Capsule including internal heater, heat-not-burn (HNB) aerosol-generating device, and method of generating aerosol

Abstract

A capsule for a heat-not-burn (HNB) aerosol-generating device can include a housing and a heater within the housing. The housing has an inner surface defining a chamber configured to hold an aerosol-forming substrate. Further, the housing has an outer surface constituting a first face, an opposite second face, and side faces of the capsule. The first face and the second face of the capsule are permeable to aerosol. The heater has a first end portion, a middle portion, and a second end portion. The first end portion and the second end portion of the heater can be outer segments constituting portions of the side faces of the capsule. The middle portion of the heater is an inner segment disposed within the chamber of the housing.

Description

Technical Field

[0001] This disclosure relates to capsules, heated non-combustible (HNB) aerosol generating apparatus, and methods for generating aerosols without involving large-scale pyrolysis of the aerosol forming substrate. Background Technology

[0002] Some electronic devices are configured to heat plant material to a temperature sufficient to release its components, while maintaining the temperature below the ignition point of the plant material to avoid any significant pyrolysis. Such devices may be called aerosol generating devices (e.g., heated non-combustible aerosol generating devices), and the heated plant material may be tobacco. In some cases, the plant material can be introduced directly into the heating chamber of the aerosol generating device. In other cases, the plant material can be pre-packaged in a separate container for easy insertion and removal from the aerosol generating device. Summary of the Invention

[0003] At least one embodiment relates to a capsule for a heated non-combustible (HNB) aerosol generating apparatus. In an exemplary embodiment, the capsule may include a housing and a heater within the housing. The housing has an inner surface defining a chamber configured to hold an aerosol-forming substrate. Furthermore, the housing has an outer surface forming a first face, an opposing second face, and a side face of the capsule. The first and second faces of the capsule are permeable to aerosols. The heater has a first end portion, a middle portion, and a second end portion. The first and second end portions of the heater are outer segments that form portions of the side face of the capsule. The middle portion of the heater is an inner segment disposed within the chamber of the housing.

[0004] At least one embodiment relates to a heated non-burning (HNB) aerosol generating apparatus. In an exemplary embodiment, the aerosol generating apparatus may include a capsule and an apparatus body. The capsule includes an aerosol forming substrate. Furthermore, the capsule includes a first permeable surface, an opposing second permeable surface, and side surfaces. The apparatus body may include a heating pad configured to generate an aerosol by conductively heating the aerosol forming substrate within the capsule. In this example, the apparatus body may be configured to receive the capsule such that the heating pad engages with and covers either the first or second permeable surface of the capsule.

[0005] At least one embodiment relates to a method for generating an aerosol. In an exemplary embodiment, the method may include: attaching a capsule between a first pad and a second pad. The capsule includes an aerosol-forming substrate and includes a first permeable surface, an opposing second permeable surface, and side surfaces. The method may additionally include: heating the aerosol-forming substrate using at least one of the first pad or the second pad, such that the generated aerosol passes through at least one of the first pad or the second pad. Attached Figure Description

[0006] The various features and advantages of the non-limiting embodiments of this disclosure will become clearer when the detailed description is reviewed in conjunction with the accompanying drawings. The drawings are provided for illustrative purposes only and should not be construed as limiting the scope of the claims. Unless expressly indicated, the drawings should not be considered to be drawn to scale. Various dimensions in the drawings may be enlarged for clarity.

[0007] Figure 1 This is a perspective view of the first side of the capsule for an aerosol generating apparatus according to an exemplary embodiment.

[0008] Figure 2 yes Figure 1 A perspective view of the second side opposite to the cyst.

[0009] Figure 3 yes Figure 1 An exploded view of the cyst body.

[0010] Figure 4 yes Figure 2 An exploded view of the cyst body.

[0011] Figure 5 yes Figure 3 A separate view of the heater and the third frame.

[0012] Figure 6 yes Figure 4 A separate view of the heater and the third frame.

[0013] Figure 7 This is a perspective view of the first side of another capsule for an aerosol generating apparatus according to an exemplary embodiment.

[0014] Figure 8 yes Figure 7 A perspective view of the second side opposite to the cyst.

[0015] Figure 9 yes Figure 7 An exploded view of the cyst body.

[0016] Figure 10 yes Figure 8 An exploded view of the cyst body.

[0017] Figure 11 yes Figure 9 A separate view of the heater and the third frame.

[0018] Figure 12 yes Figure 10 A separate view of the heater and the third frame.

[0019] Figure 13This is a plan view of a patterned sheet related to the manufacture of a heater, according to an exemplary embodiment.

[0020] Figure 14 This is a perspective view of a partially assembled capsule, which includes components from... Figure 13 Heaters obtained from patterned sheets.

[0021] Figure 15 This is a plan view of another patterned sheet related to the manufacture of a heater, according to an exemplary embodiment.

[0022] Figure 16 This is a plan view of another patterned sheet related to the manufacture of a heater, according to an exemplary embodiment.

[0023] Figure 17 This is a plan view of another patterned sheet related to the manufacture of a heater, according to an exemplary embodiment.

[0024] Figures 18 to 20 This is a perspective view of a method for manufacturing a capsule for an aerosol generating apparatus according to an exemplary embodiment.

[0025] Figure 21 This is a schematic cross-sectional view of an aerosol generating apparatus according to an exemplary embodiment.

[0026] Figure 22 This is a perspective view of another capsule for an aerosol generating apparatus according to an exemplary embodiment.

[0027] Figure 23 yes Figure 22 An internal view of the capsule.

[0028] Figure 24 yes Figure 22 A cross-sectional plan view of the cyst.

[0029] Figure 25 yes Figure 22 A cross-sectional side view of the cyst.

[0030] Figure 26 This is a disengaged perspective view of the engagement assembly for the capsule according to an exemplary embodiment.

[0031] Figure 27 yes Figure 26 Partial joint perspective view of the joint components.

[0032] Figure 28 yes Figure 26 A cross-sectional view of the joint components. Detailed Implementation

[0033] This document discloses some detailed exemplary embodiments. However, the specific structural and functional details disclosed herein are merely representative and for the purpose of describing exemplary embodiments. Exemplary embodiments may be implemented in many alternative forms and should not be considered limited to the exemplary embodiments listed herein.

[0034] Therefore, while exemplary embodiments can be modified and alternatively implemented in various ways, exemplary embodiments thereof are shown by way of example in the accompanying drawings and will be described in detail herein. However, it should be understood that there is no intention to limit the exemplary embodiments to the specific forms disclosed; rather, the exemplary embodiments will cover all modifications, equivalents, and alternatives thereof. Throughout the description of the accompanying drawings, the same reference numerals denote the same elements.

[0035] It should be understood that when an element or layer is referred to as "on another element or layer," "connected 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, directly connected to, attached to, adjacent to, or cover the other element or layer, or there may be intermediate elements or layers. Conversely, when an element is referred to as "directly located on another element or layer," "directly connected to another element or layer," or "directly attached to another element or layer," there are no intermediate elements or layers. Throughout the specification, the same reference numerals denote the same elements. As used herein, the term "and / or" includes any and all combinations or sub-combinations of one or more of the listed related items.

[0036] It should be understood that although the terms first, second, third, etc., used herein may describe different elements, regions, layers, and / or portions, these elements, regions, layers, and / or portions should not be limited by these terms. These terms are used only to distinguish one element, region, layer, or portion from another. Therefore, the first element, region, layer, or portion discussed below may be referred to as the second element, region, layer, or portion without departing from the teachings of the exemplary embodiments.

[0037] For ease of description, spatially related terms (e.g., "below," "below," "lower," "above," "upper," etc.) may be used 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 orientations depicted in the drawings, spatially related terms are intended to include different orientations of the device in use or operation. For example, if the device in the drawings is flipped, an element described as "below" or "below other elements or features" would be oriented "above other elements or features." Therefore, the term "below" can include both above and below orientations. The device may be oriented in other ways (rotated 90 degrees or in other orientations), and the spatially related descriptive terms used herein shall be interpreted accordingly.

[0038] The terminology used herein is for the purpose of describing different exemplary embodiments only and is not intended to limit the exemplary embodiments. The singular forms “a,” “an,” and “described” as used herein 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 “comprising,” “including,” “containing,” and / or “comprising” indicate the presence of the stated features, integrals, steps, operations, and / or elements, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, and / or groups thereof.

[0039] When the terms “approximately” or “substantially” are used in connection with numerical values ​​in this specification, it is intended that the relevant numerical value includes manufacturing or operational tolerances (e.g., ±10%) around the value. Furthermore, when the terms “generally” and “substantially” are used in connection with geometry, it is intended that a precise geometry is not required, but rather that the boundaries of the shape are within the scope of this disclosure. Moreover, regardless of whether a numerical value or shape is modified to “approximately,” “generally,” or “substantially,” it should be understood that these values ​​and shapes should be interpreted to include manufacturing or operational tolerances (e.g., ±10%) around the value or shape.

[0040] Unless otherwise defined, all terms used herein (including technical and scientific terms) shall have the same meaning as commonly understood by one of ordinary skill in the art to which the exemplary embodiments pertain. It should be further understood that, unless expressly defined herein, terms (including those defined in commonly used dictionaries) shall be interpreted as having a meaning consistent with their meaning in the context of the relevant technical field and shall not be interpreted in an idealized or overly formal sense.

[0041] The hardware may be implemented using processing or control circuitry, such as, but not limited to, one or more processors, one or more central processing units (CPUs), one or more microcontrollers, one or more arithmetic logic units (ALUs), one or more digital signal processors (DSPs), one or more microcomputers, one or more field-programmable gate arrays (FPGAs), one or more system-on-a-chip (SoCs), one or more programmable logic units (PLUs), one or more microprocessors, one or more application-specific integrated circuits (ASICs), or any other device or devices capable of responding to and executing instructions in a defined manner.

[0042] Figure 1 This is a perspective view of the first side of the capsule for an aerosol generating apparatus according to an exemplary embodiment. Figure 2 yes Figure 1 A perspective view of the second side of the cyst. See also Figures 1 to 2 The capsule 100 can be configured to be received within an aerosol generating device (e.g., a heated non-combustible aerosol generating device). In the figures, the capsule 100 has a layered structure and a generally planar form. The proximal end of the capsule 100 can have a curved proximal edge, while the opposite distal end can have a linear distal edge. Furthermore, a pair of linear side edges can connect the curved proximal edge and the linear distal edge. The pair of linear side edges can be parallel to each other. Additionally, the junction between the linear side edges and the linear distal edge can be rounded.

[0043] Although the capsule 100 is shown in the figures as resembling a rectangle with semi-circular ends (e.g., elongated semicircles), it should be understood that other configurations are possible. For example, the shape may be circular, giving the capsule 100 a disc-like appearance. In another example, the capsule 100 may be elliptical or runway-like. In other examples, the capsule 100 may have a (regular or irregular) polygonal shape, including triangles, rectangles (e.g., squares), pentagons, hexagons, heptagons, or octagons. The layered structure and generally planar form of the capsule 100 facilitates stacking, allowing multiple capsules to be stored in an aerosol generating device or other containers for dispensing new capsules or receiving discarded capsules. In an exemplary embodiment, the thickness of the capsule 100 is between 1 and 4 mm (e.g., between 1 and 2 mm).

[0044] The capsule 100 may include: a housing and a heater 170 within the housing (e.g., Figure 5 The shell of the capsule 100 has an inner surface defining a chamber configured to hold the aerosol-forming substrate 160 (e.g., Figure 5Furthermore, the shell of the capsule 100 has an outer surface that forms a first surface, an opposing second surface, and a side surface of the capsule 100. The first and second surfaces of the capsule 100 are permeable to aerosols. The side surface of the capsule 100 lies between the first and second surfaces. This side surface can be considered as the periphery of the capsule 100.

[0045] The shell of the capsule 100 includes a first frame 130 and a second frame 140 (e.g., Figure 3 The first frame 130 and the second frame 140 may have the same shape and size (e.g., based on a plan view) and be aligned such that the outer walls are substantially flush with each other, but the exemplary embodiments are not limited thereto. The first frame 130 and the second frame 140 may be formed of suitable polymers, such as polyetheretherketone (PEEK), liquid crystal polymer (LCP), and / or ultra-high molecular weight polyethylene (UHMWPE). The first frame 130 and the second frame 140 may be joined via a welded arrangement.

[0046] The first permeable structure 110 is secured and exposed by the first frame 130. Similarly, the second permeable structure 120 is secured and exposed by the second frame 140. As will be discussed in more detail herein, a third frame 150 is disposed between the first permeable structure 110 and the second permeable structure 120 (and between the first frame 130 and the second frame 140). The capsule 100 is configured to hold an aerosol-forming substrate 160, which may be within the third frame 150 and between the first permeable structure 110 and the second permeable structure 120. The first recess 133 (e.g., a first pit portion) in the first frame 130 and the second recess 143 (e.g., a second pit portion) in the second frame 140 may be derived from an injection molding process. In this respect, the size, location, and / or shape of the first recess 133 and the second recess 143 may vary depending on the manufacturing technique (or may be completely absent).

[0047] The first permeable structure 110 and the second permeable structure 120 can be in the form of a mesh sheet, a perforated sheet, or a combination thereof. For example, both the first permeable structure 110 and the second permeable structure 120 can be in the form of a mesh sheet. In another example, both the first permeable structure 110 and the second permeable structure 120 can be in the form of a perforated sheet (e.g., 80, 100, or 250 mesh equivalent). The perforated sheet can be a sheet perforated mechanically or chemically (e.g., via photochemical processing / etching). In yet another example, one of the first permeable structure 110 or the second permeable structure 120 can be in the form of a mesh sheet, while the other of the first permeable structure 110 or the second permeable structure 120 can be in the form of a perforated sheet. The first permeable structure 110 and the second permeable structure 120 (and the first frame 130 and the second frame 140) can have substantially the same dimensions based on a plan view (e.g., ±10% of a given dimension).

[0048] like Figure 1 As shown, the combination of the exposed surface of the first permeable structure 110 and the adjacent (e.g., substantially coplanar / parallel) surfaces of the first frame 130 can be considered as the first surface of the capsule 100. Similarly, as Figure 2 As shown, the combination of the exposed surface of the second permeable structure 120 and the adjacent (e.g., substantially coplanar / parallel) surfaces of the second frame 140 can be considered as the second side of the capsule 100. In one example, the first side, the second side, or both may comprise a perforated sheet. In another example, the first side, the second side, or both may comprise a mesh sheet. In yet another example, one of the first side or the second side may comprise a perforated sheet, while the other of the first side or the second side may comprise a mesh sheet.

[0049] As described above, and as will be discussed in more detail herein, heater 170 (e.g., Figure 5 A heater 170 may be disposed within the capsule 100 to heat the aerosol forming substrate 160. Among other things, the heater 170 may include a first end portion 172 and a second end portion 176 configured to receive current from a power source during activation of the heater 170. When the heater 170 is activated, the temperature of the aerosol forming substrate 160 may rise, and aerosols may be generated and released through the first permeable structure 110 and / or the second permeable structure 120 of the capsule 100.

[0050] like Figures 1 to 2As shown, the combination of the exposed surface of the third frame 150 and the adjacent sidewalls of the first frame 130 and the second frame 140 can be considered as the side of the capsule 100. Furthermore, the first end portion 172 and the second end portion 176 can be the outer segments of the heater 170, which also constitute portions of the side of the capsule 100. The outward-facing surfaces of the first end portion 172 and the second end portion 176 of the heater 170 can be coplanar, but the exemplary embodiment is not limited thereto.

[0051] As discussed herein, an aerosol forming substrate is a material or combination of materials capable of generating aerosols. An aerosol relates to a substance generated or output by the disclosed, claimed apparatus and its equivalents. The material may include compounds (e.g., nicotine), wherein the material, when heated, generates an aerosol comprising the compound. Heating may be below combustion temperature to generate an aerosol without involving significant pyrolysis of the aerosol forming substrate or the generation of substantial combustion byproducts (if any). Therefore, in exemplary embodiments, no pyrolysis occurs during heating and aerosol generation. In other cases, some pyrolysis and combustion byproducts may be present, but the extent may be relatively small and / or merely incidental.

[0052] The aerosol-forming substrate can be a fibrous material. For example, the fibrous material can be a plant-based material. This fibrous material is configured to release a compound upon heating. The compound can be a natural 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, tobacco plugs, reconstituted tobacco, compressed tobacco, shaped tobacco, or powdered tobacco; and combinations from one or more tobacco plants, such as yellow tobacco and red tobacco.

[0053] In some exemplary embodiments, the tobacco material may include material from any member of the genus *Nicotiana*. Furthermore, the tobacco material may include a mixture of two or more different tobacco varieties. Examples of suitable types of tobacco material that may be used include, but are not limited to, flue-cured tobacco, Khabarovsk tobacco, dark tobacco, Maryland tobacco, oriental tobacco, rare tobacco, specialty tobacco, and mixtures thereof. The tobacco material may be provided in any suitable form, including but not limited to, tobacco sheets, processed tobacco material (e.g., bulked or expanded tobacco), processed tobacco stems (e.g., rolled or cut expanded tobacco stems), reconstituted tobacco material, and mixtures thereof. In some exemplary embodiments, the tobacco material is present in the form of substantially dry tobacco substance. Furthermore, in some cases, the tobacco material may be mixed and / or combined with at least one of propylene glycol, glycerin, its derivatives, or combinations thereof.

[0054] The compound may also be a natural component of a medicinal plant with medically acceptable therapeutic effects.

[0055] Furthermore, the compound may be, or may additionally include, non-natural additives subsequently introduced into the fibrous material. In one example, the fibrous material may include a synthetic material. In another example, the fibrous material may include a natural material, such as a cellulose material (e.g., non-tobacco). In any example, the introduced compound may include nicotine and / or a flavoring agent. The flavoring agent may be derived from natural sources, such as plant extracts (e.g., tobacco extracts) and / or artificial sources. In yet another example, when the fibrous material includes tobacco, the compound may be, or may additionally include one or more flavorings (e.g., menthol, peppermint, vanilla). Thus, the compound within the aerosol-forming substrate may include naturally occurring components and / or non-naturally occurring additives. In this regard, it should be understood that the existing level of natural components in the aerosol-forming substrate can be increased by supplementation. For example, the existing level of nicotine in tobacco can be increased by supplementing with an extract containing nicotine.

[0056] Figure 3 yes Figure 1 An exploded view of the cyst body. Figure 4 yes Figure 2 An exploded view of the cyst body. See also: Figures 3 to 4 The first frame 130 has a first inner surface and a first outer surface. Furthermore, the first frame 130 defines a first opening 131. In an exemplary embodiment, the sidewalls of the first opening 131 have opposing linear portions and optionally, opposing curved portions, wherein one curved portion may be adjacent to a proximal end of the first frame 130, and the other curved portion may be adjacent to an opposing distal end of the first frame 130. A first permeable structure 110 may be fixed to the first inner surface of the first frame 130 so as to be exposed by the first opening 131. From a different perspective, the first permeable structure 110 may also be considered to cover the first opening 131. Furthermore, the first permeable structure 110 may define a first hole 112. The position and size of the first hole 112 may be determined such that it receives a first protrusion 135 when the first permeable structure 110 is fixed to the first frame 130.

[0057] The second frame 140 has a second inner surface and a second outer surface. Furthermore, the second frame 140 defines a second opening 141. In an exemplary embodiment, the sidewalls of the second opening 141 have opposing linear portions and, optionally, opposing curved portions, wherein one curved portion may be adjacent to a proximal end of the second frame 140, and the other curved portion may be adjacent to an opposing distal end of the second frame 140. A second permeable structure 120 may be fixed to a second inner surface of the second frame 140 so as to be exposed by the second opening 141. From a different perspective, the second permeable structure 120 may also be considered to cover the second opening 141. The size and shape of the second opening 141 may correspond to (e.g., mirror image of) the size and shape of the first opening 131. Furthermore, the second permeable structure 120 may define a second hole 122. The position and size of the second hole 122 may be determined such that it accommodates a second protrusion 145 when the second permeable structure 120 is fixed to the second frame 140.

[0058] The third frame 150 defines the cavity 151 (e.g., Figure 5 The cavity 151 is configured to receive an aerosol forming substrate 160. The combination of the sidewalls of the cavity 151 with the inner surfaces of the first permeable structure 110 and the second permeable structure 120 (which cover the cavity 151) can be considered as defining a chamber. In an exemplary embodiment, the sidewalls of the cavity 151 have opposing linear portions and opposing curved portions, wherein one curved portion is adjacent to the proximal end of the third frame 150, and the other curved portion is adjacent to the opposing distal end of the third frame 150. Based on the plan view, the dimensions of the third frame 150 may be substantially the same as those of the first permeable structure 110 and the second permeable structure 120 (e.g., ±10% of a given dimension). The third frame 150 may also define orifices 152a and 152b adjacent to its distal end. In addition to the construction materials used for the first frame 130 and the second frame 140, the third frame 150 may also be formed of other suitable materials, such as ceramics, sintered glass, and / or bonded fibers (e.g., cardboard).

[0059] The heater 170 is configured to extend through the third frame 150 and into the cavity 151. Furthermore, the heater 170 can be considered to be supported by the third frame 150. The heater 170 includes a first end portion 172, a middle portion 174, and a second end portion 176. The first end portion 172 and the second end portion 176 of the heater 170 are outer segments that also form portions of the sidewalls of the capsule 100. The middle portion 174 of the heater 170 is an inner segment disposed within the capsule 100 (e.g., within a cavity containing the aerosol forming substrate 160). The first end portion 172, the middle portion 174, and the second end portion 176 of the heater 170 are portions of a continuous structure. In an exemplary embodiment, the middle portion 174 of the heater 170 has both planar and coiled forms.

[0060] Aerosol forming substrate 160 may be disposed within the cavity 151 of the third frame 150 so as to be located on both sides of the intermediate portion 174 of the heater 170. In one example, the aerosol forming substrate 160 may be in a solidified form (e.g., sheet, tray, tablet) configured to maintain its shape to allow the aerosol forming substrate 160 to be placed in a uniform manner within the cavity 151 of the third frame 150. In this example, one aerosol forming substrate 160 may be disposed on one side of the intermediate portion 174 of the heater 170, while another aerosol forming substrate 160 may be disposed on the other side of the intermediate portion 174 of the heater 170 (e.g., to substantially fill the cavity 151 of the third frame 150 and sandwich / embed the intermediate portion 174 of the heater 170 therein). Alternatively, the aerosol forming substrate 160 may be in a loose form (e.g., particles, fibers, dregs, fragments, strips) that does not have a set shape but is configured to present the shape of the cavity 151 of the third frame 150 upon introduction.

[0061] The first permeable structure 110 and the second permeable structure 120 can be secured to the first frame 130 and the second frame 140, respectively, using various attachment techniques. For example, the attachment techniques may involve injection molding (e.g., insert molding, overmolding). In another example, the attachment techniques may involve ultrasonic welding. In other examples, the attachment techniques may involve adhesives (e.g., tapes, glues) deemed food-safe or otherwise acceptable by regulatory agencies. Alternatively, instead of individual attachment techniques, the first permeable structure 110 and the second permeable structure 120 may be clamped (or otherwise constrained) to the third frame 150 by the first frame 130 and the second frame 140, respectively.

[0062] The first frame 130 includes at least one first connector projecting from a first inner surface of the first frame 130. The at least one first connector of the first frame 130 may be in the form of a first connector 138. In an exemplary embodiment, the first connector 138 may extend along the edge of the first inner surface of the first frame 130 in the form of a ridge (e.g., a first ridge). The ridge may define a groove extending along its entire length, similar to an elevated groove or a recessed / grooved ridge. Alternatively or concurrently, the ridge may have a tapered ridge line and thus may be referred to as a tapered ridge. Although the first connector 138 is shown as being separated into multiple discrete structures (e.g., four discrete structures), it should be understood that the exemplary embodiments are not limited thereto. For example, alternatively, the first connector 138 may be a single continuous structure extending along its edge to completely surround the first inner surface of the first frame 130.

[0063] Similarly, the second frame 140 includes at least one second connector projecting from the second inner surface of the second frame 140. The at least one second connector of the second frame 140 may be in the form of a second connector 148. The second connector 148 of the second frame 140 and the first connector 138 of the first frame 130 are complementary structures configured to mate with each other. In an exemplary embodiment, the second connector 148 may extend along the edge of the second inner surface of the second frame 140 in the form of a ridge (e.g., a second ridge). This ridge may define a groove extending along its entire length, similar to an elevated groove or a recessed / grooved ridge. Alternatively or as an alternative, the ridge may have a tapered ridge line, and thus may be referred to as a tapered ridge. Although the second connector 148 is shown as being separated into multiple discrete structures (e.g., four discrete structures), it should be understood that the exemplary embodiments are not limited thereto. For example, alternatively, the second connector 148 may be a single continuous structure extending peripherally to completely surround the second inner surface of the second frame 140.

[0064] exist Figures 3 to 4In the non-limiting embodiment shown, the first connector 138 of the first frame 130 is separated into four discrete structures, two of which may be elevated grooves and the other two may be tapered ridges. Conversely, the second connector 148 of the second frame 140 may be separated into four discrete structures, two of which are tapered ridges and the other two are elevated grooves. A mixed combination of elevated grooves and tapered ridges of the first frame 130 is configured to mate with a mixed combination of tapered ridges and elevated grooves of the second frame 140 during assembly of the capsule 100. It should be understood that various combinations of elevated grooves and tapered ridges are possible for the first frame 130 and the second frame 140. Furthermore, when the capsule 100 is assembled, each of the first permeable structure 110 and the second permeable structure 120 may have lug-like extensions (e.g., four lug-like extensions) respectively disposed between the discrete structures of the first connector 138 and the second connector 148.

[0065] The tapered ridge of the first connector 138 and / or the second connector 148 may have a shoulder portion and a sloping portion that rises from the shoulder portion to form the tapered ridge line. The tapered ridge line can serve as an energy conductor during assembly (e.g., to facilitate soldering). The corresponding overhead grooves of the first connector 138 and / or the second connector 148 may have edge portions and a groove bottom. Figures 3 to 4 As shown, the bottom of the elevated trench can be a flat bottom. Alternatively, the bottom of the elevated trench can be a V-shaped bottom. In an exemplary embodiment of the connection between the first frame 130 and the second frame 140, the inclined portion of the tapered ridge is configured to contact the bottom of the corresponding elevated trench, while the shoulder portion of the tapered ridge abuts against the edge portion of the elevated trench. Therefore, the mating surfaces of the first connector 138 and the second connector 148 can be configured in opposite or complementary ways to facilitate mating.

[0066] When the mixed group of elevated trenches and conical ridges in each frame is composed such that: the elevated trenches are located on one linear side edge and the conical ridges are located on another linear side edge (e.g.) Figures 3 to 4 As shown, the first frame 130 and the second frame 140 can be the same component. In this example, orienting the first frame 130 and the second frame 140 to face each other for mating results in a complementary arrangement. Therefore, a single component can be used interchangeably as either the first frame 130 or the second frame 140, thereby simplifying the manufacturing process.

[0067] For assembly of the capsule 100, after the aerosol forming substrate 160 is disposed within the cavity 151 of the third frame 150 (e.g., on either side of the intermediate portion 174 of the heater 170), the first frame 130 can be connected to the second frame 140. In this example, when the first frame 130 is connected to the second frame 140, the third frame 150 is sandwiched between the first permeable structure 110 and the second permeable structure 120. During assembly, at least one first connector of the first frame 130 is configured to engage with at least one second connector of the second frame 140 to form at least one connection (e.g., four connections). For example, the raised groove (and / or tapered ridge) of the first connector 138 is configured to mate with the corresponding tapered ridge (and / or raised groove) of the second connector 148. Furthermore, the engagement between the first connector 138 of the first frame 130 and the second connector 148 of the second frame 140 can be achieved via a welding arrangement (e.g., ultrasonic welding). Furthermore, when the capsule 100 is assembled, the outer sidewall of the first frame 130 may be substantially flush with the outer sidewall of the second frame 140, but the exemplary embodiment is not limited thereto. Once assembled, opening the capsule 100 is difficult or infeasible without damaging the connector, frame, and / or other aspects of the capsule 100. Therefore, the capsule 100 is relatively tamper-proof against unauthorized actions by third parties.

[0068] The capsule 100 has been described as comprising (among others) a first frame 130 separate from the second frame 140. Alternatively, in some instances, the first frame 130 and the second frame 140 may be manufactured as a single structure configured to fold during assembly such that the first connector 138 engages with the second connector 148. For example, the first frame 130 and the second frame 140 may resemble a clamshell structure, wherein the linear distal edge of the first frame 130 is connected to the linear distal edge of the second frame 140 using a reduced-thickness integral portion serving as a fold line. In another example, the linear side edges of the first frame 130 may be connected to the linear side edges of the second frame 140 using a reduced-thickness integral portion serving as a fold line. With the clamshell structure, it should be understood that one or more connections (e.g., along the fold line) may be omitted from the capsule 100.

[0069] Figure 5 yes Figure 3 A separate view of the heater and the third frame. Figure 6 yes Figure 4 A separate view of the heater and the third frame. See also Figures 5 to 6The heater 170 includes a first end portion 172, a first arm portion 173, a middle portion 174, a second arm portion 175, and a second end portion 176. The first arm portion 173 and the second arm portion 175 may define holes 178a and 178b, respectively, but exemplary embodiments are not limited thereto. In one example, the first end portion 172 and the second end portion 176 may be coplanar. Furthermore, the first arm portion 173, the middle portion 174, and the second arm portion 175 may be coplanar. In this example, the plane corresponding to the first end portion 172 and the second end portion 176 may be orthogonal to the plane corresponding to the first arm portion 173, the middle portion 174, and the second arm portion 175. Furthermore, the heater 170 may be symmetrical about its longitudinal axis. The longitudinal axis of the heater 170 may lie in a plane corresponding to the first arm portion 173, the middle portion 174, and the second arm portion 175, so as to divide the middle portion 174 in two and extend (e.g., equidistantly) between the first end portion 172 and the second end portion 176.

[0070] In an exemplary embodiment, heater 170 is configured to undergo Joule heating (also known as ohmic / resistive heating) when an electric current is applied thereto. More specifically, heater 170 may be formed of one or more conductors and is configured to generate heat when an electric current passes through it. The current may be supplied from a power source (e.g., a battery) within the aerosol generating apparatus to a first end portion 172 and a second end portion 176 of heater 170. Suitable conductors for heater 170 include iron-based alloys (e.g., stainless steel, aluminoferrite), nickel-based alloys (e.g., nickel-chromium alloys), and / or ceramics (e.g., metal-coated ceramics). The intermediate portion 174 of heater 170 may have a thickness of approximately 0.1–0.3 mm (e.g., 0.15–0.25 mm) and a resistance of approximately 0.5–2.5 ohms (e.g., 1–2 ohms).

[0071] Current from a power source within the aerosol generating device can be transmitted via electrodes configured to electrically contact a first end portion 172 and a second end portion 176 of the heater 170 when the capsule 100 is inserted into the aerosol generating device. In a non-limiting embodiment, the electrodes may be spring-loaded to enhance engagement with the heater 170 of the capsule 100. The direction of the spring load on the electrodes may be along the longitudinal axis of the heater 170 and orthogonal to the plane corresponding to the first end portion 172 and the second end portion 176. In addition to or instead of spring loading, movement of the electrodes (e.g., engagement, disengagement) may be achieved by mechanical actuation. Furthermore, the supply of current from the aerosol generating device to the capsule 100 may be manually operated (e.g., button activated) or automatically operated (e.g., inhalation activated).

[0072] The third frame 150 may be a monolithic structure. In some exemplary embodiments, the heater 170 may be embedded within the third frame 150. For example, the heater 170 may extend through the third frame 150 via slots 154a and 154b. In this example, the middle portion 174 of the heater 170 is located within the cavity 151 of the third frame 150, while the first arm portion 173 and the second arm portion 175 of the heater 170 are located within the distal portion of the third frame 150, and the first end portion 172 and the second end portion 176 of the heater 170 are located outside the cavity 151 and abut against the distal sidewall of the third frame 150. Furthermore, the holes 178a and 178b of the heater 170 may be aligned with the holes 152a and 152b of the third frame 150, respectively. The holes 178a and 178b may have been formed (e.g., pre-formed) in the heater 170 before it is embedded within the third frame 150. Alternatively, after the heater 170 is embedded within the third frame 150, the holes 178a and 178b in the heater 170 may subsequently be formed together with the holes 152a and 152b in the third frame 150. The embedding of the heater 170 within the third frame 150 may be achieved via injection molding.

[0073] The central portion 174 of heater 170 can be in the form of a pattern spanning most of the open area in cavity 151. For example, this pattern could cause the central portion 174 of heater 170 to meander or undulate around the center of cavity 151 of third frame 150. In such an example, the central portion 174 of heater 170 can alternate between extending towards the center of cavity 151 and extending away from the center of cavity 151. Figures 5 to 6 As shown, the undulations of the middle portion 174 of the heater 170 may take the form of five protrusions (e.g., convex corners, wings, fingers) that do not contact the sidewall of the cavity 151 of the third frame 150, but the exemplary embodiments are not limited thereto.

[0074] Figure 7 This is a perspective view of the first side of another capsule for an aerosol generating apparatus according to an exemplary embodiment. Figure 8 yes Figure 7 A perspective view of the second side of the cyst. See also Figures 7 to 8 The capsule 200 can be configured to be received within an aerosol generating device (e.g., a heated non-combustible aerosol generating device). Figures 7 to 8 The cyst 200 in the middle can be similar to Figures 1 to 2The capsule 100 differs in form from the heater and the third frame, which will be discussed in more detail herein. Therefore, the above-disclosed common features should be understood to apply to this section and will not be repeated for the sake of brevity. In the figures, the capsule 200 has a layered structure and a generally planar shape. The proximal end of the capsule 200 may have a curved proximal edge, while the opposite distal end may have a linear distal edge. Furthermore, a pair of linear side edges may connect the curved proximal edge and the linear distal edge. The pair of linear side edges may be parallel to each other. Furthermore, the junction between the linear side edge and the linear distal edge may be in the form of a rounded corner.

[0075] Although capsule 200 is shown in the figures as resembling a rectangle with semi-circular ends (e.g., elongated semicircles), it should be understood that other configurations are possible. For example, the shape can be circular, giving capsule 200 a disc-like appearance. In another example, capsule 200 can be elliptical or runway-like. In other examples, capsule 200 can have a (regular or irregular) polygonal shape, including triangles, rectangles (e.g., squares), pentagons, hexagons, heptagons, or octagons. The layered structure and generally planar form of capsule 200 facilitate stacking, allowing multiple capsules to be stored in an aerosol generating device or other containers for dispensing new capsules or receiving discarded capsules.

[0076] The capsule 200 may include: a housing and a heater 270 within the housing (e.g., Figure 11 The shell of capsule 200 has an inner surface defining a chamber configured to hold an aerosol-forming substrate. Furthermore, the shell of capsule 200 has an outer surface forming a first surface, an opposing second surface, and a side surface of capsule 200. The first and second surfaces of capsule 200 are permeable to aerosols. The side surface of capsule 200 lies between the first and second surfaces. This side surface can be considered as the periphery of capsule 200.

[0077] The shell of the capsule 200 includes a first frame 230 and a second frame 240. The first frame 230 and the second frame 240 may have the same shape and size (e.g., based on a plan view) and be aligned such that their outer sidewalls are substantially flush with each other, but exemplary embodiments are not limited thereto. The first frame 230 and the second frame 240 may be formed of suitable polymers, such as polyetheretherketone (PEEK), liquid crystal polymer (LCP), and / or ultra-high molecular weight polyethylene (UHMWPE). The first frame 230 and the second frame 240 may be joined via a welded arrangement.

[0078] The first permeable structure 210 is secured and exposed by the first frame 230. Similarly, the second permeable structure 220 is secured and exposed by the second frame 240. As will be discussed in more detail herein, a third frame 250 is disposed between the first permeable structure 210 and the second permeable structure 220 (and between the first frame 230 and the second frame 240). The capsule 200 is configured to hold an aerosol-forming substrate, which may be within the third frame 250 and between the first permeable structure 210 and the second permeable structure 220. The first recess 233 (e.g., a first pit portion) in the first frame 230 and the second recess 243 (e.g., a second pit portion) in the second frame 240 may be derived from an injection molding process. In this respect, the size, location, and / or shape of the first recess 233 and the second recess 243 may vary depending on the manufacturing technique (or may be completely absent).

[0079] The first permeable structure 210 and the second permeable structure 220 can be in the form of a mesh sheet, a perforated sheet, or a combination thereof. For example, both the first permeable structure 210 and the second permeable structure 220 can be in the form of a mesh sheet. In another example, both the first permeable structure 210 and the second permeable structure 220 can be in the form of a perforated sheet (e.g., 80, 100, or 250 mesh equivalent). The perforated sheet can be a sheet perforated mechanically or chemically (e.g., via photochemical processing / etching). In yet another example, one of the first permeable structure 210 or the second permeable structure 220 can be in the form of a mesh sheet, while the other of the first permeable structure 210 or the second permeable structure 220 can be in the form of a perforated sheet. The first permeable structure 210 and the second permeable structure 220 (and the first frame 230 and the second frame 240) can have substantially the same dimensions based on a plan view (e.g., ±10% of a given dimension).

[0080] like Figure 7 As shown, the combination of the exposed surface of the first permeable structure 210 and the adjacent (e.g., substantially coplanar / parallel) surfaces of the first frame 230 can be considered as the first surface of the capsule 200. Similarly, as Figure 8 As shown, the combination of the exposed surface of the second permeable structure 220 and the adjacent (e.g., substantially coplanar / parallel) surfaces of the second frame 240 can be considered as the second side of the capsule 200. In one example, the first side, the second side, or both may comprise a perforated sheet. In another example, the first side, the second side, or both may comprise a mesh sheet. In yet another example, one of the first side or the second side may comprise a perforated sheet, while the other of the first side or the second side may comprise a mesh sheet.

[0081] As described above, and as will be discussed in more detail herein, heater 270 (e.g., Figure 11 A heater 270 may be disposed within the capsule 200 to heat the aerosol forming substrate. The heater 270 may, among other things, include a first end portion 272 and a second end portion 276 configured to receive current from a power source during activation of the heater 270. When the heater 270 is activated, the temperature of the aerosol forming substrate may rise, and aerosols may be generated and released through the first permeable structure 210 and / or the second permeable structure 220 of the capsule 200.

[0082] like Figures 7 to 8 As shown, the combination of the exposed surface of the third frame 250 with the adjacent sidewalls of the first frame 230 and the second frame 240 can be considered as the sidewalls of the capsule 200. The first end portion 272 and the second end portion 276 can be external segments of the heater 270, protruding beyond the shell (e.g., and sides) of the capsule 200 (e.g., to facilitate electrical connection to a power source). The first end portion 272 and the second end portion 276 of the heater 270 can be coplanar, but the exemplary embodiments are not limited thereto. The first end portion 272 and the second end portion 276 of the heater 270 can also define holes 278a and 278b, respectively. In another example, the first end portion 272 and the second end portion 276 of the heater 270 can be... Figure 2 The first end portion 172 and the second end portion 176 are similarly configured to form portions of the side of the capsule 200. In this example, although Figure 2 The first end portion 172 and the second end portion 176 constitute the lateral portion located at the distal end of the capsule 100, but Figure 7 The first end portion 272 and the second end portion 276 can form a lateral portion located at the proximal end of the capsule 200.

[0083] Figure 9 yes Figure 7 An exploded view of the cyst body. Figure 10 yes Figure 8 An exploded view of the cyst body. See also: Figures 9 to 10The first frame 230 has a first inner surface and a first outer surface. Furthermore, the first frame 230 defines a first opening 231. In an exemplary embodiment, the sidewalls of the first opening 231 have opposing linear portions and, optionally, opposing curved portions, wherein one curved portion may be adjacent to a proximal end of the first frame 230, and the other curved portion may be adjacent to an opposing distal end of the first frame 230. A first permeable structure 210 may be fixed to the first inner surface of the first frame 230 so as to be exposed by the first opening 231. From a different perspective, the first permeable structure 210 may also be considered to cover the first opening 231. Furthermore, the first permeable structure 210 may define a first hole 212. The position and size of the first hole 212 may be determined such that it accommodates a first protrusion 235 when the first permeable structure 210 is fixed to the first frame 230.

[0084] The second frame 240 has a second inner surface and a second outer surface. Furthermore, the second frame 240 defines a second opening 241. In an exemplary embodiment, the sidewalls of the second opening 241 have opposing linear portions and, optionally, opposing curved portions, wherein one curved portion may be adjacent to the proximal end of the second frame 240, while the other curved portion may be adjacent to the opposing distal end of the second frame 240. A second permeable structure 220 may be fixed to the second inner surface of the second frame 240 so as to be exposed by the second opening 241. From a different perspective, the second permeable structure 220 may also be considered as covering the second opening 241. The size and shape of the second opening 241 may correspond to (e.g., mirror image of) the size and shape of the first opening 231. Furthermore, the second permeable structure 220 may define a second hole 222. The position and size of the second hole 222 may be determined such that it accommodates a second protrusion 245 when the second permeable structure 220 is fixed to the second frame 240.

[0085] The third frame 250 defines a cavity 251 configured to receive an aerosol-forming substrate. As will be discussed in more detail herein, the third frame 250 may be formed from components 250a and 250b. The combination of the sidewalls of the cavity 251 with the inner surfaces of the first permeable structure 210 and the second permeable structure 220 (which cover the cavity 251) can be considered as defining a chamber. In an exemplary embodiment, the sidewalls of the cavity 251 have opposing linear portions and opposing curved portions, wherein one curved portion is adjacent to the proximal end of the third frame 250, and the other curved portion is adjacent to the opposing distal end of the third frame 250. Based on the plan view, the dimensions of the third frame 250 may be substantially the same as those of the first permeable structure 210 and the second permeable structure 220 (e.g., ±10% of a given dimension). In addition to the construction materials used for the first frame 230 and the second frame 240, the third frame 250 may also be formed from other suitable materials, such as ceramics, sintered glass, and / or bonded fibers (e.g., cardboard).

[0086] The heater 270 is configured to extend through the third frame 250 and into the cavity 251. Furthermore, the heater 270 can be considered to be supported by the third frame 250. The heater 270 includes a first end portion 272, a middle portion 274, and a second end portion 276. The first end portion 272 and the second end portion 276 of the heater 270 are external segments disposed outside the capsule 200. The first end portion 272 and the second end portion 276 of the heater 270 may also define orifices 278a and 278b, respectively, but the exemplary embodiment is not limited thereto. The middle portion 274 of the heater 270 is an internal segment disposed within the capsule 200 (e.g., within a cavity containing an aerosol forming substrate). The first end portion 272, the middle portion 274, and the second end portion 276 of the heater 270 are portions of a continuous structure. In the exemplary embodiment, the middle portion 274 of the heater 270 has a planar and coiled form.

[0087] The first permeable structure 210 and the second permeable structure 220 can be secured to the first frame 230 and the second frame 240, respectively, using various attachment techniques. For example, the attachment techniques may involve injection molding (e.g., insert molding, overmolding). In another example, the attachment techniques may involve ultrasonic welding. In other examples, the attachment techniques may involve adhesives (e.g., tapes, glues) deemed food-safe or otherwise acceptable by regulatory agencies. Alternatively, instead of individual attachment techniques, the first permeable structure 210 and the second permeable structure 220 may be clamped (or otherwise constrained) to the third frame 250 by the first frame 230 and the second frame 240, respectively.

[0088] The first frame 230 includes at least one first connector projecting from a first inner surface of the first frame 230. The at least one first connector of the first frame 230 may be in the form of a first connector 238. In an exemplary embodiment, the first connector 238 may extend along the edge of the first inner surface of the first frame 230 in the form of a ridge (e.g., a first ridge). The ridge may define a groove extending along its entire length, similar to an elevated groove or a recessed / grooved ridge. Alternatively or concurrently, the ridge may have a tapered ridge line and thus may be referred to as a tapered ridge. Although the first connector 238 is shown as being separated into multiple discrete structures (e.g., four discrete structures), it should be understood that the exemplary embodiments are not limited thereto. For example, alternatively, the first connector 238 may be a single continuous structure extending along its edge to completely surround the first inner surface of the first frame 230.

[0089] Similarly, the second frame 240 includes at least one second connector projecting from the second inner surface of the second frame 240. The at least one second connector of the second frame 240 may be in the form of a second connector 248. The second connector 248 of the second frame 240 and the first connector 238 of the first frame 230 are complementary structures configured to mate with each other. In an exemplary embodiment, the second connector 248 may extend along the edge of the second inner surface of the second frame 240 in the form of a ridge (e.g., a second ridge). This ridge may define a groove extending along its entire length, similar to an elevated groove or a recessed / grooved ridge. Alternatively, the ridge may have a tapered ridge line and thus may be referred to as a tapered ridge. Although the second connector 248 is shown as being separated into multiple discrete structures (e.g., four discrete structures), it should be understood that the exemplary embodiments are not limited thereto. For example, alternatively, the second connector 248 may be a single continuous structure extending peripherally to completely surround the second inner surface of the second frame 240.

[0090] exist Figures 9 to 10In the non-limiting embodiment shown, the first connector 238 of the first frame 230 is separated into four discrete structures, two of which may be elevated grooves and the other two may be tapered ridges. Conversely, the second connector 248 of the second frame 240 may be separated into four discrete structures, two of which are tapered ridges and the other two are elevated grooves. A mixed configuration of elevated grooves and tapered ridges of the first frame 230 is configured to mate with a mixed configuration of tapered ridges and elevated grooves of the second frame 240 during assembly of the capsule 200. It should be understood that various combinations of elevated grooves and tapered ridges are possible for the first frame 230 and the second frame 240. Furthermore, when the capsule 200 is assembled, each of the first permeable structure 210 and the second permeable structure 220 may have lug-like extensions (e.g., four lug-like extensions) respectively disposed between the discrete structures of the first connector 238 and the second connector 248.

[0091] The tapered ridge of the first connector 238 and / or the second connector 248 may have a shoulder portion and a sloping portion that rises from the shoulder portion to form the tapered ridge line. The tapered ridge line can serve as an energy conductor during assembly (e.g., to facilitate soldering). The corresponding overhead grooves of the first connector 238 and / or the second connector 248 may have edge portions and a groove bottom. Figures 9 to 10 As shown, the bottom of the elevated trench can be a flat bottom. Alternatively, the bottom of the elevated trench can be a V-shaped bottom. In an exemplary embodiment of the connection between the first frame 230 and the second frame 240, the inclined portion of the tapered ridge is configured to contact the bottom of the corresponding elevated trench, while the shoulder portion of the tapered ridge abuts against the edge portion of the elevated trench. Therefore, the mating surfaces of the first connector 238 and the second connector 248 can be configured in opposite or complementary ways to facilitate mating.

[0092] When the mixed group of elevated trenches and conical ridges in each frame is composed such that: the elevated trenches are located on one linear side edge and the conical ridges are located on another linear side edge (e.g.) Figures 9 to 10 As shown, the first frame 230 and the second frame 240 can be the same component. In this example, orienting the first frame 230 and the second frame 240 to face each other for mating results in a complementary arrangement. Therefore, a single component can be used interchangeably as either the first frame 230 or the second frame 240, thereby simplifying the manufacturing process.

[0093] For assembly of the capsule 200, after the aerosol forming substrate is disposed within the cavity 251 of the third frame 250 (e.g., on either side of the intermediate portion 274 of the heater 270), the first frame 230 can be connected to the second frame 240. In this example, when the first frame 230 is connected to the second frame 240, the third frame 250 will be sandwiched between the first permeable structure 210 and the second permeable structure 220. During assembly, at least one first connector of the first frame 230 is configured to engage with at least one second connector of the second frame 240 to form at least one connection (e.g., four connections). For example, the raised groove (and / or tapered ridge) of the first connector 238 is configured to mate with the corresponding tapered ridge (and / or raised groove) of the second connector 248. Furthermore, the engagement between the first connector 238 of the first frame 230 and the second connector 248 of the second frame 240 can be achieved via a welding arrangement (e.g., ultrasonic welding). Furthermore, when the capsule 200 is assembled, the outer sidewall of the first frame 230 may be substantially flush with the outer sidewall of the second frame 240, but the exemplary embodiment is not limited thereto. Once assembled, opening the capsule 200 is difficult or infeasible without damaging the connector, frame, and / or other aspects of the capsule 200. Therefore, the capsule 200 is relatively tamper-proof against unauthorized actions by third parties.

[0094] The capsule 200 has been described as comprising (among others) a first frame 230 separate from the second frame 240. Alternatively, in some instances, the first frame 230 and the second frame 240 may be manufactured as a single structure configured to fold during assembly such that the first connector 238 engages with the second connector 248. For example, the first frame 230 and the second frame 240 may resemble a clamshell structure, wherein the linear distal edge of the first frame 230 is connected to the linear distal edge of the second frame 240 using a reduced-thickness integral portion serving as a fold line. In another example, the linear side edges of the first frame 230 may be connected to the linear side edges of the second frame 240 using a reduced-thickness integral portion serving as a fold line. With the clamshell structure, it should be understood that one or more connections (e.g., along the fold line) may be omitted from the capsule 200.

[0095] Figure 11 yes Figure 9 A separate view of the heater and the third frame. Figure 12 yes Figure 10 A separate view of the heater and the third frame. See also Figures 11 to 12The heater 270 includes a first end portion 272, a first arm portion 273, a middle portion 274, a second arm portion 275, and a second end portion 276. As described above, the first end portion 272 and the second end portion 276 of the heater 270 may define holes 278a and 278b, respectively. Furthermore, the first arm portion 273 and the second arm portion 275 may define holes 278c and 278d, respectively, but the exemplary embodiments are not limited thereto. In one example, the heater 270 may have a planar form. Therefore, the first end portion 272, the first arm portion 273, the middle portion 274, the second arm portion 275, and the second end portion 276 may be coplanar. Alternatively, the heater 270 may have a configuration in which the first end portion 272 and the second end portion 276 are similar to the first end portion 172 and the second end portion 176 of the heater 170 (e.g., Figures 5 to 6 (The folded configuration shown). Furthermore, heater 270 may be symmetrical about its longitudinal axis. The longitudinal axis of heater 270 may lie in a plane corresponding to heater 270 so as to divide the intermediate portion 274 in two and extend (e.g., equidistantly) between the first end portion 272 and the second end portion 276.

[0096] In an exemplary embodiment, heater 270 is configured to undergo Joule heating (also known as ohmic / resistance heating) when an electric current is applied thereto. More specifically, heater 270 may be formed of one or more conductors and is configured to generate heat when an electric current passes through it. The electric current may be supplied from a power source (e.g., a battery) within the aerosol generating apparatus to a first end portion 272 and a second end portion 276 of heater 270. Suitable conductors for heater 270 include iron-based alloys (e.g., stainless steel, iron-aluminate), nickel-based alloys (e.g., nickel-chromium alloys), and / or ceramics (e.g., metal-coated ceramics). The intermediate portion 274 of heater 270 may have a thickness of approximately 0.1–0.3 mm (e.g., 0.15–0.25 mm) and a resistance of approximately 0.5–2.5 ohms (e.g., 1–2 ohms).

[0097] Current from a power source within the aerosol generating device can be transmitted via electrodes configured to electrically contact a first end portion 272 and a second end portion 276 of the heater 270 when the capsule 200 is inserted into the aerosol generating device. In a non-limiting embodiment, the electrodes within the aerosol generating device may be spring-loaded to enhance engagement with the heater 270 of the capsule 100. For example, the spring-loaded first electrode within the aerosol generating device may have a circular or beveled engagement portion configured to electrically contact the first end portion 272 of the heater 270 such that the engagement portion sits within a hole 278a in the first end portion 272. Similarly, the spring-loaded second electrode within the aerosol generating device may have a circular or beveled engagement portion configured to electrically contact the second end portion 276 of the heater 270 such that the engagement portion sits within a hole 278b in the second end portion 276. In this example, the engagement of the first and second electrodes of the aerosol generating device with the first end portion 272 and the second end portion 276 of the heater 270, respectively, can produce a confirming click. The direction of the spring loading on the electrodes can be orthogonal to the plane of the heater 270. In addition to or instead of spring loading, the movement of the electrodes (e.g., engagement, disengagement) can be achieved by mechanical actuation. Furthermore, the supply of current from the aerosol generating device to the capsule 200 can be manually operated (e.g., button activation) or automatically operated (e.g., inhalation activation).

[0098] The third frame 250 can be constructed as components 250a and 250b, or constituted by components 250a and 250b, which are configured to engage and clamp the heater 270 between them. For example, components 250a and 250b can define corresponding openings 251a and 251b, respectively, in the cavity 251 forming the third frame 250. In this example, when assembled, the middle portion 274 of the heater 270 is located within the cavity 251 of the third frame 250, while the first arm portion 273 and the second arm portion 275 of the heater 270 are located at least within the proximal and side portions of the third frame 250, and the first end portion 272 and the second end portion 276 of the heater 270 are located outside the cavity 251 and extend beyond the proximal end of the third frame 250.

[0099] In an exemplary embodiment, component 250b may include a ridge portion 257, and component 250a may define a corresponding recessed portion 254 (or vice versa), the recessed portion being configured to receive the ridge portion 257 when components 250a and 250b are engaged. In such an embodiment, when heater 270 is clamped by components 250a and 250b of the third frame 250, the ridge portion 257 may be located between a first end portion 272 and a second end portion 276 of heater 270, insulating them from each other. Furthermore, component 250b may include protrusions 255a and 255b, and component 250a may define corresponding holes 252a and 252b (or vice versa), the holes 252a and 252b being configured to receive the protrusions 255a and 255b, respectively, when components 250a and 250b are engaged. Furthermore, the protrusions 255a and 255b of component 250b can extend through the first arm portion 273 and the second arm portion 275 of heater 270 via holes 278c and 278d, respectively.

[0100] Component 250a is configured to be received by component 250b to form a third frame 250. In an exemplary embodiment, the dimensions of component 250a are determined to sit within a corresponding recess in component 250b. In such an embodiment, the outer sidewall of component 250a may engage with the inner sidewall of component 250b. This engagement may be via an interference fit (also referred to as a press-fit or friction fit). Furthermore, the dimensions of the thickness of component 250a and / or the depth of the corresponding recess in component 250b may be determined such that when heater 270 is sandwiched between components 250a and 250b, the outer surface of component 250a is substantially flush with the edge of component 250b. Although the third frame 250 is disclosed as being composed of components 250a and 250b, it should be understood that in other instances, the third frame 250 may be a monolithic structure. In such an instance, heater 270 may be embedded within the third frame 250 via injection molding.

[0101] The central portion 274 of heater 270 can be in the form of a pattern spanning most of the open area in cavity 251. For example, this pattern could cause the central portion 274 of heater 270 to meander or undulate around the center of cavity 251 of third frame 250. In such an example, the central portion 274 of heater 270 could alternate between extending towards the center of cavity 251 and extending away from the center of cavity 251. Figures 11 to 12 As shown, the undulations of the middle portion 274 of the heater 270 may take the form of five protrusions (e.g., convex corners, wings, fingers) that do not contact the sidewall of the cavity 251 of the third frame 250, but the exemplary embodiments are not limited thereto.

[0102] Figure 13This is a plan view of a patterned sheet related to the manufacture of a heater, according to an exemplary embodiment. See also Figure 13 The sheet can be cut or otherwise processed (e.g., stamping, electrochemical etching, die-cutting, laser cutting) to produce a patterned sheet 370'. The sheet is formed of one or more conductors configured to undergo Joule heating (also known as ohmic / resistance heating). Suitable conductors for the sheet include iron-based alloys (e.g., stainless steel, aluminoferrite), nickel-based alloys (e.g., nickel-chromium alloys), and / or ceramics (e.g., metal-coated ceramics). For example, stainless steel can be of the SS316L type known in the art, but the example embodiments are not limited thereto. The thickness of the sheet can be approximately 0.1–0.3 mm (e.g., 0.15–0.25 mm).

[0103] The patterned sheet 370' includes a heater having a first end portion 372, an intermediate portion 374, and a second end portion 376. The first end portion 372 and the second end portion 376 may define holes 378a and 378b, respectively. Sheet portion 309 is connected to the first end portion 372, the intermediate portion 374, and the second end portion 376 via a cut portion 311. During subsequent steps of the manufacturing process, the cut portion 311 is cut to allow the heater 370 ( Figure 14 The first end portion 372, the middle portion 374, and the second end portion 376 are separated from the sheet portion 309. Although six cut portions 311 are shown, it should be understood that the exemplary embodiments are not limited thereto.

[0104] Figure 14 This is a perspective view of a partially assembled capsule, the capsule comprising... Figure 13 Heaters obtained from patterned sheets. Figure 14 The partially assembled capsules in the middle can be similar to Figures 7 to 12 The corresponding aspect of the capsule 200 in the text. For example, Figure 14 The second permeable structure 320, the second frame 340, and the second connector 348 can be combined as follows: Figure 9 The second permeable structure 220, the second frame 240, and the second connector 248 described herein. Therefore, the relevant disclosures of the above common features should be understood to apply to this section, and for the sake of brevity, they will not be repeated.

[0105] In an exemplary embodiment, the proximal portion of the third frame 350 defines a recess or channel configured to receive a heater 370. Each segment of the heater 370 seated in the channel within the third frame 350 may be wider than a segment of the heater 370 located within the cavity of the third frame 350 (e.g., the middle portion 374). Each of these wider segments of the heater 370 will have a lower resistance than a narrower segment of the heater 370 and can therefore be used as a heat release segment.

[0106] The central portion 374 of heater 370 can be in the form of a pattern spanning most of the open area in the cavity of third frame 350. For example, the pattern could cause the central portion 374 of heater 370 to meander or undulate around the center of the cavity of third frame 350. In such an example, the central portion 374 of heater 370 can alternate between extending towards the center of the cavity and extending away from the center of the cavity. Figure 14 As shown, the undulations of the middle portion 374 of the heater 370 may take the form of six protrusions (e.g., convex corners, wings, fingers) that do not contact the sidewalls of the cavity of the third frame 350, but the exemplary embodiments are not limited thereto.

[0107] Although Figure 14 Not shown, but it should be understood that a first frame and a first permeable structure (as discussed herein) and an inner frame (which complements the third frame 350) can be provided to surround the aerosol forming substrate to complete the assembly of the capsule. The complementary inner frame can mimic the third frame 350 while omitting the channels for the heater 370. In such an example, the complementary inner frame can have inner and outer surfaces that are entirely planar. Alternatively, the complementary inner frame can include ridges configured to sit between the wider sections of the heater 370 within the channels of the third frame 350 when the capsule is assembled.

[0108] Figure 15 This is a plan view of another patterned sheet related to the manufacture of a heater, according to an exemplary embodiment. See also Figure 15 Sheets can be cut or otherwise processed (e.g., stamping, electrochemical etching, die-cutting, laser cutting) to produce patterned sheets 470'. The patterned sheets 470' can be combined as follows... Figure 13The patterned sheet 370' described herein, except for the presence of arm portions, is described in the figure. Therefore, the relevant disclosures regarding the common features described above should be understood to apply to this section, and for the sake of brevity, they will not be repeated. As shown, the patterned sheet 470' includes a heater having a first end portion 472, a first arm portion 473, an intermediate portion 474, a second arm portion 475, and a second end portion 476. The first end portion 472 and the second end portion 476 may define holes 478a and 478b, respectively. The first arm portion 473 and the second arm portion 475 may serve as a support structure and a heat release section. Sheet portion 409 is connected to the first end portion 472, the first arm portion 473, the second arm portion 475, and the second end portion 476 via a cut portion 411. During subsequent steps of the manufacturing process, the cut portion 411 is cut to allow the first end portion 472, the first arm portion 473, the second arm portion 475, and the second end portion 476 of the heater to be separated from sheet portion 409. Although six cut portions 411 are shown, it should be understood that the exemplary embodiments are not limited thereto. Furthermore, the first arm portion 473 and the second arm portion 475 may include alignment tabs (e.g., six alignment tabs) adjacent to the cut portions 411 to facilitate placement of the heater during bladder assembly.

[0109] Figure 16 This is a plan view of another patterned sheet related to the manufacture of a heater, according to an exemplary embodiment. See also Figure 16 Sheets can be cut or otherwise processed (e.g., stamping, electrochemical etching, die-cutting, laser cutting) to produce patterned sheets 570'. The patterned sheets 570' can be combined as follows... Figure 15The patterned sheet 470' described herein, except for the form of the middle portion of the heater, is also included. Therefore, the relevant disclosures regarding the common features described above should be understood to apply to this section, and for the sake of brevity, they will not be repeated. As shown, the patterned sheet 570' includes a heater having a first end portion 572, a first arm portion 573, a middle portion 574, a second arm portion 575, and a second end portion 576. The first end portion 572 and the second end portion 576 may define holes 578a and 578b, respectively. The first arm portion 573 and the second arm portion 575 may serve as a support structure and a heat release section. The middle portion 574 may have a wound form, including annular, wheel-shaped, and / or arched shapes, and resemble a maze or fingerprint. Sheet portion 509 is connected to the first end portion 572, the first arm portion 573, the second arm portion 575, and the second end portion 576 via a cut portion 511. During subsequent steps of the manufacturing process, the cut portions 511 are cut to allow the first end portion 572, the first arm portion 573, the second arm portion 575, and the second end portion 576 of the heater to separate from the sheet portion 509. Although six cut portions 511 are shown, it should be understood that the exemplary embodiments are not limited thereto. Furthermore, the first arm portion 573 and the second arm portion 575 may include alignment tabs (e.g., six alignment tabs) adjacent to the cut portions 511 to facilitate placement of the heater during assembly of the capsule.

[0110] Figure 17 This is a plan view of another patterned sheet related to the manufacture of a heater, according to an exemplary embodiment. See also Figure 17 Sheets can be cut or otherwise processed (e.g., stamping, electrochemical etching, die-cutting, laser cutting) to produce patterned sheets 670'. The patterned sheets 670' can be combined as follows... Figure 15The patterned sheet 470' described herein, except for the form of the intermediate portion of the heater, is also included. Therefore, the relevant disclosures regarding the common features described above should be understood to apply to this section, and for the sake of brevity, they will not be repeated. As shown, the patterned sheet 670' includes a heater having a first end portion 672, a first arm portion 673, an intermediate portion 674, a second arm portion 675, and a second end portion 676. The first end portion 672 and the second end portion 676 may define holes 678a and 678b, respectively. The first arm portion 673 and the second arm portion 675 may serve as a support structure and a heat release section. The intermediate portion 674 may have a wound form, similar to compression oscillation, or a serrated shape having multiple parallel segments (e.g., eight to twelve parallel segments). Sheet portion 609 is connected to the first end portion 672, the first arm portion 673, the second arm portion 675, and the second end portion 676 via a cut portion 611. During subsequent steps of the manufacturing process, the cut portions 611 are cut to allow the first end portion 672, the first arm portion 673, the second arm portion 675, and the second end portion 676 of the heater to separate from the sheet portion 609. Although six cut portions 611 are shown, it should be understood that the exemplary embodiments are not limited thereto. Furthermore, the first arm portion 673 and the second arm portion 675 may include alignment tabs (e.g., six alignment tabs) adjacent to the cut portions 611 to facilitate placement of the heater during assembly of the capsule.

[0111] Figures 18 to 20 This is a perspective view of a method for manufacturing a capsule for an aerosol generating apparatus according to an exemplary embodiment. See also Figure 18 Partially assembled capsules can be similar to Figures 7 to 12 The corresponding aspect of the capsule 200 in the text. For example, Figure 18 The second permeable structure 620, the second frame 640, and the second connector 648 can be combined as follows: Figure 9 The second permeable structure 220, the second frame 240, and the second connector 248 described herein. Therefore, the relevant disclosures of the above common features should be understood to apply to this section, and for the sake of brevity, they will not be repeated.

[0112] After the second permeable structure 620, the third frame 650, and the aerosol-forming substrate (not shown) are disposed within the second frame 640, the patterned sheet 670' can be positioned such that the intermediate portion 674 is aligned with the opening defined by the third frame 650 to hold the aerosol-forming substrate. In an exemplary embodiment, the inner contours of the first arm portion 673 and the second arm portion 675 correspond to the shape and size of the opening defined by the third frame 650. The intermediate portion 674 of the heater can be in the form of a pattern spanning a large portion of the opening area in the opening of the third frame 650. For example, the pattern can cause the intermediate portion 674 of the heater to oscillate above the opening of the third frame 650. In such an example, the intermediate portion 674 of the heater can alternate between extending proximal to the second frame 640 and extending distally to the second frame 640.

[0113] like Figure 18 As shown, when the second connector 648 of the second frame 640 is separated into four discrete structures (e.g., two raised grooves and two tapered ridges), four spaces are defined between them. In an exemplary embodiment, the four spaces include a proximal space, a distal space, and two opposing side spaces. During assembly, a patterned sheet 670' is positioned on the second frame 640 such that the outer segments of the heater (including the first end portion 672 and the second end portion 676) extend through the proximal space of the second frame 640. Furthermore, the positioning of the patterned sheet 670' causes three pairs of alignment tabs on the first arm portion 673 and the second arm portion 675 to sit in the distal space and the two opposing side spaces. Additionally, the outer contours of the first arm portion 673 and the second arm portion 675 substantially correspond to the shape and size of the third frame 650 and the inner surface of the second frame 640, resulting in a relatively tight fit.

[0114] See Figure 19 The first insert 602 sits on the proximal portion of the third frame 650 between the first arm portion 673 and the second arm portion 675. Furthermore, the second insert 604 sits on the distal portion of the third frame 650 between the first arm portion 673 and the second arm portion 675. In an exemplary embodiment, each of the first insert 602 and the second insert 604 is in the form of a strip (e.g., silicone) with a thickness substantially corresponding to the thickness of the patterned sheet 670' and a width substantially corresponding to the gap between the first arm portion 673 and the second arm portion 675. The first insert 602 and the second insert 604 may also be aligned with the longitudinal axis of the patterned sheet 670', wherein the longitudinal axis bisects the intermediate portion 674 and extends (e.g., equidistantly) between the first arm portion 673 and the second arm portion 675. The first insert 602 and the second insert 604 can serve as plugs to improve passage through the first permeable structure 610 ( Figure 20 The first insert 602 and the second insert 604 can be used as insulating spacers to prevent or reduce the occurrence of electrical short circuits.

[0115] See Figure 20 An inner frame defining the opening (e.g., the same as the third frame 650) is disposed on a patterned sheet 670' together with an additional aerosol-forming substrate in the opening of the inner frame, followed by a first permeable structure 610 and a first frame 630 to (among other things) encapsulate the aerosol-forming substrate therein. The first permeable structure 610 and the first frame 630 may be combined as follows: Figure 7 The first permeable structure 210 and the first frame 230 are described in the diagram. Furthermore, the first recess 633 can be joined as follows: Figure 7 The first recess 233 is described in the image. Therefore, the above related disclosures should be understood to apply to this section, and for the sake of brevity, they will not be repeated. The first frame 630 and the second frame 640 may be connected by a welded arrangement. After the first frame 630 and the second frame 640 are connected, the cut portion 611 is cut (e.g., die-cut, laser-cut) to separate the sheet portion 609 from the capsule.

[0116] Figure 21 This is a schematic cross-sectional view of an aerosol generating apparatus according to an exemplary embodiment. See also Figure 21 The aerosol generating device 1000 (e.g., a heated non-combustible aerosol generating device) includes a mouthpiece 1015 and a device body 1025. A power supply 1035 and control circuitry 1045 may be disposed within the device body 1025 of the aerosol generating device 1000. The power supply 1035 may include one or more batteries (e.g., a rechargeable dual-battery arrangement). The aerosol generating device 1000 is configured to receive a capsule 700, which may be as described in conjunction with any embodiment herein. The aerosol generating device 1000 also includes a bonding assembly 1055 configured to electrically contact the capsule 700. In an exemplary embodiment, the bonding assembly 1055 includes a first electrode and a second electrode configured to electrically contact a first end portion and a second end portion of a heater of the capsule 700, respectively.

[0117] When the capsule 700 is inserted into the aerosol generating device 1000, the control circuit 1045 can instruct the power supply 1035 to supply current to the first and second electrodes of the coupling assembly 1055. The supply of current 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 capsule 700 can be heated to generate an aerosol. Furthermore, changes in the resistance of the heater can be used to monitor and control the aerosolization temperature. The generated aerosol can be extracted from the aerosol generating device 1000 via the mouthpiece 1015.

[0118] Figure 22 This is a perspective view of another capsule for an aerosol generating apparatus according to an exemplary embodiment. Figure 23 yes Figure 22 An internal view of the capsule. Figure 24 yes Figure 22 A cross-sectional plan view of the cyst. Figure 25 yes Figure 22 A cross-sectional side view of the cyst. See also Figures 22 to 25 The capsule 800 can be configured to be received within an aerosol generating device (e.g., a heated non-combustible aerosol generating device). The proximal end of the capsule 800 (e.g., Figure 22 The upper end of the middle section may have a curved proximal edge, while the opposite distal end (e.g., Figure 22 The lower end of the edge (of the edge) can have a linear distal edge. Furthermore, a pair of linear side edges can connect the curved proximal edge and the linear distal edge. The pair of linear side edges can be parallel to each other. Additionally, the junction of the linear side edges and the linear distal edge can be in the form of a rounded corner.

[0119] Although the capsule 800 is shown in the figure as resembling a rectangle with a curved handle, it should be understood that other configurations are possible. For example, the shape can be circular, giving the capsule 800 a disc-like appearance. In another example, the capsule 800 can be elliptical or runway-like. In other examples, the capsule 800 can have a (regular or irregular) polygonal shape, including triangles, rectangles (e.g., squares), pentagons, hexagons, heptagons, or octagons. The generally planar form of the capsule 800 facilitates stacking, allowing multiple capsules to be stored in an aerosol generating device or other containers for dispensing new capsules or receiving discarded capsules.

[0120] The capsule 800 includes a shell and a heater within the shell. The shell of the capsule 800 has an inner surface defining a chamber configured to hold an aerosol-forming substrate. Furthermore, the shell of the capsule 800 has an outer surface forming a first surface, an opposing second surface, and a side surface of the capsule 800. The first and second surfaces of the capsule 800 are permeable to aerosols. The side surface of the capsule 800 is located between the first and second surfaces. The side surface can be considered as the periphery of the capsule 800.

[0121] The shell of the capsule 800 includes a first frame 830 and a second frame 840. The outer surface of the first frame 830 can be considered as a first surface of the capsule 800. Similarly, the outer surface of the second frame 840 can be considered as a second surface of the capsule 800. The first frame 830 and the second frame 840 may have the same shape and size (e.g., based on a plan view) and be aligned such that the outer sidewalls are substantially flush with each other, but exemplary embodiments are not limited thereto. The first frame 830 and the second frame 840 may be formed of suitable polymers, such as polyetheretherketone (PEEK), liquid crystal polymer (LCP), and / or ultra-high molecular weight polyethylene (UHMWPE). The first frame 830 and the second frame 840 may be joined via a welded arrangement (e.g., ultrasonic welding) or with an adhesive (e.g., tape, glue) deemed food-safe by regulatory authorities or otherwise acceptable.

[0122] The second frame 840 may be in the form of a container defining a cavity or containing space. In an exemplary embodiment, the sidewalls of the cavity defined by the second frame 840 have opposing linear portions and, optionally, opposing curved portions, wherein one curved portion may be adjacent to the proximal end of the second frame 840, and the other curved portion may be adjacent to the opposing distal end of the second frame 840. The first frame 830 may be in the form of a lid configured to engage with the second frame 840 to close the cavity. The combination of the cavity of the second frame 840 and the corresponding inner surface of the first frame 830 (which covers the cavity) can be considered as defining a chamber.

[0123] like Figure 22 As shown, the first frame 830 defines a first through-hole 832 that coincides with the cavity of the second frame 840, while the peripheral region of the first frame 830 that coincides with the edge of the second frame 840 has no through-hole. Similarly, as Figures 23 to 24 As shown, the second frame 840 defines a second perforation 842 within the cavity. The pattern and size of the first perforation 832 may mimic the pattern and size of the second perforation 842 (e.g., staggered and 80, 100, or 250 mesh equivalent), but the exemplary embodiment is not limited thereto. The first perforation 832 and the second perforation 842 may be implemented mechanically or chemically (e.g., via photochemical processing / etching).

[0124] A heater is disposed within the capsule 800 to heat the aerosol forming substrate. In an exemplary embodiment, the heater extends through the second frame 840 and into the cavity. For example, the heater can be embedded within the second frame 840 by injection molding. The heater may be in the form of a strip having a length, width, and thickness, wherein the width is greater than the thickness, and the direction of the width is orthogonal to the first and second faces of the capsule 800. The heater includes a first end portion 872, a middle portion 874, and a second end portion 876. The first end portion 872, the middle portion 874, and the second end portion 876 of the heater are portions of a continuous structure. At least the middle portion 874 of the heater has a coiled (e.g., serpentine) form. The coiled form of the middle portion 874 may include a plurality of parallel and evenly spaced segments (e.g., eight such segments).

[0125] The central portion 874 of the heater may be in the form of a pattern that spans most of the open area within the cavity of the second frame 840. For example, the pattern may cause the central portion 874 of the heater to meander within the cavity of the second frame 840. In such an example, the central portion 874 of the heater may alternate between extending proximally toward the second frame 840 and extending distally toward the second frame 840. Figures 23 to 24 As shown, the undulations of the middle portion 874 of the heater may be in the form of three or four protrusions (e.g., fingers) that do not contact the sidewalls of the cavity of the second frame 840, but the exemplary embodiments are not limited thereto.

[0126] The first end portion 872 and the second end portion 876 of the heater are external sections configured to receive current from a power source during heater activation. The intermediate portion 874 of the heater is an internal section disposed within the capsule 800 (e.g., within a cavity of a housing containing an aerosol-forming substrate). When the heater is activated, the temperature of the aerosol-forming substrate can be increased (by means of thermal contact between the aerosol-forming substrate and the intermediate portion 874), and aerosols can be generated and released through the first perforation 832 and / or the second perforation 842 of the capsule 800.

[0127] The combination of the sidewalls of the first frame 830 and the second frame 840 can be considered as the side of the capsule 800. Furthermore, the first end portion 872 and the second end portion 876 can be: the outer section of the heater, which also constitutes a portion of the side of the capsule 800. For example, as... Figures 23 to 24 As shown, the first end portion 872 and the second end portion 876 of the heater may extend through the distal end of the second frame 840 and wrap around to the proximal end, while conforming to the outer contour of the second frame 820, but the exemplary embodiment is not limited thereto.

[0128] To assemble the capsule 800, the first frame 830 can be connected to the second frame 840 after the aerosol-forming substrate is disposed within the cavity of the second frame 840. The aerosol-forming substrate can be in a loose form (e.g., particles, fibers, residue, fragments, strips) without a defined shape, but configured to fill the space between the wound portions 874 of the heater and take on the shape of the cavity of the second frame 840. Based on the strip-like form of the heater, the intermediate portion 874 can be considered as forming a channel or partition within the cavity of the second frame 840 for receiving the aerosol-forming substrate. Furthermore, as described above, the joining between the first frame 830 and the second frame 840 can be achieved via a welded arrangement or with an adhesive deemed food-safe or otherwise acceptable by a regulatory agency. Additionally, when the capsule 800 is assembled, the outer wall of the first frame 830 can be substantially flush with the outer wall of the second frame 840, but the exemplary embodiments are not limited thereto. Once assembled, opening the capsule 800 without damaging the first frame 830, the second frame 840, and / or other aspects of the capsule 800 is difficult or infeasible. Therefore, the capsule 800 is relatively tamper-proof against unauthorized actions by third parties.

[0129] In an exemplary embodiment, the heater is configured to undergo Joule heating (also known as ohmic / resistance heating) when an electric current is applied thereto. More specifically, the heater may be formed of one or more conductors and configured to generate heat when an electric current passes through it. The current may be supplied from a power source (e.g., a battery) within the aerosol generating apparatus to a first end portion 872 and a second end portion 876 of the heater. Suitable conductors for the heater include iron-based alloys (e.g., stainless steel, iron-aluminate compounds), nickel-based alloys (e.g., nickel-chromium alloys), and / or ceramics (e.g., metal-coated ceramics). The intermediate portion 874 of the heater may have a resistance of approximately 0.5–2.5 ohms (e.g., 1–2 ohms).

[0130] Current from a power source within the aerosol generating device can be transmitted via electrodes configured to electrically contact a first end portion 872 and a second end portion 876 of the heater when the capsule 800 is inserted into the aerosol generating device. In a non-limiting embodiment, the electrodes may be spring-loaded to enhance engagement with the heater of the capsule 800. Furthermore, the first end portion 872 and the second end portion 876 of the heater can provide relatively large contact surfaces for the electrodes to facilitate proper and consistent electrical connection. The direction of the spring loading of the electrodes may be orthogonal to the side of the capsule 800. In addition to or instead of spring loading, movement of the electrodes (e.g., engagement, disengagement) can be achieved by mechanical actuation. Furthermore, the supply of current from the aerosol generating device to the capsule 800 can be manually operated (e.g., button activated) or automatically operated (e.g., inhalation activated).

[0131] Figure 26 This is a disengaged perspective view of the engagement assembly for the capsule according to an exemplary embodiment. See also Figure 26 The aerosol generating apparatus may include a device body having a coupling assembly configured to engage a capsule 900 containing an aerosol forming substrate. The capsule 900 includes a first permeable surface, an opposing second permeable surface, and side surfaces. The coupling assembly of the device body may include at least one heating pad configured to generate an aerosol by conductively heating the aerosol forming substrate within the capsule 900. For example, the device body may be configured to receive the capsule 900 such that the heating pad engages and covers the first and / or second permeable surfaces of the capsule 900. In another example, the coupling assembly of the device body may further include a sealing gasket combined with the heating pad. In this example, the device body may be configured to receive the capsule 900 such that the capsule 900 is sandwiched between the heating pad and the sealing gasket.

[0132] Capsule 900 may be similar to the corresponding aspects of capsule 100 and / or capsule 200 discussed herein. For example, Figure 26 The first frame 930, the second frame 940, the second permeable structure 920, and the second recess 943 can be combined as follows: Figure 8 The first frame 230, the second frame 240, the second permeable structure 220, and the second recess 243 are described herein. Furthermore, Figure 26 The third frame 950 in the middle can be combined as follows Figure 2 The third frame 150 and / or Figure 8 The third frame 250 describes this. Therefore, the relevant disclosures regarding the common features mentioned above should be understood to apply to this section, and for the sake of brevity, they will not be repeated.

[0133] The engagement assembly of the device body may include a first pad 1110, a second pad 1120, and / or a retainer 1150. The first pad 1110 may include a platform portion 1114 defining a plurality of first perforations 1112 (e.g., a 5x6 array). The dimensions of the platform portion 1114 of the first pad 1110 may correspond to a first opening in the first frame 930 (through which a first permeable structure is exposed). Although in Figure 26 The middle part is hidden, but the first opening and the first permeable structure can be combined as follows. Figure 10 The first opening 231 and the first permeable structure 210 are described in the figure. The first pad 1110 may also include a raised portion (e.g., a sealing ridge) surrounding the platform portion 1114. The height of the raised portion may be less than the height of the platform portion 1114. As shown, the raised portion substantially follows the shape of the platform portion 1114 and extends at least along the distal edge and side edges of the first pad 1110, but the exemplary embodiments are not limited thereto.

[0134] In addition, although Figure 26 Hidden in (but in Figure 28 (as shown in the diagram), but the second pad 1120 may include a platform portion defining a plurality of second perforations 1122 (e.g., a 5x5 array). The dimensions of the platform portion of the second pad 1120 may correspond to a second opening in the second frame 940 (through which the second permeable structure 920 is exposed). Although in Figure 26 The middle is not marked, but the second opening can be joined as shown. Figure 10 The second opening 241 is described in the second pad 1120. The second pad 1120 may also include a raised portion (e.g., a sealing ridge) surrounding the platform portion (as described in conjunction with the first pad 1110).

[0135] The first pad 1110 and / or the second pad 1120 may be formed of silicone or other heat-resistant polymers. In an exemplary embodiment, the first pad 1110 may be a heating pad configured to generate an aerosol by conducting heat to an aerosol-forming substrate within the capsule 900, while the second pad 1120 may be a sealing pad. In another example, both the first pad 1110 and the second pad 1120 may be heating pads. When the first pad 1110 and / or the second pad 1120 are constructed as heating pads, they may include integrated heating elements known in the art. Furthermore, in some instances, when using heating pads to heat the aerosol-forming substrate, the capsule 900 may be a capsule without heaters. Therefore, the first pad 1110 and / or the second pad 1120 as heating pads can be used as a primary means of heating the aerosol-forming substrate within the capsule 900. Alternatively, the first pad 1110 and / or the second pad 1120 as heating pads can be used as a supplementary means of aerosol forming substrate within the heating bladder 900, wherein the primary means is through a heater (e.g., heater 170) as described herein.

[0136] The retainer 1150 is configured to receive and support the bladder 900. As shown, the retainer 1150 includes an edge 1152 and a shelf 1154. The shelf 1154 may extend around the entire lower portion (e.g., the lower half) of the inner sidewall of the retainer 1150, but the exemplary embodiment is not limited thereto. The shelf 1154 is configured to support the bladder 900 when it is received within the retainer 1150. The retainer 1150 may be a fixed or movable component of an engagement assembly of the device body. When configured as a movable component, the retainer 1150 may be configured to slide outward (e.g., laterally) from the device body to allow the bladder 900 to sit within the retainer 1150.

[0137] Figure 27 yes Figure 26 Partial joint perspective view of the joining components. See also Figure 27The capsule 900 is partially engaged with the engagement assembly. Specifically, as shown, the capsule 900 is received to sit within the retainer 1150. In an exemplary embodiment, the opening defined by the retainer 1150 substantially corresponds to the shape and size of the capsule 900 (e.g., based on a plan view). Therefore, when the capsule 900 is located within the opening defined by the retainer 1150 and rests against the shelf 1154, only relatively small degrees of freedom of movement exist (e.g., rotation and / or lateral movement within the plane of the capsule 900). Furthermore, the depth of the opening defined by the retainer 1150 for the capsule 900 can substantially correspond to the thickness of the first frame 930. The depth of the opening defined by the retainer 1150 can be the distance along the inner sidewall from the edge 1152 to the shelf 1154.

[0138] Figure 28 yes Figure 26 A cross-sectional view of the joint components. See also... Figure 28 The capsule 900 is fully engaged with the engagement assembly. Specifically, as shown, the capsule 900 is supported by a shelf 1154 of the retainer 1150 and sandwiched between a first pad 1110 and a second pad 1120. The first pad 1110 and the second pad 1120 can be configured to move in an axial direction (e.g., along the longitudinal axis of the device body) to hold the capsule 900. In an exemplary embodiment, the platform portion 1114 of the first pad 1110 abuts against a first permeable structure of the capsule 900, while an adjacent portion (e.g., including a sealing ridge) abuts against a first frame 930 to establish a seal. Similarly, the platform portion of the second pad 1120 abuts against a second permeable structure 920 of the capsule 900, while an adjacent portion (e.g., including a sealing ridge) abuts against a second frame 940 to establish a seal.

[0139] When the first pad 1110 and the second pad 1120 are engaged in the capsule 900, the plurality of first perforations 1112 of the first pad 1110 may be staggered or otherwise offset with the plurality of second perforations 1122 of the second pad 1120. In this example, air flowing through the plurality of first perforations 1112 and entering the capsule 900 will have a longer residence time or dwell time within the aerosol-forming substrate in the capsule 900 (e.g., compared to a case where the first perforations 1112 are aligned with the second perforations 1122). The longer residence time or dwell time within the aerosol-forming substrate in the capsule 900 can increase the amount of volatiles carried by the air flowing through it. Therefore, the quantity and / or quality of aerosols exiting the capsule 900 and exiting through the plurality of second perforations 1122 of the second pad 1120 (via the second permeable structure 920) can be improved.

[0140] Using the capsule and apparatus disclosed herein, an aerosol-forming substrate can be heated to generate an aerosol. In an exemplary embodiment, the method of generating an aerosol may include: attaching a capsule 900 between a first pad 1110 and a second pad 1120 of the aerosol-generating apparatus. As described above, the capsule 900 includes an aerosol-forming substrate and includes a first permeable surface, an opposing second permeable surface, and side surfaces. The method may additionally include: heating the aerosol-forming substrate with at least one of the first pad 1110 or the second pad 1120, such that the generated aerosol exits the permeable surface of the capsule 900 and passes through at least one of the first pad 1110 or the second pad 1120. The generated aerosol can be transmitted via a mouthpiece (e.g., Figure 21 The mouthpiece 1015 is extracted from the aerosol generating device. Alternatively, in addition to external heating by the first pad 1110 and / or the second pad 1120, the aerosol forming substrate within the capsule 900 may be internally heated by one or more internal heaters disclosed herein.

[0141] In addition to the non-limiting embodiments described herein, further details of the substrates, capsules, devices, and methods discussed herein can be found in the following applications: U.S. Application No. 16 / 451,662, filed June 25, 2019, entitled "CAPSULES, HEAT-NOT-BURN (HNB) AEROSOL-GENERATING DEVICES, AND METHODS OF GENERATING AN AEROSOL", Atty.Dkt.No.24000NV-000522-US; and U.S. Application No. 16 / 252,951, filed January 21, 2019, entitled "CAPSULES, HEAT-NOT-BURN (HNB) AEROSOL-GENERATING DEVICES, AND METHODS OF GENERATING AN AEROSOL". AEROSOL (Vacuum Encapsulation, Heated Non-combustible (HNB) Aerosol Generating Apparatus and Method for Generating Aerosols), Atty.Dkt. No. 24000NV-000521-US; U.S. Application No. 15 / 845,501, filed December 18, 2017, entitled "VAPORIZING DEVICES AND METHODS FOR DELIVERING A COMPOUND USING THE SAME (Evaporation Apparatus and Method for Delivering Compounds Using the Same), Atty.Dkt. No. 24000DM-000012-US; and U.S. Application No. 15 / 559,308, filed September 18, 2017, entitled "VAPORIZER FOR VAPORIZING ANACTIVE The disclosures of Atty.Dkt.No.24000DM-000003-US-NP, each of which is incorporated herein by reference in its entirety.

[0142] While many exemplary embodiments have been disclosed herein, it should be understood that other variations are possible. Such variations should not be considered as departing from the spirit and scope of this disclosure, and it will be apparent to those skilled in the art that all such modifications are intended to be included within the scope of the following claims.

Claims

1. A capsule for an aerosol generating device, comprising: A housing having an inner surface defining a chamber configured to hold an aerosol-forming substrate, the housing having an outer surface forming a first face, an opposing second face, and a side face of the capsule, the first face and the second face being permeable to aerosols, the housing having a first frame, a second frame, and a third frame, the third frame being located between the first frame and the second frame; as well as A heater having a first end portion, a middle portion, and a second end portion, the first end portion and the second end portion being outer segments that form portions of the side surface of the bladder, and the middle portion being an inner segment disposed within the cavity of the housing.

2. The capsule as described in claim 1, wherein, The first side, the second side, or both include a perforated sheet.

3. The capsule as described in claim 1, wherein, The first side, the second side, or both comprise a mesh sheet.

4. The capsule as claimed in claim 1, wherein, The side is located between the first surface and the second surface.

5. The capsule as claimed in claim 1, wherein, The side is the outer periphery of the capsule.

6. The capsule as claimed in claim 1, wherein, The third frame defines the cavity.

7. The capsule as claimed in claim 6, wherein, The heater extends through the third frame and into the cavity.

8. The capsule as claimed in claim 6, wherein, The third frame is constructed as two components configured to engage and clamp the heater between them.

9. The capsule as claimed in claim 8, wherein, The two components define corresponding openings in the cavity that forms the third frame.

10. The capsule as claimed in claim 8, wherein, One of the two components includes a ridge portion, and the other of the two components defines a corresponding recess portion, the recess portion being configured to receive the ridge portion when the two components are engaged.

11. The capsule as claimed in claim 10, wherein, When the heater is held between two components of the third frame, the ridge portion is located between the first end portion and the second end portion of the heater.

12. The capsule as claimed in claim 1, wherein, The first end portion, the middle portion, and the second end portion of the heater are continuous structural parts.

13. The capsule as claimed in claim 1, wherein, The middle portion of the heater has a planar and wound shape.

14. The capsule as claimed in claim 1, wherein, The middle part of the heater has a resistance between 0.5 and 2.5 ohms.

15. The capsule as claimed in claim 1, wherein, The heater may be in the form of a strip having a length, width, and thickness, wherein the width is greater than the thickness, and the direction of the width is orthogonal to the first and second surfaces of the bladder.

16. The capsule as claimed in claim 1, wherein, The capsule has a thickness between 1 and 4 mm.

17. The capsule as claimed in claim 1, wherein, The aerosol forming substrate includes plant materials.

18. The capsule of claim 17, wherein, The plant material includes tobacco.

19. An aerosol generating apparatus, comprising: A capsule, the capsule comprising: The housing has: An inner surface defining a cavity configured to retain an aerosol-forming substrate. The outer surface, which constitutes a first surface, an opposing second surface, and a side surface of the capsule, wherein the first surface and the second surface are permeable to aerosols, and A first frame, a second frame, and a third frame, wherein the third frame is located between the first frame and the third frame. Between the second framework, and A heater having a first end portion, a middle portion, and a second end portion, the first end portion and the second end portion being outer sections forming portions of the side surface of the bladder, the middle portion being an inner section disposed within the cavity of the shell; and The device body includes a heating pad configured to generate an aerosol by conductively heating an aerosol-forming substrate within the capsule, and the device body is configured to receive the capsule such that the heating pad engages with and covers a first permeable surface or a second permeable surface of the capsule.

20. The aerosol generating apparatus as described in claim 19, wherein, The device body also includes a sealing gasket, and the device body is configured to receive the capsule such that the capsule is sandwiched between the heating pad and the sealing gasket.

21. A method for generating an aerosol, comprising: The capsule is joined between the first pad and the second pad, the capsule comprising: The housing has: An inner surface defining a cavity configured to retain an aerosol-forming substrate. The outer surface, which constitutes a first surface, an opposing second surface, and a side surface of the capsule, wherein the first surface and the second surface are permeable to aerosols, and A first frame, a second frame, and a third frame, wherein the third frame is located between the first frame and the third frame. Between the second framework, and A heater having a first end portion, a middle portion, and a second end portion, the first end portion and the second end portion being outer segments that form portions of the side surface of the bladder, and the middle portion being an inner segment disposed within the cavity of the shell; as well as The aerosol forming substrate is heated using at least one of the first pad or the second pad, such that the generated aerosol passes through at least one of the first pad or the second pad.

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