1 to Figure 2 The same as in, except that the perforations are generally circular and arranged in offset rows along the flavor carrier 760.

[0084] The perforations 785, not shown, may be the same or different than the perforations 770. The perforations 785 may be aligned with the perforations 770 and may be approximately the same size. In other example embodiments, the perforations 785 may have different sizes and / or may not be aligned with the perforations 770.

[0085] Fig.11 According to at least one example embodiment Figure 1 A cross-sectional view of the flavor cartridge along line XI-XI.

[0086] like Fig.11 As shown, in some example embodiments, the perforations 785 in the wall 792 of the inner housing 780 are aligned with the perforations 770 in the wall 775 of the outer housing 765 .

[0087] Fig.12 is a cross-sectional view of a flavor cartridge according to at least one example embodiment.

[0088] like Fig.12 As shown, in some example embodiments, the perforations 785 in the wall 792 of the inner housing 780 are not aligned with the perforations 770 in the wall 775 of the outer housing 765 such that a tortuous flow path is formed through the flavor chamber 790 .

[0089] Fig.13 is a perspective view of a flavor cartridge according to at least one example embodiment.

[0090] In at least one example embodiment, Fig.13 As shown, one or more features of the flavor carrier 760 are substantially the same as one or more features described herein, except that the flavor carrier 760, rather than including an outer shell 765 and an inner shell 780 and a flavor chamber 790 between the outer shell 765 and the inner shell 780, is formed by a paper tube 2505 impregnated with at least one flavorant. The thickness of the tube 2505 is approximately the same as the gap between the outer shell 765 and the inner shell 780 described herein. The tube 2505 includes a plurality of perforations 2500 therein. The perforations 2500 can be any desired shape and / or configuration.

[0091] Fig.14 is a schematic diagram illustrating airflow through an aerosol generating device including a flavor carrier according to at least one example embodiment.

[0092] exist Fig.14 In one example embodiment shown, the aerosol generated by the aerosol generating device 1000 (indicated by the arrows) enters the inner housing 780 and flows laterally through the inner housing perforations 785, through the flavor material 795 in the flavor chamber 790, and through the outer housing perforations 770 into the space between the outer housing 765 and the device body of the aerosol generating device 1000, and exits through the mouth end of the aerosol generating device. As the aerosol passes through the flavor material 795, aroma, flavor and / or ingredients from the flavor material 795 can be eluted into the aerosol. In some example embodiments, as the aerosol flows through the flavor carrier 760, some of the aerosol or a portion of the aerosol can be filtered out.

[0093] In some example embodiments not shown, the flavor carrier may include one or more features from one or more embodiments described herein.

[0094] Example embodiments have been disclosed herein, and it should be understood that other variations are possible. Such variations should not be regarded as departing from the spirit and scope of the present disclosure, and all such modifications obvious to those skilled in the art are intended to be included within the scope of the following claims.

Claims

1. An aerosol generating device, comprising: Device body; a mouthpiece located at the end of the device body; plant material, said plant material being in said device body; a heating element within the device body, the heating element configured to heat the plant material; and A flavor carrier, the flavor carrier being in the device body and being located between the heating element and the mouthpiece, the flavor carrier comprising, An outer shell extending in a longitudinal direction, the outer shell comprising: an outer housing wall defining at least one outer housing perforation, and an inner housing extending in a longitudinal direction, the inner housing being coaxial with the outer housing, the outer housing and the inner housing defining a flavor chamber, the flavor chamber being configured to contain a flavor material, the inner housing including an inner housing wall defining at least one inner housing perforation; a gasket at the second end of the flavor carrier, the gasket having no passage therethrough and being impermeable to aerosol; and an adapter having a U-shape such that the flavor carrier is nested within the adapter, the adapter including a bottom surface defining a cover at a first end of the flavor carrier, the cover defining a channel therein in fluid communication with an air passageway defined by the inner housing, and the adapter being configured to secure the flavor carrier to the device body.

2. The aerosol generating device according to claim 1, wherein: The gasket is formed from one or more materials including a polymer, a metal, or both a polymer and a metal.

3. The aerosol generating device according to claim 1, wherein: The outer housing has an outer diameter ranging from 3.0 mm to 5.0 mm.

4. The aerosol generating device according to claim 1, wherein: The inner housing has an outer diameter ranging from 1.0 mm to 3.0 mm.

5. The aerosol generating device according to claim 1, wherein: The flavor material includes plant material, gel, film, flavor tablet, powder, compressed powder, flavor beads, sub-combinations thereof, or combinations thereof.

6. The aerosol generating device according to claim 1, wherein: The outer housing wall and the inner housing wall each have a thickness ranging from 0.5 mm to 1.5 mm.

7. The aerosol generating device according to claim 1, wherein: The outer shell wall and the inner shell wall are each formed from one or more materials including paper, fabric, metal, polymer, subcombinations thereof, or combinations thereof.

8. The aerosol generating device according to claim 1, wherein: The at least one outer shell perforation comprises a plurality of perforations, the plurality of outer shell perforations.

9. The aerosol generating device according to claim 8, wherein: The plurality of outer shell perforations are arranged in at least one column.

10. The aerosol generating device according to claim 1, wherein: The at least one inner casing penetration aperture comprises a plurality of inner casing penetration apertures.

11. The aerosol generating device according to claim 10, wherein: The plurality of inner shell perforations are arranged in at least one column.

12. The aerosol generating device according to claim 1, wherein: The adapter is formed of one or more materials including a polymer, a metal, or both a polymer and a metal, the adapter being impermeable to aerosols.

13. The aerosol generating device according to claim 1, wherein: The at least one outer shell penetration includes a plurality of outer shell penetrations, the at least one inner shell penetration includes a plurality of inner shell penetrations, and the plurality of outer shell penetrations are aligned with the plurality of inner shell penetrations.

14. The aerosol generating device according to claim 1, wherein: The at least one outer shell penetration includes a plurality of outer shell penetrations, the at least one inner shell penetration includes a plurality of inner shell penetrations, and the plurality of outer shell penetrations are not aligned with the plurality of inner shell penetrations.

15. The aerosol generating device according to claim 1, wherein: The plant material comprises tobacco.

16. A flavor carrier, comprising: An outer shell extending in a longitudinal direction, the outer shell comprising: an outer housing wall defining at least one outer housing perforation; as well as An inner housing extending in a longitudinal direction, the inner housing being coaxial with the outer housing, the outer housing and the inner housing defining a flavor chamber, the flavor chamber being configured to contain a flavor material, the inner housing comprising, an inner housing wall defining at least one inner housing perforation; a cover at a first end of the outer housing of the flavor carrier, the cover engaging the outer housing of the flavor carrier and defining a passageway located in a middle portion thereof; a gasket at the second end of the outer shell of the flavor carrier, the gasket having no passage therethrough and being impermeable to aerosol; as well as An adapter having a U-shape so that the outer shell of the flavor carrier is nested within the adapter, the adapter including a bottom surface, the bottom surface defining the cover located at the first end of the flavor carrier, the cover defining the channel located in the middle thereof, the channel being in fluid communication with the air passage defined by the inner shell, and the adapter being configured to secure the flavor carrier to the device body of the aerosol generating device.

17. The flavor carrier according to claim 16, wherein The gasket is formed from one or more materials including a polymer, a metal, or both a polymer and a metal.

18. The flavor carrier according to claim 16, wherein The outer housing has an outer diameter ranging from 3.0 mm to 5.0 mm.

19. The flavor carrier according to claim 16, wherein The inner housing has an outer diameter ranging from 1.0 mm to 3.0 mm.

20. The flavor carrier according to claim 16, wherein The flavor material includes plant material, gel, film, flavor tablet, powder, compressed powder, flavor beads, sub-combinations thereof, or combinations thereof.

21. The flavor carrier of claim 16, wherein: The outer housing wall and the inner housing wall each have a thickness ranging from 0.5 mm to 1.5 mm.

22. The flavor carrier of claim 16, wherein: The outer shell wall and the inner shell wall are each formed from one or more materials including paper, fabric, metal, polymer, or any combination thereof.

23. The flavor carrier of claim 16, wherein: The at least one outer shell perforation includes a plurality of perforations.

24. The flavor carrier of claim 23, wherein: The plurality of outer shell perforations are arranged in at least one column.

25. The flavor carrier of claim 16, wherein: The at least one inner casing penetration aperture comprises a plurality of inner casing penetration apertures.

26. The flavor carrier of claim 25, wherein The plurality of inner shell perforations are arranged in at least one column.

27. The flavor carrier of claim 16, wherein: The adapter is formed of one or more materials including a polymer, a metal, or both a polymer and a metal, the adapter being impermeable to aerosols.

28. The flavor carrier of claim 16, wherein: The at least one outer shell penetration includes a plurality of outer shell penetrations, the at least one inner shell penetration includes a plurality of inner shell penetrations, and the plurality of outer shell penetrations are aligned with the plurality of inner shell penetrations.

29. The flavor carrier of claim 16, wherein: The at least one outer shell penetration includes a plurality of outer shell penetrations, the at least one inner shell penetration includes a plurality of inner shell penetrations, and the plurality of outer shell penetrations are not aligned with the plurality of inner shell penetrations.

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