Heat-not-burn device and flavor carrier

Abstract

To provide a flavor carrier for an aerosol-generating device.SOLUTION: A flavor carrier 760 includes an outer housing 765 extending in a longitudinal direction, an inner housing 780 extending in the longitudinal direction, and a flavor chamber 790 disposed between the outer housing and the inner housing. The outer housing includes at least one outer housing perforation 770 defined in the wall 775 of the outer housing. The inner housing includes at least one inner housing perforation 785 defined in the wall 792 of the inner housing. The flavor chamber is configured to contain a flavoring material 795.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] [CROSS REFERENCE TO RELATED APPLICATIONS] This application claims priority to U.S. Application No. 16 / 375,191, filed April 4, 2019, the entire contents of which are incorporated herein by reference.

[0002] The present disclosure relates to capsules, heat-not-burn (HNB) aerosol generators, and methods for generating aerosols without substantial thermal decomposition of the aerosol-generating substrate. [Background technology]

[0003] Some electronic devices are configured to heat the plant material to a temperature sufficient to release components of the plant material while maintaining a temperature below the combustion point of the plant material to avoid substantial thermal decomposition of the plant material. Such devices may be referred to as aerosol generating devices (e.g., heat-not-burn aerosol generating devices), and the plant material to be heated may be tobacco. In some examples, the plant material may be introduced directly into the chamber of the aerosol generating device. In other examples, the plant material may be prepackaged in individual containers for ease of insertion into and removal from the aerosol generating device.

[0004] [Summary] At least one exemplary embodiment relates to a flavor carrier for an aerosol generating device.

[0005] In at least one exemplary embodiment, a flavor carrier for an aerosol generating device includes a longitudinally extending outer housing, a longitudinally extending inner housing, and a flavor chamber between the outer housing and the inner housing. The outer housing includes at least one outer housing perforation defined in an outer housing wall. The inner housing is coaxially disposed with the outer housing. The inner housing includes at least one inner housing perforation defined in an inner housing wall. The flavor chamber is configured to contain a flavor material.

[0006] In at least one exemplary embodiment, an adapter is on an end of the flavor carrier. The adapter is configured to secure the flavor carrier within the aerosol generating device. The adapter defines a channel therein. The channel is in fluid communication with an air passage defined in the inner housing. The adapter is formed of at least one of a polymer and a metal, and the adapter is substantially impermeable to the aerosol.

[0007] In at least one exemplary embodiment, the flavor carrier further comprises a gasket at a second end of the flavor carrier, the gasket being substantially impermeable to aerosols, the gasket being formed of at least one of a polymer and a metal.

[0008] In at least one exemplary embodiment, the outer housing has an outer diameter ranging from about 3.0 mm to about 10.0 mm, or from about 3.0 mm to about 5.0 mm. The inner housing has an outer diameter ranging from about 1.0 mm to about 3.0 mm.

[0009] In at least one exemplary embodiment, the flavor material comprises at least one of a botanical material, a gel, a film, and flavor beads.

[0010] In at least one exemplary embodiment, at least one of the outer housing wall and the inner housing wall has a thickness in a range of about 0.5 mm to about 1.5 mm, and at least one of the outer housing wall and the inner housing wall is formed from at least one of paper, cloth, metal, and polymer.

[0011] At least one exemplary embodiment relates to an aerosol generating device.

[0012] In at least one exemplary embodiment, an aerosol generating device includes a plant material, a heating element configured to heat the plant material, and a flavor carrier. The flavor carrier includes a longitudinally extending outer housing, a longitudinally extending inner housing, and a flavor chamber between the outer housing and the inner housing. The outer housing includes at least one outer housing perforation defined in an outer housing wall. The inner housing is coaxially disposed with the outer housing. The inner housing includes at least one inner housing perforation defined in an inner housing wall. The flavor chamber is configured to contain a flavor material. [Brief description of the drawings]

[0013] Various features and advantages of the non-limiting embodiments herein will become more apparent upon consideration of the detailed description in conjunction with the accompanying drawings. The accompanying drawings are provided for illustrative purposes only and should not be construed as limiting the scope of the claims. The accompanying drawings are not to be considered as drawn to scale unless explicitly stated. Various dimensions of the drawings may be exaggerated for clarity.

[0014] [Figure 1] FIG. 1 is a schematic diagram of an aerosol generating device according to one example embodiment.

[0015] [Diagram 2]FIG. 2 is a cross-sectional view of a flavor carrier and a mouthpiece of the aerosol generating device of FIG. 1 according to at least one exemplary embodiment.

[0016] [Diagram 3] FIG. 3 is a perspective view of a flavor carrier of an aerosol generating device in accordance with at least one exemplary embodiment.

[0017] [Figure 4] FIG. 4 is a perspective view of a flavor carrier of an aerosol generating device in accordance with at least one exemplary embodiment.

[0018] [Diagram 5] FIG. 5 is a perspective view of a flavor carrier of an aerosol generating device in accordance with at least one exemplary embodiment.

[0019] [Figure 6] FIG. 6 is a perspective view of a flavor carrier of an aerosol generating device in accordance with at least one exemplary embodiment.

[0020] [Figure 7] FIG. 7 is a perspective view of a flavor carrier of an aerosol generating device in accordance with at least one exemplary embodiment.

[0021] [Figure 8] FIG. 8 is a perspective view of a flavor carrier of an aerosol generating device in accordance with at least one exemplary embodiment.

[0022] [Figure 9] FIG. 9 is a perspective view of a flavor carrier of an aerosol generating device in accordance with at least one exemplary embodiment.

[0023] [Figure 10] FIG. 10 is a perspective view of a flavor carrier of an aerosol generating device in accordance with at least one exemplary embodiment.

[0024] [Figure 11] FIG. 11 is a cross-sectional view of the flavor cartridge of FIG. 1 along line XI-XI according to at least one exemplary embodiment.

[0025] [Figure 12] FIG. 12 is a cross-sectional view of a flavor cartridge along line XI-XI in accordance with at least one exemplary embodiment.

[0026] [Figure 13] FIG. 13 is a perspective view of a flavor cartridge in accordance with at least one exemplary embodiment.

[0027] [Figure 14] FIG. 14 is a schematic diagram illustrating the flow of air through an aerosol generating device including a flavor carrier according to at least one exemplary embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0028] [Detailed explanation] Several detailed exemplary embodiments are disclosed herein. However, the specific structural and functional details disclosed herein are merely representative for purposes of describing the exemplary embodiments. However, the exemplary embodiments may be embodied in many alternative forms and should not be construed as being limited to only the exemplary embodiments described herein.

[0029] Thus, while exemplary embodiments are susceptible to various modifications and alternative forms, exemplary embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that 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 alternatives thereof. Like numbers refer to like elements throughout the description of the figures.

[0030] When an element or layer is referred to as being "on," "connected to," "coupled to," "attached to," "adjacent to," or "covering" another element or layer, it should be understood that it may be directly connected to, coupled to, attached to, adjacent to, or covering the other element or layer, or that intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly connected to," or "directly coupled to" another element or layer, there are no intervening elements or layers. As used herein, like numbers refer to like elements. As used herein, the term "and / or" includes any and all combinations or subcombinations of one or more of the associated listed items.

[0031] In this specification, terms such as first, second, third, etc. may be used to describe various elements, regions, layers, and / or sections, but it should be understood that these elements, regions, layers, and / or sections should not be limited by these terms. These terms are used only to distinguish one element, region, layer, or section from another region, layer, or section. Thus, a first element, region, layer, or section described below can be referred to as a second element, region, layer, or section without departing from the teachings of the exemplary embodiments.

[0032] For ease of description, spatially relative terms (e.g., "beneath," "below," "lower," "above," "upper," etc.) may be used herein to describe the relationship of one element or feature to another element or feature as depicted in the figures. It should be understood that the spatially relative terms are intended to encompass different orientations of the device during use and operation in addition to the orientation depicted in the figures. For example, if a device in the figures were turned over, elements described as "below" or "beneath" other elements or features would be oriented "above" the other elements or features. Thus, the term "below" may encompass both an orientation of above and below. Also, the device may be otherwise oriented (rotated 90 degrees, oriented in other directions), and the spatially relative descriptors used herein would be interpreted accordingly.

[0033] The terms used herein are for the purpose of describing various exemplary embodiments only and are not intended to limit the exemplary embodiments. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms unless the context clearly indicates otherwise. It will be further understood that the terms "includes," "including," "comprises," and / or "comprising," as used herein, specify the presence of stated features, integers, steps, operations, and / or elements, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, and / or groups thereof.

[0034] In this specification, when the words "about" and "substantially" are used in connection with numerical values, unless expressly defined otherwise, the associated numerical value is intended to include a tolerance of ±10% around the stated numerical value.

[0035] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by a person of ordinary skill in the art to which the illustrated embodiment belongs. Furthermore, terms, including those defined in commonly used dictionaries, should be interpreted as having a meaning consistent with the meaning in the context of the relevant art, and will not be interpreted in an idealized or overly formal sense unless expressly defined herein.

[0036] FIG. 1 is a schematic diagram of an aerosol generating device according to one example embodiment.

[0037] 1, an aerosol generating device 1000 (e.g., a Heat-Not-Burng (HNB) AEROSOL-GENERATING DEVICE) may include a mouthpiece 1015 and a device body 1025. A power source 1035 and control circuitry 1045 may be disposed within the device body 1025 of the aerosol generating device 1000. The aerosol generating device 1000 is configured to receive a capsule 1020, which may include a plant material such as tobacco, as described in U.S. Patent Application No. 16 / 252,951, filed January 21, 2019, entitled “CAPSULES, HEAT-NOT-BURNG (HNB) AEROSOL-GENERATING DEVICES, AND METHODS OF GENERATING AN AEROSOL,” the entire contents of which are incorporated herein by reference.

[0038] As described herein, an aerosol-generating substrate is a material or combination of materials that may be converted into an aerosol. Aerosol refers to a substance that is generated or emitted by the disclosed and claimed devices, and equivalents thereof. The material may include a compound (e.g., nicotine, cannabinoids), and when the material is heated, an aerosol containing the compound is generated. The heating may be below combustion temperatures to generate the aerosol without substantial thermal decomposition of the aerosol-generating substrate or substantial generation of combustion by-products (if any). Thus, in exemplary embodiments, no thermal decomposition occurs during heating and the resulting generation of the aerosol. In other instances, there may be thermal decomposition and combustion by-products, but the extent is considered to be relatively minor and / or merely incidental.

[0039] The aerosol-generating substrate may be a fibrous material. For example, the fibrous material may be a plant material. The fibrous material is configured to release a compound when heated. The compound may be a naturally occurring component of the fibrous material. For example, the fibrous material may be 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, formed tobacco, or powdered tobacco, and combinations thereof, from one or more species of tobacco plants, such as Nicotiana rustica and Nicotiana tabacum.

[0040] In some exemplary embodiments, the tobacco material may include material from any member of the Nicotiana genus. Additionally, the tobacco material may include a blend of two or more different tobacco varieties. Examples of suitable types of tobacco material that may be used include, but are not limited to, flue-cured tobacco, burley tobacco, dark tobacco, Maryland tobacco, Oriental tobacco, rare tobacco, specialty tobacco, blends thereof, and the like. The tobacco material may be provided in any suitable form, including, but not limited to, tobacco lamina, processed tobacco material such as volume expanded tobacco or puffed tobacco, processed tobacco stems such as cut roll or cut puffed stems, reconstituted tobacco material, blends thereof, and the like. In some exemplary embodiments, the tobacco material is in the form of a substantially dried tobacco mass. Additionally, in some examples, the tobacco material may be mixed and / or combined with at least one of propylene glycol, glycerin, subcombinations thereof, or combinations thereof.

[0041] The compound may also be a natural component of a medicinal plant that has a medically recognized therapeutic effect. For example, the medicinal plant may be cannabis and the compound may be a cannabinoid. Cannabinoids interact with receptors in the body to produce a variety of effects. As a result, cannabinoids are used for a variety of medicinal uses (e.g., treating pain, nausea, epilepsy, and psychiatric disorders). The fibrous material may include leaf and / or flower material of one or more species of cannabis plants, such as Cannabis sativa, Cannabis indica, and Cannabis ruderalis. In some examples, the fibrous material is a mixture of 60-80% (e.g., 70%) Cannabis sativa and 20-40% (e.g., 30%) Cannabis indica.

[0042] Examples of cannabinoids include tetrahydrocannabinolic acid (THCA), tetrahydrocannabinol (THC), cannabidiol acid (CBDA), cannabidiol (CBD), cannabinol (CBN), cannabicyclo (CBL), cannabichromene (CBC), cannabigerol (CBG), etc. 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) may be converted to tetrahydrocannabinol (THC) and cannabidiol (CBD), respectively, via heating. In an exemplary embodiment, heat from first heater 110 and / or second heater 120 may cause decarboxylation to convert tetrahydrocannabinolic acid (THCA) in capsule 100 to tetrahydrocannabinol (THC) and / or to convert cannabidiol acid (CBDa) in capsule 100 to cannabidiol (CBD).

[0043] In the case where both tetrahydrocannabinolic acid (THCA) and tetrahydrocannabinol (THC) are present in the capsule 100, decarboxylation and the resulting conversion reduces tetrahydrocannabinolic acid (THCA) and increases tetrahydrocannabinol (THC). At least 50% (e.g., at least 87%) of the tetrahydrocannabinolic acid (THCA) may be converted to tetrahydrocannabinol (THC) during heating of the capsule 100. Similarly, in the case where both cannabidiolic acid (CBDA) and cannabidiol (CBD) are present in the capsule 100, decarboxylation and the resulting conversion reduces cannabidiolic acid (CBDA) and increases cannabidiol (CBD). At least 50% (e.g., at least 87%) of the cannabidiol acid (CBDA) may be converted to cannabidiol (CBD) during heating of the capsule 100.

[0044] Alternatively, the compound may be a non-naturally occurring additive that is subsequently introduced into the fibrous material. In such an example, the fibrous material may comprise at least one of cotton, polyethylene, polyester, rayon, combinations thereof, and the like (e.g., in the form of gauze). In another example, the fibrous material may be a cellulosic material, and the compound introduced may be a flavorant from nicotine, cannabinoids, and / or plant extracts (e.g., tobacco extract, cannabis extract).

[0045] In at least one exemplary embodiment, the aerosol generating device 1000 may also include a first electrode 1055a, a second electrode 1055b, a third electrode 1055c, and a fourth electrode 1055d configured to electrically contact the capsule 1020. In at least one exemplary embodiment, the first electrode 1055a and the third electrode 1055c may be in electrical contact with the first heater 110a, and the second electrode 1055b and the fourth electrode 1055d may be in electrical contact with the second heater 110b. However, it should be understood that in non-limiting embodiments including a capsule having only one heater, the first electrode 1055a and the third electrode 1055c (or the second electrode 1055b and the fourth electrode 1055d) may be omitted.

[0046] When the capsule 1020 is inserted into the aerosol generating device 1000, the control circuitry 1045 may instruct the power source 1035 to supply current to the first electrode 1055a, the second electrode 1055b, the third electrode 1055c, and / or the fourth electrode 1055d. The supply of current from the power source 1035 may be in response to manual operation (e.g., button activation) or automatic operation (e.g., puff activation). As a result of the current, the capsule 1020 may heat up and generate an aerosol. Additional details of the aerosol generating device 1000, including the capsule 1020, mouthpiece 1015, device body 1025, power source 1035, control circuitry 1045, first electrode 1055a, second electrode 1055b, third electrode 1055c, and fourth electrode 1055d, are described in U.S. Application No. 15 / 845,501, entitled "VAPORIZING DEVICES AND METHODS FOR DELIVERING A COMPOUND USING THE SAME," filed on December 18, 2017 (Atty. Dkt. No. 24000DM-000012-US), the disclosure of which is incorporated herein by reference in its entirety.

[0047] In at least one exemplary embodiment, as shown in FIG. 1, the aerosol generating device 1000 may also include a flavor carrier 760. The flavor carrier 760 may include a longitudinally extending outer housing 765, a longitudinally extending inner housing 780, and a flavor chamber 790 between the outer housing 765 and the inner housing 780. The outer housing 765 and / or the inner housing 780 may be generally cylindrical. In other exemplary embodiments, the cross-section of the outer housing 765 and / or the inner housing 780 may be generally elliptical, rectangular, square, triangular, polygonal, and / or have any other cross-sectional shape. In some exemplary embodiments, the cross-section of the outer housing 765 may be generally the same shape as the cross-section of the inner housing 780. In some exemplary embodiments, the cross-section of the outer housing 765 may have a different shape than the cross-section of the inner housing 780. The outer housing 765 includes at least one outer housing perforation 770 defined in a wall 775 of the outer housing 765. In at least one exemplary embodiment, the inner housing 780 may be coaxial with the outer housing 765. In other exemplary embodiments, the inner housing 780 is not coaxial with the outer housing 765. In some exemplary embodiments, the inner housing 780 is within the outer housing 765. In some exemplary embodiments, at least a portion of the inner housing 780 is within at least a portion of the outer housing 765. In some exemplary embodiments, the cross-sectional area of ​​the inner housing 780 is smaller than the cross-sectional area of ​​the outer housing 765. In some exemplary embodiments, the cross-sectional area of ​​the inner housing 780 is generally circular, the cross-sectional area of ​​the outer housing 765 is generally circular, and the cross-sectional diameter of the inner housing 780 is smaller than the cross-sectional diameter of the outer housing 765. In other exemplary embodiments, other arrangements or variations may be used. The inner housing 780 includes at least one inner housing perforation 785 defined in a wall 792 of the inner housing 780. The flavor chamber 790 is configured to receive a flavor material 795.

[0048] In at least one exemplary embodiment, an adapter 797 is at the end of the flavor carrier 760. The adapter 797 is configured to secure the flavor carrier 760 within the device body 1025 of the aerosol generation device 1000. The adapter 797 may be a ring-shaped body that fits snugly over the exterior surface of the outer housing 765 of the flavor carrier 760. The adapter 797 is sized to provide a friction fit between the outer housing 765 of the flavor carrier 760 and the inner surface 700 of the device body 1025 of the aerosol generation device 1000.

[0049] In at least one exemplary embodiment, the adapter 797 is formed of one or more materials including a polymer, a metal, a subcombination thereof, or a combination thereof. Because the adapter 797 is substantially impermeable to the aerosol, the aerosol is forced to flow through the flavor carrier 760 where aromas and / or flavors from the flavor material 795 are eluted into the aerosol.

[0050] In at least one exemplary embodiment, the outer housing 765 of the flavor carrier 760 is a hollow cylinder having an outer diameter in the range of about 3.0 mm to about 10.0 mm (e.g., about 3.0 mm to about 5.0 mm, about 3.5 mm to about 4.5 mm, or about 3.75 mm to about 4.25 mm, etc.). In other exemplary embodiments, the outer housing 765 of the flavor carrier 760 is a hollow cylinder having an outer diameter less than about 3.0 mm, or greater than or equal to about 10.0 mm.

[0051] In at least one exemplary embodiment, the inner housing 780 is a hollow cylinder having an outer diameter in the range of about 1.0 mm to about 3.0 mm (e.g., about 1.5 mm to about 2.5 mm, about 1.75 mm to about 2.25 mm, etc.). In other exemplary embodiments, the inner housing 780 of the flavor carrier 760 is a hollow cylinder having an outer diameter of less than about 1.0 mm, or about 3.0 mm or greater. The diameters of the inner housing 780 and the outer housing 765 may be selected to provide a desired volume of the flavor chamber 790 defined between the inner housing 780 and the outer housing 765.

[0052] In at least one exemplary embodiment, the wall 775 of the outer housing 765 and the wall 792 of the inner housing 780, or each, have a thickness in a range from about 0.5 mm to about 1.5 mm (e.g., from about 0.75 mm to about 1.25 mm). In some exemplary embodiments, the wall 775 and / or the wall 792 have a thickness less than about 0.5 mm or greater than about 1.5 mm. In some exemplary embodiments, the wall 775 of the outer housing 765 and the wall 792 of the inner housing 780, or both, are formed of one or more materials including paper, cloth, metal, polymer, and / or any other suitable material.

[0053] In at least one exemplary embodiment, the flavoring material 795 includes botanical materials, gels, films, flavor bits, powders, compressed powder discs, flavor beads, and / or any other flavoring materials. In some exemplary embodiments, the botanical materials can include tobacco botanical materials, cannabis botanical materials, and / or other botanical materials. In other exemplary embodiments, the botanical materials can include non-tobacco botanical materials, such as teas, herbs, and the like.

[0054] In some exemplary embodiments, the flavoring material 795 may include a gel. The gel may include a polymer, one or more flavorants and / or botanicals suspended in the gel.

[0055] In other exemplary embodiments, the flavor material 795 may include a film. The film may be formed of at least one polymer and one or more flavorants. The film or films may be within the flavor chamber 790 and wrapped around the inner housing 780 and / or may be provided in the form of a tube such that the tube is inserted within the flavor chamber 790 around the inner housing 780. In some examples, the film may be water-soluble and / or may disintegrate upon exposure to heat such that the film disintegrates as the aerosol passes through the flavor chamber 790. In other examples, the film may be porous. Other types of films may be used.

[0056] In some exemplary embodiments, the flavoring material 795 includes flavor beads that include at least one polymer and at least one flavorant. The flavoring beads may include an outer shell surrounding an inner core. The inner core and / or the outer shell may include menthol or other volatile flavors. For example, the inner core may include a mint flavor, such as peppermint, spearmint, or other flavors.

[0057] In at least one exemplary embodiment, the flavor beads can each have a diameter ranging from about 0.5 mm to about 5 mm (e.g., from about 1 mm to about 4 mm, from about 2 mm to about 3 mm, etc.). In other exemplary embodiments, the flavor beads can each have a diameter less than about 0.5 mm and greater than about 5 mm. The flavor beads can be manufactured to include the features of the flavor beads and / or flavor capsules disclosed in U.S. Patent No. 7,878,962, issued February 1, 2011 to Karles et al., and U.S. Patent No. 7,578,298, issued August 25, 2009 to Karles et al., the entire contents of each of which are incorporated herein by reference.

[0058] In at least one exemplary embodiment, the flavoring material 795 is in the form of a paper impregnated and / or coated with one or more flavorants.

[0059] In some exemplary embodiments, if the flavor material 795 is a film or paper, the film or paper may be shredded before being placed in the flavor chamber 790. In some exemplary embodiments, the shredded film or paper may be mixed with at least one botanical material and / or flavor beads.

[0060] In at least one exemplary embodiment, the flavor material 795 may be coated with a second material comprising at least one polymer and / or flavor valant. The flavor valant of the coating may be the same flavor valant incorporated in the flavor material 795 underlying the coating, or the flavor valant of the coating may be a different flavor valant than the flavor valant of the flavor material 795 underlying the coating. In at least one exemplary embodiment, the flavor material 795 comprises a cellulosic material having one or more flavor valant(s).

[0061] In at least one exemplary embodiment, the flavor valant is a volatile flavor valant. In at least one exemplary embodiment, the flavor valant may be any flavor valant commonly used in foods, confectionery, or other oral products. Exemplary flavor valant includes, but is not limited to, berry flavors such as pomegranate, acai, raspberry, blueberry, strawberry, boysenberry, and cranberry. Other exemplary flavor valant includes, but is not limited to, menthol, peppermint, spearmint, wintergreen, bourbon, scotch, whiskey, cognac, hydrangea, lavender, chocolate, licorice, citrus and other fruit flavors such as apple, peach, pear, cherry, plum, orange, lime, grape, and grapefruit, gamma octalactone, vanillin, ethyl vanillin, breath flavors, butter, rum, coconut, almond, pecan, walnut, hazelnut, French vanilla, macadamia, sugar cane, Natural or synthetic flavors and aromas include maple, blackcurrant, caramel, banana, malt, espresso, Kahlua, white chocolate, spice flavors such as cinnamon, clove, coriander, basil, oregano, garlic, mustard, nutmeg, rosemary, thyme, tarragon, dill, sage, anise, and fennel, methyl salicylate, linalool, jasmine, coffee, olive oil, sesame oil, sunflower oil, bergamot oil, geranium oil, lemon oil, ginger oil, balsamic vinegar, rice wine vinegar, red wine vinegar, etc. Flavoring Ingredients 795 may contain one or more flavorants.

[0062] In at least one exemplary embodiment, the flavoring material 795 includes a polymer, which is a water soluble or water insoluble polymer. The polymer may be natural or synthetic. The polymer may be a hydrocolloid. Other exemplary polymers include, but are not limited to, starch, dextrin, gum arabic, guar gum, chitosan, cellulose, polyvinyl alcohol, polylactide, gelatin, soy protein, whey protein, and the like.

[0063] FIG. 2 is a cross-sectional view of a flavor carrier and a mouthpiece of an aerosol generating device in accordance with at least one exemplary embodiment.

[0064] In at least one exemplary embodiment, the flavor carrier 760 and the mouthpiece 800 may be joined such that the adapter 797 surrounds a portion of the flavor carrier 760 and the mouthpiece 800 mates with an end of the adapter 797 .

[0065] In at least one exemplary embodiment, mouthpiece 800 is formed of materials including plastic, metal, wood, and / or other suitable materials. In at least one exemplary embodiment, mouthpiece 800 is formed of at least one plastic material, such as polyethylene or polypropylene. Mouthpiece 800 may be rounded and may not include sharp edges. In other examples, the cross-section of mouthpiece 800 may be generally rectangular, oval, square, triangular, polygonal, and / or have any other cross-sectional shape. In some exemplary embodiments, mouthpiece 800 may include sharp edges. In some examples, the surface of mouthpiece 800 may be generally smooth.

[0066] The adapter 797 is generally U-shaped and cylindrical such that the flavor carrier 760 fits within the adapter 797. A bottom wall 910 of the adapter 797 defines a channel 900 that directs the aerosol into the flavor carrier 760 when the flavor carrier 760 and the adapter 797 are engaged with the device body 1025 of the aerosol generation device 1000. The adapter 797 also includes a flange portion 920 that engages with the device body 1025 of the aerosol generation device 1000. Thus, the flavor carrier 765 of FIG. 2 can be retrofitted to the aerosol generation device 1000 by removing the existing mouthpiece and inserting the adapter 797 into the housing of the aerosol generation device 1000.

[0067] FIG. 3 is a perspective view of a flavor carrier of an aerosol generating device in accordance with at least one exemplary embodiment.

[0068] In at least one exemplary embodiment, as shown in FIG. 3, the flavor carrier 760 is generally the same as in FIGS. 1 and 2, except that the perforations 785 in the wall 792 of the inner housing 780 are aligned with the perforations 770 in the wall 775 of the outer housing 765. The perforations 785 and the perforations 770 may be arranged in a row. In other exemplary embodiments, the perforations 785 in the wall 792 of the inner housing 780 are not aligned with the perforations 770 in the wall 775 of the outer housing 765. In some exemplary embodiments, the wall 792 and / or the wall 775 may each include 1 to about 20 rows of perforations 770, 785 (e.g., about 2 to about 18, about 4 to about 16, about 6 to about 14, about 8 to about 12, or about 10 to about 12). In some exemplary embodiments, the wall 792 and / or the wall 775 may each include 20 or more rows. In some exemplary embodiments, each row of perforations 770, 785 in wall 792 and / or wall 775 may include 1 to about 20 perforations 770, 785 (e.g., about 2 to about 18, about 4 to about 16, about 6 to about 14, about 8 to about 12, or about 10 to about 12). In some exemplary embodiments, each row of perforations 770, 785 in wall 792 and / or wall 775 may include 20 or more perforations. The perforations 770, 785 may be the same size or different sizes. The perforations 770, 785 may be generally circular in shape, triangular, rectangular, oval, square, polygonal, or other shapes in some exemplary embodiments. The perforations 770 may be the same or different size and / or shape as the perforations 785. In some exemplary embodiments, the perforations 770, 785 may be larger at a first end of the flavor carrier 760 than at a second end of the flavor carrier 760. In at least one exemplary embodiment, the perforations 770, 785 in the center of the flavor carrier 760 may be larger or smaller than the perforations 770, 785 at either end of the flavor carrier. In at least one exemplary embodiment, each perforation 770, 785 has substantially the same diameter (e.g., from about 0.1 mm in diameter to about 5.0 mm in diameter).

[0069] FIG. 4 is a perspective view of a flavor carrier of an aerosol generating device in accordance with at least one exemplary embodiment.

[0070] In at least one exemplary embodiment, as shown in FIG. 4, the flavor carrier 760 is generally similar to FIGS. 1 and 2, except that the adapter 797 is in the form of a cover 1100 that is disposed over an end of the flavor carrier 760. The cover 1100 also defines a channel 1110 therein. The aerosol is directed into the inner housing 780 and then through perforations 785 in a wall 792 of the inner housing 780 and into the flavor chamber 790. The aerosol may then exit the flavor chamber 790 via perforations 770 provided in a wall 775 of the outer housing 765.

[0071] FIG. 5 is a perspective view of a flavor carrier of an aerosol generating device in accordance with at least one exemplary embodiment.

[0072] In at least one exemplary embodiment, as shown in FIG. 5, the flavor carrier 760 is generally similar to FIGS. 1 and 2, except that it further comprises a gasket 1200 at a second end of the flavor carrier 760. The gasket 1200 is substantially impermeable to aerosols so as to force the aerosols through perforations 770 in a wall 775 of an outer housing 765 of the flavor carrier 760. The gasket 1200 is formed of one or more materials including polymers, metals or combinations thereof, and / or other suitable materials. In at least one exemplary embodiment, the gasket 1200 is formed of one or more materials including food grade generally recognized as safe (GRAS) materials.

[0073] FIG. 6 is a perspective view of a flavor carrier of an aerosol generating device in accordance with at least one exemplary embodiment.

[0074] In at least one exemplary embodiment, the mouthpiece 800 fits around an end portion of the flavor carrier 760, as shown in FIG.

[0075] FIG. 7 is a perspective view of an outer housing of a flavor carrier in accordance with at least one exemplary embodiment.

[0076] In at least one exemplary embodiment, the perforations 770 in the outer housing 765 are elongated and extend parallel to the longitudinal direction of the flavor carrier 760. As shown, the perforations 770 may be generally rectangular in shape. In at least one exemplary embodiment, the perforations 785 in the inner housing 780, not shown, may be the same as or different from the perforations 770 shown in FIG. 7, e.g., in shape, size, and / or pattern. The perforations 785 may be aligned with the perforations 770 and may be approximately the same size. In other exemplary embodiments, the perforations 785 may have a different size and / or may not be aligned with the perforations 770.

[0077] FIG. 8 is a perspective view of a flavor carrier of an aerosol generating device in accordance with at least one exemplary embodiment.

[0078] In at least one exemplary embodiment, the perforations 770 in the outer housing 765 are elongated and extend perpendicular to the longitudinal axis of the flavor carrier 760 .

[0079] In an exemplary embodiment, the perforations 785 of the inner housing 780, not shown, may be the same as or different from the perforations 770 shown in Figure 8, e.g., in shape, size and / or pattern. The perforations 785 may be aligned with and approximately the same size as the perforations 770. In other exemplary embodiments, the perforations 785 may have a different size and / or may not be aligned with the perforations 770.

[0080] FIG. 9 is a perspective view of a flavor carrier of an aerosol generating device in accordance with at least one exemplary embodiment.

[0081] In at least one exemplary embodiment, as shown in FIG. 9, the perforations 770 in the outer housing 765 are generally circular or oval in shape and are arranged in uniform rows and / or columns along the outer housing 765 .

[0082] In an exemplary embodiment, the perforations 785 of the inner housing 780, not shown, may be the same as or different from the perforations 770 shown in Figure 9, e.g., in shape, size, and / or pattern. The perforations 785 may be aligned with and approximately the same size as the perforations 770. In other exemplary embodiments, the perforations 785 may have a different size and / or may not be aligned with the perforations 770.

[0083] FIG. 10 is a perspective view of a flavor carrier of an aerosol generating device in accordance with at least one exemplary embodiment.

[0084] In at least one exemplary embodiment, as shown in FIG. 10, the flavor carrier 760 is generally similar to FIGS. 1-2, except that the perforations are generally circular and arranged in offset rows along the flavor carrier 760.

[0085] Perforations 785, not shown, may be the same as or different from perforations 770. Perforations 785 may be aligned with and approximately the same size as perforations 770. In other exemplary embodiments, perforations 785 may have a different size and / or may not be aligned with perforations 770.

[0086] FIG. 11 is a cross-sectional view of the flavor cartridge of FIG. 1 along line XI-XI according to at least one exemplary embodiment.

[0087] As shown in FIG. 11, in some exemplary embodiments, the perforations 785 in the wall 792 of the inner housing 780 align with the perforations 770 in the wall 775 of the outer housing 765 .

[0088] FIG. 12 is a cross-sectional view of a flavor cartridge in accordance with at least one exemplary embodiment.

[0089] As shown in FIG. 12, in some exemplary embodiments, the perforations 785 in the wall 792 of the inner housing 780 do not align with the perforations 770 in the wall 775 of the outer housing 765, such that a tortuous flow path is formed through the flavor chamber 790.

[0090] FIG. 13 is a perspective view of a flavor cartridge in accordance with at least one exemplary embodiment.

[0091] In at least one exemplary embodiment, as shown in FIG. 13, one or more features of the flavor carrier 760 are generally the same as one or more features described herein, except that instead of including an outer housing 765 and an inner housing 780 having a flavor chamber 790 therebetween, the flavor carrier 760 is formed of a paper tube 2505 impregnated with at least one flavorant. The tube 2505 has a thickness approximately the same as the gap between the outer housing 765 and the inner housing 780 described herein. The tube 2505 includes a plurality of perforations 2500 therein. The perforations 2500 may be of any desired shape and / or configuration.

[0092] FIG. 14 is a schematic diagram illustrating the flow of air through an aerosol generating device including a flavor carrier according to at least one exemplary embodiment.

[0093] In one exemplary embodiment shown in FIG. 14, the aerosol (indicated by arrows) generated by the aerosol generating device 1000 enters the inner housing 780, flows laterally through perforations 785 in the inner housing, through flavor material 795 in the flavor chamber 790, through perforations 770 in the outer housing, into the space between the outer housing 765 and the device body of the aerosol generating device 1000, and exits the mouth end of the aerosol generating device. As the aerosol passes through the flavor material 795, aromas, flavors and / or ingredients from the flavor material 795 may be eluted into the aerosol. In some exemplary embodiments, a portion of the aerosol or a portion of the aerosol may be filtered as the aerosol flows through the flavor carrier 760.

[0094] In some exemplary embodiments not shown, the flavor carrier can include one or more features from one or more of the embodiments described herein.

[0095] While exemplary embodiments have been disclosed herein, it should be understood that other variations are possible and such variations are not to be regarded as a departure from the spirit and scope of the present disclosure, and all such modifications that would be apparent to one skilled in the art are intended to be included within the scope of the following claims.

Claims

1. An aerosol generating device, comprising: A vegetable material, a heating element, and a flavor carrier; the heating element is configured to heat the plant material; The flavor carrier comprises an outer housing and an inner housing each extending longitudinally; the outer housing comprises an outer housing wall; the outer housing wall defines at least one outer housing aperture; the inner housing is coaxial with the outer housing, the outer housing and the inner housing defining a flavor chamber, the flavor chamber configured to contain a flavor material; the inner housing comprises an inner housing wall; The aerosol generating device, wherein the inner housing wall defines at least one inner housing perforation.

2. The aerosol generating device according to claim 1, The aerosol generating device, wherein the flavor carrier further comprises a cover provided on an end of the flavor carrier.

3. The aerosol generating device according to claim 2, The cover defines a channel therein, the channel being in fluid communication with an air passage defined by the inner housing.

4. The aerosol generating device according to claim 2, The aerosol generating device, wherein the flavor carrier further comprises a cover at a second end of the flavor carrier.

5. The aerosol generating device according to claim 4, The aerosol generating device, wherein the gasket of the cover at the second end is substantially impermeable to aerosols.

6. The aerosol generating device according to claim 5, The aerosol generating device, wherein the gasket is formed of one or more materials including a polymer, a metal, or both a polymer and a metal.

7. The aerosol generating device according to claim 1, The aerosol generating device, wherein the outer housing has an outer diameter in the range of about 3.0 mm to about 5.0 mm.

8. The aerosol generating device according to claim 1, The aerosol generating device, wherein the inner housing has an outer diameter in the range of about 1.0 mm to about 3.0 mm.

9. The aerosol generating device according to claim 1, The aerosol generating device, wherein the flavor material comprises a botanical material, a gel, a film, a flavor bit, a powder, a compressed powder, a flavor bead, a subcombination thereof, or a combination thereof.

10. The aerosol generating device according to claim 1, The aerosol generating device, wherein the outer housing wall and the inner housing wall each have a thickness in the range of about 0.5 mm to about 1.5 mm.

11. The aerosol generating device according to claim 1, An aerosol generating device, wherein the outer housing wall and the inner housing wall are each formed from one or more materials including paper, cloth, metal, polymer, subcombinations thereof, or combinations thereof.

12. The aerosol generating device according to claim 1, The at least one outer housing perforation comprises a plurality of outer housing perforations.

13. The aerosol generating device according to claim 12, An aerosol generating device, wherein the plurality of outer housing perforations are arranged in at least one row.

14. The aerosol generating device according to claim 1, The at least one inner housing perforation comprises a plurality of inner housing perforations.

15. The aerosol generating device according to claim 14, An aerosol generating device, wherein the plurality of inner housing perforations are arranged in at least one row.

16. The aerosol generating device according to claim 1, It also comes with an adapter, the adapter is configured to mate with a portion of the flavor carrier; the adapter is formed of one or more materials including a polymer, a metal, or both a polymer and a metal; The aerosol generating device, wherein the adapter is substantially impermeable to the aerosol.

17. The aerosol generating device according to claim 1, An aerosol generating device, wherein at least one of the outer housing perforations includes a plurality of outer housing perforations, and at least one of the inner housing perforations includes a plurality of inner housing perforations, and the plurality of outer housing perforations are aligned with the plurality of inner housing perforations.

18. The aerosol generating device according to claim 1, An aerosol generating device, wherein at least one of the outer housing perforations includes a plurality of outer housing perforations, and at least one of the inner housing perforations includes a plurality of inner housing perforations, and the plurality of outer housing perforations are not aligned with the plurality of inner housing perforations.

19. The aerosol generating device according to claim 1, The aerosol generating device, wherein the plant material comprises tobacco.

20. A flavor carrier, comprising: The device includes an outer housing and an inner housing each extending longitudinally; the outer housing comprises an outer housing wall; the outer housing wall defines at least one outer housing aperture; the inner housing is coaxial with the outer housing, the outer housing and the inner housing defining a flavor chamber, the flavor chamber configured to contain a flavor material; the inner housing comprises an inner housing wall; The inner housing wall defines at least one inner housing perforation.

21. 21. The flavor carrier of claim 20, The flavor carrier further comprises a cover provided on an end of the flavor carrier.

22. 22. The flavor carrier of claim 21, The cover defines a channel therein, the channel being in fluid communication with an air passage defined by the inner housing.

23. 22. The flavor carrier of claim 21, The flavor carrier further comprising a cover at a second end of the flavor carrier.

24. 24. The flavor carrier of claim 23, A flavor carrier, wherein the gasket of the cover at the second end is substantially impermeable to aerosols.

25. 25. The flavor carrier of claim 24, The flavor carrier, wherein the gasket is formed of one or more materials including a polymer, a metal, or both a polymer and a metal.

26. 21. The flavor carrier of claim 20, The outer housing has an outer diameter in the range of about 3.0 mm to about 5.0 mm.

27. 21. The flavor carrier of claim 20, The inner housing has an outer diameter in the range of about 1.0 mm to about 3.0 mm.

28. 21. The flavor carrier of claim 20, The flavor carrier, wherein the flavor material comprises a botanical material, a gel, a film, a flavor bit, a powder, a compressed powder, a flavor bead, subcombinations thereof, or combinations thereof.

29. 21. The flavor carrier of claim 20, The flavor carrier, wherein each of the outer housing wall and the inner housing wall has a thickness in the range of about 0.5 mm to about 1.5 mm.

30. 21. The flavor carrier of claim 20, The flavor carrier, wherein the outer housing wall and the inner housing wall are each formed of one or more materials including paper, cloth, metal, polymer, subcombinations thereof, or combinations thereof.

31. 21. The flavor carrier of claim 20, The at least one outer housing perforation comprises a plurality of outer housing perforations.

32. 32. The flavor carrier of claim 31, A flavor carrier, wherein the plurality of outer housing perforations are arranged in at least one row.

33. 21. The flavor carrier of claim 20, The at least one inner housing perforation comprises a plurality of inner housing perforations.

34. 33. The flavor carrier of claim 32, A flavor carrier, wherein the plurality of inner housing perforations are arranged in at least one row.

35. 21. The flavor carrier of claim 20, It also comes with an adapter, the adapter is configured to mate with a portion of the flavor carrier; the adapter is formed of one or more materials including a polymer, a metal, or both a polymer and a metal; The adapter is substantially impermeable to aerosols.

36. 21. The flavor carrier of claim 20, A flavor carrier, wherein the at least one outer housing perforation includes a plurality of outer housing perforations and the at least one inner housing perforation includes a plurality of inner housing perforations, the plurality of outer housing perforations being aligned with the plurality of inner housing perforations.

37. 21. The flavor carrier of claim 20, A flavor carrier, wherein at least one of the outer housing perforations includes a plurality of outer housing perforations and at least one of the inner housing perforations includes a plurality of inner housing perforations, the plurality of outer housing perforations being out of alignment with the plurality of inner housing perforations.

Images