Capsule, heat-not-burn (HNB) aerosol generator, and aerosol generation method

Abstract

A capsule for a heat-not-burn (HNB) aerosol generating device can include an inner body and an outer body about the inner body, the inner body and the outer body being concentric, the inner body and the outer body at least partially defining a cavity, an aerosol-forming substrate within the cavity, a first cap at a first end of the cavity, and a second cap at a second end of the cavity, the first cap and the second cap configured to allow air flow from the first end of the cavity to the second end of the cavity.

Description

[Technical field]

[0001] The present disclosure relates to capsules, heat-not-burn (HNB) aerosol generators, and methods for generating aerosols without substantial thermal decomposition of the aerosol-forming substrate.

[0002] Some electronic devices are configured to heat the plant material to a temperature sufficient to release components of the plant material while maintaining the temperature below its ignition temperature so as to avoid self-sustaining or self-sustaining combustion of the plant material (i.e., as opposed to the plant material catching fire like a lit end cigarette). Such devices can be characterized as generating an aerosol of the components released by heating, and may be referred to as heat-not-burn aerosol generating devices, or heat-not-burn devices.

[0003] It is understood that heating the plant material below its ignition temperature may, in some circumstances, produce incidental and insubstantial levels of oxidation or other pyrolysis by-products. However, in some embodiments, the heating in the aerosol generating device is below the pyrolysis temperature of the plant material and produces an aerosol that has no or insubstantial levels of pyrolysis by-products of the plant material. Thus, in exemplary embodiments, pyrolysis of the plant material does not occur during heating and the resulting production of the aerosol. In other embodiments, there may be incidental pyrolysis with the production of insignificant levels of oxidation or other pyrolysis by-products relative to the major components released by heating the plant material. Summary of the Invention

[0004] At least one embodiment relates to a capsule for a heat-not-burn (HNB) aerosol generating device. In an exemplary embodiment, the capsule can include an inner body, an outer body about the inner body, the inner body and the outer body being concentric, the inner body and the outer body at least partially defining a cavity, an aerosol-forming substrate within the cavity, a first cap at a first end of the cavity, and a second cap at a second end of the cavity, the first cap and the second cap configured to permit air flow from the first end of the cavity to the second end of the cavity.

[0005] In at least one exemplary embodiment, the inner body has a higher thermal conductivity than the outer body.

[0006] In at least one exemplary embodiment, the inner body defines an inner receiving area, the inner body includes a plurality of protrusions facing the inner receiving area, the cavity and the inner receiving area being on opposite sides of the inner body.

[0007] In at least one exemplary embodiment, the longitudinal axes of the plurality of projections extend along the length of the inner body.

[0008] In at least one exemplary embodiment, the plurality of protrusions have a rectangular cross-section.

[0009] In at least one exemplary embodiment, the plurality of protrusions have a curved cross-section.

[0010] In at least one exemplary embodiment, the second cap includes a plurality of openings in a circular pattern.

[0011] In at least one exemplary embodiment, the second cap includes a plurality of apertures, the length of the plurality of apertures being perpendicular to a radius of the second cap.

[0012] In at least one exemplary embodiment, the second cap includes a plurality of openings, the long sides of the plurality of openings being in a radial direction of the second cap.

[0013] In at least one exemplary embodiment, the inner body is on the second cap.

[0014] In at least one exemplary embodiment, the inner body includes multiple layers.

[0015] At least one embodiment relates to an aerosol generating device including a capsule including an inner body defining an inner space and an outer body surrounding the inner body, the inner body and the outer body having a common center point, the inner body and the outer body at least partially defining a cavity, an aerosol-forming substrate within the cavity, a first cap at a first end of the cavity, and a second cap at a second end of the cavity, the first cap and the second cap configured to permit air flow from the first end of the cavity to the second end of the cavity, the aerosol generating device further including a heater dimensioned to fit into the inner space and contact the inner body, the heater configured to heat the inner body to generate an aerosol from the aerosol-forming substrate.

[0016] In at least one exemplary embodiment, the inner body has a higher thermal conductivity than the outer body.

[0017] In at least one exemplary embodiment, the inner body defines an inner receiving area, the inner body includes a plurality of protrusions facing the inner receiving area, the cavity and the inner receiving area being on opposite sides of the inner body.

[0018] In at least one exemplary embodiment, the longitudinal axes of the plurality of projections extend along the length of the inner body.

[0019] In at least one exemplary embodiment, the plurality of protrusions have a rectangular cross-section.

[0020] In at least one exemplary embodiment, the plurality of protrusions have a curved cross-section.

[0021] In at least one exemplary embodiment, the second cap includes a plurality of openings in a circular pattern.

[0022] In at least one exemplary embodiment, the second cap includes a plurality of apertures, the long sides of the plurality of apertures being perpendicular to a radius of the second cap.

[0023] In at least one exemplary embodiment, the second cap includes a plurality of openings, the long sides of the plurality of openings being in a radial direction of the second cap.

[0024] In at least one exemplary embodiment, the inner body is on the second cap.

[0025] In at least one exemplary embodiment, the inner body includes multiple layers.

[0026] In at least one exemplary embodiment, upon insertion of the heater, the inner diameter of the inner body expands to accommodate the diameter of the heater.

[0027] In at least one exemplary embodiment, the aerosol generating device further includes a mouthpiece coupled to the capsule. [Brief description of the drawings]

[0028] 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. For clarity, various dimensions of the drawings may be exaggerated.

[0029] [Figure 1A] FIG. 1 illustrates an aerosol generating device in accordance with at least one exemplary embodiment. [Figure 1B] FIG. 1 illustrates an aerosol generating device in accordance with at least one exemplary embodiment. [Figure 1C] FIG. 1 illustrates an aerosol generating device in accordance with at least one exemplary embodiment. [Figure 1D] FIG. 1 illustrates an aerosol generating device in accordance with at least one exemplary embodiment. [Figure 1E] FIG. 1 illustrates an aerosol generating device in accordance with at least one exemplary embodiment. [Figure 1F] FIG. 1 illustrates an aerosol generating device in accordance with at least one exemplary embodiment. [Figure 1G] FIG. 1 illustrates an aerosol generating device in accordance with at least one exemplary embodiment.

[0030] [Figure 2A] FIG. 1 illustrates a capsule in accordance with at least one exemplary embodiment. [Figure 2B] FIG. 1 illustrates a capsule in accordance with at least one exemplary embodiment. [Figure 2C] FIG. 1 illustrates a capsule in accordance with at least one exemplary embodiment. [Figure 2D] FIG. 2 illustrates an inner body of a capsule in accordance with at least one exemplary embodiment.

[0031] [Figure 3A]FIG. 1 illustrates a capsule and heater in accordance with at least some example embodiments. [Figure 3B] FIG. 1 illustrates a capsule and heater in accordance with at least some example embodiments. [Figure 3C] FIG. 1 illustrates a capsule and heater in accordance with at least some example embodiments. [Figure 3D] FIG. 1 illustrates a capsule and heater in accordance with at least some example embodiments.

[0032] [Figure 4A] FIG. 2 illustrates a perspective view of an inner body of a capsule in accordance with at least one exemplary embodiment.

[0033] [Figure 4B] 4B is a side view of the inner body of FIG. 4A;

[0034] [Figure 5A] 13 is a perspective view of an inner body of a capsule in accordance with at least another exemplary embodiment;

[0035] [Figure 5B] FIG. 5B is a side view of the inner body of FIG. 5A.

[0036] [Figure 6A] FIG. 2 illustrates an inner body of a capsule in accordance with at least one exemplary embodiment. [Figure 6B] FIG. 2 illustrates an inner body of a capsule in accordance with at least one exemplary embodiment.

[0037] [Figure 7A] FIG. 2 illustrates an inner body of a capsule in accordance with at least one exemplary embodiment. [Figure 7B] FIG. 2 illustrates an inner body of a capsule in accordance with at least one exemplary embodiment. [Figure 7C]FIG. 2 illustrates an inner body of a capsule in accordance with at least one exemplary embodiment.

[0038] [Figure 8A] FIG. 1 illustrates an end cap in accordance with at least one exemplary embodiment.

[0039] [Figure 8B] FIG. 2B shows the airflow patterns of the inner body using the end caps of FIGS. 2A-3A.

[0040] [Figure 8C] FIG. 8B illustrates the airflow pattern of the inner body using the end cap shown in FIG. 8A.

[0041] [Figure 9A] FIG. 1 illustrates a capsule and mouthpiece in accordance with at least one exemplary embodiment. [Figure 9B] FIG. 1 illustrates a capsule and mouthpiece in accordance with at least one exemplary embodiment. [Figure 9C] FIG. 1 illustrates a capsule and mouthpiece in accordance with at least one exemplary embodiment.

[0042] [Figure 10A] FIG. 1 illustrates an exemplary embodiment of a heater. [Figure 10B] FIG. 1 illustrates an exemplary embodiment of a heater.

[0043] [Figure 11] FIG. 1 is a block diagram of a control system for an apparatus in accordance with at least one example embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0044] Several detailed example embodiments are disclosed herein. However, the specific structural and functional details disclosed herein are merely representative for describing the example embodiments. However, the example embodiments may be embodied in many alternative forms and should not be construed as being limited to only the example embodiments described herein.

[0045] Thus, while exemplary embodiments are susceptible to various modifications and alternative forms, exemplary embodiments thereof are shown by way of example in the drawings and will be described in detail herein. It is to be understood, however, that there is no intention to limit the exemplary embodiments to the particular forms disclosed, but on the contrary, 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.

[0046] When an element or layer is referred to as being "on," "connected," "coupled," "attached," "adjacent," or "overlying" another element or layer, it should be understood that there may be intervening elements or layers that are directly on, connected to, coupled, attached, adjacent, or overlying the other element or layer. In contrast, when an element is referred to as being "directly on," "directly connected," or "directly attached" to another element or layer, there are no intervening elements or layers present. Like numbers refer to like elements throughout this specification. As used herein, the term "and / or" includes any and all combinations or subcombinations of one or more of the associated listed items.

[0047] There are terms such as first, second, third, etc., which should be understood. Although the terms may be used herein to describe various elements, regions, layers, and / or sections, 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 called a second element, region, layer, or section without departing from the teachings of the exemplary embodiments.

[0048] 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 other elements or features as depicted in the figures for ease of description. It should be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the term "below" may encompass both an orientation of above and below. The device may be in other orientations (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0049] 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, unless the context clearly indicates otherwise. It will be further understood that as used herein, the terms "comprises," "comprising," and / or "comprising" 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.

[0050] When the terms "about" and "substantially" are used herein in connection with numerical values, unless expressly defined otherwise, the associated numerical values ​​are intended to include a tolerance of ±10% around the stated numerical value.

[0051] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by those skilled in the art to which the exemplary embodiments belong. 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 should not be interpreted in an idealized or overly formal sense unless expressly defined in this specification.

[0052] The hardware may be implemented using processing or control circuitry such as, but not limited to, one or more processors, one or more central processing units (CPUs), one or more microcontrollers, one or more arithmetic logic units (ALUs), one or more digital signal processors (DSPs), one or more microcomputers, one or more field programmable gate arrays (FPGAs), one or more systems on a chip (SoCs), one or more programmable logic units (PLUs), one or more microprocessors, one or more application specific integrated circuits (ASICs), or any other device or apparatus capable of responding to and executing instructions in a defined manner.

[0053] 1A-1G illustrate an aerosol generating device according to at least one exemplary embodiment.

[0054] FIG. 1A is a front perspective view of an aerosol generating device according to an exemplary embodiment. FIG. 1B is a rear perspective view of the aerosol generating device of FIG. 1A. FIG. 1C is an upstream perspective view of the aerosol generating device of FIG. 1A. Referring to FIGS. 1A-C, an aerosol generating device 10 is configured to receive and heat an aerosol-forming substrate to generate an aerosol. The aerosol generating device 10 includes, among other things, a front housing 1202 coupled to a frame 1208 (e.g., a chassis), a heating module 1203, a rear housing 1204, and a bottom housing 1206. A door 1210 is also pivotally coupled / attached to the front housing 1202. For example, the door 1210 is configured to move or swing about a hinge 1212 and reversibly engage / disengage with the front housing 1202 via a latch 1214 to transition between an open position and a closed position. An aerosol-forming substrate, which may be contained within a capsule 100 (e.g., FIG. 3A), may be loaded into the aerosol generation device 10 via a heating module 1203. During operation of the aerosol generation device 10, the generated aerosol may be drawn from the aerosol generation device 10 via an aerosol outlet 1102 defined by a mouthpiece 1104 of the mouthpiece 1100 (e.g., FIG. 1G).

[0055] As shown in FIG. 1B, the aerosol generating device 10 includes a first button 1218 and a second button 1220. The first button 1218 may be a preheat button, and the second button 1220 may be a power button (or vice versa). Furthermore, one or both of the first button 1218 and the second button 1220 may include a light-emitting diode (LED) configured to emit visible light when the first button 1218 and / or the second button 1220 are pressed. If both the first button 1218 and the second button 1220 include an LED, the emitted light may be the same color or different colors. Also, the lights may be the same intensity or different intensities. Furthermore, the lights may be configured as continuous lights or intermittent lights. For example, the light associated with the power button (e.g., the second button 1220) may flash / blink to indicate that the power source (e.g., the battery) is low and needs to be charged. Although the aerosol generating device 10 is shown as having two buttons, it should be understood that more (e.g., three) or fewer buttons may be provided depending on the desired interface and functionality.

[0056] The aerosol generating device 10 may have a cuboid shape including a front surface, a rear surface opposite the front surface, a first side surface between the front surface and the rear surface, a second side surface opposite the first side surface, a downstream end surface, and an upstream end surface opposite the downstream end surface. As used herein, "upstream" (and conversely "downstream") refers to the flow of aerosol, and "proximal" (and conversely "distal") refers to an adult operator of the aerosol generating device 10 during aerosol generation. Although the aerosol generating device 10 is illustrated as having a cube-like shape (e.g., a rounded rectangular prism) with a polygonal cross-section, it should be understood that the exemplary embodiments are not limited thereto. For example, in some embodiments, the aerosol generating device 10 can have a cylinder-like shape with a circular cross-section (e.g., in the case of a circular cylinder) or an elliptical cross-section (e.g., in the case of an elliptical cylinder).

[0057] As shown in FIG. 1C, the aerosol generating device 10 includes an inlet insert 1222 configured to allow ambient air to enter the device body 1200 (e.g., FIG. 2). In an exemplary embodiment, the inlet insert 1222 defines an orifice as an air inlet in fluid communication with the aerosol outlet 1102. As a result, when a draw (e.g., a puff) or negative pressure is applied to the aerosol outlet 1102, ambient air is drawn into the device body 1200 through the orifice of the inlet insert 1222. The size (e.g., diameter) of the orifice of the inlet insert 1222 is adjusted to provide a desired overall resistance to restriction (RTD), while also taking into account other variables in the flow path (e.g., capsule 100). In other embodiments, the inlet insert 1222 can be omitted entirely, such that the air inlet is defined by the bottom housing 1206.

[0058] The aerosol generating device 10 may further include a jack 1224 and a port 1226. In an exemplary embodiment, the jack 1224 allows for downloading of operational information for research and development (R&D) purposes (e.g., via an RS232 cable). The port 1226 is configured to receive current from an external power source (e.g., via a USB / mini-USB cable) to charge an internal power source within the aerosol generating device 10. In addition, the port 1226 may also be configured to transmit data to and / or receive data (e.g., via a USB / mini-USB cable) from another aerosol generating device or other electronic device (e.g., a phone, tablet, computer). Furthermore, the aerosol generating device 10 may be configured to wirelessly communicate with another electronic device, such as a phone, via application software (app) installed on the electronic device. In such an example, an adult operator may control or otherwise interface with the aerosol generating device 10 (e.g., locate the aerosol generating device, review usage information, change operating parameters) through the app.

[0059] FIG. 1D is a front perspective view of the aerosol generating device of FIGS. 1A-1C, and FIG. 1E shows the mouthpiece 1104 and capsule 100 separated from the device body. With reference to FIGS. 1D-1E, the aerosol generating device 10 includes a device body 1200 configured to receive the capsule 100 and the mouthpiece 1104. In an exemplary embodiment, the device body 1200 defines a receptacle 1228 configured to receive the heating module 1203. The receptacle 1228 may be in the form of a cylindrical socket having diametrically opposed side slots extending outwardly to accommodate the electrical ends / contacts of the heating module 1203. However, it should be understood that the receptacle 1228 may be in other forms based on the shape / configuration of the heating module 1203.

[0060] As described above, the device body 1200 includes a door 1210 configured to open to allow insertion of the capsule 100 and mouthpiece 1104 and configured to close to retain the capsule 100. The mouthpiece 1104 includes a mouth end (e.g., at the outlet 1102) and an opposing capsule end (e.g., for interfacing with the capsule 100 and heating module 1203). In an exemplary embodiment, the capsule end is configured to prevent the mouthpiece 1104 from dislodging from the capsule 100 and heating module 1203 when the door 1210 of the device body 1200 is closed. When received / secured within the device body 1200 and ready for aerosol generation, the capsule 100 is within the heating module 1203 and may be hidden from view while the mouthpiece 1104 defining the aerosol outlet 1102 of the mouthpiece 1100 is visible. As shown, the mouthpiece 1104 may be closer to the front of the device body 1200 than to the rear.

[0061] In some embodiments, the device body 1200 of the aerosol generating device 10 may optionally include a mouthpiece sensor and / or a door sensor. The mouthpiece sensor may be located on the rim of the receptacle 1228 (e.g., adjacent to the front of the device body 1200). The door sensor may be located in a portion of the front housing 1202 adjacent to the hinge 1212 and within the swing path of the door 1210. In an exemplary embodiment, the mouthpiece sensor and the door sensor are spring-loaded (e.g., retractable) protrusions configured as safety switches. For example, the mouthpiece sensor may be retracted / depressed (e.g., activated) when the mouthpiece 1104 is fully engaged with the capsule 100 loaded in the heating module 1203. Additionally, the door sensor may be retracted / depressed (e.g., activated) when the door 1210 is fully closed. In such a case, the control circuitry of the device body 1200 may permit current to be supplied to the capsule 100 to heat the aerosol-forming substrate therein (e.g., pre-heating is permitted when the first button 1218 is pressed). Conversely, the control circuitry of the device body 1200 (e.g., controller 2105) may prevent or stop the supply of current if the mouthpiece sensor and / or the door sensor are not activated or deactivated (e.g., released). Thus, if the mouthpiece 1104 is not fully inserted and / or the door 1210 is not fully closed, heating of the aerosol-forming substrate will not commence. Similarly, if the door 1210 is opened during heating of the aerosol-forming substrate, the current supply to the capsule 100 is interrupted / stopped.

[0062] A capsule 100, described in further detail herein (e.g., shown in Figures 2A-2C), generally includes a housing defining an entrance opening, an exit opening, an inner wall, an outer wall, and a chamber defined by the entrance opening, the exit opening, the inner wall, and the outer wall. An aerosol-forming substrate is disposed within the chamber of the housing. Additionally, a heater may extend into the space defined by the inner and outer walls of the housing.

[0063] The control circuitry can instruct the power source to provide current to the heater. The current from the power source can be provided in response to manual (e.g., button activation) or automatic (e.g., draw / puff activation). As a result of the current, the capsule 100 can be heated to generate an aerosol. Furthermore, changes in the resistance of the heater can be used to monitor and control the aerosolization temperature. The generated aerosol can be inhaled from the aerosol generating device 10 via the mouthpiece 1104. Furthermore, the control circuitry (e.g., controller 2105) can provide current from the power source to the heater to maintain the temperature of the capsule 100 during the draw.

[0064] FIG. 1F is a cross-sectional view of the aerosol generating device 10 taken along line 1F-1F' in FIG. 1D. FIG. 1G is a cross-sectional view of the aerosol generating device 10 taken along line 1G-1G' in FIG. 1D. Referring to FIG. 1F-1G, the frame 1208 (e.g., a metal chassis) serves as a base for the internal components of the aerosol generating device 10, which may be directly or indirectly attached thereto. With respect to the structures / components shown in the figures and already described above, it should be understood that such related teachings are also applicable to this section and have not been repeated for the sake of brevity. In the exemplary embodiment, the bottom housing 1206 is fixed to the upstream end of the frame 1208. Between the receptacle 1228 and the bottom housing 1206 is an inlet channel 1230 configured to direct an incoming flow of ambient air along path A to the capsule 100 in the receptacle 1228. The inlet insert 1222, through which incoming air may enter the aerosol generation device 10, may be disposed at a distal end of the inlet channel 1230. Additionally, the receptacle 1228 and / or the inlet channel 1230 may include a flow sensor 1231 (e.g., an integrated flow sensor that detects at least one of the magnitude of airflow, the direction of airflow, a pressure change, or a pressure magnitude).

[0065] The power source 1234 therein (e.g., FIG. 2E) may be attached to the rear side of the frame 1208. Electrical connections may be provided to facilitate the supply of electrical current to establish an electrical connection with the heater 1300 (e.g., in the receptacle 1228) in the heating module 1203. For example, the electrical connection 1236a may establish the necessary electrical connection between the power source 1234 and the heater 1300 via the two electrodes of the heater 1300 and a control circuit (e.g., the controller 2105) on the first printed circuit board (PCB) 1238. The electrical connection 1236a may be a pair of wires connected to the two electrodes. However, the illustrated embodiment is not limited thereto.

[0066] The aerosol generating device 10 may also include multiple printed circuit boards (PCBs) configured to facilitate its operation. In an exemplary embodiment, a first printed circuit board 1238 (e.g., a bridge PCB for power and I2C) and a second printed circuit board 1240 (e.g., a human machine interface (HMI) PCB) are connected to the frame 1208. In another example, a third printed circuit board 1242 (e.g., a serial port PCB) is fixed to the front of the frame 1208 and is located behind the inlet channel 1230. However, it should be understood that the exemplary embodiments of the printed circuit boards herein should not be construed as limiting, as their size, shape, and location may vary depending on the desired characteristics of the aerosol generating device 10.

[0067] PCB 1238 provides power from power supply 1234 to electrical connection 1236a when a condition of retraction is reached (eg, when the device is powered on and a predetermined pressure change is reached).

[0068] The mouthpiece 1104 defines an aerosol outlet 1102 in the form of a single outlet or multiple small outlets (e.g., 2-6 outlets). In one embodiment, the multiple outlets may be in the form of four outlets. The outlets may be radially arranged and / or angled outwardly to emit diverging streams of aerosol.

[0069] In an exemplary embodiment, at least one of a filter or a flavor medium may be optionally disposed within the mouthpiece 1104. In such an example, the filter and / or flavor medium are downstream from the chamber 1305 of the capsule 100 such that the aerosol generated therein passes through at least one of the filter or flavor medium before exiting through the at least one aerosol outlet 1102. The filter may reduce or prevent particles from the aerosol-forming substrate (e.g., from being inadvertently inhaled from the capsule 100). The filter may also help lower the temperature of the aerosol to provide a desired mouthfeel. The flavor medium (e.g., flavor beads) may release flavorings as the aerosol passes therethrough to impart a desired flavor to the aerosol. The flavorings may be the same as those described above in connection with the aerosol-forming substrate. Additionally, the filter and / or flavor medium may have a coupled or loose form as described above in connection with the aerosol-forming substrate.

[0070] The first annular member 150a (e.g., a resilient O-ring) is upstream of the capsule 100 and prevents air from flowing through the holder 1307 for the heater 1300 when the capsule 100 is fully inserted into the heating module 1203, establishing an air seal between the heater 1300 and the capsule. The aerosol generating device 10 may also include a second annular member 150b (e.g., a resilient O-ring) seated in the receptacle 1228. As a result, most, if not all, of the air drawn into the heating module 1203 passes through the annular portion of the capsule 100. In an exemplary embodiment, the first annular member 150a and the second annular member 150b may be formed of clear silicone.

[0071] The power source 1234 may be a 900 mAh battery, but the example embodiment is not limited thereto. In view of the sensor 1231 and the first button 1218 and the second button 1220, the operation of the aerosol generating device 10 may be automatic (e.g., puff-activated) or manual (e.g., button-activated). In at least one example embodiment, the sensor 1231 may be a microelectromechanical system (MEMS) flow or pressure sensor, or another type of sensor configured to measure airflow, such as a hot wire anemometer.

[0072] When the aerosol generating device 10 is activated, the capsule 100 in the device body 1200 may be heated to generate an aerosol. In an exemplary embodiment, activation of the aerosol generating device 10 may be triggered by detection of airflow by the sensor 1231 and / or generation of a signal associated with pressing the first button 1218 and / or the second button 1220. With respect to airflow detection, drawing or application of negative pressure to the aerosol outlet 1102 of the mouthpiece 1104 draws ambient air into the device body 1200 via the inlet channel 1230, where the air may first pass through the inlet insert 1222. Once inside the device body 1200, the air travels through the inlet channel 1230 and is detected by the sensor 1231. After the sensor 1231, the air continues through the receptacle 1228 and enters the capsule 100 in the area around the heater 1300. Specifically, the air flows through an opening in the capsule 100. Additionally, control circuitry (e.g., controller 2105) may provide current from power supply 1234 to heater 1300 to maintain the temperature of the capsule 100 during the draw.

[0073] Detection of airflow by the sensor 1231 can cause the control circuit to provide current to the heater 1300 via the electrical connection 1236a. This results in an increase in temperature of the heater 1300, which in turn increases the temperature of the capsule 100 by thermal conduction, which in turn increases the temperature of the aerosol-forming substrate in the chamber of the capsule 100, which releases volatile substances to generate aerosol. The generated aerosol is entrained in the air flowing in the chamber. In particular, the aerosol generated in the chamber exits the aerosol generating device 10 from the aerosol outlet 1102 of the mouthpiece 1104.

[0074] 2A-2C illustrate a capsule according to at least one exemplary embodiment. More specifically, FIG. 2A illustrates a perspective view of capsule 200, FIG. 2B illustrates a cross-sectional view of capsule 200 along line B-B', and FIG. 2C illustrates a top view of capsule 200.

[0075] As shown in FIG. 2B, the capsule 200 includes an outer body 215, an inner body 250, and end caps 280a, 280b.

[0076] The outer body 215 may be cylindrical with a single wall 217 and may be referred to as an outer tube. Although some exemplary embodiments are described as the outer body 215 being cylindrical, exemplary embodiments are not limited thereto and the outer body 215 may be rectangular or other shapes having interior space.

[0077] The wall 217 defines openings 219, 220 at opposite ends 222, 224, respectively, of the outer body 215. Ends 222 and 224 are opposite ends of the outer body 215. The wall 217 further defines an inner space 226 within the outer body 215 that extends from one end 222 to end 224. In some exemplary embodiments, the outer body 215 may include aluminum, paperboard, pulp, plastic, combinations thereof, or subcombinations thereof.

[0078] In some exemplary embodiments, the thickness of wall 217 is between 100 and 200 μm when wall 217 is metal. In exemplary embodiments in which outer body 215 is a plastic or paper-based material (e.g., pulp or paperboard), the thickness of the outer body may be between 800 and 1500 μm. Wall 255 (described below) may have the same thickness as wall 217. Capsule 200 may have a height (or length) of about 15 mm to 20 mm (e.g., 16.3 mm), although exemplary embodiments are not limited thereto.

[0079] End caps 280 reside in the openings 219, 220, respectively.

[0080] As shown in FIGS. 2A-2C, the end cap 280 includes a first circular portion 282, an inner wall 284, and a second circular portion 286.

[0081] The first circular portion 282 has a minimum outer diameter OD1_MIN that is greater than the outer diameter OD2 of the outer body 215 such that a portion of the first circular portion 282 can overlap each of the ends 222, 224 of the outer body 215. The maximum diameter of the first circular portion is about 10 to 11 mm (e.g., 10.6 mm).

[0082] A first surface 284a of the inner wall 284 defines an inner diameter and circumference of the first circular portion 282. The inner wall 284 extends from the first circular portion 282 to the second circular portion 286 such that the first circular portion 282 and the second circular portion 286 are on different planes but are parallel. In the example shown in FIG. 2B, the inner wall 284 is perpendicular to the first circular portion 282 and the second circular portion 286. However, exemplary embodiments are not limited in this respect and the inner wall can extend from the first circular portion 282 to the second circular portion 286 at any angle.

[0083] The outer diameter of the inner wall 284 and the outer diameter of the second circular portion 286 are such that the second circular portion 286 can be inserted into the outer body as a friction fit. Thus, the end cap 280 may be a compressible material, and the outer diameter of the second circular portion 286 may be greater than the inner diameter of the outer body 215 before the second circular portion 286 of the end cap 280 is inserted into the outer body 215.

[0084] The end caps 280 may be made of a thermally insulating material such as plastic, paperboard, pulp, combinations thereof, or subcombinations thereof. The end caps 280 reduce energy transfer from the inner body 250 to the outer body 215 and provide a temperature gradient within the aerosol-forming substrate.

[0085] Second circular portion 286 defines a concentric opening 292 extending therethrough. More specifically, second circular portion 286 includes a circular cold rolled end 294 that defines concentric opening 292. In the example shown in FIG. 2B, concentric opening 292 is circular, but may also be polygonal, such as a square or triangle.

[0086] The second circular portion further includes a plurality of openings 296 .

[0087] The plurality of apertures 296 are circularly arranged within the second circular portion 286 such that the plurality of apertures 296 form a circle concentric with the concentric opening 292. The apertures 296 may extend through the end cap 280 and be equidistantly spaced apart, although the example embodiment is not limited in this respect. The number of apertures 296 may be based on computational fluid dynamics analysis.

[0088] The openings 296 allow air to enter the capsule 200. More specifically, air enters through the openings 296, flows into the inner space 226, and exits through the openings 296 in the opposing end cap.

[0089] The opening 296 is sized such that the aerosol-forming substrate does not fall out of the opening and is not drawn out of the capsule. In some exemplary embodiments, the width of the opening 296 is 0.3 mm. In other exemplary embodiments, the diameter of the opening 296 may be larger or smaller depending on the particle size of the aerosol-forming substrate in the capsule 200. In some exemplary embodiments where the opening is not circular, the opening may have a length of 2 mm and / or a length equal to the thickness of the aerosol-generating substrate bed (e.g., a bed of tobacco). As described in more detail below, the shape of the opening may vary based on the desired airflow and temperature of the aerosol exiting the capsule 200.

[0090] The inner body 250 extends within the outer body 215 along the longitudinal axis of the outer body 215 .

[0091] The inner body 250 may be cylindrical with a single wall 255 and may be referred to as an inner tube. The inner body 250 may have the same length as the outer body 215, and may be 15 mm or about 15 mm. In other exemplary embodiments, the lengths may be different and / or the inner body 250 and the outer body 215 may have different lengths.

[0092] Although some exemplary embodiments are described with the inner body 250 being cylindrical, exemplary embodiments are not limited thereto and the inner body 250 may be rectangular or other shapes having an interior space. For example, the inner body 250a may include fins 298 that extend into the aerosol-forming substrate 299, as shown in FIG. 2D. Furthermore, as shown in FIG. 2D, the capsule is not limited to a cylindrical shape. For example, the outer body of the capsule may be shaped as described in U.S. Publication No. 17 / 151,340, the entire contents of which are incorporated herein by reference.

[0093] The inner body 250 extends through a concentric opening 292 in one end cap 280 and extends through a concentric opening 292 in the opposing end cap 280. The single wall 255 may also include rolled edges 260 that are rolled onto the cold rolled ends 294, respectively, to connect the inner body 250 to the end caps 280. In other exemplary embodiments, the inner body 250 may be connected to the end caps 280 by, for example, a snap fit connection, a swaging connection, an adhesive connection, or a friction fit connection. In other exemplary embodiments, the outer body 215 and the end caps 280 may be connected by welding the outer body 215 and the end caps 280 together.

[0094] The wall 255 can have a thickness to transfer sufficient heat to the aerosol-forming substrate, sustain a load that arises when the heater is inserted into the inner body 250, and deform to provide the desired thermal contact with the heater. In some exemplary embodiments, the thickness of the wall 255 can be at or about 0.1 mm.

[0095] The inner surface of wall 255 defines openings 261, 262 into inner body 250. Openings 261, 262 may be coplanar with ends 222, 224, respectively, and / or the apex of rolled edge 260. Ends 222 and 224 are opposing ends of outer body 215. The inner surface of wall 255 further defines an inner space 265 within inner body 250 that extends from one apex of rolled edge 260 to the apex of the opposing edge 260 (e.g., extends the length of inner body 250 along the longitudinal axis of inner body 250).

[0096] The wall 255, the wall 217 and the end cap 280 define a cavity 270 for accommodating the aerosol-forming substrate. In an exemplary embodiment, the cavity 270 is the volume between the wall 255, the wall 217 and the end cap 280. The length within the cavity 270 between the two end caps 280 is 10-15 mm (e.g., 12.1 mm). It should be understood that the length between the two end caps 280 can be increased or decreased to vary the volume of material within the cavity 270. Additionally, increasing the length between the two end caps 280 may increase the resistance to withdrawal (RTD). In some exemplary embodiments, the width of the cavity 270 (the distance between the wall 255 and the wall 217) may be 2 mm. The inner diameter of the wall 255 defining the space 265 may be 3-4 mm (e.g., 3.2 mm). In some exemplary embodiments, the cavity is about 450-500 mm. 3 (For example, 480 mm 3 )

[0097] Cavity 270 may be annular, with wall 255 providing an inner annular boundary and wall 217 providing an outer annular boundary, although the example embodiment is not so limited. End cap 280 prevents the aerosol-forming substrate from exiting the space between wall 255 and wall 217.

[0098] The outer body 215 and the inner body 250 may be made of the same material or different materials. The outer body 215 and the inner body 250 may each comprise a suitable thermally conductive material, such as aluminum, an aluminum alloy, stainless steel, a copper alloy, or combinations thereof. In some exemplary embodiments, the outer body 215 may be paperboard, pulp, plastic, combinations thereof, or subcombinations thereof.

[0099] End cap 280 may be a thermally conductive or non-thermally conductive material. In some exemplary embodiments, the end cap is a non-thermally conductive material to increase the energy delivered to the material (e.g., the aerosol-forming substrate) within cavity 270.

[0100] 2C, the first circular portion 282 includes tabs 290 disposed at periodic intervals around the circumference of the first circular portion 282. However, example embodiments are not limited thereto, and the first circular portion 282 may exclude the tabs 290. The tabs 290 minimize / reduce heat exposure to an external housing (e.g., the housing of the aerosol generating device).

[0101] 3A-3D illustrate a capsule and heater according to at least some example embodiments.

[0102] As shown in Figure 3A, the heater 300 may be inserted into the space 265 of the inner body 250. The heater 300 may extend the entire length of the cavity 270. The heater 300 may be the heater 1300 described with reference to Figures 1F and 1G.

[0103] In the exemplary embodiment, heater 300 is in thermal communication with capsule 200 .

[0104] In the exemplary embodiment, the heater 300 heats an aerosol-forming substrate 320 within the capsule 200 to generate an aerosol 322. In the exemplary embodiment, at least a portion of the heater 300 contacts the capsule 200 such that heat generated by the heater 300 is transferred to the capsule 200. The capsule 200 is made of a thermally conductive material and utilizes the heat generated by the heater 300 to heat the aerosol-forming substrate 320.

[0105] In some exemplary embodiments, the heater 300 warms the inner body 250, and the inner body 250 transfers heat from the heater 300 to the aerosol-forming substrate 320, but the heater 300 does not burn and / or combust the aerosol-forming substrate 320. In some exemplary embodiments, the heater 300 includes a sleeve that acts as a shim and increases contact with the capsule 200. Additionally or alternatively, the inner body 250 is designed to increase contact and heat transfer between the heater 300 and the capsule 200.

[0106] The heater 300 may heat the aerosol-forming substrate 320 to a temperature between 125° C. and 320° C., and more preferably between 250° C. and 280° C., although example embodiments are not so limited. For example, the heater 300 may be controlled to heat at a desired temperature based on the type of aerosol-forming substrate 320 in the capsule 200, the density of the aerosol-forming substrate in the capsule 200, the additives in the aerosol-forming substrate, subcombinations thereof, or combinations thereof. Additionally, the heater 300 may be controlled using a proportional-integral-derivative controller that uses multiple temperature set points to normalize aerosol generation.

[0107] The air flows along the path 330 and enters the capsule 200 through the opening 296a. The heater 300 is capable of heating the aerosol-forming substrate 320 to an extent that the flavoring, nicotine and / or ingredients in the aerosol-forming substrate 320 are at least partially extracted (e.g., aerosolized) to create an aerosol 322 that is extracted from the aerosol-forming substrate 320. The heater 300 heats the capsule 200 and the aerosol-forming substrate 320 to an extent that the aerosol-forming substrate 320 and the flavoring, nicotine and / or other materials of the aerosol-forming substrate 320 remain below their combustion temperature.

[0108] As a result, the air mixes with the aerosol-forming substrate 320 to form an aerosol 322, which exits the capsule 200 through the opening 296b.

[0109] As discussed herein, an aerosol-forming substrate is a material or combination of materials that can produce an aerosol. Aerosols relate to substances that are generated or output by the disclosed and claimed, and equivalents thereof. The material can include a compound (e.g., nicotine, cannabinoids, cannabimimetic agents) that is released when the material is heated. In such cases, when the material is heated, an aerosol containing the compound is generated. The heating can be below the ignition temperature to avoid self-sustaining or self-sustaining combustion of the material (i.e., as opposed to the material being ignited like a lit cigarette). It is understood that heating a material below its ignition temperature may, in some circumstances, generate accidental and insubstantial levels of oxidation or other pyrolysis byproducts. However, in some embodiments, the heating in the aerosol generating device is below the pyrolysis temperature of the material and generates an aerosol that has no or insubstantial levels of pyrolysis byproducts of the material. Thus, in exemplary embodiments, pyrolysis of the material does not occur during the heating and resulting generation of the aerosol. In other examples, there may be incidental pyrolysis involving the production of oxidation or other pyrolysis by-products at insignificant levels relative to the primary components released upon heating of the material.

[0110] The aerosol-forming substrate material can include a fibrous material. For example, the fibrous material can be a plant material. The fibrous material is configured to release a compound when heated. The compound can be a naturally occurring component of the fibrous material. For example, the fibrous material is a plant material such as tobacco, and the released compound is 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 tobacco plants, such as Nicotiana rustica and Nicotiana tabacum.

[0111] In some exemplary embodiments, the tobacco material may include material from any member of the Nicotiana genus. Additionally, the tobacco raw material may include a blend of two or more different tobacco varieties. Examples of suitable types of tobacco raw materials 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, processed tobacco materials, such as tobacco lamina, volume-expanded tobacco or puffed tobacco, processed tobacco stems, such as cut rolled stems or cut puffed stems, reconstituted tobacco materials, blends thereof, and the like. In some exemplary embodiments, the tobacco material is in the form of a substantially dried mass of tobacco. Additionally, in some embodiments, the tobacco material may be mixed and / or combined with at least one of propylene glycol, glycerin, subcombinations thereof, or combinations thereof.

[0112] The compounds in the generated aerosol may also be naturally occurring components of medicinal plants that have medically recognized physiological effects (e.g., therapeutic effects, prophylactic effects). For example, the medicinal plants may be cannabis plants or cannabimimetic plants (i.e., plants that have similar pharmacological effects as cannabis). In the case of cannabis plants, the compounds may be cannabinoids. Cannabinoids interact with receptors in the body, resulting in a variety of actions. As a result, cannabinoids have been used for a variety of medicinal purposes (e.g., treatment of pain, nausea, epilepsy, psychiatric disorders, etc.). The fibrous material may include leaf and / or flower material of one or more cannabis plants, such as Cannabis sativa, Cannabis indica, and Cannabis ruderalis. In one embodiment, the fibrous material is a mixture of 60-80% (e.g., 70%) Cannabis sativa and 20-40% (e.g., 30%) Cannabis indica. In the case of cannabimimetic plants, the compounds may be cannabimimetic agents. Cannabimimetic agents interact with receptors in the body and produce pharmacological effects similar to those of cannabinoids.

[0113] Examples of cannabinoids include tetrahydrocannabinolic acid (THCA), tetrahydrocannabinol (THC), cannabidiol acid (CBDA), cannabidiol (CBD), cannabinol (CBN), cannabicyclol (CBL), cannabichromene (CBC), and cannabigerol (CBG). Tetrahydrocannabinolic acid (THCA) is the precursor of tetrahydrocannabinol (THC), and cannabidiol acid (CBDA) is the precursor of cannabidiol (CBD). Tetrahydrocannabinolic acid (THCA) and cannabidiol acid (CBDA) can be converted to tetrahydrocannabinol (THC) and cannabidiol (CBD), respectively, by heating. In an exemplary embodiment, heat from a heater (e.g., of the heating assembly 340 shown in FIG. 8) can cause decarboxylation to convert tetrahydrocannabinolic acid (THCA) to tetrahydrocannabinol (THC) and / or cannabidiol acid (CBDA) to cannabidiol (CBD).

[0114] When both tetrahydrocannabinolic acid (THCA) and tetrahydrocannabinol (THC) are present, decarboxylation and the resulting conversion will result in a decrease in tetrahydrocannabinolic acid (THCA) and an increase in tetrahydrocannabinol (THC). At least 50% (e.g., at least 87%) of tetrahydrocannabinolic acid (THCA) may be converted to tetrahydrocannabinol (THC) during heating. Similarly, when both cannabidiolic acid (CBDA) and cannabidiol (CBD) are present, decarboxylation and the resulting conversion will result in a decrease in cannabidiolic acid (CBDA) and an increase in cannabidiol (CBD). At least 50% (e.g., at least 87%) of cannabidiol acid (CBDA) may be converted to cannabidiol (CBD) during heating.

[0115] Furthermore, the compound to be released may be or may further include a non-naturally occurring additive that is subsequently introduced into the fibrous material. In one example, the fibrous material may include 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 (e.g., a non-tobacco and / or non-cannabis material). In either example, the compound to be introduced may include nicotine, a cannabinoid, a cannabimimetic agent, and / or a flavoring agent. The flavoring agent is obtained from a natural source, such as a plant extract (e.g., tobacco extract, cannabis extract, cannabimimetic extract), and / or an artificial source. In yet another example, when the fibrous material includes tobacco and / or cannabis, the compound may be or may additionally include one or more flavoring agents (e.g., menthol, mint, vanilla). Thus, the compound in the aerosol-forming substrate may include naturally occurring components and / or non-naturally occurring additives. In this regard, it should be understood that the existing level of a naturally occurring component of an aerosol-forming substrate may be increased by supplementation. For example, the amount of nicotine contained in a cigarette can be increased by supplementing with an extract containing nicotine. Similarly, the existing level of one or more cannabinoids contained in a quantity of cannabis can be increased by supplementing with an extract containing such cannabinoids. Similarly, the existing level of one or more cannabimimetic agents in a quantity of cannabimimetic material can be increased by supplementing with an extract containing such cannabimimetic agents.

[0116] In at least some exemplary embodiments, cavity 270 can contain between 180 and 320 mg of tobacco.

[0117] Heater 300 has a cylindrical shape. In at least some exemplary embodiments, heater 300 is shaped to fit into space 265 and contact wall 255.

[0118] The heater 300 may be a ceramic cartridge heater that heats the capsule 200 by conduction. In another exemplary embodiment, the heater 300 may include a heating coil wound around a ceramic mandrel.

[0119] In some exemplary embodiments, the heater 300 may be a machined heater that includes a central spine formed from a high temperature material (e.g., ceramic) and a resistive heating coil wound around the spine. The resistive heating coil is configured to heat the spine, which in turn heats the capsule.

[0120] In another example embodiment, the heater 300 may be a filament heater that includes a glass tube that encases a wire-wound resistive heating coil. The heating coil is in thermal contact with the inner surface of the tube, and the outer surface is in direct thermal contact with the capsule. In another example embodiment, the filament heater may include a heater stamped or printed on a flexible substrate instead of a resistive coil. The heater may be rolled up and placed inside a glass tube (or thin stainless steel tubing).

[0121] The heater may be cylindrical and is connected to wires 326a and 326b to receive power from a power source via a controller (e.g., controller 2105). Wires 326a and 326b may be electrical connections 1236a shown in FIGS. 1F-1G.

[0122] The heater 300 is configured to heat the aerosol-forming substrate, which may result in an increase in the temperature of the aerosol-forming substrate and the generation of an aerosol.

[0123] In an exemplary embodiment, the heater 300 is configured to undergo Joule heating (also known as Ohmic / resistive heating) upon application of an electric current. More specifically, the heater 300 may be formed of conductors (same or different) and configured to generate heat when an electric current passes through the conductor. The electric current may be provided by a power source. Suitable conductors for the heater 300 include iron-based alloys (e.g., stainless steel) and / or nickel-based alloys (e.g., nichrome). The heater 300 has a resistance of 1 Ω, and the heater 400 has a diameter of about 2 mm and a length of about 15 mm. Additionally, although the heater is shown as cylindrical in FIGS. 3A-3D, it should be understood that in some exemplary embodiments, the heater may be of a different shape.

[0124] Current from the power source may be transmitted through electrodes / wires 326a and 326b connected to the heater 300. Additionally, the supply of current to the heater 300 may be manually operated (e.g., button activated) or automatically operated (e.g., puff activated).

[0125] The mount 350 holds the heater 300. The mount 350 includes an inner annular portion 355 and an outer portion 380. The inner annular portion 355 is initially within a first portion 382 of the outer portion 380. The inner annular portion 355 includes a number of protrusions 357 that protrude into an inner space of the inner annular portion 355. The protrusions 357 form a connection interface with the heater 300. The protrusions 357 contact the heater 300 and provide sufficient friction with the heater 300 to prevent the heater 300 from being separated from the mount 350 when the capsule 200 is pulled out of the heater 300.

[0126] The plurality of protrusions 357 reduce the amount of contact between the mount 350 and the heater 300 .

[0127] The second section 384 of the outer portion has a smaller inner diameter than the first section 382. The electrodes / wires 326a and 326b extend through the second section 384 and couple to the heater 300.

[0128] Mount 350 may be a high temperature plastic, such as liquid crystal polymer (LCP), polyetheretherketone (PEEK), and / or a high temperature ceramic (e.g., relatively high temperature rating and relatively low thermal conductivity). Inner annular portion 355 and outer portion 380 may be the same material to match thermal expansion.

[0129] 3B-3C show an exemplary embodiment of a heater that includes a sleeve.

[0130] 3B, the heater 300b includes a heat generating post 395b with fins 397b extending around the heat generating post 395b. When the heater 300b is inserted into the inner body 250, the fins 397b contact the wall 255 and are compressed toward the heat generating post 395b. The fins 397b transfer heat from the heat generating post 395b to the wall 255 of the inner body 20.

[0131] 3C, the heater 300c includes a heat generating post 395c and a C-shaped sleeve 397c around the heat generating post 395c. When the heater 300c is inserted into the inner body 250, the C-shaped sleeve 397c contacts the inner body 250 and is compressed toward the heat generating post 395c. The C-shaped sleeve 397c transfers heat from the heat generating post 395b to the wall 255 of the inner body 250.

[0132] Heater 300d, shown in FIG. 3D, is the same as heater 300c, except that the C-shaped sleeve and heating post are angled (as shown in region 398) to increase contact between the heating post and the C-shaped sleeve.

[0133] FIG. 4A illustrates a perspective view of an inner body of a capsule according to at least one exemplary embodiment, and FIG. 4B illustrates a side view of the inner body of FIG. 4A.

[0134] 4A-4B illustrate an inner body 250a according to at least one exemplary embodiment. The inner body 250a is similar to the inner body 250, and the inner body 250a may be used in the capsule 200. Therefore, for the sake of brevity, the differences between the inner body 250a and the inner body 250 will be described.

[0135] The inner body 250a includes a wall 255a. The wall 255a defines an inner space 465 of the inner body 250a. The wall 255a includes a plurality of ribs 415 that form recesses in an outer surface of the wall 255a and protrude into the inner space 465. The ribs 415 are rectangular in shape. As the ribs 415 protrude into the inner space 265, the ribs 415 enable direct thermal contact between the inner body 250a and the heater 300.

[0136] The ribs 415 extend along the longitudinal axis of the inner body 250a. In the example shown in FIG. 4A, the wall 255a includes flats 420a and 420b at opposing ends 222a and 224a, respectively. The flats 420a and 420b are flat surfaces of the wall 255a around the circumference of a selected length of the wall 255a. The ribs 415 extend between the flats 420a and 420b. The ribs 415 function as a shim between the wall 255a and the heater.

[0137] In another exemplary embodiment, the ribs 415 may extend the entire length of the inner body 250a.

[0138] The ribs 415 are semi-flexible and compress when the heater is inserted into the inner body 250 to create a friction fit and allow direct contact between the ribs 415 and the heater. The heater may contact the ribs 415 over the entire length of the ribs. As shown in FIG. 4B, the ribs 415 have a rectangular cross-section.

[0139] FIG. 5A is a perspective view of an inner body of a capsule in accordance with at least one exemplary embodiment, and FIG. 5B is a side view of the inner body of FIG. 5A.

[0140] 5A-5B illustrate an inner body 250b according to at least one exemplary embodiment. The inner body 250b is similar to the inner body 250a, and the inner body 250b may be used in the capsule 200. Therefore, for the sake of brevity, the differences between the inner body 250b and the inner body 250a will be described.

[0141] Inner body 250b is the same as inner body 250, except that inner body 250b includes a plurality of ribs 515 that are curved instead of rectangular. More specifically, each rib 515 includes a first linear side 520 and a second linear side 522. A rounded side 524 connects first linear side 520 and second linear side 522 at a first end, and a rounded side 526 connects first linear side 520 and second linear side 522 at a second end. First linear side 520, second linear side 522, rounded side 524, and rounded side 526 define an edge of concave surface 530.

[0142] In the exemplary embodiment shown in Figures 4A-4B and 5A-5B, the ribs 415 and 515 are formed after the cylindrical body of the inner body is formed. For example, a thin sheet of aluminum is rolled into a cylindrical shape and pressed to form the ribs. In embodiments where the sheet is longer than the inner body, the sheet is cut after the ribs are formed, thereby producing multiple inner bodies.

[0143] The thickness and number of ribs can be determined based on empirical data or using finite element analysis (FEA). The thickness of the ribs is also based on the heater width tolerance and the ability to remain flexible while maintaining the desired thermal contact capability with the heater.

[0144] 6A-6B illustrate an inner body according to at least one exemplary embodiment.

[0145] 6A is a top view of the inner body 600. The dimensions and material of the inner body 600 can be the same as those of the inner body 250.

[0146] The inner body 600 is similar to the inner body 250, except that the inner body 600 includes a rolled sheet that is formed into a plurality of layers 610a, 610b, 610c in a coiled shape to create a biased spring in the position shown in Figure 6A. More specifically, the sheet is rolled from a first tongue 620 (the innermost portion of the inner body 600) to a second tongue 625 (the outermost portion of the inner body 600). The layers 610a, 610b, 610c overlap.

[0147] The wall thickness is not constant because of overlap caused by coiling. The inner diameter of the coil body is set smaller than the outer diameter of the heater to ensure that the coil body can flex outward to rest on the heater. In an exemplary embodiment, the inner diameter of the coiled body can be set to 2.9 mm for use with a heater with an outer diameter of 3.2 mm (i.e., ensuring contact under all manufacturing tolerances).

[0148] The outer diameter of the inner body 600 is based on the thickness of the sheet (e.g., 50 μm, 100 μm or 150 μm, and the number of turns, e.g., 2 or 3). The number of turns is a way to control the force and strength of the spring. In an exemplary embodiment, for a 100 μm sheet and two full wraps (i.e., 2 or 3 layer thickness), the outer diameter of the coil body will be 3.1 to 3.2 mm (i.e., 2.9 + 2 x 0.1 to 2.9 + 3 x 0.1).

[0149] The inner diameter of the inner body 600 is smaller than the diameter of the heater 300. Thus, when the heater 300 is inserted into the inner body 600 or the inner body 600 is placed on the heater 300, the rolled sheet expands / partially unwinds, causing the inner diameter of the inner body 600 to expand to a diameter larger than that of the heater 300. The bias of the inner body coils and springs increases the thermal conductivity between the inner body 600 and the heater 300.

[0150] The bias of the coils and springs of the inner body 600 increases the proportion of the inner body that is in direct thermal contact with the heater 300 when the inner body 600 is inserted over the heater 300, thus improving thermal conductivity between the inner body 600 and the heater.

[0151] Although the number of layers is three, it should be understood that there may be more or fewer layers and the layers may be more or less thick.

[0152] To manufacture the inner body 600, a central mandrel can be used in a rolling operation that provides the desired curvature of the first tongue 620 of the sheet.

[0153] 6B shows a cross-sectional view of inner body 600 within capsule 650. Capsule 650 is similar to capsule 200, except that capsule 650 includes an inner body 600.

[0154] 7A-7C illustrate an inner body according to at least one example embodiment.

[0155] 7A shows an inner body 700 according to an exemplary embodiment. The inner body 700 is similar to the inner body 600 except that the inner body 700 includes a number of grooves 705 at the ends 710 and 715 of the inner body 700. The grooves 705 may be, but are not limited to, U-shaped. The grooves may be other shapes that allow the ends 710, 715 to be rolled / swung over the end cap 280.

[0156] Figure 7B shows the heater inserted into an inner body 700. The arrangement in Figure 7B is the same as that shown in Figure 3A, except that an inner body 700 is included and ends 710, 715 are not rolled / swaged.

[0157] As shown in FIG. 7C, groove 705 stretches as end 710 is rolled / swung onto end cap 280 to form tab 720.

[0158] Figure 8A illustrates an end cap according to at least one exemplary embodiment, Figure 8B illustrates the airflow patterns of an inner body using the end caps of Figures 2A-3A, and Figure 8C illustrates the airflow patterns of an inner body using the end cap shown in Figure 8A.

[0159] As shown in FIG. 8A, the end cap 800 includes a plurality of apertures 810 arranged in a circular pattern. The end cap 800 is the same as the end cap 280 except for the apertures. Therefore, for the sake of brevity, only the differences will be described. As shown in FIG. 2C, the length of the apertures 296 in the end cap 280 extends in a direction perpendicular to the circumferential axis of the second circular portion 286. In contrast, in FIG. 8A, the length of the apertures 810 extends along and / or parallel to the circumferential axis of the second circular portion 286. Although 22 apertures are shown, it should be understood that the end cap 800 may include more or less than 22 apertures. In the example shown in FIG. 8A, the apertures 810 are located at the outermost edge of the second circular portion 286 (i.e., with a length equal to the radius from the center C of the second circular portion 286).

[0160] Although FIG. 8A illustrates the openings 810 at the outermost edge of the second circular portion 286, it should be understood that the openings 810 may be closer to the center C and may be arranged in a non-circular pattern.

[0161] The openings 810 can be positioned to produce a desired airflow pattern and temperature. For example, Figure 8B shows the airflow pattern of the inner body using end cap 280, and Figure 8C shows the airflow pattern of the inner body using end cap 800 (shown in Figure 8A). For simplicity, elements of the capsule are not shown in Figures 8B-8C.

[0162] 8B , air flow 820 generally flows a distance d1 from heater 300 due to the length of opening 296 in end cap 280 extending in a direction perpendicular to the circumferential axis of second circular portion 286. In contrast, air flow 830 generally flows a distance d2 from heater 300 due to the length of opening 296 in end cap 280 extending in a direction along and / or parallel to the circumferential axis of second circular portion 286 and opening 810 being at the outermost edge of second circular portion 286. Distance d2 is greater than distance d1. At distance d2, air is moving through a region of the substrate that is further away from the heater surface and therefore a cooler region of the substrate.

[0163] As a result, generated aerosol 835 exits capsule 840 at a lower temperature than generated aerosol 825 exiting capsule 845. Capsule 845 is the same as the capsule shown in Figures 2A-3A, and capsule 840 is the same as the capsule shown in Figures 2A-3A with end cap 800 instead of end cap 280. As mentioned above, the openings may be positioned differently than those shown in Figures 2A-3A and 8 to produce different desired airflow patterns and temperatures.

[0164] Figures 9A-9C show an exemplary embodiment of a capsule integrated into a mouthpiece. Figure 9A shows a first perspective view of the integrated capsule and mouthpiece 900. Figure 9B shows a second perspective view of the integrated capsule and mouthpiece 900. Figure 9C shows a cross-sectional view of the integrated capsule and mouthpiece 900 along line 9-9.

[0165] As shown in Figures 9A and 9C, the one-piece mouthpiece includes a mouthpiece 910 and a capsule 920. The mouthpiece 910 defines a channel 912 that communicates with the capsule 920. In the exemplary embodiment shown in Figures 9A and 9C, the mouthpiece 910 is cylindrical. However, in other example embodiments, the mouthpiece may be other shapes, such as a rectangular prism.

[0166] The mouthpiece 910 includes a first cylindrical portion 930 , a second cylindrical portion 935 and a third cylindrical portion 937 .

[0167] The mouthpiece 910 may be a recyclable and / or degradable material, such as aluminum, cardboard, or a biological polymer. Additionally, the aluminum may be uncoated. However, a cardboard mouthpiece may also be coated with a polymer. In some exemplary embodiments, the mouthpiece 910 may include a sticker on the exterior surface to maintain the structural integrity of the mouthpiece 910.

[0168] As shown in FIG. 9C, the channel 912 gradually increases in diameter from the first end 942 of the first cylindrical portion 930 to the outlet end 945 of the mouthpiece 910.

[0169] The capsule 920 may be coupled to the mouthpiece 910 by a friction fit. The capsule 920 includes an outer cylindrical wall 940. An inner diameter of the outer cylindrical wall 940 may be dimensioned such that the third cylindrical portion 937 may be inserted into a space within the outer cylindrical wall 940 to form a friction fit. It should be understood that although the exemplary embodiments have been described with respect to a cylindrical friction fit, the exemplary embodiments are not limited thereto.

[0170] Mouthpiece 910 and capsule 920 are coupled such that, upon application of negative pressure, air flows through an opening in capsule 920 into channel 912 and out through outlet 945 .

[0171] The capsule 920 includes an inner body 955 and an outer body 960. As with the exemplary embodiment described with reference to Figures 2A-7C, the inner body 955 and the outer body 960 are concentric. The inner body 955 may be the same as the inner body 700.

[0172] 9C, the outer body 960 defines the overall length of the cavity 970. End caps 950 are fitted over either end of the outer body 960. The end caps 950 are attached to the inner body 955 by swaging and folding the inner tube 955 over a portion of the end caps 950.

[0173] 10A illustrates an exemplary embodiment of a heater. According to the exemplary embodiment, a heater 10000 can be used in a capsule. As shown, the heater 10000 includes a flat region 10005 and a grooved region 10010. Both the flat region 10005 and the grooved region 10010 extend from a neck portion 10015 of the heater 10000 to a tapered portion 10020 at the opposite end of the heater 10000.

[0174] Both the flat region 10005 and the grooved region 10010 extend helically along the heater 10000 such that the flat segments 10005a and the grooved segments 10010a alternate when viewed from the side. The heater wire 10025 is disposed within the grooved region 10010. The heater wire 10025 forms a minor diameter of the heater 10000 that may not contact the capsule when the heater 10000 is inserted into the capsule. The flat region 10005 defines a major diameter of the heater 10000 and contacts the capsule when the heater 10000 is inserted into the capsule. The heater 10000 may further include a mounting portion 10030 for mounting the heater 10000 to a heater holder.

[0175] The flat region 10005 and the grooved region 10010 may be made from the same material, which may be a high temperature material such as ceramic.

[0176] Wires 10035 and 10040 extend through the holder and connect to or form part of the heater wire 10025 .

[0177] FIG. 10B shows an exemplary embodiment of a heater. According to an exemplary embodiment, a heater 10500 can be used in the capsule. The heater 10500 includes a glass tube 10505 and a holder 10510 that holds the glass tube 10505. The glass tube 10505 can be cylindrical, but is not limited thereto. For example, the glass tube 10505 can be shaped to be inserted into the capsule, and thus the shape of the glass tube 10505 can correspond to the shape of an inner space (e.g., space 265) in the inner body (e.g., inner body 250) of the capsule. A spiral heater 10515 extends into a cavity 10520 defined by a wall 10525 of the glass tube 10505. The spiral heater 10515 can extend over the entire length of the glass tube 10505. A portion of the spiral heater 10515 contacts the glass tube 10505. As a result, when the spiral heater 10515 generates heat, the spiral heater 10515 transfers the heat to the glass tube 10505 .

[0178] Wires 10535 and 10540 extend through the holder 10510 and connect to or form part of the spiral heater 10515 .

[0179] 11 is a block diagram of a control system of the device according to at least one exemplary embodiment. In an exemplary embodiment, the control system 11000 includes a controller 2105 operably connected to the power source 1234 and the sensor 1231. In an exemplary embodiment, the controller 2105 receives input signal(s) from the sensor(s) 1231, and the controller 2105 controls the operation of the aerosol generating device 10, including providing current from the power source 1234 to the heater 11005 to heat the aerosol generating substrate, based at least in part on the signal(s) from the sensor(s) 1231. The heater 11005 may be any heater described according to an exemplary embodiment, for example, the heater 1300 and / or the heater 300.

[0180] In the exemplary embodiment, the control system 11000 is operatively and electrically connected to the heater via an electrical connection 1236 a that enables the control system 11000 to selectively send electrical current to the heater 11005 .

[0181] While a number of exemplary embodiments have been disclosed herein, it should be understood that other variations are possible. Such variations are not to be regarded as departing from the spirit and scope of the present disclosure, and all such modifications that would be obvious to one skilled 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: an inner body defining an inner receiving area configured to receive a heater and including a rolled sheet forming a plurality of spring-loaded layers; an outer body around the inner body, the inner body and the outer body having the same center point, the inner body and the outer body at least partially defining a cavity; an aerosol-forming substrate within the cavity; a first cap at a first end of the cavity; a second cap at a second end of the cavity; the cavity and the inner receiving area are on opposite sides of the spring-biased layers, whereby the spring-biased layers at least partially define the cavity and the spring-biased layers at least partially define the inner receiving area; The capsule, wherein the first cap and the second cap are configured to allow air to flow from a first end of the cavity to a second end of the cavity.

2. The capsule of claim 1, The capsule, wherein the inner body has a higher thermal conductivity than the outer body.

3. The capsule of claim 1, The capsule, wherein the second cap includes a plurality of openings in a circular pattern.

4. The capsule of claim 1, the second cap includes a plurality of openings; A capsule, wherein the long sides of the plurality of openings are perpendicular to the radius of the second cap.

5. The capsule of claim 1, the second cap includes a plurality of openings; A capsule, wherein the long sides of the plurality of openings are in a radial direction of the second cap.

6. The capsule of claim 1, The capsule, wherein the inner body is overlying the second cap.

7. An aerosol generating device comprising: a capsule; and a heater; The capsule comprises: an inner body defining an inner space and including a rolled sheet forming a plurality of spring-loaded layers; an outer body around the inner body, the inner body and the outer body having the same center point, the inner body and the outer body at least partially defining a cavity; an aerosol-forming substrate within the cavity; a first cap at a first end of the cavity; a second cap at a second end of the cavity; the cavity and the inner space are on opposite sides of the spring-biased layers, whereby the spring-biased layers at least partially define the cavity and the spring-biased layers at least partially define the inner space; the first cap and the second cap are configured to allow air to flow from a first end of the cavity to a second end of the cavity; The heater is a housing sized to fit into the inner space and contact the inner body; an aerosol generating device configured to heat the inner body to generate an aerosol from the aerosol-forming substrate;

8. The aerosol generating device according to claim 7, The aerosol generating device, wherein the inner body has a higher thermal conductivity than the outer body.

9. The aerosol generating device according to claim 7, The aerosol generating device, wherein the second cap includes a plurality of openings in a circular pattern.

10. The aerosol generating device according to claim 7, the second cap includes a plurality of openings; An aerosol generating device, wherein the long sides of the plurality of openings are perpendicular to the radius of the second cap.

11. The aerosol generating device according to claim 7, the second cap includes a plurality of openings; An aerosol generating device, wherein the long sides of the plurality of openings are in the radial direction of the second cap.

12. The aerosol generating device according to claim 7, The aerosol generating device, wherein the inner body is on top of the second cap.

13. The aerosol generating device according to claim 7, An aerosol generating device, wherein the inner diameter of the inner body expands to correspond to the diameter of the heater when the heater is inserted.

14. The aerosol generating device according to claim 7, The aerosol generating device further includes a mouthpiece coupled to the capsule.

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