Capsules including internal filters, heat-not-burn (HNB) aerosol-generating devices, and methods of generating aerosol

Abstract

To provide capsules, heat-not-burn (HNB) aerosol-generating devices, and methods of generating aerosol without involving a substantial pyrolysis of an aerosol-forming substrate.SOLUTION: A capsule 100 for an aerosol-generating device may include a housing, a filter 120, and an aerosol-forming substrate. The housing may have a gas-permeable end and a gas-impermeable end. The filter may be disposed within the housing so as to be adjacent to the gas-impermeable end. The aerosol-forming substrate may be disposed within the housing so as to be between the filter and the gas-permeable end. The housing may be configured to facilitate heating of the aerosol-forming substrate via conduction and / or convection so as to generate aerosol.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present disclosure relates to a capsule, a heat-not-burn (HNB) aerosol generating device, and an aerosol generating method that does not substantially pyrolyze an aerosol-forming substrate.

Background Art

[0002] Some electronic devices are configured to heat a plant-based material to a temperature sufficient to release the components of the plant-based material while maintaining a temperature below the combustion point of the plant-based material so as to avoid substantial pyrolysis of the plant-based material. Such devices may be referred to as aerosol generating devices (e.g., heat-not-burn aerosol generating devices), and the plant-based material to be heated may be tobacco. In some embodiments, the plant-based material may be introduced directly into the heating chamber of the aerosol generating device. In other embodiments, the plant-based material may be pre-packaged in individual containers to facilitate insertion and removal into the aerosol generating device.

[0003] [Summary] At least one embodiment relates to a capsule for a heat-not-burn (HNB) aerosol generating device. In an exemplary embodiment, the capsule may include a housing, a filter, and an aerosol-forming substrate. The housing may have a gas-permeable end and a gas-impermeable end. The filter may be disposed within the housing adjacent to the impermeable end. The aerosol-forming substrate may be disposed within the housing between the filter and the gas-permeable end. The housing may be configured to facilitate heating of the aerosol-forming substrate via either or both of conduction and convection to generate an aerosol.

[0004] At least one embodiment relates to a heat-not-burn (HNB) aerosol generating device. In an exemplary embodiment, the aerosol generating device may include a device body, a mouthpiece, and a heating assembly. The device body may define a compartment configured to receive a capsule containing an aerosol-forming substrate and a filter. The mouthpiece may include a conduit portion. The mouthpiece may be configured to engage with the device body such that the conduit portion extends through the aerosol-forming substrate and into the filter of the capsule. The heating assembly may be disposed within the device body. The heating assembly may be configured to heat the aerosol-forming substrate within the capsule via either or both of conduction and convection so as to generate an aerosol exiting the capsule via the conduit portion of the mouthpiece.

[0005] At least one embodiment relates to a method of generating an aerosol. In an exemplary embodiment, the method may include heating a capsule including a housing, a filter, and an aerosol-forming substrate. The housing may have a gas-permeable end and a gas-impermeable end. The method may further include directing a suction flow of air along a serpentine path through the capsule. The serpentine path may include an entrained flow section and a filtered flow section. The entrained flow section may extend from the gas-permeable end of the housing, through the aerosol-forming substrate, and to the filter. The filtered flow section may extend from the filter to the gas-permeable end of the housing. Brief Description of the Drawings

[0006] The various features and advantages of the non-limiting embodiments of this specification will become more apparent by considering 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 should not be considered as being drawn to scale unless explicitly noted otherwise. For clarity, various dimensions in the drawings may be exaggerated.

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DETAILED DESCRIPTION OF THE INVENTION

[0017] Some detailed exemplary embodiments are disclosed herein. However, the specific structural and functional details disclosed herein are merely representative for the purpose of describing the exemplary embodiments. However, the exemplary embodiments may be embodied in many alternative forms and should not be construed as limited to only the exemplary embodiments described herein.

[0018] Accordingly, the exemplary embodiments are capable of various changes and alternative forms, but the exemplary embodiments will be illustrated in the drawings and described in detail herein. However, it is to be understood that there is no intention to limit the exemplary embodiments to the particular forms disclosed, and on the contrary, the exemplary embodiments are intended to cover all modifications, equivalents, and alternatives thereof. Through the description of the figures, like numbers refer to like elements.

[0019] When an element or layer is said to be "on," "connected to," "coupled to," "attached to," "adjacent to," or "covering" another element or layer, it should be understood that it may be directly on, connected to, coupled to, attached to, adjacent to, or covering the other element or layer, or there may be intervening elements or layers. On the other hand, when an element is said to be "directly on," "directly connected to," or "directly coupled to" another element or layer, there are no intervening elements or layers. In this specification, the same number means the same element. In this specification, the term "and / or" includes any and all combinations or sub-combinations of one or more of the associated listed items.

[0020] 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 only used to distinguish one element, region, layer, or section from another region, layer, or section. Thus, the first element, region, layer, or section described below could be referred to as the second element, region, layer, or section without departing from the teachings of the exemplary embodiments.

[0021] In this specification, for ease of explanation, spatially relative terms (such as "beneath", "below", "lower", "above", "upper", etc.) are used to describe the relationship between one element or function and another element or function as shown in the figures. It should be understood that spatially relative terms are intended to encompass different orientations of the device in use and operation in addition to the orientation depicted in the figures. For example, if the device in the figure is turned over, elements described as "below" or "beneath" other elements or features will face "above" the other elements or features. Thus, the term "below" can potentially encompass both upward and downward orientations. Also, the device may be oriented in other directions (it may be rotated 90 degrees or oriented in other directions), and the spatially relative descriptors used in this specification are to be interpreted accordingly.

[0022] The terms used in this specification are for the purpose of describing various exemplary embodiments only and are not intended to limit the exemplary embodiments. The singular forms "a", "an", and "the" used in this specification are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "includes", "including", "comprises", and / or "comprising" as used in this specification identify the presence of the described features, integers, steps, operations, and / or elements, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, and / or groups thereof.

[0023] In this specification, when the words "about" and "substantially" are used in connection with a numerical value, unless otherwise explicitly defined, it is intended to include manufacturing or operational tolerances (e.g., ±10%) around the recited numerical value. Further, when the terms "generally" or "substantially" are used in connection with a geometric shape, the accuracy of the geometric shape is not required, but the freedom with respect to the shape is intended to be within the scope of the present disclosure. Further, when a numerical value or shape is expressed in terms of any of "about", "generally", or "substantially", it should be understood that these numerical values and shapes are to be interpreted as including manufacturing or operational tolerances (e.g., ±10%) around the recited numerical value or shape.

[0024] Unless otherwise specifically defined, all terms used in this specification (including technical and scientific terms) have the same meaning as commonly understood by one of ordinary skill in the art to which the illustrated embodiments belong. Further, terms including those defined in commonly used dictionaries are to be interpreted as having a meaning that coincides with the meaning in the context of the relevant art and are not to be interpreted in an idealized or overly formal sense unless explicitly defined herein.

[0025] Hardware can be implemented using a processing circuit or a control circuit such as one or more processors, one or more CPUs (Central Processing Units), one or more microcontrollers, one or more ALUs (Arithmetic Logic Units), one or more DSPs (Digital Signal Processors), one or more microcomputers, one or more FPGAs (Field Programmable Gate Arrays), one or more SoCs (System-on-Chip), one or more programmable logic units (PLUs), one or more microprocessors, one or more ASICs (Application Specific Integrated Circuits), or other devices that can execute in response to instructions in a defined manner, but are not limited thereto.

[0026] Figure 1 is a first perspective view of a capsule for an aerosol generating device according to an exemplary embodiment. Figure 2 is a second perspective view of the capsule of Figure 1. Referring to Figures 1 and 2, the capsule 100 may be configured to be received within an aerosol generating device (e.g., a heat-not-burn aerosol generating device). The capsule 100 includes a housing configured to hold an aerosol-forming substrate and to promote heating of the aerosol-forming substrate via conduction and / or convection to generate an aerosol.

[0027] As shown, the capsule 100 may have a shape similar to a cylinder. In such a shape, the capsule 100 may have a circular cross-section. However, it should be understood that other forms and shapes are also possible. For example, as an alternative, the capsule 100 may have a shape similar to a triangular prism, a cuboid, a pentagonal prism, or a hexagonal prism. In a shape similar to a triangular prism, the capsule 100 may have a triangular cross-section (e.g., the shape of an equilateral triangle). When having a shape similar to a cuboid, the capsule 100 may have a square cross-section or a rectangular cross-section. When having a shape similar to a pentagonal prism, the capsule 100 may have a pentagonal cross-section. When having a shape similar to a hexagonal prism, the capsule 100 may have a hexagonal cross-section.

[0028] The housing of the capsule 100 has a gas-permeable end and a gas-impermeable end. As discussed in more detail herein, the gas-permeable end of the housing is configured to hold the aerosol-forming substrate while allowing air to enter the capsule and aerosol to exit the capsule. The filter 120 (FIG. 3) may be disposed within the housing adjacent to the gas-impermeable end. Further, the aerosol-forming substrate is disposed within the housing such that it is between the filter 120 and the gas-permeable end.

[0029] In an exemplary embodiment, the housing of the capsule 100 includes a container 130 and an end cap 110. The container 130 has a closed end 134 and an open end 132 (FIG. 3). The closed end 134 of the container 130 may have a rounded edge. However, it should be understood that other configurations are also possible (e.g., chamfered edges). The container 130 is made of a conductive material. For example, the conductive material may be a metal, and the metal may include aluminum, its alloys, or stainless steel. As a result, the container 130 may promote the heating of the internal aerosol-forming substrate, at least via conduction.

[0030] During assembly, the end cap 110 is disposed at the open end 132 of the container 130 so as to surround the aerosol-forming substrate and the filter 120 therein. For example, most of the end cap 110 may be inserted into the container 130. The engagement between the end cap 110 and the container 130 may be effected via an interference fit (which may also be referred to as a pressure fit or a friction fit). Further, instead of or in addition to the interference fit, the end cap 110 may be fixed to the container 130 using an adhesive (e.g., glue) that is considered acceptable by the regulatory authorities in terms of food safety or otherwise. The end cap 110 may be formed of a suitable plastic (e.g., via molding). The exemplary embodiments are not limited to this.

[0031] The end cap 110 of the capsule 100 defines a plurality of openings. In this regard, the end cap 110 may be regarded as the gas-permeable end of the housing, and the closed end 134 of the container 130 may be regarded as the gas-impermeable end. As shown, the plurality of openings of the end cap 110 includes an outlet opening 114 surrounded by an inlet opening 112. Although 8 inlet openings 112 are shown in FIG. 1, it should be understood that different quantities (e.g., 6 inlet openings, 10 inlet openings) may be implemented based on various factors that can affect the air flow within the capsule 100 (e.g., the density of the aerosol-forming substrate, the permeability of the filter 120). In an exemplary embodiment, the quantity and size of the inlet openings 112 may be designed to provide a desired resistance to draw (RTD). For example, the capsule 100 may be designed to have an RTD between 90 and 110 mmHg.

[0032] The inlet openings 112 of the end cap 110 may be equidistant from each other by a first distance. In other words, each of the inlet openings 112 may be equidistant from an adjacent inlet opening 112 by the first distance. Further, the inlet openings 112 may be equidistant from the center (e.g., the diametrical center) of the end cap 110 by a second distance. Although the exemplary embodiments are not limited thereto, the first distance may be smaller than the second distance. For example, when the number of the inlet openings 112 decreases, the first distance may be larger than the second distance. During operation of the aerosol generating device, air enters the capsule 100 through the inlet openings 112, and the aerosol exits the capsule 100 through the outlet opening 114 (e.g., as a result of engagement with a mouthpiece such as the mouthpiece 310 in FIG. 5). Each of the inlet openings 112 may be smaller than the outlet opening 114.

[0033] FIG. 3 is an exploded perspective view of the capsule of FIG. 1. FIG. 4 is an exploded perspective view of the capsule of FIG. 2. Referring to FIGS. 3 and 4, the filter 120 is configured to be inserted into the container 130 through the open end 132 during assembly of the capsule 100. When fully seated within the container 130, the filter 120 is configured to be adjacent to or pressed against the inner end face corresponding to the closed end 134. To facilitate placement within the container 130, the bottom of the filter 120 may be shaped (e.g., having a rounded edge) to conform to the inner surface corresponding to the closed end 134. The filter 120 may further be sized such that its outer sidewall interfaces with the inner sidewall of the container 130 to provide a snug fit. In such an example, the filter 120 may grip the inner sidewall of the container 130 sufficiently to maintain its seated position (e.g., sufficient to overcome gravity if the container 130 is inverted).

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

[0035] Filter 120 may be formed of a fibrous material or a foam material. In one example, the fibrous material of filter 120 may include cellulose acetate fibers. In another example, the foam material may include an open-cell foam. Further, filter 120 may include additives configured to modify the aerosol produced within capsule 100. For example, the additives may include activated carbon and / or flavorants embedded within filter 120. In an exemplary embodiment, filter 120 may include materials of tobacco filters as known in the art.

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

[0037] In one example, the aerosol-forming substrate may be in a single, integrated form. It is a form configured to maintain its shape so that the aerosol-forming substrate can be disposed integrally within container 130. In such an example, the single, combined form of the aerosol-forming substrate may be cylindrical while defining a through-hole configured to be oriented to coincide with the outlet opening 114 in end cap 110 and the orifice 122 in filter 120 (so as to substantially correspond to the volume of the chamber within capsule 100).

[0038] In another example, the aerosol-forming substrate may be a plurality of combined forms configured to allow the individual forms to be arranged in the container 130 in an individual manner. In such an example, each of the plurality of combined forms may be similar to a round tablet or disk defining a through hole configured to be aligned with the outlet opening 114 of the end cap 110 and the orifice 122 of the filter 120. Each of the plurality of combined forms may contain the same or different types of aerosol-forming substrates. As a result, various combinations of aerosol-forming substrates are loaded into the container 130, and a desired functional appeal can be achieved.

[0039] Alternatively, instead of or in addition to the combined forms described above, the aerosol-forming substrate may be a loose form (e.g., particles, fibers, dust, fragments, chips) configured to have no set shape but rather to take the shape of the chamber within the capsule 100. In such an example, it should be understood that the loose form of the aerosol-forming substrate generally has an average size larger than the diameter of the openings (e.g., the inlet opening 112, the outlet opening 114) within the end cap 110 and the orifice 122 within the filter 120.

[0040] As discussed herein, the aerosol-forming substrate is a material or combination of materials that can result in an aerosol. The aerosol is related to the substance produced or output by the disclosed devices, claims, and their equivalents. The material may include a compound (e.g., nicotine, cannabinoid), and when the material is heated, an aerosol containing the compound is produced. The heating may be below the combustion temperature so as to produce an aerosol without substantial thermal decomposition of the aerosol-forming substrate or substantial production of combustion by-products (if any). Thus, in an exemplary embodiment, no thermal decomposition occurs during heating and the resulting production of the aerosol. In other examples, there may be some thermal decomposition and combustion by-products, but the degree is relatively minor and / or may be considered merely incidental.

[0041] The aerosol-forming substrate may be a fibrous material. For example, the fibrous material may be a plant-based material. The fibrous material is configured to release a compound when heated. The compound may be a component naturally derived from the fibrous material. For example, the fibrous material may be a plant-based material such as tobacco, and the released compound may be nicotine. The term "tobacco" includes any tobacco plant-based material, including tobacco leaves, tobacco plugs, reconstituted tobacco, compressed tobacco, shaped tobacco, or powdered tobacco, and combinations of one or more tobacco plants such as Nicotiana rustica and Nicotiana tabacum.

[0042] In some exemplary embodiments, the tobacco material may include material from any member of the genus Nicotiana. Further, the tobacco material may include a blend of two or more different tobacco varieties. Examples of suitable types of tobacco materials that may be used include, but are not limited to, flue-cured tobacco, burley tobacco, dark tobacco, Maryland tobacco, Oriental tobacco, rare tobacco, special tobacco, blends thereof, and the like. The tobacco material may be provided in any suitable form, including, but not limited to, processed tobacco materials such as tobacco lamina, volume-expanded tobacco, or cased tobacco, processed tobacco stems such as cut-rolled tobacco or cut-cased tobacco, 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. Further, in some exemplary embodiments, the tobacco material may be mixed and / or combined with propylene glycol, glycerin, a partial combination thereof, or at least one of combinations thereof.

[0043] Alternatively, the compound may be a component naturally derived from a medicinal plant that has been medically proven to have a 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 exert various effects. As a result, cannabinoids have been used for various medicinal purposes (e.g., treatment of pain, nausea, epilepsy, mental disorders). The fibrous material may include leaves and / or flower materials from one or more cannabis plants such as Cannabis sativa, Cannabis indica, and Cannabis ruderalis. In some embodiments, the fibrous material is a mixture of 60-80% (e.g., 70%) Cannabis sativa and 20-40% (e.g., 30%) Cannabis indica.

[0044] Examples of cannabinoids include tetrahydrocannabinolic acid (THCA), tetrahydrocannabinol (THC), cannabidiolic acid (CBDA), cannabidiol (CBD), cannabinol (CBN), cannabinocyclol (CBL), cannabichromene (CBC), cannabigerol (CBG), etc. Tetrahydrocannabinolic acid (THCA) is a precursor of tetrahydrocannabinol (THC), and cannabidiolic acid (CBDA) is a precursor of cannabidiol (CBD). Tetrahydrocannabinolic acid (THCA) and cannabidiolic acid (CBDA) can be converted to tetrahydrocannabinol (THC) and cannabidiol (CBD), respectively, via heating. In an exemplary embodiment, decarboxylation may be caused to convert tetrahydrocannabinolic acid (THCA) in the capsule 100 to tetrahydrocannabinol (THC) by heat from a heater (e.g., the heating assembly 340 shown in FIG. 8), and / or decarboxylation may be caused to convert cannabidiolic acid (CBDA) in the capsule 100 to cannabidiol (CBD).

[0045] In an example where both tetrahydrocannabinolic acid (THCA) and tetrahydrocannabinol (THC) are present in capsule 100, decarboxylation and the resulting conversion will cause a decrease in tetrahydrocannabinolic acid (THCA) and an increase in tetrahydrocannabinol (THC). At least 50% (e.g., at least 87%) of the tetrahydrocannabinolic acid (THCA) may be converted to tetrahydrocannabinol (THC) during heating of capsule 100. Similarly, in an example where both cannabidiolic acid (CBDA) and cannabidiol (CBD) are present in capsule 100, decarboxylation and the resulting conversion will cause a decrease in cannabidiolic acid (CBDA) and an increase in cannabidiol (CBD). During heating of capsule 100, at least 50% (e.g., at least 87%) of the cannabidiolic acid (CBDA) may be converted to cannabidiol (CBD).

[0046] Furthermore, the compound may subsequently contain, or may subsequently additionally contain, additives of non-natural origin introduced into the fibrous material. In one example, the fibrous material may comprise at least one of cotton, polyethylene, polyester, rayon, combinations thereof, etc. (e.g., in the form of gauze). In another embodiment, the fibrous material may be a cellulose material (e.g., a non-tobacco and / or non-cannabis material). In any of the examples, the introduced compound may contain nicotine, cannabinoids, and / or flavorants. The flavorants may be of natural origin, such as plant extracts (e.g., tobacco extracts, cannabis extracts), and / or of artificial origin. In yet another example, when the fibrous material contains tobacco and / or cannabis, the compound may be, or may additionally contain, one or more flavorants (e.g., menthol, mint, vanilla). Thus, the compound in the aerosol-forming substrate may contain components of natural origin and / or additives of non-natural origin. In this regard, it should be understood that the level of components of natural origin in the aerosol-forming substrate can be increased by replenishment. For example, the amount of nicotine contained in tobacco may be increased by replenishment with an extract containing nicotine. Similarly, the amount of one or more cannabinoids contained in cannabis may be increased by replenishment with an extract containing such cannabinoids.

[0047] FIG. 6 is a first perspective view of an aerosol generating device according to an exemplary embodiment. FIG. 7 is a second perspective view of the aerosol generating device of FIG. 6. Referring to FIGS. 6-7, the aerosol generating device 300 is configured to receive a capsule 200 (FIG. 8) containing an aerosol-forming substrate. As shown, the aerosol generating device 300 may have a cylinder-like form. In such a form, the aerosol generating device 300 may have a circular cross-section. However, it should be understood that other forms and shapes are possible. For example, as an alternative, the aerosol generating device 300 may have a form similar to a triangular prism, a cuboid, a pentagonal prism, or a hexagonal prism. In a form similar to a triangular prism, the aerosol generating device 300 may have a triangular cross-section (e.g., the shape of an equilateral triangle). In a shape similar to a cuboid, the aerosol generating device 300 may have a square cross-section or a rectangular cross-section. In a shape similar to a pentagonal prism, the aerosol generating device 300 may have a pentagonal cross-section. In a shape similar to a hexagonal prism, the aerosol generating device 300 may have a hexagonal cross-section.

[0048] As shown in the drawings, the form of the aerosol generating device 300 may correspond to the form of the capsule 200 (e.g., a cylindrical form for both the aerosol generating device 300 and the capsule 200). However, in other embodiments, the form of the aerosol generating device 300 may be different from the form of the capsule 200. For example, the capsule 200 may have a cylindrical form, but the aerosol generating device 300 may have one of the different forms disclosed herein (e.g., a cuboid form), or vice versa.

[0049] The aerosol generating device 300 includes a device body 330, a mouthpiece 310 configured to engage with the device body 330, and a heating assembly 340 (FIG. 8) within the device body 330. The mouthpiece 310 defines an aerosol outlet 312. The aerosol outlet 312 may be centrally located so as to coincide with the longitudinal central axis of the device body 330. The device body 330 may be formed of an insulating material (e.g., ceramic, metal coated with ceramic) to reduce or minimize heat loss. Further, the device body 330 defines a plurality of air inlets 334. The plurality of air inlets 334 may be arranged along the periphery of the surface of the upstream end of the device body 330 (e.g., in a circular arrangement). As used herein, "upstream" (and conversely "downstream") relates to the flow of the aerosol, and "proximal" (and conversely "distal") relates to the adult operator of the device during aerosol generation.

[0050] Each of the plurality of air inlets 334 within the device body 330 may be larger than the aerosol outlet 312 within the mouthpiece 310. Although 12 air inlets 334 are shown in FIG. 7, it should be understood that different amounts may be implemented (e.g., 10 air inlets, 14 air inlets) based on the desired distribution of air flow within and through the aerosol generating device 300. Further, a gasket 320 may be disposed between the mouthpiece 310 and the device body 330. The gasket 320 may serve to ensure a relatively airtight seal such that the incoming air enters the aerosol generating device 300 essentially only through the air inlets 334 within the device body 330.

[0051] FIG. 8 is an exploded perspective view of the aerosol generating device of FIG. 6. FIG. 9 is an exploded perspective view of the aerosol generating device of FIG. 7. Referring to FIGS. 8-9, the device body 330 defines a compartment 332, and a heating assembly 340 is disposed within the compartment 332. The device body 330 is configured to receive the capsule 200 within the compartment 332 such that the capsule 200 is in thermal contact with the heating assembly 340. The capsule 200 of FIGS. 8-9 may be the same as the capsule 100 of FIGS. 1-5. For example, the end cap 210, inlet opening 212, outlet opening 214, filter 220 (FIG. 10), orifice 222 (FIG. 10), and container 230 of the capsule 200 may be as described in relation to the end cap 110, inlet opening 112, outlet opening 114, filter 120, orifice 122, and container 130 of the capsule 100. Although not shown, it should be understood that the capsule 200 may also contain internally an aerosol-forming substrate as described in relation to the aerosol-forming substrate of the capsule 100. As a result, the above related disclosure of common features should be understood to apply to this section and may not be repeated for the sake of brevity.

[0052] The mouthpiece 310 includes a head portion 314 and a conduit portion 316. The conduit portion 316 defines an aperture 318 at its upstream end and defines an internal channel that fluidly connects the aperture 318 to the aerosol outlet 312. The mouthpiece 310 is configured to engage the device body 330 so as to enclose the capsule 200 and the heating assembly 340 therein. Further, a gasket 320 may be clamped between the mouthpiece 310 and the device body 330. In particular, the gasket 320 may have an annular form configured to be clamped between the head portion 314 of the mouthpiece 310 and the rim of the device body 330.

[0053] In an exemplary embodiment, the capsule 200 can be regarded as a consumable that is removed and replaced with a new capsule before the operation of the aerosol generating device 300 is resumed (for example, when the aerosol-forming substrate therein is depleted or considered expired). In this regard, the capsule 200 can also be regarded as disposable. On the other hand, the mouthpiece 310, the gasket 320, the heating assembly 340, and the device body 330 can be regarded as durable parts designed to be used multiple times in the aerosol generating device 300 (if not the lifespan of the aerosol generating device 300). In this regard, the mouthpiece 310, the gasket 320, the heating assembly 340, and the device body 330 can also be regarded as reusable.

[0054] The heating assembly 340 is configured to heat the aerosol-forming substrate in the capsule 200 and generate an aerosol through either or both of conduction and convection. As shown, the heating assembly 340 may include a first heater 342 and a second heater 344. In an exemplary embodiment, the first heater 342 and the second heater 344 are separate structures configured to enable independent operation. Alternatively, the first heater 342 and the second heater 344 may be a continuous structure configured to enable concurrent operation. The first heater 342 may serve to heat the aerosol-forming substrate in the capsule 200 through conduction, and the combination of the first heater 342 and the second heater 344 may serve to heat the aerosol-forming substrate in the capsule 200 through convection.

[0055] The first heater 342 may be in the form of an inner coil, and the second heater 344 may be in the form of an outer coil surrounding the inner coil. In such an example, the first heater 342 and the second heater 344 may be arranged concentrically in a spiral shape about the longitudinal central axis of the apparatus main body 330. Further, the wire diameter, pitch, coil angle, free length, and / or the material of the structure of the first heater 342 may be the same as the wire diameter, pitch, coil angle, free length, and / or the material of the structure of the second heater 344. However, the exemplary embodiments are not limited thereto. Further, the free length of the first heater 342 and the second heater 344 may have a size that is at least the height of the container 230 of the capsule 200. Thereby, heating of the aerosol-forming substrate therein during aerosol generation can be enhanced. In another example, the first heater 342 and the second heater 344 may be in the form of a ceramic heater, a silicon heater, and / or a flexible polymer heater.

[0056] In the coil configuration, the inner diameter of the first heater 342 may substantially correspond to the outer diameter of the capsule 200. As a result, the first heater 342 may physically contact (e.g., press against) the container 230 of the capsule 200 when the capsule 200 is received in the compartment 332 of the apparatus main body 330. Further, the outer diameter of the second heater 344 may substantially correspond to the inner diameter of the apparatus main body 330. As a result, the second heater 344 may contact (e.g., press against) the inner side wall of the apparatus main body 330. Further, based on the position of the heating assembly 340 in the compartment 332 of the apparatus main body 330, the air inlet 334 may be between the first heater 342 and the second heater 344. As a result, the air flowing into the apparatus main body 330 through the air inlet 334 flows between the first heater 342 and the second heater 344 and becomes a heating flow entering the capsule 200, heating the aerosol-forming substrate therein through convection.

[0057] Although the coil configuration has been described above, it should be understood that other configurations are also possible for the first heater 342 and the second heater 344. For example, the first heater 342 and the second heater 344 may be structured as a waveform configured to surround the capsule 200. In such an example, the first heater 342 and the second heater 344 may alternately repeat extending towards the rim at the proximal end of the device body 330 and extending towards the distal end of the device body 330. In particular, the amplitude of the waveform of the first heater 342 and the second heater 344 may have a size that is about half the height of the container 230 of the capsule 200, while the height of the waveform of the first heater 342 and the second heater 344 may have a size on the order of the height of the container 230 of the capsule 200. The heating of the aerosol-forming substrate therein during aerosol generation can be enhanced.

[0058] The waveforms of the first heater 342 and the second heater 344 may be similar to a compressed amplitude or a zigzag, and may have a plurality of parallel segments (for example, those extending longitudinally with respect to the device body 330). In particular, the waveform may include a pulse wave (for example, a rectangular wave), a triangular wave, a sawtooth wave, or a sine wave. The waveform of the first heater 342 may be of the same type as the waveform of the second heater 344, but the illustrated embodiments are not limited to this. In an example where the capsule 200 has a non-cylindrical form (for example, a form similar to a triangular prism, a cuboid, a pentagonal prism, or a hexagonal prism), it should be understood that the heater pattern (for example, which may be cut from a sheet material) may be bent as needed. Thereby, appropriate first and second heaters can be obtained that can better accommodate the capsule 200 (for example, improve thermal contact).

[0059] In an exemplary embodiment, the first heater 342 and the second heater 344 are configured to undergo Joule heating (which is also known as ohmic / resistive heating) when an electric current is applied thereto. More specifically, the first heater 342 and the second heater 344 may be formed of one or more conductors and configured to generate heat when an electric current passes therethrough. The electric current may be supplied (e.g., independently) from a power source (e.g., a battery) within the aerosol generating device 300 to the first heater 342 and the second heater 344. Suitable conductors for the first heater 342 and the second heater 344 include iron-based alloys (e.g., stainless steel) and / or nickel-based alloys (e.g., nichrome). The first heater 342 and the second heater 344 may have a resistance of about 0.4 to 2.5 ohms (e.g., 1.0 to 2.0 ohms).

[0060] Figure 10 is a cross-sectional view of the aerosol generating device of FIG. 6. Referring to FIG. 10, to enable the operation of the aerosol generating device 300, the capsule 200 is inserted into the compartment 332 of the device body 330 and is arranged to be received by the first heater 342. In the case of the resilient configuration of the first heater 342 as an inner coil, the first heater 342 may physically grip the capsule 200. In such a manner, while holding the capsule 200 in a desired position, the thermal contact between the capsule 200 and the container 230 can be improved. When the capsule 200 is seated within the device body 330, an annular space is defined by the outer sidewall of the capsule 200 and the inner sidewall of the device body 330. As shown, the first heater 342 and the second heater 344 are within this annular space, the first heater 342 faces the outer sidewall of the capsule 200, and the second heater 344 faces the inner sidewall of the device body 330.

[0061] When the capsule 200 is seated, the mouthpiece 310 is configured to engage with the device body 330 to surround the capsule 200, and the conduit portion 316 passes through the outlet opening 214 of the end cap 210, through the aerosol-forming substrate, and extends into the filter 220 of the capsule 200. The conduit portion 316 of the mouthpiece 310 may have an upstream tip that is rounded to facilitate insertion into the capsule 200. In some embodiments, the upstream tip of the conduit portion 316 of the mouthpiece 310 may be tapered (e.g., pointed). This can further facilitate its insertion through the aerosol-forming substrate within the capsule 200.

[0062] As shown in FIG. 10, when the capsule 200 is enclosed within the compartment 332 of the device body 330, the gasket 320 is sandwiched between the mouthpiece 310 and the device body 330. Further, the upstream tip of the conduit portion 316 of the mouthpiece 310 will be embedded within the orifice 222 of the filter 220. In particular, the aperture 318 at the upstream tip of the conduit portion 316 will also be covered, surrounded, or otherwise obscured by the filter 220. As a result, any flow entering the aperture 318 must first pass through the filter 220. The aperture 318 may be a through-hole. In such a manner, two inlets to the conduit portion 316 of the mouthpiece 310 can be provided. In some embodiments, the aperture 318 may be in the form of two intersecting through-holes (e.g., an x-configuration, a cross-configuration). This can provide four inlets to the conduit portion 316 of the mouthpiece 310.

[0063] As described above, the gasket 320 can help ensure a relatively airtight seal so that the incoming air enters the aerosol generating device 300 essentially only through the air inlet 334 in the device body 330. In one example, the gasket 320 may be a separate component disposed between the mouthpiece 310 and the device body 330. In another embodiment, the gasket 320 may be part of the mouthpiece 310 (e.g., adhered to the underside of the head portion 314 of the mouthpiece 310). In yet another example, the gasket 320 may be part of the device body 330 (e.g., adhered to the rim of the device body 330).

[0064] During operation of the aerosol generating device 300, the incoming air (e.g., ambient air) is drawn into the device body 330 through the plurality of air inlets 334. The plurality of air inlets 334 at the upstream end of the device body 330 helps to disperse the air coming in around the capsule 200. The operation of the heating assembly 340 can include manual operation (e.g., button actuation) and / or automatic operation (e.g., puff actuation). Further, the first heater 342 and the second heater 344 of the heating assembly 340 may be actuated simultaneously or sequentially. Further, since the first heater 342 and the second heater 344 are configured to enable independent operation, the first heater 342 and the second heater 344 may have different heating profiles and thus may be at different temperatures at a given point in time.

[0065] For example, in response to a manual or automatic operation, both the first heater 342 and the second heater 344 may be activated simultaneously to start heating. In another example, upon activation of the first button, the first heater 342 may start heating the capsule 200, and upon subsequent puff activation, the second heater 344 (in combination with the first heater 342) may start heating the incoming air to generate a heated air stream. In yet another embodiment, the order may be reversed, for example, the second heater 344 starts heating in response to the first button activation, and the first heater 342 starts heating in response to the subsequent puff activation. Further, in each of the above embodiments, the heating may include a preheating step (to shorten the time required to reach the target / aerosolization temperature) including the first heater 342 and / or the second heater 344, followed by a main heating step including both the first heater 342 and the second heater 344. Here, the preheating step is performed, for example, by button operation at a temperature below the target temperature / aerosolization temperature, and the full heating step is performed, for example, by puff activation at the target temperature / aerosolization temperature. Appropriate temperature sensing may be achieved via a thermocouple or by monitoring the resistance of the first heater 342 and the second heater 344.

[0066] Air flowing into the device body 330 through the plurality of air inlets 334 is drawn into the internal annular space so as to flow (e.g., in a first longitudinal direction) between the first heater 342 and the second heater 344, and heats the incoming air within the heated air flow. When the heated air reaches the head portion 314 of the mouthpiece 310, its direction changes to a path (e.g., a first radial path) that is inward toward the inlet opening 212 of the end cap 210. The heated air entering the capsule 200 through the inlet opening 212 of the end cap 210 then flows (e.g., in a second longitudinal direction) through the aerosol-forming substrate (which is between the conduit portion 316 of the mouthpiece 310 and the container 230 of the capsule 200) and entrains the volatiles released therefrom. As described above, as a result of the first heater 342, the aerosol-forming substrate within the capsule 200 may generate an aerosol by being heated through conduction. Further, as a result of both the first heater 342 and the second heater 344, the heated air entering the capsule 200 may further heat the aerosol-forming substrate through convection to enhance the generation of the aerosol.

[0067] When the generated aerosol within the capsule 200 enters the filter 220, its direction changes to an inward path (e.g., a second radial path) toward the aperture 318 of the conduit portion 316 of the mouthpiece 310. As a result of passing through the filter 220, the generated aerosol becomes a filtered aerosol. The filtered aerosol exits the capsule 200 via the conduit portion 316 of the mouthpiece 310. In particular, when the aperture 318 is a through-hole having two inlets, the filtered aerosol from both inlets converges to form a combined aerosol. The combined aerosol flows (e.g., in a third longitudinal direction) through the internal channels of the conduit portion 316 and the head portion 314 to reach the aerosol outlet 312.

[0068] Although not shown, it should be understood that the aerosol generating device 300 may include additional structures / components configured to provide a desired aesthetic and / or functionality. For example, the aerosol generating device 300 may include an external housing structure designed to be visually appealing, or may include an external housing structure sized to be portable and configured to facilitate handling (e.g., having an ergonomic shape for single-handed operation). Also, a power supply and control circuitry may be provided within the external housing structure. The power supply may include one or more batteries (e.g., an arrangement of rechargeable batteries). The control circuitry may instruct the power supply to supply current to the first heater 342 and the second heater 344. The instruction to supply current from the power supply may be responsive to manual operation (e.g., button actuation) and / or automatic operation (e.g., puff actuation). As a result of the current, the capsule 200 may be heated conductively and / or convectively by the first heater 342 and the second heater 344 to generate an aerosol. The aerosol generated within the capsule 200 may be drawn from the aerosol generating device 300 via the aerosol outlet 312 and optionally an additional mouthpiece accessory.

[0069] Using the capsules and devices disclosed herein, an aerosol-forming substrate can be heated conductively and / or convectively to generate an aerosol. In an exemplary embodiment, a method of generating an aerosol may include heating a capsule including a housing, a filter, and an aerosol-forming substrate. The housing may have a gas-permeable end and a gas-impermeable end. The method may further include directing a suction flow of air along a serpentine path through the capsule. The serpentine path may include an entrained flow section and a filtered flow section. The entrained flow section may extend from the gas-permeable end of the housing, through the aerosol-forming substrate, to the filter. The filtered flow section may extend from the filter to the gas-permeable end of the housing.

[0070] In addition to the non-limiting embodiments described herein, additional details of the substrates, capsules, devices, and methods discussed herein may be described in U.S. Application No. 16 / 451,662, U.S. Application No. 16 / 252,951, U.S. Application No. 15 / 845,501, and U.S. Application No. 15 / 559,308. The disclosure of each of these is hereby incorporated by reference in its entirety. U.S. Application No. 16 / 451,662 was filed on June 25, 2019, has the title "CAPSULES, HEAT-NOT-BURN (HNB) AEROSOL-GENERATING DEVICES, AND METHODS OF GENERATING AN AEROSOL", and has Attorney Docket No. No. 24000NV-000522-US. U.S. Application No. 16 / 252,951 has a filing date of January 21, 2019, has the title "CAPSULES, HEAT-NOT-BURN (HNB) AEROSOL-GENERATING DEVICES, AND METHODS OF GENERATING AN AEROSOL", and has Attorney Docket No. No.24000NV-000521-US. U.S. Application No. 15 / 845,501 was filed on December 18, 2017, has the title "VAPORIZING DEVICES AND METHODS FOR DELIVERING A COMPOUND USING THE SAME", and has Attorney Docket No. No. 24000DM-000012-US. U.S. Application No. 15 / 559,308 was filed on September 18, 2017, has the title "VAPORIZER FOR VAPORIZING AN ACTIVE INGREDIENT", and has Attorney Docket No. 24000DM-000003-US-NP.

[0071] Although numerous exemplary embodiments are disclosed herein, it should be understood that other variations are possible. Such variations are not considered to be a departure from the spirit and scope of the present disclosure, and all such modifications as would be apparent to one of ordinary skill in the art are intended to be included within the scope of the following claims.

Claims

1. A capsule for an aerosol generating device, comprising: a housing having a gas-permeable end portion and a gas-impermeable end portion; a filter disposed in the housing adjacent to the gas-impermeable end portion; an aerosol-forming substrate disposed in the housing between the filter and the gas-permeable end portion, wherein the housing is configured to promote heating of the aerosol-forming substrate via either or both of conduction and convection to generate an aerosol.

2. The capsule according to claim 1, wherein the gas-permeable end portion of the housing is configured to retain the aerosol-forming substrate while allowing air to enter the capsule and the aerosol to exit the capsule.

3. The capsule according to claim 1, wherein the housing includes a container and an end cap.

4. The capsule according to claim 3, wherein the container has a closed end and an open end.

5. The capsule according to claim 4, wherein the end cap is disposed at the open end of the container.

6. The capsule according to claim 4, wherein the end cap is the gas-permeable end portion of the housing, and the closed end of the container is the gas-impermeable end portion.

7. The capsule according to claim 3, wherein most of the end cap is inserted into the container.

8. The capsule according to claim 3, wherein the container is made of metal.

9. The capsule according to claim 8, wherein the metal includes aluminum.

10. The capsule according to claim 3, wherein the end cap includes a plurality of openings.

11. The capsule according to claim 10, wherein the plurality of openings includes an outlet opening surrounded by an inlet opening.

12. The capsule according to claim 11, wherein each of the inlet openings is smaller than the outlet opening.

13. The capsule according to claim 11, wherein the amount and size of the inlet openings are configured to provide the capsule with a draw resistance (RTD) between 90 and 110 mmHg.

14. ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ In the capsule according to claim 11, the outlet opening coincides with the central axis in the longitudinal direction of the container, wherein.

15. In the capsule according to claim 11, the filter includes an orifice oriented in the same direction as the outlet opening of the end cap, wherein.

16. In the capsule according to claim 15, the orifice in the filter is configured such that the passage of the aerosol through the filter includes a radial path towards the orifice, wherein.

17. In the capsule according to claim 15, the orifice in the filter is a central through-hole, wherein.

18. In the capsule according to claim 1, the aerosol-forming substrate includes a plant-based material, wherein.

19. In the capsule according to claim 18, the plant-based material includes tobacco, wherein.

20. An aerosol generating device, comprising: a device body having a compartment configured to receive a capsule containing an aerosol-forming substrate and a filter; a mouthpiece including a conduit portion, the conduit portion being configured to engage with the device body such that the conduit portion extends through the aerosol-forming substrate into the filter of the capsule; a heating assembly within the device body, the heating assembly being configured to heat the aerosol-forming substrate within the capsule via either conduction or convection or both so as to generate an aerosol exiting the capsule via the conduit portion of the mouthpiece; comprising, wherein.

21. In the aerosol generating device according to claim 20, the aerosol-forming substrate and the filter are arranged within the capsule such that air entering the capsule passes through the aerosol-forming substrate before reaching the filter, and the aerosol passes through the filter before exiting the capsule, wherein.

22. A method of generating an aerosol, comprising: heating a capsule including a housing, a filter, and an aerosol-forming substrate; directing a suction flow of air along a serpentine path through the capsule, wherein the housing has a gas-permeable end and a gas-impermeable end, and the serpentine path includes an entrained flow section and a filtered flow section, ​ The entrained flow path portion extends from the gas-permeable end of the housing, through the aerosol-forming substrate, to the filter, and the filtered flow path portion extends from the filter to the gas-permeable end of the housing. Method.

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