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

Abstract

A capsule for an aerosol-generating device can include a housing, a filter, and an aerosol-forming substrate. The housing can have a gas-permeable end and a non-permeable end. The filter can be disposed within the housing so as to be adjacent to the non-permeable end. The aerosol-forming substrate can be disposed within the housing so as to be located between the filter and the gas-permeable end. The housing can be configured to facilitate heating of the aerosol-forming substrate by one of conduction, convection, or both conduction and convection so as to generate an aerosol.

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 plant material being heated 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 individual containers for easy insertion into 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, a filter, and an aerosol-forming substrate. The housing may have a gas-permeable end and an impermeable end. The filter may be disposed within the housing adjacent to the impermeable end. The aerosol-forming substrate may be disposed within the housing between the filter and the gas-permeable end. The housing may be configured to facilitate heating of the aerosol-forming substrate by one of the following methods: conduction, convection, or both conduction and convection, in order to generate an aerosol.

[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 an apparatus body, a mouthpiece, and a heating assembly. The apparatus body may define a compartment configured to receive a capsule containing an aerosol forming substrate and a filter. The mouthpiece may include a conduit portion. The mouthpiece may be configured to engage with the apparatus body such that the conduit portion extends through the aerosol forming substrate and into the filter of the capsule. The heating assembly may be disposed within the apparatus body. The heating assembly may be configured to heat the aerosol forming substrate within the capsule by one of the following methods: conduction, convection, or both conduction and convection, to generate an aerosol exiting the capsule via the conduit portion of the mouthpiece.

[0005] At least one embodiment relates to a method for generating an aerosol. In an exemplary embodiment, the method may include: heating a capsule, the capsule including a shell, a filter, and an aerosol-forming substrate. The shell may have a gas-permeable end and an impermeable end. Furthermore, the method may include: guiding a stream of drawn-in air through the capsule along a tortuous path. The tortuous path may include an entrainment section and a filtration section. The entrainment section may be from the gas-permeable end of the shell through the aerosol-forming substrate to the filter. The filtration section may be from the filter to the gas-permeable end of the shell. Attached Figure Description

[0006] The various features and advantages of the non-limiting embodiments of the invention 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 explicitly stated otherwise, the drawings are not considered to be drawn to scale. Various dimensions in the drawings may be enlarged for clarity.

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

[0008] Figure 2 yes Figure 1 The second perspective view of 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 1 A cross-sectional view of the capsule when it is attached to the mouthpiece.

[0012] Figure 6 This is a first perspective view of an aerosol generating apparatus according to an exemplary embodiment.

[0013] Figure 7 yes Figure 6 A second perspective view of the aerosol generating apparatus.

[0014] Figure 8 yes Figure 6 An exploded view of the aerosol generation device.

[0015] Figure 9 yes Figure 7 An exploded view of the aerosol generation device.

[0016] Figure 10 yes Figure 6 Cross-sectional view of the aerosol generation device. Detailed Implementation

[0017] 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.

[0018] Therefore, while exemplary embodiments can have various modifications and alternative forms, their exemplary embodiments 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 alternative forms thereto. Throughout the description of the accompanying drawings, the same reference numerals denote the same elements.

[0019] 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," "coupled to another element or layer," "attached to another element or layer," "adjacent to another element or layer," or "covering another element or layer," the element or layer may be directly located on, directly connected to, coupled 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 coupled 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.

[0020] 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.

[0021] For ease of description, spatially related terms (e.g., "below," "below," "down," "above," "upper," etc.) may be used to describe the relationship between one element or feature shown in the accompanying drawings and another element or feature. It should be understood that, in addition to the orientations depicted in the accompanying drawings, spatially related terms are intended to include different orientations of the device in use or operation. For example, if the device in the accompanying drawings is flipped, an element described as "below" 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.

[0022] 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.

[0023] 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 not to require a precise geometry, 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.

[0024] 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.

[0025] 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 capable of responding to and executing instructions in a defined manner.

[0026] Figure 1 This is a first perspective view of a capsule for an aerosol generating apparatus according to an exemplary embodiment. Figure 2 yes Figure 1 A second perspective view of the cyst. See also Figures 1 to 2 The capsule 100 may be configured to be received within an aerosol generating apparatus (e.g., a heated non-combustible aerosol generating apparatus). The capsule 100 includes a housing configured to hold an aerosol forming substrate and to facilitate heating of the aerosol forming substrate by conduction and / or convection to generate an aerosol.

[0027] As shown in the figure, the capsule 100 can have a cylindrical shape. Due to this shape, the capsule 100 can have a circular cross-section. However, it should be understood that other shapes and forms are also possible. For example, in alternatives, the capsule 100 can have a triangular prism, cuboid, pentagonal prism, or hexagonal prism shape. Due to its triangular prism shape, the capsule 100 can have a triangular cross-section (e.g., an equilateral triangle shape). Due to its cuboid prism shape, the capsule 100 can have a square or rectangular cross-section. Due to its pentagonal prism shape, the capsule 100 can have a pentagonal cross-section. Due to its hexagonal prism shape, the capsule 100 can have a hexagonal cross-section.

[0028] The shell of capsule 100 has a gas-permeable end and an impermeable end. As will be discussed in more detail herein, the gas-permeable end of the shell is configured to: retain the aerosol-forming substrate while allowing air to enter the capsule and allowing aerosol to exit the capsule. Filter 120 ( Figure 3 The filter 120 can be disposed within the housing so as to be adjacent to the impermeable end. Furthermore, the aerosol forming substrate is disposed within the housing so as to be located between the filter 120 and the gas permeable end.

[0029] In an exemplary embodiment, the shell of the capsule 100 includes a container 130 and an end cap 110. The container 130 has a closed end 134 and an open end 132. Figure 3The closed end 134 of container 130 may have a rounded edge. However, it should be understood that other configurations are also possible (beveled edges). Container 130 is made of a conductive material. For example, the conductive material may be a metal, and the metal may include aluminum, its alloys, or stainless steel. As a result, container 130 can be conveniently heated within it by at least conduction to form an aerosol substrate.

[0030] During assembly, end cap 110 is disposed at the open end 132 of container 130 to enclose the aerosol forming substrate and filter 120 therein. For example, a large portion of end cap 110 can be inserted into container 130. The engagement between end cap 110 and container 130 can be via an interference fit (also referred to as a press-fit or friction fit). Alternatively, instead of an interference fit or other than an interference fit, end cap 110 can also be secured to container 130 with an adhesive (e.g., glue) deemed food-safe or acceptable by regulatory authorities. End cap 110 can be formed from suitable plastic (e.g., by molding), but exemplary embodiments are not limited thereto.

[0031] The end cap 110 of the capsule 100 defines a plurality of openings. In this respect, the end cap 110 can be considered as the gas-permeable end of the capsule, while the closed end 134 of the container 130 can be considered as the impermeable end. As shown, the plurality of openings in the end cap 110 include an outlet opening 114 surrounded by an inlet opening 112. Although in Figure 1 Eight inlet openings 112 are shown, but it should be understood that different numbers (e.g., six inlet openings, ten inlet openings) can be implemented based on various factors that may affect airflow within the capsule 100 (e.g., the density of the aerosol-forming substrate, the permeability of the filter 120). In an exemplary embodiment, the number and size of the inlet openings 112 can be designed to generate a desired suction resistance (RTD) for the capsule 100, such as an RTD between 90 and 110 mm Hg.

[0032] The inlet openings 112 in the end cap 110 may be equidistant from each other by a first distance. In other words, each inlet opening 112 may be equidistant from its adjacent inlet opening 112 by a first distance. Furthermore, the inlet openings 112 may be equidistant from the center (e.g., the diameter center) of the end cap 110 by a second distance. The first distance may be smaller than the second distance, but the exemplary embodiment is not limited thereto. For example, if the number of inlet openings 112 is reduced, the first distance may be greater than the second distance. During operation of the aerosol generating device, air enters the capsule 100 through the inlet openings 112, and aerosol exits the capsule 100 through the outlet openings 114 (e.g., due to contact with a mouthpiece (such as...). Figure 5 (The mouthpiece 310 in the middle) is engaged. Each inlet opening 112 may be smaller than the outlet opening 114.

[0033] 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 filter 120 is configured to be inserted into the container 130 via the open end 132 during assembly of the capsule 100. When fully seated within the container 130, the filter 120 is configured to be adjacent to or abut against the inner end face corresponding to the closed end 134. To facilitate seating within the container 130, the bottom shape of the filter 120 can be configured (e.g., with rounded edges) to conform to the inner surface corresponding to the closed end 134. Furthermore, the filter 120 can be sized such that its outer sidewalls abut against the inner sidewalls of the container 130, resulting in a tight-fitting arrangement. In this example, the filter 120 can sufficiently clamp the inner sidewalls of the container 130 to maintain its seated position (e.g., sufficient to overcome gravity even when the container 130 is inverted).

[0034] The filter 120 defines an orifice 122 configured to align with an outlet opening 114 in the end cap 110 when the capsule 100 is assembled. In an exemplary embodiment, the orifice 122 in the filter 120 may be the same or substantially the same size as the outlet opening 114 in the end cap 110. Furthermore, the orifice 122 in the filter 120 may be a central through-hole. However, in another embodiment, the orifice 122 in the filter 120 may be a central blind hole.

[0035] The filter 120 may be formed of a fibrous material or a foam material. In one example, the fibrous material for the filter 120 may include cellulose acetate. In another example, the foam material may include open-cell foam. Furthermore, the filter 120 may include additives configured to alter the aerosol generated within the capsule 100. For example, the additive may include activated charcoal and / or flavoring agents embedded within the filter 120. In an exemplary embodiment, the filter 120 may include cigarette filter materials known in the art.

[0036] Figure 5 yes Figure 1 A cross-sectional view of the capsule when it is engaged with the mouthpiece. See also Figure 5The capsule 100 includes a chamber configured to receive an aerosol forming substrate 160. As shown, the chamber may be defined by an inner wall of a container 130 and opposing inner surfaces of a filter 120 and an end cap 110. In an exemplary embodiment, an outlet opening 114 in the end cap 110 coincides with the central longitudinal axis of the container 130. Furthermore, as described above, when the capsule 100 is assembled, an orifice 122 in the filter 120 may be aligned with the outlet opening 114 in the end cap 110. As a result, in this example, the orifice 122 in the filter 120 may also coincide with the central longitudinal axis of the container 130. As will be discussed in more detail herein, the filter 120 and the aerosol forming substrate 160 are disposed within the capsule such that during aerosol generation, air entering the capsule 100 via an inlet opening 112 in the end cap 110 passes through the aerosol forming substrate 160 in the chamber before reaching the filter 120. Furthermore, due to engagement with the mouthpiece 310, the aerosol generated in the chamber passes through the filter 120 before exiting the capsule 100 via the outlet opening 114 in the end cap 110. The orifice 122 in the filter 120 can be configured such that the passage of aerosol through the filter 120 includes an inward radial path toward the orifice 122.

[0037] In one example, the aerosol forming substrate can be a single, consolidated form configured to maintain its shape to allow the aerosol forming substrate to be placed uniformly within the container 130. In this example, the single, consolidated form of the aerosol forming substrate can be cylindrical (so as to substantially correspond to the volume of the chamber within the capsule 100) while defining a through-hole configured to align with an outlet opening 114 in the end cap 110 and an orifice 122 in the filter 120.

[0038] In another example, the aerosol forming substrate can be a plurality of consolidated forms configured to allow each consolidated form to be placed individually within the container 130. In this example, each of the plurality of consolidated forms can resemble a disc or disk defining a through-hole configured to align with an outlet opening 114 in the end cap 110 and an orifice 122 in the filter 120. Each of the plurality of consolidated forms can comprise the same type or different types of aerosol forming substrate. As a result, various combinations of aerosol forming substrates can be loaded into the container 130 to achieve desired sensory appeal.

[0039] Alternatively, as an alternative to or supplement to the solidified forms discussed above, the aerosol forming substrate can be in a loose form (e.g., particles, fibers, residue, fragments, strips) that does not have a defined shape but is configured to present the shape of a chamber within the capsule 100. In this example, it should be understood that the loose form of the aerosol forming substrate typically has an average size larger than the diameter of the openings in the end cap 110 (e.g., inlet opening 112, outlet opening 114) and the orifice 122 in the filter 120.

[0040] 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 an aerosol comprising the compound is generated when the material is heated. Heating may be below combustion temperature to generate an aerosol without involving significant pyrolysis of the aerosol forming substrate or significant generation of 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 their extent may be relatively small and / or merely incidental.

[0041] 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 thereof, from one or more tobacco plants (e.g., yellow tobacco and red tobacco).

[0042] 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, Burley 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.

[0043] The compound may also be a natural component of a medicinal plant with medically acceptable therapeutic effects.

[0044] 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 at least one of cotton, polyethylene, polyester, synthetic fibers, combinations thereof, etc. (e.g., in the form of gauze). In another example, the fibrous material may be a cellulose material (e.g., non-tobacco). In any example, the introduced compound may include nicotine and / or flavoring agents. Flavoring agents 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 flavoring agents (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.

[0045] Figure 6 This is a first perspective view of an aerosol generating apparatus according to an exemplary embodiment. Figure 7 yes Figure 6 A second perspective view of the aerosol generating apparatus. See also Figures 6 to 7 The aerosol generating apparatus 300 is configured to receive a capsule 200 containing an aerosol forming substrate. Figure 8 As shown in the figure, the aerosol generating device 300 can have a cylindrical shape. Due to this shape, the aerosol generating device 300 can have a circular cross-section. However, it should be understood that other shapes and forms are also possible. For example, in alternatives, the aerosol generating device 300 can have a triangular prism, cuboid, pentagonal prism, or hexagonal prism shape. Due to its triangular prism shape, the aerosol generating device 300 can have a triangular cross-section (e.g., an equilateral triangle shape). Due to its cuboid shape, the aerosol generating device 300 can have a square or rectangular cross-section. Due to its pentagonal prism shape, the aerosol generating device 300 can have a pentagonal cross-section. Due to its hexagonal prism shape, the aerosol generating device 300 can have a hexagonal cross-section.

[0046] As shown in the figure, the form of the aerosol generating device 300 can correspond to the form of the capsule 200 (e.g., both the aerosol generating device 300 and the capsule 200 can be cylindrical). However, in other instances, the form of the aerosol generating device 300 can differ from that of the capsule 200. For example, the capsule 200 can be cylindrical, while the aerosol generating device 300 can be one of the different forms disclosed herein (e.g., cuboid), or vice versa.

[0047] The aerosol generating device 300 includes: a device body 330; a nozzle 310 configured to engage with the device body 330; and a heating assembly 340. Figure 8 The aerosol outlet 312 is located within the device body 330. The nozzle 310 defines an aerosol outlet 312. The aerosol outlet 312 may be centrally located to align with the central longitudinal axis of the device body 330. The device body 330 may be formed of an insulating material (e.g., ceramic, ceramic-coated metal) to reduce or minimize heat loss. Furthermore, the device body 330 defines a plurality of air inlets 334. The plurality of air inlets 334 may be arranged (e.g., in a circular arrangement) along the periphery of the upstream end face of the device body 330. As used herein, “upstream” (conversely, “downstream”) relates to the flow of aerosols, while “proximal” (conversely, “far”) relates to an adult operator of the device during aerosol generation.

[0048] Each of the plurality of air inlets 334 in the main body of the device 330 may be larger than the aerosol outlet 312 in the mouthpiece 310. Although in Figure 7 The diagram shows twelve air inlets 334, but it should be understood that different numbers (e.g., ten air inlets, fourteen air inlets) can be achieved based on the desired distribution of airflow within and through the aerosol generating device 300. Furthermore, a gasket 320 can be disposed between the mouthpiece 310 and the device body 330. The gasket 320 helps ensure a relatively airtight seal, so that incoming air will enter essentially only the aerosol generating device 300 via the air inlets 334 in the device body 330.

[0049] Figure 8 yes Figure 6 An exploded view of the aerosol generation device. Figure 9 yes Figure 7 An exploded view of the aerosol generation apparatus. See also: Figures 8 to 9 The device body 330 defines a compartment 332, and a heating component 340 is disposed within the compartment. The device body 330 is configured to receive a capsule 200 within the compartment 332, such that the capsule 200 is in thermal contact with the heating component 340. Figures 8 to 9 The cyst 200 in the middle can be with Figures 1 to 5The capsule 100 is identical to that in the capsule 200. For example, the end cap 210, inlet opening 212, outlet opening 214, and filter 220 of the capsule 200 are the same. Figure 10 ), orifice 222 ( Figure 10 The capsule 100 and container 230 can be as described with end cap 110, inlet opening 112, outlet opening 114, filter 120, orifice 122, and container 130. Although not shown, it should be understood that the capsule 200 may also include an aerosol forming substrate, which can be described with the aerosol forming substrate of the capsule 100. Therefore, the relevant disclosure of the above common features should be understood to apply to this section, and for the sake of brevity, it will not be repeated.

[0050] The mouthpiece 310 includes a head portion 314 and a conduit portion 316. The conduit portion 316 defines an orifice 318 at its upstream end and an internal channel fluidly connecting the orifice 318 to an aerosol outlet 312. The mouthpiece 310 is configured to engage a device body 330 to enclose the capsule 200 and the heating assembly 340 therein. Furthermore, a gasket 320 may be clamped between the mouthpiece 310 and the device body 330. Specifically, the gasket 320 may be annular in form, configured to be clamped between the head portion 314 of the mouthpiece 310 and the edge of the device body 330.

[0051] In an exemplary embodiment, the capsule 200 can be considered a consumable component, which is removed (e.g., once the aerosol-forming substrate therein is depleted or deemed expired) and replaced with a new capsule before operation of the aerosol generating device 300 resumes. In this respect, the capsule 200 can also be considered disposable. On the other hand, the mouthpiece 310, gasket 320, heating assembly 340, and device body 330 can be considered durable components, designed to withstand multiple operations of the aerosol generating device 300 (if not the lifespan of the aerosol generating device 300). In this respect, the mouthpiece 310, gasket 320, heating assembly 340, and device body 330 can also be considered reusable.

[0052] The heating assembly 340 is configured to heat the aerosol-forming substrate within the capsule 200 by one of the following methods: conduction, convection, or both conduction and convection, in order to generate an aerosol. As shown, the heating assembly 340 may include a first heater 342 and a second heater 344. In an exemplary embodiment, the first heater 342 and the second heater 344 are separate structures configured to allow independent operation. Alternatively, the first heater 342 and the second heater 344 may be a continuous structure configured to operate simultaneously. The first heater 342 may be primarily responsible for heating the aerosol-forming substrate within the capsule 200 by conduction, while the combination of the first heater 342 and the second heater 344 may be responsible for heating the aerosol-forming substrate within the capsule 200 by convection.

[0053] The first heater 342 may be in the form of an inner coil, while the second heater 344 may be in the form of an outer coil surrounding the inner coil. In this example, the first heater 342 and the second heater 344 may be arranged concentrically to spiral around the central longitudinal axis of the device body 330. Furthermore, the wire diameter, pitch, coil angle, free length, and / or construction material of the first heater 342 may be the same as those of the second heater 344, but the exemplary embodiment is not limited thereto. Additionally, the free lengths of the first heater 342 and the second heater 344 may be at least the height of the container 230 of the capsule 200 to enhance heating of the aerosol-forming substrate therein during aerosol generation. In another example, the first heater 342 and the second heater 344 may be in the form of a ceramic heater, a silicon heater, and / or a flexible polymer heater.

[0054] Due to the coil configuration, the inner diameter of the first heater 342 can substantially correspond to the outer diameter of the capsule 200. As a result, when the capsule 200 is received within the compartment 332 of the device body 330, the first heater 342 can physically contact (e.g., compress) the container 230 of the capsule 200. Furthermore, the outer diameter of the second heater 344 can substantially correspond to the inner diameter of the device body 330. As a result, the second heater 344 can contact (e.g., press against) the inner wall of the device body 330. Additionally, based on the positioning of the heating assembly 340 within the compartment 332 of the device body 330, an air inlet 334 can be located between the first heater 342 and the second heater 344. As a result, the incoming air entering the device body 330 via the air inlet 334 will flow between the first heater 342 and the second heater 344, thus becoming a heating flow entering the capsule 200 and convectively heating the aerosol forming substrate therein.

[0055] While coil configurations have been discussed above, it should be understood that other configurations are possible for the first heater 342 and the second heater 344. For example, the first heater 342 and the second heater 344 may be constructed as waveforms configured to surround the capsule 200. In such an example, the first heater 342 and the second heater 344 may alternate between extending towards the proximal edge of the device body 330 and towards the distal end of the device body 330. In particular, the size of the waveforms of the first heater 342 and the second heater 344 may have an amplitude approximately half the height of the container 230 of the capsule 200, while the wave height of the waveforms of the first heater 342 and the second heater 344 may have an amplitude approximately the height of the container 230 of the capsule 200, to enhance heating of the aerosol-forming substrate therein during aerosol generation.

[0056] The waveforms of the first heater 342 and the second heater 344 can resemble compression oscillations or sawtooth patterns, and can have multiple parallel segments (e.g., extending longitudinally relative to the device body 330). Specifically, the waveforms can include pulse waves (e.g., rectangular waves), triangular waves, sawtooth waves, or sine waves. The waveform of the first heater 342 can be of the same type as the waveform of the second heater 344, but exemplary embodiments are not limited thereto. In instances where the capsule 200 has a non-cylindrical form (e.g., resembling a triangular prism, cuboid, pentagonal prism, or hexagonal prism), it should be understood that the heater patterns can be bent as needed (e.g., cut from sheet material) to obtain suitable first and second heaters capable of better accommodating the capsule 200 (e.g., improving thermal contact with the capsule 200).

[0057] In an exemplary embodiment, the first heater 342 and the second heater 344 are configured to undergo Joule heating (also known as ohmic / resistance heating) when an electric current is applied thereto. More specifically, the first heater 342 and the second heater 344 may be formed of one or more conductors and configured to generate heat when an electric current passes through them. The current may be supplied to the first heater 342 and the second heater 344 from a power source (e.g., a battery) within the aerosol generating apparatus 300 (e.g., independently). Conductors suitable for the first heater 342 and the second heater 344 include iron-based alloys (e.g., stainless steel) and / or nickel-based alloys (e.g., nickel-chromium alloys). The first heater 342 and the second heater 344 may have a resistance of approximately 0.4–2.5 ohms (e.g., 1.0–2 ohms).

[0058] Figure 10 yes Figure 6 A cross-sectional view of the aerosol generation device. See also... Figure 10To enable the aerosol generating device 300 to operate, the capsule 200 is inserted into the compartment 332 of the device body 330 for reception by the first heater 342. With the first heater 342 configured as an internal coil, it can physically hold the capsule 200 in a desired position while also improving thermal contact with the container 230 of the capsule 200. When the capsule 200 is seated within the device body 330, an annular space is defined by the outer wall of the capsule 200 and the inner wall of the device body 330. As shown, the first heater 342 and the second heater 344 are located within this annular space, with the first heater 344 abutting against the outer wall of the capsule 200 and the second heater 342 abutting against the inner wall of the device body 330.

[0059] Once the capsule 200 is seated, the mouthpiece 310 is configured to engage with the device body 330 to seal the capsule 200, such that the conduit portion 316 extends through the outlet opening 214 in the end cap 210, through the aerosol-forming substrate, and into the filter 220 of the capsule 200. The conduit portion 316 of the mouthpiece 310 may have an upstream tip that is rounded to facilitate its insertion into the capsule 200. In some instances, the upstream tip of the conduit portion 316 of the mouthpiece 310 may be tapered (e.g., to a point) to further facilitate its insertion through the aerosol-forming substrate within the capsule 200.

[0060] like Figure 10 As shown, when the bladder 200 is enclosed within the compartment 332 of the device body 330, the gasket 320 will be clamped between the mouthpiece 310 and the device body 330. Furthermore, the upstream tip of the conduit portion 316 of the mouthpiece 310 will be embedded within the orifice 222 of the filter 220. Specifically, the orifice 318 in the upstream tip of the conduit portion 316 will also be covered, surrounded, or otherwise shielded by the filter 220. As a result, any fluid entering the orifice 318 must first pass through the filter 220. The orifice 318 may be a through-hole to provide two inlets into the conduit portion 316 of the mouthpiece 310. In some instances, the orifice 318 may be in the form of two intersecting through-holes (e.g., x-configuration, cross configuration) to provide four inlets into the conduit portion 316 of the mouthpiece 310.

[0061] As described above, the gasket 320 helps ensure a relatively airtight seal, so that incoming air enters substantially only into the aerosol generating apparatus 300 via the air inlet 334 in the device body 330. In one embodiment, the gasket 320 may be a separate component disposed between the mouthpiece 310 and the device body 330. In another embodiment, the gasket 320 may be part of the mouthpiece 310 (e.g., adhered to the underside of the head portion 314 of the mouthpiece 310). In yet another embodiment, the gasket 320 may be part of the device body 330 (e.g., adhered to the edge of the device body 330).

[0062] During operation of the aerosol generating device 300, incoming air (e.g., ambient air) is drawn into the device body 330 via multiple air inlets 334. The multiple air inlets 334 in the upstream end of the device body 330 facilitate the distribution of the incoming air around the capsule 200. Activation of the heating assembly 340 can involve manual operation (e.g., button activation) and / or automatic operation (e.g., suction activation). Furthermore, the first heater 342 and the second heater 344 of the heating assembly 340 can be activated simultaneously or sequentially. Moreover, because the first heater 342 and the second heater 344 are configured to allow independent operation, the first heater 342 and the second heating device 344 can have different heating profiles, and therefore, can be at different temperatures at a given point in time.

[0063] For example, in response to manual or automatic operation, the first heater 342 and the second heater 344 can be activated simultaneously to begin heating. In another example, upon initial button activation, the first heater 342 can begin heating the capsule 200, and upon subsequent suction activation, the second heater 344 (in combination with the first heater 342) can begin heating the incoming air to generate a heated airflow. In yet another example, the order can be reversed, such that the second heater 344 begins heating in response to initial button activation, while the first heater 342 begins heating in response to subsequent suction activation. Furthermore, in each of the above examples, heating may include a preheating step involving the first heater 342 and / or the second heater 344 (to reduce the time required to reach the target / atomization temperature) (below the target / atomization temperature via button activation), followed by a full heating step involving both the first heater 344 and the second heater 342 (at the target / atomization temperature via suction activation). The associated temperature sensing can be achieved via thermocouples or by monitoring the resistance of the first heater 342 and the second heater 344.

[0064] Air entering the device body 330 via multiple air inlets 334 is drawn into an internal annular space to flow between the first heater 342 and the second heater 344 (e.g., in a first longitudinal direction), heating the incoming air into a heated airflow. When the heated air reaches the head portion 314 of the mouthpiece 310, its direction changes to an inward path (e.g., in a first radial direction) toward the inlet opening 212 in the end cap 210. The heated air entering the capsule 200 via the inlet opening 212 in the end cap 210 then (e.g., in a second longitudinal direction) flows through the aerosol forming substrate (located between the conduit portion 316 of the mouthpiece 310 and the container 230 of the capsule 200) to entrain volatiles released therefrom. As described above, as a result of the first heater 342, aerosols can be generated by conductive heating of the aerosol forming substrate within the capsule 200. Furthermore, as a result of both the first heater 342 and the second heater 344, the heated air entering the capsule 200 can further heat the aerosol forming substrate through convection to enhance aerosol generation.

[0065] Once the aerosol generated within the capsule 200 enters the filter 220, the direction changes to an inward path (e.g., a second radial direction) toward the orifice 318 in the conduit portion 316 of the mouthpiece 310. As a result of passing through the filter 220, the generated aerosol becomes filtered aerosol. The filtered aerosol exits the capsule 200 via the conduit portion 316 of the mouthpiece 310. In particular, when the orifice 318 is a through-hole with two inlets, the filtered aerosol from both inlets will converge to form a combined aerosol (e.g., in a third longitudinal direction) flowing through an internal channel in the conduit portion 316 and the head portion 314 leading to the aerosol outlet 312.

[0066] Although not shown, it should be understood that the aerosol generating device 300 may include additional structures / components configured to provide desired aesthetics and / or functionality. For example, the aerosol generating device 300 may include an external housing structure designed to be visually appealing while being sized for portability and configured for ease of manipulation (e.g., an ergonomic shape for one-handed operation). Furthermore, a power supply and control circuitry may be housed within the external housing structure. The power supply may include one or more batteries (e.g., a rechargeable battery arrangement). The control circuitry may instruct the power supply to supply current to the first heater 342 and the second heater 344. The instruction to supply current from the power supply may be responsive to manual operation (e.g., button activation) and / or automatic operation (e.g., inhalation activation). As a result of the current, the capsule 200 may be conductively heated and / or convectively heated by the first heater 342 and the second heater 344 to generate an aerosol. The aerosol generated within the capsule 200 may be inhaled from the aerosol generating device 300 via an aerosol outlet 312 and an optional additional mouthpiece accessory.

[0067] Using the capsule and apparatus disclosed herein, aerosol-forming substrate can be conductively heated and / or convectively heated to generate an aerosol. In an exemplary embodiment, a method for generating an aerosol may include: heating a capsule comprising a shell, a filter, and an aerosol-forming substrate. The shell may have a gas-permeable end and an impermeable end. Furthermore, the method may include: guiding a stream of drawn-in air through the capsule along a tortuous path. The tortuous path may include an entrainment section and a filtration section. The entrainment section may be from the gas-permeable end of the shell through the aerosol-forming substrate to the filter. The filtration section may be from the filter to the gas-permeable end of the shell.

[0068] 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 (Vessel, 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 ACOMPOUND 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.

[0069] 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 a gas-permeable end and an impermeable end, the housing including a container and an end cap, the end cap defining a plurality of openings, and the plurality of openings including an outlet opening surrounded by an inlet opening; A filter is disposed within the housing so as to be adjacent to the impermeable end; as well as An aerosol forming substrate is disposed within the housing so as to be located between the filter and the gas-permeable end, the housing being configured to facilitate heating of the aerosol forming substrate by one of the following methods: conduction, convection, or both conduction and convection, in order to generate an aerosol.

2. The capsule of claim 1, wherein, The gas-permeable end of the shell is configured to retain the aerosol-forming substrate and allow air to enter the capsule and aerosol to leave the capsule.

3. The capsule as described in claim 1, wherein, The container has a closed end and an open end.

4. The capsule as described in claim 3, wherein, The end cap is disposed at the open end of the container.

5. The capsule as described in claim 3, wherein, The end cap is the gas-permeable end of the shell, and the closed end of the container is the impermeable end.

6. The capsule as claimed in claim 1, wherein, Most of the end cap is inserted into the container.

7. The capsule as claimed in claim 1, wherein, The container is made of metal.

8. The capsule as claimed in claim 7, wherein, The metal includes aluminum.

9. The capsule as claimed in claim 1, wherein, Each of the inlet openings is smaller than the outlet opening.

10. The capsule as claimed in claim 1, wherein, The number and size of the inlet openings are configured to provide the bladder with a suction resistance (RTD) between 90 and 110 mm Hg.

11. The capsule as claimed in claim 1, wherein, The outlet opening aligns with the central longitudinal axis of the container.

12. The capsule as claimed in claim 1, wherein, The filter defines an orifice aligned with the outlet opening of the end cap.

13. The capsule as claimed in claim 12, wherein, The orifices in the filter are configured such that the aerosol passes through the filter via a radial path toward the orifices.

14. The capsule as claimed in claim 12, wherein, The orifice in the filter is a central through hole.

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

16. The capsule of claim 15, wherein, The plant material includes tobacco.

17. An aerosol generating apparatus, comprising: The main body of the device defines a compartment; The capsule as claimed in claim 1, wherein the capsule is received in the compartment; A mouthpiece, the mouthpiece including a conduit portion, the mouthpiece being configured to engage with the device body such that the conduit portion extends through the aerosol-forming substrate and into the filter of the bladder; as well as A heating assembly located within the main body of the device, the heating assembly being configured to heat the aerosol forming substrate within the capsule by one of the following methods: conduction, convection, or both conduction and convection, in order to generate aerosol exiting the capsule via a conduit portion of the mouthpiece.

18. The aerosol generating apparatus as claimed in claim 17, wherein, The aerosol forming substrate and the filter are disposed within the capsule such that air entering the capsule passes through the aerosol forming substrate before reaching the filter, and the aerosol passes through the filter before leaving the capsule.

19. A method for generating an aerosol, comprising: A heated capsule, the capsule comprising a shell, a filter, and an aerosol forming substrate. The housing has a gas-permeable end and a gas-impermeable end. The housing includes a container and an end cap. The end cap defines a plurality of openings, including an outlet opening surrounded by an inlet opening. The filter is disposed within the housing so as to be adjacent to the impermeable end, and The aerosol forming substrate is disposed within the housing so as to be located between the filter and the gas-permeable end, and the housing is configured to facilitate heating the aerosol forming substrate by one of the following methods: conduction, convection, or both conduction and convection, in order to generate an aerosol; as well as The airflow drawn in is guided through the capsule along a tortuous path, which includes an entrainment section and a filtration section. The entrainment section extends from the gas-permeable end of the housing through the aerosol-forming substrate to the filter. The filtration section extends from the filter to the gas-permeable end of the housing.

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