Closed capsule with airflow, heated-button (HNB) aerosol generating device, and method for generating aerosols

Abstract

A capsule for an aerosol generating device includes a housing. The housing includes an inner frame defining an opening. The housing defines at least one air inlet and at least one air outlet. The capsule further includes an aerosol generating material at least partially within the opening and a heater supported by the inner frame and extending across at least a portion of the opening. The at least one air inlet, the opening, and the at least one air outlet collectively define at least one air flow path through the capsule. The air flow path is longer than a thickness of the capsule.

Description

[Technical field]

[0001] The present disclosure relates to capsules, heated-button (HNB) aerosol generating devices, and methods for generating aerosols without substantial thermal decomposition of the aerosol-forming material. [Background technology]

[0002] Some electronic devices are configured to heat the plant material to a temperature sufficient to release its components while avoiding substantial thermal decomposition of the plant material by maintaining the temperature below the combustion point of the plant material. Such devices may be referred to as aerosol-generating devices (e.g., heated aerosol-generating devices), and the heated plant material may be tobacco. In some examples, the plant material may be directly introduced into the heating chamber of the aerosol-generating device. In other examples, the plant material may be pre-packaged in individual containers to facilitate insertion into or removal from the aerosol-generating device. Summary of the Invention [Means for solving the problem]

[0003] At least one exemplary embodiment relates to a capsule for an aerosol generating device.

[0004] In at least one exemplary embodiment, a capsule for an aerosol generating device includes a housing. The housing includes a first frame defining a cavity. The housing defines at least one air flow inlet and at least one air flow outlet. The capsule further includes an aerosol generating material at least partially within the cavity and a heater supported by the first frame. The heater extends across at least a portion of the cavity. The at least one air flow inlet, the cavity, and the at least one air flow outlet collectively form at least one air flow passage through the capsule. The air flow passage is longer than a thickness of the capsule.

[0005] In at least one exemplary embodiment, the aerosol-generating material includes plant material. The plant material includes tobacco.

[0006] In at least one exemplary embodiment, the first frame is an inner frame, the inner frame including a first surface, a second surface, a first end, a second end, a first side, and a second side. At least one air flow inlet extends through the first end of the inner frame and at least one air flow outlet extends through the second end of the inner frame. The at least one air flow inlet includes a first air flow inlet and a second air flow inlet. The first air flow inlet extends through the first side of the inner frame and the second air flow inlet extends through the first end of the inner frame. The at least one air flow outlet extends through the second end of the inner frame.

[0007] In at least one exemplary embodiment, the capsule further includes a diffuser configured to redirect air from the at least one air flow inlet toward the at least one air flow outlet. The diffuser includes at least one channel in a first surface of the inner frame. The diffuser includes a main channel extending longitudinally from the at least one air flow inlet and at least one secondary channel in fluid communication with the main channel. The at least one secondary channel includes at least one parallel channel parallel to the main channel and at least one angled channel at an angle relative to the main channel.

[0008] In at least one exemplary embodiment, the heater has a serpentine shape.

[0009] At least one exemplary embodiment relates to a capsule assembly for an aerosol generating device.

[0010] In at least one exemplary embodiment, a capsule assembly for an aerosol generating device includes a capsule. The capsule includes a housing including a first frame defining a cavity. The capsule further includes an aerosol generating material at least partially within the cavity and a heater supported by the inner frame. The heater extends across at least a portion of the cavity. The capsule assembly further includes a capsule enclosure surrounding at least a portion of the housing. The capsule enclosure defines at least one air flow inlet and at least one air flow outlet. The at least one air flow inlet, the cavity, and the at least one air flow outlet collectively form at least one air flow passage through the capsule assembly. The air flow passage is longer than a thickness of the capsule.

[0011] In at least one exemplary embodiment, the capsule disclosure further includes a capsule enclosure airflow channel extending between the at least one airflow inlet and the at least one airflow outlet. The capsule enclosure airflow channel defines a portion of the at least one airflow passage. The at least one airflow passage extends diagonally across at least a portion of the cavity of the first frame. In at least one exemplary embodiment, the at least one airflow passage extends diagonally across at least a portion of the heater and the aerosol generating material.

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

[0013] In at least one exemplary embodiment, the aerosol generating device includes a device body configured to receive a capsule. The capsule includes a housing including a first frame defining a cavity, at least one air flow inlet, and at least one air flow outlet. The capsule further includes an aerosol generating material at least partially within the cavity, and a heater supported by the first frame and extending across at least a portion of the cavity. The at least one air flow inlet, the cavity, and the at least one air flow outlet collectively form at least one air flow path through the capsule. The air flow path is longer than a thickness of the capsule. The aerosol generating device further includes a plurality of electrodes within the device body. The plurality of electrodes are configured to be in electrical contact with a heater of the capsule. The aerosol generating device further includes a power source configured to provide electrical current to the heater of the capsule via the plurality of electrodes.

[0014] In at least one exemplary embodiment, the aerosol-generating material includes plant material. The plant material includes tobacco.

[0015] In at least one exemplary embodiment, the first frame is an inner frame. The inner frame includes a first surface, a second surface, a first end, a second end, a first side, and a second side.

[0016] In at least one exemplary embodiment, the at least one air flow inlet extends through a first end of the inner frame and the at least one air flow outlet extends through a second end of the inner frame. The at least one air flow inlet includes a first air flow inlet and a second air flow inlet. The first air flow inlet extends through a first side of the inner frame, the second air flow inlet extends through the first end of the inner frame, and the at least one air flow outlet extends through the second end of the inner frame.

[0017] In at least one exemplary embodiment, the capsule further includes a diffuser configured to redirect air from the at least one air flow inlet toward the at least one air flow outlet. The diffuser includes at least one channel in a first surface of the inner frame. In at least one exemplary embodiment, the diffuser includes a main channel extending longitudinally from the at least one air flow inlet and at least one secondary channel in fluid communication with the main channel. The at least one secondary channel includes at least one parallel channel parallel to the main channel and at least one angled channel at an angle relative to the main channel.

[0018] At least one exemplary embodiment relates to a method of generating an aerosol.

[0019] In at least one exemplary embodiment, a method of generating an aerosol includes electrically contacting a capsule with a plurality of electrodes. The capsule includes a housing including an inner frame. The housing defines a cavity, at least one air flow inlet, and at least one air flow outlet. The aerosol generating material is at least partially within the cavity. The capsule further includes a heater supported by the inner frame. The heater extends across at least a portion of the cavity. The at least one air flow outlet, the at least one air flow inlet, the cavity, and the at least one air flow outlet collectively form at least one air flow passage through the capsule. The air flow passage is longer than a thickness of the capsule. The method further includes providing an electrical current to the heater of the capsule via the plurality of electrodes.

[0020] Various features and advantages of non-limiting embodiments of the present disclosure may become more apparent from a reading of the detailed description in conjunction with the accompanying drawings. The accompanying drawings are for illustrative purposes only and should not be construed as limiting the scope of the claims. The accompanying drawings should not be considered to be drawn to scale unless expressly stated. Various dimensions of the drawings may be exaggerated for clarity. The patent or patent application file contains at least one drawing executed in color. Copies of this patent or patent application publication containing color drawing(s) will be provided by the U.S. Patent and Trademark Office upon request and payment of the necessary fee. [Brief description of the drawings]

[0021] [Figure 1A] FIG. 1A is a perspective view of a first side of a capsule for an aerosol generating device according to an exemplary embodiment.

[0022] [Figure 1B] FIG. 1B is a perspective view of a second side of a capsule for an aerosol generating device according to an exemplary embodiment.

[0023] [Figure 2A] FIG. 2A is an exploded view of the capsule of FIGS. 1A and 1B, according to at least one exemplary embodiment.

[0024] [Figure 2B] FIG. 2B is an exploded view of the capsule of FIGS. 1A and 1B, according to at least one exemplary embodiment.

[0025] [Diagram 3] FIG. 3 is a plan view of a pattern sheet for manufacturing a heater in accordance with at least one example embodiment.

[0026] [Figure 4] FIG. 4 illustrates the heater-containing capsule of FIG. 3 with the second frame removed, in accordance with at least one example embodiment.

[0027] [Diagram 5] FIG. 5 is a side view of the capsule of FIG. 4, showing a fourth side as a mirror image of the third side, in accordance with at least one exemplary embodiment.

[0028] [Figure 6] FIG. 6 illustrates the capsule of FIG. 5 with the second frame removed, showing airflow through the capsule, in accordance with at least one exemplary embodiment.

[0029] [Figure 7] FIG. 7 illustrates the capsule of FIG. 4 showing an alternative air flow path through the capsule, according to at least one exemplary embodiment.

[0030] [Figure 8] FIG. 8 illustrates the capsule of FIG. 4 showing an alternative air flow path through the capsule, according to at least one exemplary embodiment.

[0031] [Figure 9] FIG. 9 is a perspective view of a capsule assembly including a capsule connected to a mouthpiece according to at least one exemplary embodiment.

[0032] [Figure 10] FIG. 10 is a side cross-sectional view of the capsule assembly of FIG. 9 according to at least one exemplary embodiment.

[0033] [Figure 11] FIG. 11 is a side cross-sectional view of the capsule assembly of FIG. 10 taken along line XI-XI in accordance with at least one exemplary embodiment.

[0034] [Figure 12] FIG. 12 is a side cross-sectional view of the assembly of FIG. 9 according to at least one exemplary embodiment.

[0035] [Figure 13] 13 is a side cross-sectional view of the capsule assembly of FIG. 12 taken along line XIII-XIII in accordance with at least one exemplary embodiment.

[0036] [Figure 14] FIG. 14 is a side cross-sectional view of the capsule assembly of FIG. 9 according to at least one exemplary embodiment.

[0037] [Figure 15] FIG. 15 is a side cross-sectional view of the capsule assembly of FIG. 14 taken along line XV-XV, in accordance with at least one exemplary embodiment.

[0038] [Figure 16] FIG. 16 is a side cross-sectional view of the capsule assembly of FIG. 9 according to at least one exemplary embodiment.

[0039] [Figure 17] FIG. 17 is a side cross-sectional view of the capsule assembly of FIG. 16 taken along line XVII-XVII in accordance with at least one exemplary embodiment.

[0040] [Figure 18] FIG. 18 is a side perspective view of a capsule assembly including a capsule surrounded by a capsule enclosure and connected to a mouthpiece in accordance with at least one exemplary embodiment.

[0041] [Figure 19] FIG. 19 is a side cross-sectional view of the capsule assembly of FIG. 18 taken along line XIX-XIX in accordance with at least one exemplary embodiment.

[0042] [Figure 20] FIG. 20 is a side cross-sectional view of the capsule assembly of FIG. 18 according to at least one exemplary embodiment.

[0043] [Figure 21]FIG. 21 is a side cross-sectional view of the capsule assembly of FIG. 18 according to at least one exemplary embodiment.

[0044] [Figure 22] FIG. 22 is a side cross-sectional view of the capsule assembly of FIG. 18 according to at least one exemplary embodiment.

[0045] [Figure 23] FIG. 23 is a schematic diagram of an aerosol generating device for use with a capsule or capsule assembly, according to at least one exemplary embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0046] Several detailed exemplary embodiments are disclosed herein. However, the specific structural and functional details disclosed herein are provided merely to describe the exemplary embodiments. However, the exemplary embodiments may be embodied in many different forms and should not be construed as being limited to only the exemplary embodiments described herein.

[0047] Thus, the exemplary embodiments are susceptible to various modifications and alterations, examples of which are shown in the drawings and described in detail herein. However, there is no intention to limit the exemplary embodiments to the particular forms disclosed, but rather the exemplary embodiments are intended to cover all modifications, equivalents and alterations. Like reference numerals refer to like elements throughout the description of the drawings.

[0048] When an element or layer is described as "on," "connected to," "coupled to," "attached to," "adjacent to," or "overlying" another element or layer, the element or layer may be directly on, connected to, coupled to, attached to, adjacent to, or overlying the other element or layer, or there may be intervening elements or layers. Conversely, when an element is described as "directly on," "directly connected to," or "directly coupled to" another element or layer, there are no intervening elements or layers. Like reference numerals refer to like elements throughout the specification. As used herein, the term "and / or" includes any and all combinations or subcombinations of one or more of the items listed with this term.

[0049] Although the terms "first", "second", "third" and the like are used in this specification to describe various members, regions, layers and / or portions, it should be understood that these members, regions, layers and / or portions are not limited to these terms. These terms are used merely to distinguish a member, region, layer or portion from another region, layer or portion. Thus, a first member, region, layer or portion described below may also be expressed as a second member, region, layer or portion without departing from the teachings of the exemplary embodiments.

[0050] Spatial relative terms (e.g., "below," "below," "lower," "above," "above," etc.) are used herein for convenience to describe the illustrated relationship of one member or members or feature to another member or feature or features. It should be understood that the spatial relative terms are intended to include various orientations of the device in use or operation in addition to the orientation shown in the figures. For example, if a device in the figures is turned over, a member described as being "below" or "below" another member or feature would then be "above" the other member or feature. Thus, the term "below" can include both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or otherwise) and the spatial relative terms used herein can be interpreted accordingly.

[0051] The terminology used herein is merely for the purpose of describing various exemplary embodiments and is not intended to limit the exemplary embodiments. As used herein, the singular forms "a," "an," and "the" are intended to include the plural unless expressly specified otherwise. It is further to be understood that, as used herein, the words "comprise," "including," "comprising," and / or "comprising" specify the presence of the features, integers, steps, operations, and / or components stated herein, but do not exclude the presence or addition of one or more other features, integers, steps, operations, components, and / or groups thereof.

[0052] In this specification, when the words "about" and "substantially" are used in connection with numerical values, the numerical values ​​to which they are used are intended to include a tolerance of ±10% of the stated numerical value, unless expressly specified otherwise. Furthermore, when the words "generally" or "substantially" are used in connection with geometric shapes, precision of the geometric shapes is not required, and shapes including tolerances are intended to be within the scope of the present disclosure. Furthermore, regardless of whether a numerical value or shape is modified by the words "about," "generally," or "substantially," it should be understood that these numerical values ​​and shapes should be interpreted as including manufacturing or operational tolerances (e.g., ±10%) for the stated numerical value or shape.

[0053] All terms used herein (including technical and scientific terms) have the same meaning as commonly understood by those skilled in the art to which the exemplary embodiments pertain, unless otherwise specified. Furthermore, these terms should be interpreted to have a meaning consistent with the meaning in the corresponding field, including words defined in commonly used dictionaries, and should not be interpreted in an idealized or overly formal sense, unless otherwise specified herein.

[0054] A processing circuit (control circuit) may be hardware including logic circuitry, a hardware / software combination such as a processor executing software, or a combination of both. More specifically, a processing circuit may include, but is not limited to, a central processing unit (CPU), an arithmetic logic unit (ALU), a digital signal processor, a microcomputer, a field programmable gate array (FPGA), a system on a chip (SoC), a programmable logic unit, a microprocessor, an application specific integrated circuit (ASIC), etc.

[0055] 1A and 1B are perspective views of a first side and a second side of a capsule for an aerosol generating device according to an exemplary embodiment;

[0056] 2A and 2B are exploded views of the capsule of FIGS. 1A and 1B, according to at least one exemplary embodiment. FIG. 2B is an exploded view of the capsule of FIGS. 1A and 1B, according to at least one exemplary embodiment.

[0057] As shown in Figures 1A, 1B, 2A and 2B, in at least one exemplary embodiment, capsule 100 may be configured to be received in an aerosol generating device (e.g., a heated aerosol generating device). In the figures, capsule 100 has a layered structure and is generally planar in configuration. The proximal end of capsule 100 may have a curved proximal edge and the opposite distal end may have a straight distal edge. Furthermore, a pair of straight side edges may connect the curved proximal end edge and the straight distal edge. The pair of straight side edges may be parallel to each other. Furthermore, the intersection of the straight side edges and the straight distal edge may be in the form of a rounded corner.

[0058] Although the drawings show capsule 100 as resembling a rectangle with semicircular (e.g., elongated semicircular, semi-elliptical) ends, it should be understood that other configurations may be employed. The shape may be, for example, circular, in which case capsule 100 has a disk-like appearance. In another example, capsule 100 may be elliptical or racetrack-like in shape. In another example, capsule 100 may be polygonal (regular or otherwise), including triangular, rectangular (including square), pentagonal, hexagonal, heptagonal, or octagonal. Capsule 100 may be easily stacked due to its layered structure and generally planar configuration, allowing multiple capsules to be stored within an aerosol generating device or other container that dispenses new or receives used capsules. In an exemplary embodiment, capsule 100 has a thickness of 1-4 mm (e.g., 1-2 mm).

[0059] The capsule 100 may include a housing 105 and a heater 170 within the housing 105. The housing 105 of the capsule 100 has an inner surface that defines a chamber configured to hold an aerosol generating material 160 (e.g., FIGS. 2A and 2B). Additionally, the housing of the capsule 100 has an outer surface that defines a second surface and a side surface opposite the first surface of the capsule 100. The first and second surfaces of the capsule 100 may or may not be permeable to the aerosol depending on the desired air flow path through the capsule and / or along and through the heater. The side surface of the capsule 100 is between the first and second surfaces. The side surface may be considered the periphery of the capsule 100.

[0060] The housing of the capsule 100 includes a first frame 130 and a second frame 140. The first frame 130 and the second frame 140 may have the same shape and size (e.g., in a plan view) and may be aligned so that the outer side walls are substantially flush with each other, although the exemplary embodiment is not limited thereto. The first frame 130 and the second frame 140 may be formed of a suitable polymer, 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 connected by a welded structure.

[0061] The first transmissive or non-transmissive structure 110 is secured and exposed by a first frame 130. Similarly, the second transmissive or non-transmissive structure 120 is secured and exposed by a second frame 140. A third frame (or inner frame) 150 is disposed between the first transmissive or non-transmissive structure 110 and the second transmissive or non-transmissive structure 120 (and between the first frame 130 and the second frame 140), as described in more detail herein. The capsule 100 is configured to hold an aerosol generating substance 160 (shown in and described with reference to FIGS. 2A and 2B). The aerosol generating substance 160 may be within the third frame 150 and between the first transmissive or non-transmissive structure 110 and the second transmissive or non-transmissive structure 120. The first recess 133 (e.g., a first depression) in the first frame 130 and the second recess 143 (e.g., a second depression) in the second frame 140 may be formed by an injection molding process. In this regard, the size, location, and / or shape of the first recess 133 and the second recess 143 may vary (or may not exist at all) depending on the manufacturing technique.

[0062] The first transparent or non-transparent structure 110 and the second transparent or non-transparent structure 120 may be in the form of a mesh sheet, a perforated sheet, a solid sheet, or any combination thereof. For example, the first transparent or non-transparent structure 110 and the second transparent or non-transparent structure 120 may both be in the form of a solid sheet, thereby forming a substantially sealed capsule structure, if desired, to ensure that the airflow passes along the aerosol generating material 160 and / or the heater 170. In another example, the first transparent or non-transparent structure 110 and the second transparent or non-transparent structure 120 may both be in the form of a perforated sheet (e.g., 80, 100 or 250 mesh equivalent), thereby allowing the airflow to pass into the capsule. The perforated sheet may be mechanically perforated or chemically perforated (e.g., photochemical machining / etching). In yet another example, one of the first transmissive or non-transmissive structure 110 and the second transmissive or non-transmissive structure 120 may be in the form of a mesh sheet, and the other of the first transmissive or non-transmissive structure 110 and the second transmissive or non-transmissive structure 120 may be in the form of a perforated sheet. The first transmissive or non-transmissive structure 110 and the second transmissive or non-transmissive structure 120 (as well as the first frame 130 and the second frame 140) may have substantially the same size in plan (e.g., ±10% of a given dimension).

[0063] As shown in FIG. 1A, the combination of the exposed surface of the first transmissive or non-transmissive structure 110 and the adjacent (e.g., substantially coplanar / parallel) surface of the first frame 130 may be considered a first surface of the capsule 100. Similarly, as shown in FIG. 1B, the combination of the exposed surface of the second transmissive or non-transmissive structure 120 and the adjacent (e.g., substantially coplanar / parallel) surface of the second frame 140 may be considered a second surface of the capsule 100. In at least one exemplary embodiment, the first surface, the second surface, or both may comprise a perforated sheet. In at least one exemplary embodiment, the first surface, the second surface, or both may comprise a mesh sheet. In yet another exemplary embodiment, either the first surface or the second surface may comprise a perforated sheet and the other of the first surface or the second surface may comprise a mesh sheet. In at least one exemplary embodiment, the first surface, the second surface, or both may comprise a solid sheet, thereby substantially sealing the capsule except for the air inlet and the air outlet. This is described herein with reference to Figures 4 to 23.

[0064] As discussed above and in more detail herein, a heater 170 (e.g., FIGS. 2A, 2B, and 3) may be disposed within capsule 100 to heat aerosol generating material 160. Heater 170 may include, among other components, a first end 172 and a second end 176 that are configured to receive electrical current from a power source when heater 170 is activated. When heater 170 is activated, the temperature of aerosol generating material 160 may increase and an aerosol may be generated and released from capsule 100.

[0065] 1A and 1B, the combination of the exposed surface of the third frame 150 and the adjacent sidewalls of the first and second frames 130, 140 may be considered a side of the capsule 100. Additionally, the first and second ends 172, 176 may be exterior segments of the heater 170, which also form part of the side of the capsule 100. The outwardly facing surfaces of the first and second ends 172, 176 of the heater 170 may be coplanar, although example embodiments are not limited thereto.

[0066] As described herein, an aerosol generating material is a material, or combination of such materials, capable of producing an aerosol. An aerosol is a material generated or produced by the devices disclosed and claimed herein and their equivalents. Such materials may include compounds (e.g., nicotine, cannabinoids) that, when heated, produce an aerosol containing the compounds. The heating may be below combustion temperatures, thereby producing the aerosol without causing substantial thermal decomposition of the aerosol generating material or substantial generation of combustion by-products, if any. Thus, in certain exemplary embodiments, no thermal decomposition occurs during heating and the resulting production of the aerosol. In other instances, there may be some thermal decomposition and combustion by-products, but the extent may be relatively small and / or may be considered merely incidental.

[0067] The aerosol-generating material may be a fibrous material. The fibrous material may be, for example, a plant material. The fibrous material is configured to release a compound when heated. The compound may be a natural component of the fibrous material. The fibrous material may be, for example, a plant material, such as tobacco, and the released compound may 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, obtained from one or more species of tobacco plants, such as Nicotiana rustica and Nicotiana tabacum.

[0068] In some exemplary embodiments, the tobacco material may include material obtained from any member of the Nicotiana genus. Additionally, the tobacco material may include a blend of two or more different tobacco species. 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, blends thereof, and the like. The tobacco material may be provided in any suitable form, including, but not limited to, tobacco layers, processed tobacco materials (e.g., expanded or expanded tobacco), processed tobacco stems (e.g., cut rolled or cut expanded stems), reconstituted tobacco materials, blends thereof, and the like. In some exemplary embodiments, the tobacco material is in the form of a substantially dry tobacco mass. Additionally, in some exemplary embodiments, the tobacco material may be mixed and / or combined with at least one of propylene glycol, glycerin, subcombinations thereof, or combinations thereof.

[0069] The compound may also be a natural component of a medicinal plant that has a medically acceptable therapeutic effect. For example, the medicinal plant may be a cannabis plant and the compound may be a cannabinoid. Cannabinoids interact with receptors in the body to produce a wide range of effects. As a result, cannabinoids have been used for a variety of medical purposes (e.g., treating pain, nausea, epilepsy, and psychiatric disorders). The fibrous material may include leaf and / or flower material obtained from one or more species of the cannabis plant (e.g., Cannabis sativa, Cannabis indica, and Cannabis ruderalis). In some examples, the fibrous material is a mixture that includes 60-80% (e.g., 70%) Cannabis sativa and 20-40% (e.g., 30%) Cannabis indica.

[0070] Examples of cannabinoids include tetrahydrocannabinolic acid (THCA), tetrahydrocannabinol (THC), cannabidiol acid (CBDA), cannabidiol (CBD), cannabinol (CBN), cannabicyclol (CBL), cannabichromene (CBC), and cannabigerol (CBG). Tetrahydrocannabinolic acid (THCA) is the precursor of tetrahydrocannabinol (THC), and cannabidiol acid (CBDA) is the precursor of cannabidiol (CBD). Tetrahydrocannabinolic acid (THCA) and cannabidiol acid (CBDA) can be converted to tetrahydrocannabinol (THC) and cannabidiol (CBD), respectively, by heating. In certain exemplary embodiments, heat from a heater (e.g., heater 170 shown in Figures 2A and 2B) may cause decarboxylation, thereby converting tetrahydrocannabinolic acid (THCA) in the capsule 100 to tetrahydrocannabinol (THC) and / or converting cannabidiol acid (CBDA) in the capsule 100 to cannabidiol (CBD).

[0071] In an example where tetrahydrocannabinolic acid (THCA) and tetrahydrocannabinol (THC) are both present in the capsule 100, the decarboxylation and resulting conversion reduces tetrahydrocannabinolic acid (THCA) and increases tetrahydrocannabinol (THC). During heating of the capsule 100, at least 50% (e.g., at least 87%) of the tetrahydrocannabinolic acid (THCA) may be converted to tetrahydrocannabinol (THC). Similarly, in an example where cannabidiolic acid (CBDA) and cannabidiol (CBD) are both present in the capsule 100, the decarboxylation and resulting conversion reduces cannabidiolic acid (CBDA) and increases cannabidiol (CBD). During heating of the capsule 100, at least 50% (e.g., at least 87%) of the cannabidiolic acid (CBDA) may be converted to cannabidiol (CBD).

[0072] Furthermore, the compound may be or may further include a non-natural additive, which is then 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 cellulosic material (e.g., a non-tobacco material and / or a non-cannabis material). In either example, the compound introduced may include nicotine, a cannabinoid, and / or a flavoring agent. The flavoring agent may be from a natural source, such as a plant extract (e.g., tobacco extract, cannabis extract), and / or may be from an artificial source. In yet another example, when the fibrous material includes tobacco and / or cannabis, the compound may be or may further include one or more flavoring agents (e.g., menthol, mint, vanilla). Thus, the compound in the aerosol generating material may include a natural component and / or a non-natural additive. In this regard, it should be understood that the level of natural components present in the aerosol generating material may be increased by supplementation. For example, the level of nicotine present in a quantity of tobacco may be increased by supplementation with a nicotine-containing extract. Similarly, the level of one or more cannabinoids present in a quantity of cannabis may be increased by supplementing with a cannabinoid-containing extract.

[0073] 2A and 2B, the first frame 130 has a first inner surface and a first outer surface. The first frame 130 further defines a first opening 131. In an exemplary embodiment, the sidewalls of the first opening 131 have straight portions facing each other and, optionally, curved portions facing each other. 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 opposite distal end of the first frame 130. The first transmissive or non-transmissive structure 110 may be fixed to the first inner surface of the first frame 130 and exposed by the first opening 131. From a different perspective, the first transmissive or non-transmissive structure 110 may be considered to cover the first opening 131. The first transmissive or non-transmissive structure 110 may further define a first aperture 112. The first aperture 112 may have a position and size capable of accommodating a first protrusion (not shown) that corresponds to the first recess 133 shown in Figures 2A and 2B when the first transmissive or non-transmissive structure 110 is fixed to the first frame 130.

[0074] The second frame 140 has a second inner surface and a second outer surface. The second frame 140 further defines a second opening 141. In an exemplary embodiment, the sidewalls of the second opening 141 have straight portions opposite each other and, optionally, curved portions opposite each other. 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 opposite distal end of the second frame 140. The second transmissive or non-transmissive structure 120 may be fixed to the second inner surface of the second frame 140 and exposed by the second opening 141. From a different perspective, the second transmissive or non-transmissive structure 120 may be considered to cover the second opening 141. The size and shape of the second opening 141 may correspond to (or be mirrored) the size and shape of the first opening 131. Further, the second transmissive or non-transmissive structure 120 may define a second aperture 122. The second aperture 122 may have a position and size capable of accommodating the second protrusion 145 when the second transmissive or non-transmissive structure 120 is fixed to the second frame 140.

[0075] The third frame 150 defines a cavity 151 configured to receive the aerosol generating material 160. The combination of the sidewalls of the cavity 151 and the inner surfaces of the first transmissive or non-transmissive structure 110 and the second transmissive or non-transmissive structure 120 (covering the cavity 151) can be considered to define a chamber. In an exemplary embodiment, the sidewalls of the cavity 151 have straight portions opposite each other and curved portions opposite each other. One curved portion is adjacent to a proximal end of the third frame 150, and the other curved portion is adjacent to an opposite distal end of the third frame 150. The third frame 150 can have substantially the same size as the first transmissive or non-transmissive structure 110 and the second transmissive or non-transmissive structure 120 in plan view (e.g., ±10% of a given dimension). The third frame 150 further defines at least one aperture 152 adjacent an end of the third frame 150. The third frame 150 may be formed from other suitable materials, in addition to the materials forming the first frame 130 and the second frame 140, such as ceramic, synthetic glass, and / or consolidated fiber (e.g., cardboard).

[0076] In at least one exemplary embodiment, the heater 170 is configured to extend through the third frame 150 into the cavity 151. The heater 170 may further be considered to be supported by the third frame 150. The heater 170 includes a first end 172, a middle portion 174, and a second end 176. The first end 172 and the second end 176 of the heater 170 are also outer segments that form part of the side of the capsule 100. The middle portion 174 of the heater 170 is an inner segment that is disposed within the capsule 100 (within the chamber of the housing that contains the aerosol generating material 160). The first end 172, the middle portion 174, and the second end 176 of the heater 170 are each part of a continuous structure. In an exemplary embodiment, the middle portion 174 of the heater 170 has a planar, serpentine configuration.

[0077] When the heater 170 is activated, the temperature of the aerosol generating material may increase, causing an aerosol to be generated and released from the capsule 100 .

[0078] In at least one exemplary embodiment, the heater 170 may be formed from a sheet of material that may be cut, photoetched, or punched into a corrugated shape, or may be otherwise machined (e.g., electrochemically etched, die cut, laser cut).

[0079] In an exemplary embodiment, the heater 170 is configured to Joule heat (also known as Ohmic / resistive heating) when an electric current is applied to it. More specifically, the heater 170 may be formed of one or more conductors and configured to generate heat when an electric current is passed through it. The electric current may be provided between a first end 172 and a second end 176 of the heater 170 from a power source (e.g., a battery) within the aerosol generating device. Suitable conductors for the heater 170 include iron-based alloys (e.g., steel, iron aluminide), nickel-based alloys (e.g., nichrome), and / or ceramics (e.g., ceramics coated with metal). The middle portion 174 of the heater 170 may have a thickness of about 0.1-0.3 mm (e.g., 0.15-0.25 mm) and a resistance of about 0.5-2.5 ohms (e.g., 1-2 ohms).

[0080] An electrical current from a power source in the aerosol generating device can be passed through the electrodes when the capsule 100 is inserted into the aerosol generating device. The electrodes are configured to be in electrical contact with the first end 172 and the second end 176 of the heater 170. In a non-limiting embodiment of the present disclosure, the electrodes in the aerosol generating device can be spring-loaded to facilitate engagement of the capsule 100 with the heater 170. For example, the spring-loaded first electrode in the aerosol generating device can have a rounded or chamfered engagement portion. The engagement portion is configured to be in electrical contact with the first end 172 of the heater 170 and disposed within an aperture in the first end 172. Similarly, the spring-loaded second electrode in the aerosol generating device can have a rounded or chamfered engagement portion. The engagement portion is configured to be in electrical contact with the second end 176 of the heater 170 and disposed within an aperture in the second end 176. In such an example, engagement of the first and second electrodes of the aerosol generating device with the first and second ends 172, 176 of the heater 170, respectively, may be confirmed by an audible click. The spring suspension of the electrodes may be orthogonal to the plane of the heater 170. Activation (e.g., engagement, disengagement) of the electrodes may be accomplished by mechanical actuation in addition to or instead of spring suspension. Furthermore, the supply of electrical current from the aerosol generating device to the capsule 100 may be manual (e.g., button-activated) or automatic (e.g., puff-activated).

[0081] The aerosol generating material 160 may be disposed within the cavity 151 of the third frame 150 on one side of the intermediate portion 174 of the heater 170 (as shown in FIG. 2A ) or on both sides (as shown in FIG. 2B ). In at least one exemplary embodiment, the aerosol generating material 160 may be in a consolidated form (e.g., a sheet, pallet, tablet) configured to maintain a shape, thereby allowing the aerosol generating material 160 to be placed in the cavity 151 of the third frame 150 in a uniform manner. In such an example, a single block of the aerosol generating material 160 may be disposed on one side of the intermediate portion 174 of the heater 170, as shown in FIG. 2A . 2B, one mass of aerosol generating material 160 may be disposed on one side of intermediate portion 174 of heater 170 and another mass of aerosol generating material 160 may be disposed on the other side of intermediate portion 174 of heater 170 (e.g., to substantially fill cavity 151 of third frame 150 with aerosol generating material 160 and sandwich / embed intermediate portion 174 of heater 170 between aerosol generating material 160). Alternatively, aerosol generating material 160 may be in a loose form (e.g., particles, fibers, powder, flakes, debris) that does not have a set shape and is configured to take the shape of cavity 151 of third frame 150 when introduced.

[0082] The first transparent or non-transparent structure 110 and the second transparent or non-transparent structure 120 may be secured to the first frame 130 and the second frame 140, respectively, by various attachment techniques. The attachment technique may include, for example, injection molding (e.g., insert molding, overmolding). In another example, the attachment technique may include ultrasonic welding. In another example, the attachment technique may include an adhesive (e.g., tape, glue) that is deemed food safe or acceptable by a regulatory agency. Alternatively, the first transparent or non-transparent structure 110 and the second transparent or non-transparent structure 120 may be clamped (or otherwise fastened) to the third frame 150 by the first frame 130 and the second frame 140, respectively, instead of using a separate attachment technique.

[0083] As shown in FIGS. 2A and 2B, the first frame 130 includes at least one connector protruding from the first inner surface of the first frame 130. The at least one 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 an 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 that extends its entire length and resemble a raised groove or a recessed / indented ridge. Additionally or alternatively, the ridge may have a tapered edge and may thus be referred to as a tapered ridge. Although the first connector 138 is shown as being separated into a plurality of discrete structures (e.g., four discrete structures), it should be understood that the exemplary embodiment is not so limited. Alternatively, for example, the first connector 138 may be a single continuous structure that extends along an edge and completely surrounds the first interior surface of the first frame 130 .

[0084] Similarly, the second frame 140 includes at least one second connector protruding from the second inner surface of the second frame 140. The at least one 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 an edge of the second inner surface of the second frame 140 in the form of a ridge (e.g., a second ridge). The ridge may define a groove that extends its entire length and resemble a raised groove or a recessed / indented ridge. Additionally or alternatively, the ridge may have a tapered edge and may thus be referred to as a tapered ridge. Although the second connector 148 is shown as being separated into a plurality of discrete structures (e.g., four discrete structures), it should be understood that the exemplary embodiment is not so limited. Alternatively, for example, the second connector 148 may be a single continuous structure that extends circumferentially and completely surrounds the second interior surface of the second frame 140 .

[0085] In the non-limiting embodiment of the present disclosure shown in Figures 2A and 2B, the first connector 138 of the first frame 130 is separated into four discrete structures. Two of the structures can be raised grooves and the other two of the structures can be tapered ridges. Conversely, the second connector 148 of the second frame 140 can be separated into four discrete structures, two of the structures are tapered ridges and the other two of the structures are raised grooves. The mixed set of raised grooves and tapered ridges of the first frame 130 are configured to be paired with the mixed set of tapered ridges and raised grooves of the second frame 140, respectively, during assembly of the capsule 100. It should be understood that the raised grooves and tapered ridges of the first frame 130 and the second frame 140 can be combined in various ways. Further, each of the first transparent or non-transparent structure 110 and the second transparent or non-transparent structure 120 may have tab-like extensions (e.g., four tab-like extensions) that are positioned between the discrete structures of the first connector 138 and the second connector 148, respectively, when the capsule 100 is assembled.

[0086] The tapered ridges of the first connector 138 and / or the second connector 148 may have a shoulder and a slope rising from the shoulder to form a tapered ridge. The tapered ridge may act as an energy director (e.g., to facilitate welding) during assembly operations. The corresponding raised grooves of the first connector 138 and / or the second connector 148 may have edges and a groove bottom. As shown in FIGS. 2A and 2B, the groove bottoms of the raised grooves may be flat bottoms. Alternatively, the groove bottoms of the raised grooves may be V-shaped bottoms. In an exemplary embodiment of the connection between the first frame 130 and the second frame 140, the slopes of the tapered ridges are configured to contact the groove bottoms of the corresponding raised grooves, and the shoulders of the tapered ridges interact with the edges of the raised grooves. As such, the mating surfaces of the first connector 138 and the second connector 148 may be configured inversely or complementary to one another to facilitate mating.

[0087] As shown in Figures 2A and 2B, when a mixed set of raised grooves and tapered ridges of each frame are grouped such that the raised grooves are on one straight side edge and the tapered ridges are on the other straight side edge, the first frame 130 and the second frame 140 can be the same part. In such an example, the first frame 130 and the second frame 140 are paired opposite each other to form a complementary structure. As a result, one part can be used interchangeably as the first frame 130 or the second frame 140, thus simplifying the manufacturing method.

[0088] To assemble the capsule 100, the first frame 130 may be connected to the second frame 140 after the aerosol generating material 160 is disposed in the cavity 151 of the third frame 150 (e.g., so that there is aerosol generating material 160 on either side of the middle portion 174 of the heater 170). In such an example, when the first frame 130 is connected to the second frame 140, the third frame 150 is sandwiched between the first transmissive or non-transmissive structure 110 and the second transmissive or non-transmissive structure 120. At least one connector of the first frame 130 is configured to engage with at least one connector of the second frame 140 during an assembly operation to form at least one connection (e.g., four connections). For example, the raised grooves (and / or tapered ridges) of the first connector 138 are configured to mate with corresponding tapered ridges (and / or raised grooves) of the second connector 148. Additionally, the coupling between the first connector 138 of the first frame 130 and the second connector 148 of the second frame 140 may be accomplished by a welded structure (e.g., ultrasonic welding). Additionally, when the capsule 100 is assembled, the outer sidewalls of the first frame 130 may be substantially flush with the outer sidewalls of the second frame 140, although the exemplary embodiment is not limited thereto. Once assembled, the capsule 100 is difficult or impractical to open without damaging the connectors, the frame, and / or other aspects of the capsule 100. As a result, the capsule 100 is tamper-resistant to unauthorized actions by a third party.

[0089] The capsule 100 has been described as having, among other components, a first frame 130 that is separate from the second frame 140. Alternatively, in some examples, the first frame 130 and the second frame 140 may be manufactured as a single structure that is configured to be folded during an assembly operation to engage the first connector 138 with the second connector 148. The first frame 130 and the second frame 140 may resemble, for example, a bivalve shell structure, where a straight distal end of the first frame 130 is connected to a straight distal end of the second frame 140, with the integral reduced thickness acting as a fold. In another example, a straight side edge of the first frame 130 may be connected to a straight side edge of the second frame 140, with the integral reduced thickness acting as a fold. It should be understood that in a bivalve shell structure, one or more connections (e.g., along a fold) may be omitted from the capsule 100.

[0090] FIG. 3 is a plan view of a pattern sheet for manufacturing a heater in accordance with at least one example embodiment.

[0091] In at least one exemplary embodiment, the pattern sheet 370 may be produced by cutting or otherwise processing (e.g., punching, electrochemically etching, die cutting, laser cutting) a sheet material, as shown in FIG. 3. The pattern sheet 370 includes a heater having a first end 372, a first arm portion 373, a middle portion 374, a second arm portion 375, and a second end 376, as shown. The first end 372 and the second end 376 may define apertures 378a and 378b, respectively. The first arm portion 373 and the second arm portion 375 may function as support structures and heat relief segments. The middle portion 374 may have a serpentine form resembling a compression wave or zigzag having multiple parallel segments (e.g., 8 to 12 parallel segments). The parallel segments may be connected to each other by U-shaped ends, as shown in FIG. 3. The sheet portion 309 is connected to the first end 372, the first arm portion 373, the second arm portion 375, and the second end 376 via breakout portions 311. In the next step of the manufacturing process, the first end 372, the first arm portion 373, the second arm portion 375, and the second end 376 of the heater can be separated from the sheet portion 309 by cutting the breakout portions 311. Although six breakout portions 311 are shown, it should be understood that the exemplary embodiment is not so limited. Additionally, the first arm portion 373 and the second arm portion 375 can include matching tabs (e.g., six matching tabs) adjacent the breakout portions 311 to facilitate placement of the heater during assembly of the capsule.

[0092] FIG. 4 illustrates the heater-containing capsule of FIG. 3 with the second frame removed, in accordance with at least one example embodiment.

[0093] In one exemplary embodiment, as shown in Figure 4, the capsule is the same as the capsule of Figures 1A, 1B, 2A and 2A, except that capsule 400 includes heater 370 shown in and described with reference to Figure 3, and second frame 140 has been removed to reveal inner frame 150, heater 370, and an opening 410 defined at least in part by first frame 130. Although not shown in Figure 4, opening 410 is also defined at least in part by second frame 140 such that when first frame 130 is joined to second frame 140, opening 410 exposes a portion of inner (third) frame 150.

[0094] FIG. 5 is a side view of the capsule of FIG. 4, showing a fourth side as a mirror image of the third side, in accordance with at least one exemplary embodiment.

[0095] In at least one exemplary embodiment, the capsule 400 of FIG. 4 is shown with the second frame 140 mated with the first frame 130, exposing the opening 410 to the inner frame 150, as shown in FIG. 5. An opening 410 in the capsule 400 is also present on the opposite side, but is not visible in the drawing. As shown, the inner frame 150 defines at least one air passage 500 (shown in FIG. 6) that extends from a side edge of the inner frame 150 to the cavity 151. In at least one exemplary embodiment, the at least one air passage 500 is aligned with the at least one opening 410, thereby allowing air flow through the at least one opening 410 and the at least one air passage 500 to the cavity 151 and through the heater 370.

[0096] In at least one exemplary embodiment, the diameter of at least one air flow passage 500 ranges from about 0.1 mm to about 5 mm (e.g., from about 0.15 mm to about 4.5 mm, from about 0.20 mm to about 4.0 mm, or from about 1.25 mm to about 3.5 mm). The diameter of the air flow passage 500 can be varied to achieve a desired resistance to draw (RTD) of the aerosol generating device.

[0097] In at least one exemplary embodiment, capsule 400 has a thickness of about 1.0 mm to about 10.0 mm (e.g., about 2.0 mm to about 9.0 mm, about 3.0 mm to about 8.0 mm, about 4.0 mm to about 7.0 mm, or about 5.0 mm to about 6.0 mm).

[0098] FIG. 6 illustrates the capsule of FIG. 5 with the second frame removed, showing airflow through the capsule, in accordance with at least one exemplary embodiment.

[0099] In at least one exemplary embodiment, as shown in FIG. 6, the capsule 400 includes four openings 410 defined between the first frame 130 and the second frame 140 (shown in FIG. 5). Each opening 410 is aligned with an air flow passage 500 or outlet 600 defined in and extending through the inner frame 150. When the capsule 400 is placed in an aerosol generating device (see FIG. 23) and activated, air is drawn through the openings 410 between the tab portions 178a and 178b at the first end 172 and the second end 176, the openings 410 along the sides of the inner frame 150, and the air flow passages 500 in the inner frame. After passing through the air flow passages 500, the air travels through the heater 370 and the aerosol-generating material (shown in FIGS. 2A and 2B) and exits the capsule 400 through the outlet 600. In at least one exemplary embodiment, the air and / or vapor exiting through the outlet 600 may then pass through a mouthpiece (as further described with reference to FIGS. 9-23). ​​The capsule 400 is generally sealed, which promotes good airflow through all openings 410 and air flow passages 500 as the air is drawn through the outlet 600. In at least one exemplary embodiment, for example, the first and second permeable or non-permeable structures 110 and 120 (shown in FIGS. 1A, 1B, 2A and 2B) are impermeable to air, thereby sealing the capsule 400. Because the capsule 400 is sealed, air generally flows longitudinally through the heater 370 and aerosol generating material (shown in FIGS. 2A and 2B), which increases the area of ​​contact with the heater 370 and the aerosol generating material.

[0100] In at least one exemplary embodiment, the diameter of the outlet 600 is in the range of about 0.1 mm to about 5 mm (e.g., about 0.15 mm to about 4.5 mm, about 0.20 mm to about 4.0 mm, or about 0.25 mm to about 3.5 mm). The diameter of the outlet 600 can be varied to achieve a desired resistance to draw (RTD) of the aerosol generating device.

[0101] FIG. 7 illustrates the capsule of FIG. 4 showing an alternative air flow path through the capsule, according to at least one exemplary embodiment.

[0102] In at least one exemplary embodiment, as shown in FIG. 7, capsule 400 is the same as capsule 400 of FIGS. 4-6, except that capsule 400 includes a diffuser 700 and capsule 400 does not include the lateral air flow passages 500 aligned with openings 410, as described with reference to FIGS. 5 and 6.

[0103] In at least one exemplary embodiment, the capsule 400 includes only one air passage 500, which is between the tab portions 178a and 178b. The outlet of the air passage 500 leads to a diffuser 700, which is configured to direct and / or redirect air from the at least one air passage 500 to the outlet 600. The diffuser 700 includes at least one channel in a first surface 705 of the inner frame 150. In at least one exemplary embodiment, the diffuser 700 includes a main channel 720 extending from the at least one air passage 500. The main channel 720 extends generally longitudinally along a surface of the inner frame 150. The diffuser 700 further includes at least one redirection channel 710 extending from the main channel 720. At least one redirection channel 710 includes a transverse and / or longitudinal channel extending from and in fluid communication with the main channel 720. The diffuser 700 further includes at least one secondary channel 730 extending from the redirection channel 720, the secondary channel 730 extending in a longitudinal direction. As shown in FIG. 7, the diffuser 700 includes six longitudinally extending secondary channels 730. In another exemplary embodiment, the diffuser 700 may include 2 to 20 (e.g., 4 to 18, 6 to 16, 8 to 14, or 10 to 12) secondary channels 710. In some exemplary embodiments, at least one secondary channel 730 is a straight channel. In at least one exemplary embodiment, the secondary channel 730 may be an angled channel with respect to the main channel 720. The secondary channels 730 may have any suitable shape and may resemble tree branches extending from the main channel 720 .

[0104] In at least one exemplary embodiment, the main channel 720, the redirection channel 710, and the at least one secondary channel 730 have a depth of about 0.1 mm to about 0.5 mm (e.g., about 0.2 mm to about 0.4 mm, or about 0.25 mm to about 0.35 mm) from the surface of the inner frame 150. Additionally, the capsule 400 is sealed such that air flows from the flow passage 500 through the diffuser 700, into the heater 370, and out through the outlet 600. The air flow path through the capsule 400 is longer than the thickness of the capsule.

[0105] FIG. 8 illustrates the capsule of FIG. 4 in accordance with at least one exemplary embodiment, showing how airflow penetrates the capsule.

[0106] In at least one exemplary embodiment, as shown in FIG. 8, the capsule is the same as capsule 400 of FIG. 7 except that the diffuser 700 is in communication only with the side opening 410, and the capsule 400 does not include the opening 410 between the tab portions 178a and 178b, nor the air flow path 500 through the inner frame 150.

[0107] 8, the diffuser 700 includes a redirecting channel 710 and a secondary channel 730. Air enters the capsule 400 through the side opening 410 and travels through the secondary channel 730 adjacent the side opening and the redirecting channel 710 to the other branch of the diffuser 700, through the heater 370, and to the outlet 600. In at least one exemplary embodiment, the channels 710 and 730 have a depth of about 0.25 mm from the first surface 705 of the inner frame 150. The air flow path through the capsule 400 is longer than the thickness of the capsule.

[0108] FIG. 9 is a perspective view of a capsule assembly including a capsule connected to a mouthpiece according to at least one exemplary embodiment.

[0109] In at least one exemplary embodiment, as shown in FIG. 9, capsule assembly 915 includes the capsule of FIG. 4, where inner frame 150 includes extension 900 connected to mouthpiece 910.

[0110] 9, capsule 400 includes inner frame 150, which includes extension 900. Extension 900 and inner frame 150 may be a single piece formed by 3D printing or other methods. Extension 900 includes neck 904 and body 906. Neck 904 may be V-shaped. Body 906 may have a generally circular cross-section and a larger diameter than capsule 400. Neck 904 and body 906 may have any suitable shape configured to connect with mouthpiece 910.

[0111] In at least one exemplary embodiment, the mouthpiece 910 may be any suitable mouthpiece, such as the mouthpiece described in U.S. Patent No. 10,064,432, which is incorporated herein by reference in its entirety. The mouthpiece 910 may include, for example, at least one outlet 920. As shown, the mouthpiece 910 includes four outlets 920, with a portion of the mouthpiece 910 fitting within the body portion 906 of the extension 900. In other exemplary embodiments, the mouthpiece 910 may include one or more outlets and / or a portion of the mouthpiece 910 may surround the extension 900 of the inner frame 150. The first frame 130 and the second frame 140 fit around the inner frame 150 and the portion of the extension 900 that extends beyond the first and second frames 130 and 140.

[0112] FIG. 10 is a side cross-sectional view of the capsule assembly of FIG. 9 according to at least one exemplary embodiment.

[0113] In at least one exemplary embodiment, as shown in FIG. 10, the capsule 400 and mouthpiece 910 are the same as those shown in FIG. 4 and FIG. 9, respectively, but with additional internal features. As shown in FIG. 10, the extension 900 defines a chamber 1020. The chamber 1020 is configured to receive a base 1010 of the mouthpiece 910. The base 1010 of the mouthpiece 910 defines a flow path 1000. The inner frame 150 and the extension 900 further define an extension channel 1030, which extends from the cavity 151 the entire length of the extension 900. The cavity 151 is in fluid communication with the flow path 1000 and the outlet 920 of the mouthpiece 910, such that aerosol and / or air exits the capsule 400 and the mouthpiece through the outlet 920.

[0114] FIG. 11 is a side cross-sectional view of the capsule assembly of FIG. 10 taken along line XI-XI in accordance with at least one exemplary embodiment.

[0115] In at least one exemplary embodiment, as shown in FIG. 11, capsule assembly 915 including capsule 400 and mouthpiece 910 is the same as capsule assembly 915 of FIGS. 9 and 10, except that capsule 400 includes vent 1110 in communication with opening 410. Inner frame 150 defines vent 1110 on a first and second surface. Vent 1110 extends from opening 410 adjacent tab portions 178a and 178b and is in fluid communication with opening 410, thereby allowing air to flow from vent 1110 in cavity 151 when mouthpiece 910 is inhaled. In at least one exemplary embodiment, vent 1110 may be molded into a surface of inner frame 150. Vent 1110 may be about 10 microns deep and / or about 10 microns wide. In some exemplary embodiments, the depth and / or width of vent 1110 may be adjusted to adjust the amount of air flowing into capsule 400. The vent 1110 may be designed to allow an adult consumer to inhale comfortably while still maintaining the aerosol generating substance 160 within the capsule 400 .

[0116] FIG. 12 is a side cross-sectional view of the assembly of FIG. 9 according to at least one exemplary embodiment.

[0117] In at least one exemplary embodiment, as shown in Figure 12, capsule assembly 915 is the same as the capsule assemblies of Figures 4, 9, and 10, except that a channel 1200 is defined by and extends through a portion of inner frame 150 instead of vent 1110 of Figure 11. As shown in Figure 12, air enters capsule 400 through opening 410, passes through channel 1200 in inner frame 150 to cavity 151, flows through extension channel 1030 to flow passage 1000 of mouthpiece 910, and exits capsule assembly 915 through outlet 920 of mouthpiece 910.

[0118] 13 is a side cross-sectional view of the capsule assembly of FIG. 12 taken along line XIII-XIII in accordance with at least one exemplary embodiment.

[0119] In at least one exemplary embodiment, as shown in FIG. 13, capsule assembly 915 is the same as the capsule assembly of FIG. 12, except that a cross section of channel 1200 and vent 1110 is shown.

[0120] FIG. 14 is a side cross-sectional view of the capsule assembly of FIG. 9 according to at least one exemplary embodiment.

[0121] FIG. 15 is a side cross-sectional view of the capsule assembly of FIG. 14 taken along line XV-XV, in accordance with at least one exemplary embodiment.

[0122] In at least one exemplary embodiment, as shown in Figures 14 and 15, the capsule assembly is the same as the capsule assembly of Figure 9, except that capsule 400 (the same as the capsule of Figure 4) includes channel 1400 and central channel 1200 (shown in and described with reference to Figures 12 and 13) within inner frame 150, and further includes mouthpiece 910 of Figures 9 and 10.

[0123] As shown in Figures 14 and 15, the capsule 400 includes a side channel 1400 that is aligned with an opening 410 established between the first frame 130 and the second frame 140. The capsule 400 further includes a central channel 1200 that is aligned with an opening 410 established between the first frame 130 and the second frame 140. When the mouthpiece 910 is inhaled, air is drawn into the capsule 400 through the opening 410, through the side channel 1400 and the central channel 1200 to the cavity 151, the extension channel 1030 and the flow passage 1000, and out of the mouthpiece 910 through the outlet 920.

[0124] In at least one exemplary embodiment, central channel 1200 may have a diameter of about 0.5 mm to about 1.5 mm. Additionally, side channel 1400 may have a diameter of about 0.5 mm to about 1.5 mm. For example, central channel 1200 and side channel 1400 may each have a diameter of about 1.0 mm.

[0125] FIG. 16 is a side cross-sectional view of the capsule assembly of FIG. 9 according to at least one exemplary embodiment.

[0126] FIG. 17 is a side cross-sectional view of the capsule assembly of FIG. 16 taken along line XVII-XVII in accordance with at least one exemplary embodiment.

[0127] In at least one exemplary embodiment, as shown in Figures 16 and 17, the capsule assembly is the same as capsule assembly 915 of Figures 14 and 15 and includes a capsule 400. Capsule 400 is the same as the capsule of Figure 4, except that it further includes two vents 1110 along the surface of inner frame 150, as shown in and described with reference to Figure 11. When mouthpiece 910 is inhaled, air is drawn into capsule 400 through bottom and side openings 410 of capsule 400, through vents 1110, central channel 1200 and side channel 1400 to cavity 151, through extension channel 1030 to flow path 1000 of the mouthpiece, and out of the capsule assembly through outlet 920.

[0128] In at least one exemplary embodiment, central channel 1200 and side channel 1400 each have a diameter of about 1 mm.

[0129] FIG. 18 is a side perspective view of a capsule assembly including a capsule surrounded by a capsule enclosure and connected to a mouthpiece in accordance with at least one exemplary embodiment.

[0130] FIG. 19 is a side cross-sectional view of the capsule assembly of FIG. 18 taken along line XIX-XIX in accordance with at least one exemplary embodiment.

[0131] In at least one exemplary embodiment, as shown in Figures 18 and 19, capsule assembly 1800 may include capsule 400 of Figure 4 and the mouthpiece of Figure 9, and further includes a capsule enclosure 1810 in place of the extension shown in and described with reference to Figures 9 to 17.

[0132] As shown in FIGS. 18 and 19, the capsule enclosure 1810 substantially surrounds the capsule 400, thereby sealing the capsule 400 (shown in FIG. 19) and forcing airflow through and / or along the heater 370 within the capsule 400. As shown in FIGS. 18 and 19, the capsule enclosure 1810 includes a first body 1820 and a second body 1830. The first body 1820 and the second body 1830 may be formed in a 3D printer or may be molded with and connected around the capsule 400 and a portion of the mouthpiece 910. The connection between the first body 1820 and the second body 1830 may be made by any suitable connection, including rubber bands, adhesives, and / or mechanical connections formed within the first body 1820 and the second body 1830.

[0133] In at least one exemplary embodiment, the capsule assembly 1810 defines a flow path 1900 therethrough. As shown in FIG. 19, the flow path 1900 includes a first flow path portion 1920 extending through a portion of the first body 1820 and a second flow path portion 1930 extending through a portion of the second body 1830. As further shown in FIG. 19, the second flow path portion 1930 may include an inlet 1940 through which air enters when the mouthpiece 910 is inhaled. The air travels through the inlet 1940 within the second flow path portion 1930 and through it into the capsule 400. The air may enter the capsule 400 from the top. Within the capsule 400, the air flows through a first transmissive or non-transmissive structure. The first transmissive or non-transmissive structure is transmissive in this exemplary embodiment. The air then travels through and / or within the aerosol generating material (as shown in and described with reference to FIGS. 2A and 2B) and into the heater 370. As shown, the air flow generally travels along the length of the heater 370 and / or diagonally across the heater 370 and exits the capsule 400 through the bottom of the capsule 400. The air exits the capsule 400 through the second permeable or non-permeable structure 120, which is permeable in this exemplary embodiment. The air travels through the second flow path portion 1930 and the capsule enclosure outlet 1950 to the flow path 1000 of the mouthpiece 910 and exits the capsule assembly 1800 through the outlet 920. The air flow path through the capsule 400 is longer than the thickness of the capsule.

[0134] In at least one exemplary embodiment, as shown in FIG. 19, tab portions 178a and 178b of capsule 400 extend outside capsule enclosure 1810, thereby facilitating electrical connection with a power source and / or control circuitry within the aerosol generating device, as further described with reference to FIG. 23.

[0135] While in at least one exemplary embodiment, the mouthpiece 910 is shown as being centered within the capsule assembly 1800, the mouthpiece 910 may be positioned off-center to avoid turns and / or reduce the number of turns within the flow path 1900.

[0136] Additionally, the inlet 1940 may be connected via tubing to a flow sensor or an area adjacent thereto, if desired.

[0137] FIG. 20 is a side cross-sectional view of the capsule assembly of FIG. 18 according to at least one exemplary embodiment.

[0138] In at least one exemplary embodiment, as shown in Figure 20, capsule assembly 1800 is the same as the capsule assemblies shown in Figures 18 and 19, except that flow paths 1900 are configured so that air enters capsule 400 at the bottom and exits at the top. The air generally travels lengthwise and / or diagonally across the capsule, thereby increasing the area of ​​contact with the aerosol generating material and / or heater 370.

[0139] FIG. 21 is a side cross-sectional view of the capsule assembly of FIG. 18 according to at least one exemplary embodiment.

[0140] In at least one exemplary embodiment, as shown in FIG. 21, capsule assembly 1800 is the same as the capsule assembly of FIG. 18, except that capsule 400 includes a vent 2100 in a first surface of inner frame 150, and flow path 1900 does not have a second flow path portion 1930 or an inlet 1940 leading thereto.

[0141] 21, air enters capsule 400 through vent 2100 and then passes longitudinally and / or diagonally through aerosol generating material and / or heater 370 to first flow path portion 1920 and through outlet 1950 to flow path 1000 in mouthpiece 910. The air flow path through capsule 400 is longer than the thickness of the capsule.

[0142] FIG. 22 is a side cross-sectional view of the capsule assembly of FIG. 18 according to at least one exemplary embodiment.

[0143] In at least one exemplary embodiment, as shown in Figure 22, the capsule assembly is the same as the capsule assembly of Figure 21, except that the capsule 400 includes two vents 2100. As shown, a first vent 2100a is in a first surface of the inner frame 150 and a second vent 2100b is in a second surface. Air enters the capsule assembly 1800 through the vents 2100a and 2100b.

[0144] FIG. 23 is a schematic diagram of an aerosol generating device for use with a capsule, according to at least one exemplary embodiment.

[0145] In at least one exemplary embodiment, as shown in FIG. 23, the aerosol generating device 2300 (e.g., a heated aerosol generating device) includes a mouthpiece 2315 and a device body 2325. A power source 2335 and a control circuit 2345 may be disposed within the device body 2325 of the aerosol generating device 2300. At least one air inlet 2365 may be defined within a wall of the device body 2325. The power source 2335 may include one or more batteries, such as lithium ion batteries (e.g., a rechargeable dual battery structure). The aerosol generating device 2300 is configured to receive the capsule 100, 400 and / or capsule assembly described herein, which may be as described in connection with any of the embodiments herein. The aerosol generating device 2300 further includes an engagement assembly 2355 configured to electrically contact the capsule 100, 400. The engagement assembly 2355 may include a first electrode 2360 and a second electrode 2362 that are configured to electrically contact the first and second ends, respectively, of the heater of the capsule.

[0146] After the capsule 100, 400 is inserted into the aerosol generating device 2300, the control circuit 2345 may instruct the power source 2335 to provide current between the first electrode 2360 and the second electrode 2362 of the engagement assembly 2355. The current supply from the power source 2335 may be in response to manual operation (e.g., button activation) or automatic operation (e.g., puff-activated). As a result of the current supply, the capsule 100, 400 may be heated to generate aerosol. Furthermore, changes in the resistance of the heater may be used to monitor and control the aerosolization temperature. The generated aerosol may be inhaled from the aerosol generating device 2300 via the mouthpiece 2315.

[0147] In at least one exemplary embodiment, activation of the aerosol generating device 2300 may heat the capsule 100, 400 within the device body 2325 to generate an aerosol. In at least one exemplary embodiment, activation of the aerosol generating device 2300 may be achieved by detection of airflow by the sensor 2375 and / or generation of a signal in conjunction with pressing the first button 2380 and / or the second button 2385. For detection of airflow, ambient air is drawn into the device body 2325 via the air inlet 2365 by suction or negative pressure on the aerosol outlet 2390 of the mouthpiece 2315. Once inside the device body 2325, the air flows through the inlet channel 2395 and is detected by the sensor 2375. A portion of the air further enters the capsule 100, 400 as described herein.

[0148] When airflow is detected by the sensor 2375, the control circuit 2345 directs the power source 2335 to provide current to the capsule 100, 400 via the first end 172 and the second end 176 of the heater 170, 370 (as described above). This results in an increase in temperature of the middle portion 174 of the heater 170, 370, which in turn increases the temperature of the aerosol-generating substance (e.g., the aerosol-generating substance 160), causing the aerosol-generating substance 160 to release volatile substances and generate an aerosol. The generated aerosol is entrained by the air flowing through the capsule 100, 400. In particular, after passing through the capsule 100, 400, the generated aerosol exits the aerosol generating device 2300 through the aerosol outlet 2390 of the mouthpiece 2315.

[0149] A processing circuit (control circuit) may be hardware including logic circuitry, a hardware / software combination such as a processor executing software, or a combination of both. More specifically, a processing circuit may include, but is not limited to, a central processing unit (CPU), an arithmetic logic unit (ALU), a digital signal processor, a microcomputer, a field programmable gate array (FPGA), a system on a chip (SoC), a programmable logic unit, a microprocessor, an application specific integrated circuit (ASIC), etc.

[0150] Further details of the capsules 100, 400 and the aerosol generating device 2300, including the mouthpiece 2315, device body 325, power source 2335, control circuitry 2345, and electrodes, may be found in U.S. patent application Ser. No. 15 / 845,501, entitled "VAPORIZING DEVICES AND METHODS FOR DELIVERING A COMPOUND USING THE SAME," filed Dec. 18, 2017 (Attorney Docket No. 24000DM-000012-US), the disclosure of which is incorporated herein by reference in its entirety. The capsules, aerosol-generating materials, and related aspects described herein are further described in more detail in U.S. patent application Ser. No. 16 / 252,951, entitled "CASULE, HEAT-NOT-BURN (HNB) AEROSOL-GENERATING DEVICES, AND METHODS OF GENERATING AN AEROSOL," filed Jan. 21, 2019 (Attorney Docket No. 24000NV-000521-US), the disclosure of which is incorporated herein by reference in its entirety.

[0151] Further details of the materials, capsules, devices and methods described herein can be found in U.S. patent application Ser. No. 16 / 451,662, filed June 25, 2019, entitled "CASULES, HEAT-NOT-BURN (HNB) AEROSOL-GENERATING DEVICES, AND METHODS OF GENERATING AN AEROSOL" (Attorney Docket No. 24000NV-000522-US), and U.S. patent application Ser. No. 16 / 252,951, filed January 21, 2019, entitled "CASULES, HEAT-NOT-BURN (HNB) AEROSOL-GENERATING DEVICES, AND METHODS OF GENERATING AN AEROSOL" (Attorney Docket No. 24000NV-000522-US). No. 15 / 845,501, filed Dec. 18, 2017, entitled "VAPORIZING DEVICES AND METHODS FOR DELIVERING A COMPOUND USING THE SAME" (Attorney Docket No. 24000DM-000012-US); U.S. Patent Application No. 15 / 559,308, filed Sep. 18, 2017, entitled "VAPORIZER FOR VAPORIZING AN ACTIVE AEROSOL" (Attorney Docket No. 24000NV-000521-US); U.S. Patent Application No. 15 / 559,308, filed Sep. 18, 2017, entitled "VAPORIZER FOR VAPORIZING AN ACTIVE AEROSOL" (Attorney Docket No. 24000DM-000012-US); No. 16 / 909,131, filed June 23, 2020, entitled "CASULES INCLUDING INTERNAL HEATERS, HEAT-NOT-BURN (HNB) AEROSOL-GENERATING DEVICES, AND METHODS OF GENERATING AN AEROSOL" (Attorney Docket No. 24000NV-000603-US).The disclosures of the above applications are incorporated herein by reference in their entireties.

[0152] Although a number of exemplary embodiments have been described herein, it should be understood that other variations are possible, and such variations should not be considered a departure from the spirit and scope of the disclosure, and it is intended that all modifications obvious to those skilled in the art be included within the scope of the following claims.

Claims

1. A capsule for an aerosol generating device, comprising a housing defining at least one air inlet and at least one air outlet, said housing including a first frame defining a cavity, said first frame being an inner frame, said first frame comprising a first surface, a second surface, a first end face, a second end face, a first side face, a second side face, and said at least one air inlet extends through said first end face of said first frame, said at least one air inlet being on the opposite side of said at least one air outlet, a housing; an aerosol generating substance at least partially within said cavity, a heater supported by said first frame and extending across at least a portion of said cavity, comprising a housing including said at least one air inlet, said cavity, and said at least one air outlet together form at least one air flow path through said capsule, said air flow path being longer than the thickness of said capsule so that air flows longitudinally through said heater and said aerosol generating substance to increase the contact range between said heater and said aerosol generating substance, said at least one air inlet includes a first air inlet and a second air inlet, said first air inlet extends through said first side face of said inner frame, said second air inlet extends through said first end face of said inner frame, and said at least one air outlet extends through said second end face of said inner frame, a capsule.

2. The capsule according to claim 1, wherein said aerosol generating substance comprises a plant material.

3. The capsule according to claim 2, wherein said plant material comprises tobacco.

4. A diffuser configured to redirect air from the at least one air inlet toward the at least one air outlet, the diffuser further comprising a diffuser including at least one channel within the first surface of the inner frame, the capsule according to claim 1.

5. A capsule for an aerosol generating device, A housing defining at least one air inlet and at least one air outlet, the housing including a first frame defining a cavity, the first frame being an inner frame, the first frame including: A first surface, A second surface, A first end face, A second end face, A first side face, A second side face, And the at least one air inlet extends through the first end face of the first frame, the at least one air inlet being on the opposite side of the at least one air outlet, the housing; An aerosol generating substance at least partially within the cavity, A heater supported by the first frame and extending across at least a portion of the cavity, Including a housing including, The at least one air inlet, the cavity, and the at least one air outlet together form at least one air flow path through the capsule, and the air flow path is longer than the thickness of the capsule so that air flows longitudinally through the heater and the aerosol generating substance to increase the contact range between the heater and the aerosol generating substance, Including a diffuser configured to redirect air from the at least one air inlet toward the at least one air outlet, The diffuser is, A main channel extending longitudinally from the at least one air inlet, At least one secondary channel in fluid communication with the main channel, A capsule comprising. **Claim 6** The capsule according to claim 5, wherein the at least one secondary channel includes at least one parallel channel parallel to the main channel and at least one angled channel having an angle with respect to the main channel. **Claim 7** The capsule according to claim 1, wherein the heater has a serpentine shape. **Claim 8** A capsule assembly for an aerosol generating device, A capsule, A housing including a first frame defining a cavity, the first frame being an inner frame, the first frame having A first surface, A second surface, A first end face, A second end face, A first side face, A second side face, Including a housing, An aerosol product substance at least partially within the cavity, A heater supported by the inner frame and extending across at least a portion of the cavity, A capsule including. A capsule enclosure surrounding at least a part of the housing, wherein the capsule enclosure defines at least one air inlet and at least one air outlet, and the at least one air inlet, the cavity, and the at least one air outlet together form at least one air flow path through the capsule assembly, and the air flow path is longer than the thickness of the capsule so that air flows longitudinally through the heater and the aerosol generating material to lengthen the contact range between the heater and the aerosol generating material, the at least one air inlet includes a first air inlet and a second air inlet, the first air inlet extends through the first side surface of the inner frame, the second air inlet extends through the first end surface of the inner frame, and the at least one air outlet extends through the second end surface of the inner frame, the capsule enclosure and, A capsule assembly including.

9. The capsule assembly according to claim 8, wherein the capsule enclosure further includes a capsule enclosure air flow channel extending between the at least one air inlet and the at least one air outlet, and the capsule enclosure air flow channel defines a part of the at least one air flow path.

10. The capsule assembly according to claim 8, wherein the at least one air flow path extends along a diagonal line of at least a part of the cavity of the first frame.

11. The capsule assembly according to claim 8, wherein the at least one air flow path extends along a diagonal line of at least a part of the heater and the aerosol generating material.

12. An aerosol generating device, A device body configured to receive a capsule, wherein the capsule is, A housing including a first frame defining a cavity, at least one air inlet, and at least one air outlet, wherein the first frame is an inner frame, and the first frame includes a first surface, a second surface, a first end face, a second end face, a first side face, a second side face, and the at least one air inlet extends through the first end face of the first frame, and the at least one air inlet is on the opposite side of the at least one air outlet, the housing; an aerosol product substance at least partially within the cavity, a heater supported by the first frame and extending across at least a portion of the cavity; comprising, the at least one air inlet, the cavity, and the at least one air outlet together form at least one air flow path through the capsule, and the air flow path is longer than the thickness of the capsule so that air flows longitudinally through the heater and the aerosol product substance to increase the contact range between the heater and the aerosol product substance, the at least one air inlet includes a first air inlet and a second air inlet, the first air inlet extends through the first side face of the inner frame, the second air inlet extends through the first end face of the inner frame, and the at least one air outlet extends through the second end face of the inner frame, a plurality of electrodes within the device body, the plurality of electrodes configured to be in electrical contact with the heater of the capsule; a power source configured to supply current to the heater of the capsule via the plurality of electrodes; an aerosol generating device comprising.

13. The aerosol generating device according to claim 12, wherein the aerosol generating substance contains plant material.

14. The aerosol generating device according to claim 13, wherein the plant material contains tobacco.

15. The aerosol generating device according to claim 13, wherein the capsule is a diffuser configured to redirect air from the at least one air inlet towards the at least one air outlet, and further includes a diffuser including at least one channel within the first surface of the inner frame.

16. An aerosol generating device, A device body configured to receive a capsule, wherein the capsule Is a housing including a first frame defining a cavity, at least one air inlet, and at least one air outlet, wherein the first frame is an inner frame, and the first frame Has a first surface, A second surface, A first end face, A second end face, A first side face, A second side face, And the at least one air inlet extends through the first end face of the first frame, and the at least one air inlet is on the opposite side of the at least one air outlet, the housing, An aerosol generating substance at least partially within the cavity, A heater supported by the first frame and extending across at least a portion of the cavity, Including, The at least one air inlet, the cavity, and the at least one air outlet together form at least one air flow path through the capsule, and the air flow path is longer than the thickness of the capsule so that air flows longitudinally within the heater and the aerosol generating material to increase the contact range between the heater and the aerosol generating material. including a diffuser configured to redirect air from the at least one air inlet toward the at least one air outlet; wherein the diffuser comprises a main channel extending longitudinally from the at least one air inlet, and at least one secondary channel in fluid communication with the main channel; and a plurality of electrodes within the device body, the plurality of electrodes being configured to make electrical contact with the heater of the capsule; a power source configured to supply an electric current to the heater of the capsule via the plurality of electrodes; An aerosol generating device comprising. **Claim 17** The aerosol generating device according to claim 16, wherein the at least one secondary channel includes at least one parallel channel parallel to the main channel and at least one angled channel having an angle with respect to the main channel. **Claim 18** A method of generating an aerosol, comprising Electrically contacting a plurality of electrodes to a capsule, the capsule including a housing, the housing including an inner frame, the inner frame including a first surface, a second surface, a first end face, a second end face, a first side face, and a second side face, the housing defining a cavity, at least one air inlet, and at least one air outlet, the at least one air inlet extending through the first end face of the inner frame, the at least one air inlet being on the opposite side of the at least one air outlet, the at least one air inlet including a first air inlet and a second air inlet, the first air inlet extending through the first side face of the inner frame, the second air inlet extending through the first end face of the inner frame, and the at least one air outlet extending through the second end face of the inner frame, the capsule including an aerosol generating substance at least partially within the cavity and a heater supported by the inner frame and extending across at least a portion of the cavity, and the at least one air inlet, the cavity, and the at least one air outlet together forming at least one air flow path through the capsule, the air flow path being longer than the thickness of the capsule such that air flows longitudinally through the heater and the aerosol generating substance to increase the contact range between the heater and the aerosol generating substance, electrically contacting a plurality of electrodes to the capsule and, Supplying an electric current to the heater of the capsule via the plurality of electrodes; A method comprising.

Images