Cap Assembly for Aerosol-Generating Devices

Abstract

The present disclosure provides a cap assembly (100) for an aerosol generating device, the cap assembly comprising an outer casing (120), the outer casing comprising polyphenylene oxide. The present disclosure also provides an aerosol generating device comprising the cap assembly.

Description

[Technical Field]

[0001] This application claims priority from European Patent Application Publication No. EP22214682.1, filed December 19, 2022, the contents and elements of which are incorporated herein by reference for all purposes.

[0002] The present disclosure relates to a cap assembly for an aerosol generating device. [Background technology]

[0003] A typical aerosol generating device may comprise a power source, an aerosol generating unit driven by the power source, an aerosol precursor that is aerosolized by the aerosol generating unit during use to generate an aerosol, and a delivery system for delivering the aerosol to a user.

[0004] A drawback of known aerosol generating devices is that the materials from which the aerosol generating device is made may not have the necessary material properties to enable optimal performance of the aerosol generating device.

[0005] Thus, despite the effort already invested in the development of aerosol generating devices, further improvements are desirable. Summary of the Invention

[0006] The present disclosure provides a cap assembly for an aerosol generating device, the cap assembly including an outer casing. In some examples, the outer casing comprises polyphenylene oxide. In this manner, the outer casing can benefit from the advantageous material properties of polyphenylene oxide, such as high heat resistance, high thermal stability, high impact strength, high shatter resistance, high chemical resistance, high fire resistance, high dimensional stability, low water absorption, and low density. The use of polyphenylene oxide may provide a favorable cost-to-benefit ratio compared to alternative materials that provide similar material properties at a desired material operating point. For example, the selection of polyphenylene oxide may provide reasonably high heat resistance at a reasonably low material volume and at a reasonably low cost.

[0007] The inventors have recognized that fabricating the outer casing from an alternative material, such as polycarbonate, may lead to cracking of the outer casing when the outer casing is subjected to repeated thermal cycles, for example, when the outer casing is subjected to repeated thermal cycles due to repeated heating from a heat source located within the outer casing. The inventors have recognized that an outer casing made at least in part from polyphenylene oxide may not suffer from the same cracking problems observed to occur with polycarbonate outer casings. The inventors have also recognized that the outer casing may be most susceptible to cracking when exposed to a heat source along an unobstructed line of sight. Therefore, it may be advantageous to include polyphenylene oxide in locations on the outer casing that are exposed to a heat source along an unobstructed line of sight. The combination of high dimensional stability and high heat resistance may allow a smaller volume of material to be used to manufacture the outer casing while simultaneously achieving the same functionality. An unobstructed line of sight may be understood to be an unobstructed field of view between two points. In the above context, an unobstructed line of sight may be understood as an unobstructed field of view between a point on the outer casing and the heat source when no consumables are inserted in the outer casing.

[0008] The material polyphenylene oxide is sometimes written as poly(p-phenylene oxide) and abbreviated as PPO. The material polyphenylene is sometimes known as polyphenylene ether, and polyphenylene ether is sometimes written as poly(p-phenylene ether) and abbreviated as PPE. The material polyphenylene oxide is sometimes called a high-temperature thermoplastic material.

[0009] In some examples, the outer casing comprises a blend of polyphenylene oxide and polystyrene. In this manner, the material performance of the outer casing can be improved. In some examples, the type of polystyrene used is high impact polystyrene, sometimes abbreviated as HIPS. In some examples, the outer casing comprises NORYL™ resin. In some examples, the blend of polyphenylene oxide and polystyrene is glass reinforced. In some examples, the blend of polyphenylene oxide and polystyrene is at least 10% glass reinforced. In some examples, the blend of polyphenylene oxide and polystyrene is at least 20% glass reinforced. The glass reinforcement may improve the mechanical strength of the material and, therefore, the mechanical strength of the outer casing.

[0010] In some examples, the outer casing includes one or more heat dissipation elements. In this way, the efficiency of the cap assembly may be improved because less heat may be dissipated into the surrounding environment. Furthermore, the one or more heat dissipation elements may protect the outer casing from heat exposure, which may allow the outer casing to be thinner. The inclusion of polyphenylene oxide in the outer casing may synergistically combine with these features to reduce the cost of the cap assembly. This is because reducing the heat exposure of the outer casing may allow the inclusion of polyphenylene oxide without suffering degradation due to high heat exposure. In other words, the selection of polyphenylene oxide for the cap assembly may represent an optimal choice that balances a suitable level of heat resistance and a suitable material volume at a suitable cost. The selection of materials used for any product is inherently a trade-off between material performance and material cost, and in this way, the inventors believe they have identified the optimal selection and use of the material polyphenylene oxide in a cap assembly for an aerosol generating device. In some examples, at least one of the heat dissipation elements is a metal plate. In some examples, the one or more heat dissipating elements are positioned parallel to an outer surface of the outer casing. In some examples, the one or more heat dissipating elements are positioned adjacent to an inner surface of the outer casing. In some examples, the one or more heat dissipating elements are held within the outer casing by friction. In some examples, the one or more heat dissipating elements are held within the outer casing by one or more clips.

[0011] In some examples, the aerosol generating device is configured to deliver an aerosol to a user for inhalation by the user. In this manner, a chemical substance, such as nicotine, can be delivered to a user for inhalation.

[0012] In some examples, the aerosol-generating device is configured to generate an aerosol by heating an aerosol-forming substrate. The aerosol-forming substrate may be a solid precursor. The solid precursor may include tobacco. Items used with the aerosol-generating device, including the aerosol-forming substrate, may be referred to as consumables. In this manner, chemicals present in the aerosol-forming substrate, such as nicotine, can be aerosolized to form an aerosol. This aerosol may be delivered to a user for inhalation.

[0013] In some examples, the cap assembly further comprises an inner chassis. In some examples, the inner chassis comprises polyetheretherketone. In some examples, the inner chassis is located within the outer casing. In this manner, the inner chassis can benefit from the advantageous material properties of polyetheretherketone, such as high heat resistance, high thermal stability, high impact strength, high shatter resistance, high chemical resistance, high fire resistance, high biodegradability resistance, low water absorption, and low density. The use of polyetheretherketone may provide a favorable cost-to-benefit ratio compared to alternative materials that provide similar material properties at a desired material operating point.

[0014] The inventors have recognized that polyetheretherketone is well suited for use in components located in close proximity to a heat source. This is because polyetheretherketone is resistant to degradation when heated or subjected to repeated heating cycles. The inventors have also recognized that other materials, such as polyphenylene oxide, also exhibit a high degree of heat resistance but are much more affordable than polyetheretherketone. Thus, the inventors have recognized that using a combination of materials at different locations, depending on, for example, proximity to a heat source, can result in a cap assembly that is both highly thermoresilient and affordable.

[0015] The material polyetheretherketone is sometimes written as polyether ether ketone and abbreviated as PEEK. The material polyetheretherketone is sometimes called a high-temperature thermoplastic material.

[0016] In some examples, the inner chassis may include two or more sections separated by insulation. In this way, the outer casing may be better insulated in a manner that may reduce the likelihood of the outer casing deteriorating due to heat exposure. In some examples, this insulation is an air gap.

[0017] In some examples, one or more heat dissipation elements are disposed between the inner chassis and the outer casing. In this manner, the outer casing can be better insulated from the inner chassis, thereby preventing the outer casing from deteriorating due to heat exposure. The use of one or more heat dissipation elements may improve the lifespan of the outer casing by reducing the magnitude of the thermal load experienced by the outer casing.

[0018] In some examples, the inner chassis includes an inner wall defining a consumable-receiving cavity and an outer wall positioned between the inner wall and the outer casing, the outer wall defining an insulating cavity positioned between the consumable-receiving cavity and the outer casing to provide thermal insulation between the consumable-receiving cavity and the outer casing. In some examples, the consumable-receiving cavity is configured to receive a heater and to engage a consumable, the consumable including an aerosol-generating substrate for heating by the heater. In some examples, the inner wall and the outer wall are integrally formed from the same material.

[0019] In this manner, heat exposure of the outer casing can be reduced, which can allow the outer casing to include polyphenylene oxide, which may not be as heat-resistant as other materials such as polyetheretherketone but may be more affordable than other materials such as polyetheretherketone. Therefore, using polyphenylene oxide when possible can reduce the overall cost of the cap assembly. In this manner, the user experience can be enhanced because the outer casing can be at a lower temperature, which can improve the user experience and safety, for example. Furthermore, the efficiency of the cap assembly can be improved because less heat can be dissipated into the surrounding environment. Furthermore, manufacturing of the aerosol generating device can be simplified. Furthermore, the consumable receiving cavity can allow for simple loading of the consumable into the inner chassis.

[0020] Defining a cavity may mean defining a boundary of the cavity. The inner wall may define a boundary of the consumable-receiving cavity. The inner surface of the inner wall may define a boundary of the consumable-receiving cavity. The outer wall may define a boundary of the insulating cavity. The inner surface of the outer wall and the outer surface of the inner wall may together define a boundary of the insulating cavity.

[0021] In some examples, the inner chassis further includes an insulating opening to the insulating cavity, which connects the insulating cavity to the ambient atmosphere. In other words, in some examples, the insulating cavity is not completely enclosed. In this manner, manufacturing of the cap assembly can be simplified. In particular, molding of the inner chassis can be facilitated. For example, a mold that may form the inner chassis may include a protruding element that creates the insulating cavity. This protruding element may be connected to another portion of the mold that creates the insulating opening.

[0022] In some examples, the insulating cavity and the consumable-receiving cavity open in opposite directions. In this way, manufacturing of the aerosol generating device can be simplified, particularly molding of the inner chassis can be facilitated, for example, improving the ease of removal of injection-molded components.

[0023] In some examples, the inner wall is tapered. In other words, in some examples, the inner wall thickness at a first end of the inner wall is greater than the inner wall thickness at a second end of the inner wall. The first end of the inner wall may be adjacent to the consumable-receiving aperture. The second end of the inner wall may be adjacent to a base of the inner wall configured to engage with the heater. In this manner, manufacturing of the cap assembly may be simplified. For example, molding of the inner chassis may be facilitated. For example, ease of removal of injection-molded components may be improved.

[0024] In some examples, the outer wall is tapered. In other words, in some examples, the thickness of the outer wall at the first end of the inner wall is greater than the thickness of the outer wall at the second end of the outer wall. The first end of the outer wall may be the end closest to the consumable-receiving aperture. The second end of the outer wall may be adjacent to a base of the outer wall configured to engage with the heater. In this manner, manufacturing of the cap assembly may be simplified. For example, molding of the inner chassis may be facilitated. For example, ease of removal of injection-molded components may be improved.

[0025] In some examples, the insulating cavity is tapered. In other words, in some examples, the width of the insulating cavity at the second end of the insulating cavity is greater than the width of the insulating cavity at the first end of the insulating cavity. The first end of the insulating cavity may be the end closest to the consumable receiving aperture. The second end of the insulating cavity may be adjacent to a base of the outer wall configured to engage with the heater. In this manner, manufacturing of the cap assembly may be simplified. For example, molding of the inner chassis may be facilitated. For example, ease of removal of injection-molded components may be improved.

[0026] In some instances, the tapering of the insulating cavity is the result of a tapered inner wall. In some instances, the tapering of the insulating cavity is the result of a tapered outer wall. In some instances, the tapering of the insulating cavity is the result of tapering both the inner and outer walls.

[0027] In some examples, the consumable receiving cavity is tapered. In other words, in some examples, the width of the consumable receiving cavity at a first end of the consumable receiving cavity is greater than the width of the consumable receiving cavity at a second end of the consumable receiving cavity. The first end of the consumable receiving cavity may be adjacent to the consumable receiving aperture. The second end of the consumable receiving cavity may be adjacent to a base of the inner wall configured to engage with the heater. In this manner, manufacturing of the cap assembly may be simplified. For example, molding of the consumable engaging component may be facilitated. For example, ease of removal of an injection-molded component may be improved.

[0028] In some instances, the tapering of the consumable-receiving cavity is the result of a tapered inner wall. In some instances, the direction in which the insulating cavity is tapered is opposite the direction in which the outer wall is tapered. In some instances, the direction in which the insulating cavity is tapered is opposite the direction in which the inner wall is tapered.

[0029] In some examples, the consumable receiving cavity and the insulating cavity are elongated vertically in the same direction. The corresponding longitudinal axes of the consumable receiving cavity and the insulating cavity may be aligned. In this manner, manufacturing of the cap assembly may be simplified. For example, molding of the inner chassis may be facilitated. For example, ease of ejection of injection-molded components may be improved.

[0030] In some examples, the aerosol-generating device further includes a heater, and the inner chassis is configured to receive at least a portion of the heater. In this manner, the heater can be used to heat a consumable located within the inner chassis to generate the aerosol. The consumable may include an aerosol-forming substrate that may form an aerosol when heated.

[0031] In some examples, the inner chassis includes a heater-receiving aperture. In this way, a portion of the heater can be located within the inner chassis while a different portion of the heater can be located outside the inner chassis.

[0032] In some examples, the inner chassis is integrally formed from polyetheretherketone. In this manner, ease of manufacture can be improved by forming the inner chassis from a single piece of material, thus potentially reducing the number of separate parts to assemble. Forming the inner chassis integrally can lead to an inner chassis structure with improved mechanical strength, and therefore an inner chassis structure that potentially requires less material volume and therefore potentially requires less material cost.

[0033] In some examples, the outer casing is integrally formed from polyphenylene oxide. In this manner, ease of manufacture can be improved by forming the outer casing from a single piece of material, thereby potentially reducing the number of separate parts to assemble. Forming the outer casing integrally can lead to an outer casing structure with improved mechanical strength, and therefore potentially reducing the required material volume and therefore the required material cost.

[0034] In some examples, the outer casing includes a consumable-receiving aperture such that at least a portion of the consumable can be inserted into the inner chassis through the consumable-receiving aperture.

[0035] In some examples, the consumable-receiving aperture may generally conform to the outer surface of the consumable. In this way, the consumable-receiving aperture may support the consumable when the consumable is inserted through the consumable-receiving aperture. There may be a friction fit between the consumable and the consumable-receiving aperture. The friction fit may prevent the consumable from slipping out of the consumable-receiving aperture.

[0036] In some examples, the cap assembly further comprises a closure, and the consumable receiving aperture is selectably blocked by the closure, thus preventing debris from entering the inner chassis at the user's discretion.

[0037] In some examples, the closure comprises polyphenylene oxide, and in this way the closure can benefit from the above-mentioned material properties of polyphenylene oxide.

[0038] In some instances, the closure includes a blend of polyphenylene oxide and polystyrene, thereby improving the material performance of the outer casing. In some instances, the type of polystyrene used is high impact polystyrene, sometimes abbreviated as HIPS.

[0039] In some examples, the closure is integrally formed from polyphenylene oxide. In this manner, ease of manufacture can be improved by forming the closure from a single piece of material, thereby potentially reducing the number of separate parts to assemble. Forming the closure integrally can lead to a closure structure with improved mechanical strength, and therefore potentially reducing the required material volume and therefore the required material cost.

[0040] In some examples, the outer surface of the closure is flush with the outer surface of the outer casing, thereby reducing the likelihood of the closure accidentally transitioning between an open position, in which the consumable-receiving aperture is exposed, and a closed position, in which the consumable-receiving aperture is blocked.

[0041] In some examples, the closure includes an attachment mechanism. In this manner, the closure can be attached to either the outer casing or the inner chassis. In some examples, the closure includes one or more attachment pegs. In some examples, the inner chassis includes one or more peg-receiving slots. In some examples, each attachment peg is positioned within a corresponding respective peg-receiving slot such that the closure is attached to the inner chassis. In some examples, the outer casing includes one or more peg-receiving slots. In some examples, each attachment peg is positioned within a corresponding respective peg-receiving slot such that the closure is attached to the outer casing.

[0042] In some examples, the inner chassis includes a consumable-receiving cavity, and the consumable-receiving aperture is an entrance to the consumable-receiving cavity. In this manner, the consumable can be inserted into the consumable-receiving cavity through the consumable-receiving aperture.

[0043] In some examples, the closure is pivotally mounted adjacent the consumable-receiving aperture and is selectively pivotable relative to the outer casing about a pivot axis to adopt an open position in which the consumable-receiving aperture is exposed and a closed position in which the consumable-receiving aperture is obstructed, thereby preventing debris from entering the inner chassis.

[0044] In some examples, the cap assembly further includes a closure control mechanism configured to control the position of the closure in a bistable manner, where the open position is a stable equilibrium position, the closed position is a stable equilibrium position, and the intermediate position is an unstable equilibrium position, thereby improving ease of operation of the closure.

[0045] In some instances, a closure control mechanism biases the closure to the open position. In this way, the functionality of the cap assembly can be improved. For example, the closure can be automatically moved to the open position, and the closure can be held in the open position. This can be useful, for example, when cleaning the consumable receiving cavity.

[0046] In some instances, a closure control mechanism biases the closure to the closed position. In this manner, the functionality of the cap assembly can be improved. For example, the closure can be automatically moved to the closed position and can be held in the closed position. This can be useful, for example, to prevent unwanted debris from entering the consumable-receiving cavity.

[0047] The term adapting may be understood to mean being stable in a referenced position. The term adapting may also be understood to mean moving to a referenced position and then being stable in that position. For example, if a user moves a closure from an intermediate position between the open and closed positions toward the open position, there may be a point at which the closure experiences a force and / or torque that moves the closure toward the open position and then becomes stable in the open position. For example, if a user moves a closure from an intermediate position between the open and closed positions toward the closed position, there may be a point at which the closure experiences a force and / or torque that moves the closure toward the closed position and then becomes stable in the closed position. It should be apparent that the two examples described above are not mutually exclusive and that a single cap assembly according to the present disclosure can bias a closure to both the open and closed positions.

[0048] In some examples, the closure control mechanism includes a lower secondary mechanism arranged to bias the closure to the open position. In this manner, the functionality of the cap assembly can be improved, for example, by preventing accidental transitions between the open and closed positions. This can be useful when cleaning the consumable-receiving cavity. The term lower in this context is used for identification purposes only and should not be construed as conveying any functional purpose.

[0049] In some examples, the closure control mechanism includes an upper sub-mechanism arranged to bias the closure to the closed position. In this manner, the functionality of the cap assembly can be improved, for example, by preventing accidental transitions between the closed and open positions. This can be useful in preventing unwanted debris from entering the consumable-receiving cavity. The term upper in this context is used for identification purposes only and should not be construed as conveying any functional purpose.

[0050] In some examples, each sub-mechanism includes a first magnetic element and a second magnetic element, which are either a first magnet and a second magnet, a magnet and a ferromagnetic element, or a ferromagnetic element and a magnet, respectively. In this manner, each sub-mechanism can bias the closure by magnetic attraction between the first magnetic element in the first position and the second magnetic element in the second position. The use of magnetic elements may result in improved durability of the cap assembly.

[0051] In some examples, the first portion of the closure includes the first magnetic element of the lower secondary mechanism, and the outer casing includes the second magnetic element of the lower secondary mechanism, such that the closure is biased to the open position. In this manner, when the closure is moved past the intermediate position toward the open position, the magnetic attraction between the first magnetic element of the lower secondary mechanism and the second magnetic element of the lower secondary mechanism may be the dominant force / torque acting on the closure such that the closure is biased to the open position. The position of the second magnetic element of the lower secondary mechanism within the outer casing may be selected such that, when the closure is in the open position, the first magnetic element of the lower secondary mechanism and the second magnetic element of the lower secondary mechanism are in close proximity to each other such that the magnetic attraction between these two magnetic elements overcomes any other forces / torques acting on the closure from the closure control mechanism. In some examples, the second magnetic element is positioned adjacent to the consumable receiving cavity.

[0052] In some examples, the closure includes a first magnetic element receiving cavity that accommodates the first magnetic element and a second magnetic element receiving cavity that accommodates the second magnetic element. In this manner, the first magnetic element and the second magnetic element can be retained within the closure. In some examples, each magnetic element is retained within its respective magnetic element receiving cavity by a frictional push fit. In some examples, each magnetic element receiving cavity includes at least one deformable element. In this manner, internal stresses within the closure can be reduced, potentially reducing the likelihood of crack propagation. Crush ribs are an example of a deformable element.

[0053] The inventors have recognized that including at least one deformable element in each magnetic element receiving cavity, coupled with fabricating the closure from polyphenylene oxide, may reduce the likelihood of crack propagation in the closure. The inventors have recognized that closures made of polycarbonate that do not include a deformable element may suffer from crack propagation due to internal stresses, such as those caused by inserting and retaining a magnetic element within the closure's magnetic element receiving cavity. The inventors have recognized that thermal cycling of the closure through repeated exposure to a heat source may further exacerbate crack propagation in polycarbonate closures. For at least this reason, it may be beneficial to form the closure from polyphenylene oxide and include at least one deformable element in each corresponding respective magnetic element receiving cavity.

[0054] In some examples, at least one deformable element is formed on a surface of the closure that defines the magnetic element receiving cavity. In this manner, ease of closure manufacture can be improved. In some examples, each magnetic element receiving cavity includes multiple deformable elements. In this manner, retention of the magnetic element within the magnetic element receiving cavity can be improved. Also, in this manner, induced stress on the surface of the closure that defines the magnetic element receiving cavity can be reduced. In some examples, the multiple deformable elements are evenly distributed about the periphery of the magnetic element receiving cavity. In some examples, the at least one deformable element is aligned with the direction of insertion of the magnetic element into the magnetic element receiving cavity. In this manner, the magnetic element can be better retained by the at least one deformable element.

[0055] In some examples, the surface of the inner chassis defining the consumable receiving cavity comprises polyetheretherketone. In this manner, the portion of the inner chassis defining the consumable receiving cavity can benefit from the above-described material properties of polyetheretherketone. Also, in this manner, the outer casing can be better insulated from the consumable receiving cavity, thereby preventing deterioration of the outer casing. In some examples, the heater has a non-uniform rotational heating profile about the longitudinal axis of the heater. In this manner, ease of heater manufacture can be improved. In some examples, the portion of the inner chassis defining the consumable receiving cavity comprises polyetheretherketone at a location where the non-uniform rotational heating profile exceeds a predetermined threshold.

[0056] In some examples, the cap assembly further includes one or more engagement mechanisms that retain the inner chassis within the outer casing. The one or more engagement mechanisms may include one or more protrusions. The one or more engagement mechanisms may include one or more corresponding protrusion-receiving cavities. The protrusions may be located on the inner chassis, the outer casing, or both. The protrusion-receiving cavities may be located within the inner chassis, the outer casing, or both.

[0057] In some instances, both the inner chassis and the outer casing include corresponding complementary interlocking elements, such that the inner chassis can be retained within the outer casing. Examples of complementary interlocking elements would be threaded holes and screws or bolts.

[0058] In some examples, the inner chassis is held within the outer casing by one or more screws, which can improve ease of assembly by allowing the inner chassis and outer casing to be connected together in a faster and more efficient manner.

[0059] In some examples, the inner chassis is held within the outer casing by a single screw, which in some examples may be configured to facilitate partial movement of the inner chassis within the outer casing.

[0060] In some examples, at least one of the one or more screws is located through the inner chassis, which may be better retained within the outer casing because the screw may be less likely to become separated from the inner chassis.

[0061] In some examples, the inner chassis is held within the outer casing by one or more clips. In this manner, ease of assembly can be improved by allowing the inner chassis and outer casing to be connected together in a faster and more efficient manner. In some examples, the one or more clips are located adjacent to the consumable-receiving cavity.

[0062] In some examples, the inner chassis is held within the outer casing by two clips. In some examples, the inner chassis is held within the outer casing by two clips and a screw. In some examples, the two clips and the screw are located on opposite sides of the consumable-receiving cavity. In this manner, the inner chassis can be assembled with the outer casing by first engaging the inner chassis with the outer casing with the two clips, and then pivoting the inner chassis about the two clips so that the screws at least partially secure the inner chassis to the outer casing.

[0063] In some examples, one or more insulating layers are included between the inner chassis and the outer casing. In this way, the heat transfer coefficient between the inner chassis and the outer casing can be reduced, thereby potentially preventing the user from being burned. The insulating layer or layers may include an air gap.

[0064] The present disclosure also provides an aerosol generating device including a cap assembly according to the present disclosure. In this manner, the advantageous material properties of polyphenylene oxide described above can, for example, prevent a user of the aerosol generating device from being burned. Furthermore, the use of polyphenylene oxide can, for example, prevent cracking of the outer casing, thereby extending the usable life of the aerosol generating device. Exemplary advantageous material properties of polyphenylene oxide include high heat resistance, high thermal stability, high impact strength, high shatter resistance, high chemical resistance, high fire resistance, high dimensional stability, low water absorption, and low density.

[0065] In some examples, the aerosol generating device further comprises an outer shell. In some examples, the outer shell is metallic. In some examples, the outer shell extends to at least partially surround the outer casing. In some examples, the outer shell is in contact with the outer casing in such a manner that heat may be transferred from the outer casing to the outer shell. In this way, the outer shell can act as a heat sink, dissipating heat from the outer casing. This may extend the life of the outer casing by reducing the magnitude of the thermal load experienced by the outer casing. In this way, the aerosol generating device may be more appealing to customers.

[0066] In some examples, one or more heat dissipation elements may each be in contact with the outer shell, so that heat absorbed by the one or more heat dissipation elements can be conducted away from the outer casing and dissipated through the outer shell, and in this way, the life of the outer casing can be improved by reducing the thermal load.

[0067] In some examples, the aerosol generating device further comprises a heater, at least a portion of which is disposed within the inner chassis of the cap assembly, such that the heater can heat a consumable at least partially located within the inner chassis in a manner capable of generating an aerosol.

[0068] In some examples, the heater has an elongated shape. For example, the heater may have a rod shape or a blade shape. In this manner, the heater may better heat the consumable by providing more uniform heating of the consumable. This may lead to improved aerosol generation by the aerosol generating device.

[0069] In some examples, the cap assembly is movable relative to the aerosol generating device. In this manner, the heater can be moved relative to the cap assembly in a manner that allows adjustment of the extent to which the heater is inserted into the inner chassis. This can be useful, for example, when cleaning the inner chassis of the cap assembly.

[0070] In some examples, one or more heat dissipation elements maintain contact with the outer shell when the cap assembly is moved relative to the aerosol generation device, thus allowing heat to be conducted away from the outer shell regardless of the position of the cap assembly relative to the aerosol generation device.

[0071] In some examples, the cap assembly is slidably attached to the aerosol generating device. In some examples, the cap assembly can be moved relative to the body between a lowered position and a raised position. In this manner, the cap assembly can facilitate the release of the consumable from the heater. In this manner, debris can be removed from the heater as the heater moves relative to the heater-receiving aperture.

[0072] In some examples, at least a portion of the heater is located within the consumable-receiving cavity such that at least a portion of the heater can heat a consumable located within the consumable-receiving cavity to generate an aerosol that can be inhaled by a user.

[0073] In some examples, the cap assembly is slidably movable between a first position relative to the aerosol generating device and a second position relative to the aerosol generating device, and when in the first position, at least a portion of the heater is located within the consumable-receiving cavity.

[0074] In some examples, when in the first position, the heater is at least partially located within the consumable-receiving cavity, and when in the second position, the heater is at least partially located outside the consumable-receiving cavity, thereby providing greater access to the heater for cleaning.

[0075] In some examples, the heater is rigidly attached to the body of the aerosol generating device such that when the cap assembly is moved relative to the body, the cap assembly also moves relative to the heater, thus exposing the heater to allow for cleaning.

[0076] The above summary summarizes some examples for the purpose of providing a basic understanding of aspects of the subject matter described herein. Accordingly, the above-described features should not be construed to narrow the scope or spirit of the subject matter described herein in any way. Furthermore, the above-described examples and / or the examples that follow can be combined in any suitable combination to provide additional examples, unless such combinations are manifestly impermissible or manifestly ineffective. Other features, aspects, and advantages of the subject matter described herein will become apparent from the following text and accompanying drawings. [Brief explanation of the drawings]

[0077] Aspects, features, and advantages of the present disclosure will become apparent from the following description of examples taken in conjunction with the accompanying drawings, in which like reference numerals refer to like elements and in which:

[0078] [Figure 1]FIG. 1 is a block system diagram illustrating an exemplary aerosol generating device. [Figure 2] FIG. 2 is a block system diagram illustrating an exemplary embodiment of the apparatus of FIG. 1 in which the aerosol generation device is configured to generate an aerosol from a solid precursor. [Figure 3] FIG. 3 is a schematic diagram illustrating an exemplary embodiment of the device of FIG. 2. [Figure 4A] 1 is a rendering of an exemplary embodiment of a cap assembly according to the present disclosure. [Figure 4B] Figure 4A is an exploded view showing the cap assembly. [Figure 5A] Figure 4A is a bottom view rendering of the closure of the cap assembly. [Figure 5B] FIG. 4B is a top view rendering of the outer casing of the cap assembly of FIG. 4A. [Figure 6] Figure 4A is a rendering of the outer casing of the cap assembly. [Figure 7] FIG. 4B is a partial view of a rendering of the outer casing of the cap assembly of FIG. 4A. [Figure 8A] FIG. 4B is a schematic diagram showing a cross section of the inner chassis of the cap assembly of FIG. [Figure 8B] Figure 4A is a rendering of the inner chassis of the cap assembly. [Figure 9] FIG. 4B is a schematic diagram showing a cross section of the cap assembly of FIG. 4A with the closure in an open position. [Figure 10] FIG. 4B is a schematic diagram showing a cross section of the cap assembly of FIG. 4A with the closure in the closed position. DETAILED DESCRIPTION OF THE INVENTION

[0079] Before describing some examples of implementing the present disclosure, it should be understood that the present disclosure is not limited by the specific structural details or process steps set forth in the following description and accompanying drawings. Rather, it will be apparent to one skilled in the art having the benefit of this disclosure that the systems, apparatuses, and / or methods described herein may be implemented differently and / or may be practiced or carried out in various alternative ways.

[0080] Unless otherwise defined herein, scientific and technical terms used in connection with the inventive concepts disclosed herein have meanings commonly understood by those of ordinary skill in the art, and known techniques and procedures may be carried out in accordance with conventional methods well known in the art and as described in various general and more specific references that may be cited and discussed herein.

[0081] Any patents, published patent applications and non-patent publications mentioned herein are hereby incorporated by reference in their entirety.

[0082] All examples embodying the present disclosure can be made and executed without undue experimentation in light of the present disclosure. While particular examples have been described, it will be apparent to those skilled in the art that changes may be made in the systems, apparatus, and / or methods, and in the steps or sequence of steps of the methods described herein, without departing from the concept, spirit, and scope of the inventive concept. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope, and concept of the inventive concept as defined by the appended claims.

[0083] The use of the terms "a" or "an" in the claims and / or herein may mean "one," as well as "one or more," "at least one," and "one or more." Thus, the terms "a," "an," and "the," as well as all singular terms, include plural referents unless the context clearly dictates otherwise. Likewise, plural terms include the singular unless the context requires otherwise.

[0084] The use of the term "or" in this disclosure (including the claims) means an inclusive "and / or" unless expressly indicated to refer only to alternatives or unless the alternatives are mutually exclusive. For example, the condition "A or B" is satisfied by any of the following: A is true (or exists) and B is false (or does not exist), A is false (or does not exist) and B is true (or exists), and A and B are both true (or exist).

[0085] As used in this specification and claims, the words "comprising," "having," "including," or "containing" (and any forms thereof, such as "comprise," "comprises," "have," "has," "includes," "includes," or "contains" and "containe") are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.

[0086] Unless expressly stated to be incompatible, or unless the physics or other aspects of an embodiment, example, or claim prohibit such a combination, features of the examples and features of the claims disclosed herein may be combined together in any suitable arrangement, particularly one that produces beneficial effects. This is not limited solely to the stated benefits, but may instead result from "posterior" benefits. That is, the combination of features is not limited by the form described, particularly by the form of dependency (e.g., numbering) of the examples, embodiments, or claims. Furthermore, this also applies to phrases such as "in one embodiment," "according to an embodiment," and the like, which are merely stylistic forms of phrasing, and should not be interpreted as limiting subsequent features for a separate embodiment to all other examples of the same or similar phrasing. That is, a reference to "an embodiment," "one embodiment," or "some embodiments" may refer to one or more and / or all of the disclosed embodiments, or combinations thereof. Similarly, a reference to "the" embodiment may not be limited to the immediately preceding embodiment. Moreover, any reference to one or more embodiments or examples should not be construed as limiting the claims.

[0087] The present disclosure may be more fully understood in light of the following description: Terms used separated by "or" may be used interchangeably.

[0088] As used herein, an "aerosol-generating device" (or "electronic (e) cigarette") may be a device configured to deliver an aerosol to a user for inhalation by the user. Additionally / alternatively, the device may be referred to as a "smoking substitute device" when intended to be used in place of a traditional combustible smoking product. As used herein, a combustible "smoking product" may refer to a cigarette, cigar, pipe, or other product that produces smoke (an aerosol containing solid particulates and gases) by heating (usually by combustion and / or pyrolysis) above its pyrolysis temperature. The aerosol generated by the device may include an aerosol having a particle size of 0.2 to 7 microns, or less than 10 microns, or less than 7 microns. This particle size may be achieved by controlling one or more of the heater temperature, the cooling rate as the vapor condenses into the aerosol, and the flow characteristics and velocity, including turbulence. The generation of aerosol by the aerosol-generating device may be controlled by an input device. The input device may be configured to be activated by a user and may, for example, include or take the form of an actuator (e.g., an actuation button) and / or an airflow sensor.

[0089] Each event that causes the aerosol generating device to generate aerosol for a period of time (which may be variable) may be referred to as an "activation" of the aerosol generating device. The aerosol generating device may be configured to allow the amount of aerosol delivered to the user to be varied from activation to activation (as opposed to delivering a fixed amount of aerosol), for example, by activating the aerosol generating unit of the device for a variable period of time (to replicate the effect of smoking a traditional combustible smoking product), for example, based on the strength / duration of the user's draw through the device's flow path.

[0090] The aerosol generating device may be portable. As used herein, the term "portable" may refer to a device that is intended for use while held by a user.

[0091] As used herein, an "aerosol generation system" may be a system that includes an aerosol generation device and optional other circuitry / components related to the functioning of the device, such as one or more external devices and / or one or more external components (where "external" is intended to mean outside the aerosol generation device). As used herein, "external device" and "external component" may include one or more of a charging device, a mobile device (which may be connected to the aerosol generation device, for example, by a wireless or wired connection), a networked-based computer (e.g., a remote server), a cloud-based computer, or any other server system.

[0092] An exemplary aerosol-generating system may be a system for managing an aerosol-generating device, such as a mobile device, a network server, and an aerosol-generating device.

[0093] As used herein, "aerosol" may include a suspension of precursors comprising one or more of solid particles, liquid droplets, and gas. The suspension may be in a gas, including air. Aerosol herein generally refers to / may include a vapor. The aerosol may include one or more components of the precursor.

[0094] As used herein, "precursor" may include one or more of a liquid, solid, gel, loose-leaf material, or other substance. The precursor may be processed by an aerosol generating unit of an aerosol generating device to generate an aerosol. The precursor may include one or more of an active ingredient, a carrier, and a flavoring. The active ingredient may include one or more of nicotine, caffeine, cannabidiol oil, and a non-medicinal formulation, e.g., a formulation not intended to treat a human disease or physiological disorder. The active ingredient may be carried by a carrier, which may be a liquid, including propylene glycol and / or glycerin. The term "flavoring" may refer to an ingredient that provides a taste and / or odor to the user. The flavoring may include one or more of ethyl vanillin (vanilla), menthol, isoamyl acetate (banana oil), and the like. The precursor may include a substrate, such as reconstituted tobacco, carrying one or more of the active ingredient, carrier, and flavoring.

[0095] As used herein, a "storage portion" may be a portion of an apparatus adapted to store a precursor. The storage portion may be implemented as a reservoir holding a fluid or a carrier of solid material depending on the embodiment of the precursor as defined above.

[0096] As used herein, a "flow path" may refer to a path or enclosed passageway through an aerosol generating device, e.g., for delivering aerosol to a user. The flow path may be positioned to receive aerosol from an aerosol generation unit. When referring to a flow path, upstream and downstream may be defined with respect to the direction of flow in the flow path, e.g., an outlet is downstream of an inlet.

[0097] As used herein, a "delivery system" may be a system that operates to deliver an aerosol to a user. The delivery system may include a mouthpiece and a flow path.

[0098] As used herein, "flow" may refer to a flow in a flow path. The flow may include an aerosol generated from a precursor. The flow may include air, which may be induced into the flow path by a puff by a user.

[0099] As used herein, a "puff" (or "inhalation" or "inhale") by a user may refer to the expansion of the user's lungs and / or oral cavity to create reduced pressure that induces flow through the flow pathway.

[0100] As used herein, "aerosol generation unit" may refer to a device configured to generate an aerosol from a precursor. The aerosol generation unit may include a unit that generates vapor directly from the precursor (e.g., a heating system or other system) or a unit that generates an aerosol directly from the precursor (e.g., an atomizer, including an ultrasonic system, a flow expansion system that operates to transport droplets of the precursor in a stream without the use of electrical energy or other systems). Multiple aerosol generation units for generating multiple aerosols (e.g., from multiple different aerosol precursors) may be present in an aerosol generation device.

[0101] As used herein, "heating system" may refer to an arrangement of at least one heating element that operates to aerosolize a precursor when heated. The at least one heating element may be electrically resistive to generate heat from an electric current passing therethrough. The at least one heating element may be arranged as a susceptor that generates heat when subjected to an alternating magnetic field. The heating system may be configured to heat the precursor to a temperature below 300 or 350°C, and the heating may include without combustion.

[0102] As used herein, a "consumable" may refer to a unit containing a precursor. The consumable may include an aerosol generation unit, for example, the aerosol generation unit may be configured as a cartomizer. The consumable may include a mouthpiece. The consumable may include an information-carrying medium. In liquid or gel embodiments of the precursor, such as e-liquids, the consumable may be referred to as a "capsule" or "pod" or an "e-liquid consumable." The capsule / pod may include a storage portion, such as a reservoir or tank, for storing the precursor. In solid material embodiments of the precursor, such as tobacco or reconstituted tobacco formulations, the consumable may be referred to as a "stick" or "package" or a "heat-not-burn consumable." In heat-not-burn consumables, the mouthpiece may be implemented as a filter, and the consumable may be configured to carry the precursor. The consumable may be implemented as a single-dose or pre-portioned amount of material, including loose-leaf products.

[0103] As used herein, "information-bearing medium" may include one or more arrangements for storing information on any suitable medium. Examples include computer-readable media; radio frequency identification (RFID) transponders; codes that encode information, such as optical codes (e.g., bar codes or QR codes) or machine-readable codes (e.g., configurations with or without cutouts that encode bits into which a pin or reader may be inserted).

[0104] As used herein, "heat not burn" (or "HNB" or "heat precursor") may refer to heating of a precursor, usually tobacco, without combustion or substantially without combustion (i.e., may undergo localized combustion of a limited portion of the precursor comprising less than 5% of the total volume).

[0105] 1, an exemplary aerosol generating device 1 includes a power source 2 for supplying electrical energy. Device 1 includes an aerosol generation unit 4 powered by power source 2. Power source 2 may include a power source in the form of a battery and / or an electrical connection to an external power source. Device 1 includes a precursor 6, which, during use, is aerosolized by aerosol generation unit 4 to generate an aerosol. Device 2 includes a delivery system 8 for delivering the aerosol to a user.

[0106] An electrical circuit (not shown in FIG. 1) may be implemented to control the interoperability of the power supply 4 and the aerosol generation unit 6 .

[0107] In another example not shown, the power supply 2 may be omitted, since for example an aerosol generation unit embodied as an atomizer with flow expansion may not require a power supply.

[0108] FIG. 2 shows an embodiment of the device 1 of FIG. 1 in which the aerosol generating device 1 is configured to generate the aerosol by a heat-not-burn process.

[0109] In this example, the apparatus 1 includes a device body 50 and a consumable item 70 .

[0110] In this example, a body 50 includes a power source 4 and a heating system 52. The heating system 54 includes at least one heating element 54. The body may additionally include any one or more of electrical circuitry 56, memory 58, a wireless interface 60, and one or more other components 62.

[0111] Electrical circuitry 56 may include processing resources for controlling one or more operations of body 50 based on instructions stored in memory 58, for example.

[0112] The wireless interface 60 may be configured to communicate wirelessly with external (eg, mobile) devices, for example via Bluetooth.

[0113] Other components 62 may include, for example, an actuator, one or more user interface devices configured to communicate information to a user, and / or a charging port (see, for example, FIG. 3).

[0114] The body 50 is configured to engage the consumable 70 in a manner such that the at least one heating element 54 of the heating system 52 penetrates the consumable solid precursor 6. During use, a user may activate the aerosol generation device 1, causing the heating system 52 of the body 50 to cause the at least one heating element 54 to heat the consumable solid precursor 6 by conductive heat transfer (without burning the solid precursor 6), generating an aerosol that the user inhales.

[0115] FIG. 3 shows an exemplary embodiment of the aerosol generating device 1 of FIG.

[0116] As shown in FIG. 3 , the consumable 70 is embodied as a stick that engages with the body 50 by inserting the stick into an aperture in the top end 53 of the body 50, which insertion causes at least one heating element 54 of the heating system 52 to penetrate the solid precursor 6.

[0117] The consumable 70 includes a solid precursor 6 on a side proximal to the body 50 and a filter on a side distal to the body 50. The filter serves as a mouthpiece for the consumable 70 and, therefore, the device 1 as a whole. The solid precursor 6 may be a reconstituted tobacco formulation.

[0118] In this example, at least one heating element 54 is a rod-shaped element having a circular cross-section. Other heating element shapes are possible, for example, at least one heating element may be blade-shaped (having a rectangular cross-section) or tubular (e.g., having a hollow cross-section).

[0119] In this example, body 50 includes cap 51. In use, cap 51 engages body 50 at top end 53. Although not apparent from FIG. 3 , cap 51 is movable relative to body 50. In particular, cap 51 is slidable and can slide along the longitudinal axis of body 50. In some examples, cap 51 may be referred to as a cap assembly.

[0120] The body 50 also includes an actuator 55 on the exterior surface of the body 50. In this example, the actuator 55 has the form of a button.

[0121] Body 50 also includes a user interface device configured to communicate information to a user, here embodied as a plurality of lights 57, which may be configured, for example, to illuminate when device 1 is activated and / or to indicate the charge status of power source 4. Other user interface devices are possible, such as for communicating information to a user tactilely or audibly.

[0122] The main body may also include an airflow sensor to detect airflow within the aerosol generating device 1 (e.g., caused by a user inhaling through the consumable item 70), which may be used, for example, to count the number of puffs.

[0123] In this example, the consumable 70 includes a flow path that carries the aerosol generated by the at least one heating element 54 to the mouthpiece of the consumable.

[0124] In this example, the aerosol generation unit 4 is provided by the heating system 52 described above, and the delivery system 8 is provided by the flow path and mouthpiece of the consumable 70 described above.

[0125] 4A and 4B, a cap assembly 100 for an aerosol-generating device, such as that embodied in any of the above examples, includes an outer casing 120, the outer casing 120 comprising polyphenylene oxide. The aerosol-generating device (not shown) is configured to deliver an aerosol to a user for inhalation by the user and is configured to generate an aerosol by heating an aerosol-forming substrate.

[0126] The outer casing 120 comprises a blend of polyphenylene oxide and polystyrene. The type of polystyrene used in the outer casing 120 is high impact polystyrene, sometimes abbreviated as HIPS. The outer casing 120 comprises NORYL™ resin, which is a blend of polyphenylene oxide and polystyrene.

[0127] The cap assembly 100 further includes an inner chassis 110, the inner chassis 110 comprising polyetheretherketone, the inner chassis 110 being positioned within the outer casing 120. The aerosol generating device (not shown) further includes a heater, the inner chassis 110 being configured to receive at least a portion of the heater. The inner chassis 110 includes a heater-receiving aperture 116.

[0128] The inner chassis 110 is integrally formed from polyetheretherketone. The outer casing 120 is integrally formed from polyphenylene oxide. The outer casing 120 includes a consumable receiving aperture 122, not visible in either FIG. 4A or FIG. 4B. The cap assembly 100 further includes a closure 124, which selectively blocks the consumable receiving aperture 122. The closure 124 includes polyphenylene oxide. The closure 124 includes a blend of polyphenylene oxide and polystyrene. The type of polystyrene used in the closure 124 is high-impact polystyrene. The closure 124 includes NORYL™ resin. The closure 124 is integrally formed from polyphenylene oxide.

[0129] The inner chassis 110 includes a consumable-receiving cavity 112, and a consumable-receiving aperture 122 (not visible in either FIG. 4A or FIG. 4B) is an entrance to the consumable-receiving cavity 112. The consumable-receiving cavity 112 is not visible in either FIG. 4A or FIG. 4B. The portion of the inner chassis 110 that defines the consumable-receiving cavity 112 comprises polyetheretherketone. The inner chassis is held within the outer casing by a series of clips 126 and screws 130, which are all examples of engagement mechanisms. The series of clips 126 are not visible in either FIG. 4A or FIG. 4B.

[0130] 5A, the closure 124 of the cap assembly 100 of FIGS. 4A and 4B is shown separated from the other components for ease of understanding. The closure includes two mounting pegs 1242, each positioned within a corresponding respective peg-receiving slot 111 (shown in FIG. 8A) in the inner chassis 110. Thus, the inner chassis 110 includes two peg-receiving slots 111.

[0131] 5B, an alternative view of the cap assembly 100 of FIGS. 4A and 4B is shown so that the position of the closure 124 relative to the outer casing 120 can be understood. The outer surface of the closure 124 is flush with the outer surface of the outer casing 120. In FIG. 5B, the closure 124 is shown in a closed position relative to the outer casing 120. As the closure 124 transitions to an open position relative to the outer casing 120, a portion of the closure 124 moves through the consumable-receiving cavity 112 (shown in FIG. 6).

[0132] 6, the outer casing 120 of the cap assembly 100 of FIGS. 4A and 4B is shown separated from the other components for ease of understanding. A consumable receiving aperture 122 is visible on the exterior surface of the outer casing 120.

[0133] 7, an alternative view of the outer casing 120 of the cap assembly 100 of FIGS. 4A and 4B is shown for ease of understanding. Located adjacent to the consumable-receiving cavity 112 is a series of clips 126. The series of clips 126 includes a first clip and a second clip.

[0134] 8A and 8B, the inner chassis 110 of the cap assembly 100 of FIGS. 4A and 4B is shown separated from the other components for ease of understanding. The inner chassis includes a consumable-receiving cavity 112, a screw-receiving aperture 118, a heater-receiving aperture 116, and a clip-receiving portion 114. When combined with the outer casing 120, closure 124, and screws 130 to form the cap assembly 100 of FIGS. 4A and 4B, a series of clips 126 on the outer casing 120 engage with the clip-receiving portion 114 of the inner chassis 110, and screws 130 are positioned through the screw-receiving aperture 118 in such a manner that the series of clips 126 and screws 130 cooperate to hold the inner chassis 110 within the outer casing 120.

[0135] The inner chassis 110 includes an inner wall 113 defining a consumable-receiving cavity 112 and an outer wall 115 positioned between the inner wall 113 and the outer casing 120 (shown in FIG. 4A ), the outer wall 115 defining an insulating cavity 117 positioned between the consumable-receiving cavity 112 and the outer casing 120 to provide thermal insulation between the consumable-receiving cavity 112 and the outer casing 120. The consumable-receiving cavity 112 is configured to receive a heater and to engage a consumable, the consumable including an aerosol-generating substrate for heating by the heater. The inner wall 113 and the outer wall 115 are integrally formed from polyetheretherketone. The inner chassis 110 further includes an insulating opening 119 to the insulating cavity 117, the insulating opening 119 connecting the insulating cavity 117 to the ambient atmosphere. The consumable-receiving cavity 112 and the insulating cavity 117 are elongated vertically along the same direction. The corresponding longitudinal axes of the consumable-receiving cavity 112 and the insulating cavity 117 are aligned. The insulating cavity 117 and the consumable-receiving cavity 112 open in opposite directions. The outer wall 115 is tapered such that the thickness of the outer wall decreases in a direction from the consumable-receiving aperture 122 (shown in FIG. 6) toward the heater-receiving aperture 116.

[0136] 9, the cap assembly 100 is shown with the closure 124 in an open position relative to the outer casing 120. Referring to FIG. 10, the cap assembly 100 is shown with the closure 124 in a closed position relative to the outer casing 120. The closure 124 is pivotally mounted adjacent the consumable-receiving aperture 122 and is selectively pivotable relative to the outer casing 120 about a pivot axis 1032 to adopt an open position in which the consumable-receiving aperture 122 is exposed and a closed position in which the consumable-receiving aperture 122 is blocked. The closure 124 moves through intermediate positions when transitioning between the open and closed positions, and when in the intermediate positions, at least a portion of the closure 124 is located within the consumable-receiving cavity 112.

[0137] In Figure 9, the closure 124 is in the open position with the pivot axis 1032 extending into the page. In Figure 10, the closure 124 is in the closed position with the pivot axis 1032 extending into the page. The orientation of the closure 124 in the open position is perpendicular to the orientation of the closure 124 in the closed position. The pivot axis 1032 is perpendicular to the insertion direction 1022 of the consumable into the consumable-receiving cavity 112.

[0138] The cap assembly 100 includes a closure control mechanism configured to bistable control the position of the closure 124, with the open position being a stable equilibrium position, the closed position being a stable equilibrium position, and the intermediate position being an unstable equilibrium position. The closure 124 includes a first portion and a second portion located on opposite sides of the pivot axis 1032. The first portion of the closure 124 moves through the consumable-receiving cavity 112 as the closure 124 transitions between the open and closed positions.

[0139] A first portion of the closure 124 includes a first magnetic element 1042 of the lower secondary mechanism housed in a first magnetic element receiving cavity 1244 (shown in FIG. 5A ) such that the closure 124 is biased to an open position, and the inner chassis 110 includes a second magnetic element 1044 of the lower secondary mechanism. A second portion of the closure 124 includes a first magnetic element 1052 of the upper secondary mechanism housed in a second magnetic element receiving cavity 1245 (shown in FIG. 5A ) such that the closure 124 is biased to a closed position, and the inner chassis 110 includes a second magnetic element 1054 of the upper secondary mechanism.

[0140] Each magnetic element receiving cavity includes a plurality of deformable elements 1246 (shown in FIG. 5A). For each magnetic element receiving cavity, the plurality of deformable elements 1246 (shown in FIG. 5A) are formed on a surface of the closure 124 that bounds the corresponding respective magnetic element receiving cavity. Each deformable element 1246 (shown in FIG. 5A) is aligned with the direction of insertion of a magnetic element into the corresponding respective magnetic element receiving cavity.

[0141] The first magnetic element 1042 of the lower sub-mechanism is a magnet, and the second magnetic element 1044 of the lower sub-mechanism is a ferromagnetic plate. The first magnetic element 1052 of the upper sub-mechanism is a second magnet, and the second magnetic element 1054 of the upper sub-mechanism is a third magnet. The poles of the second and third magnets are aligned in such a way that the closure 124 is biased to the closed position. In the closed position, the closure 124 is flush with the outer surface of the outer casing 120. When in the open position, the closure 124 is out of the path taken by the consumable when inserted into the consumable-receiving cavity 112.

[0142] In Figure 9, the first magnetic element 1042 of the lower sub-mechanism and the second magnetic element 1044 of the lower sub-mechanism are in close proximity to each other such that the magnetic attraction between these two magnetic elements overcomes other forces / torques from the closure control mechanism acting on the closure 124, so that the closure 124 is held in the open position. In Figure 10, the first magnetic element 1052 of the upper sub-mechanism and the second magnetic element 1054 of the upper sub-mechanism are in close proximity to each other such that the magnetic attraction between these two magnetic elements overcomes other forces / torques from the closure control mechanism acting on the closure 124, so that the closure 124 is held in the closed position.

[0143] The cap assembly 100 may be mounted on the aerosol generating device such that a heater is located within the heater-receiving aperture 116 such that a portion of the heater of the aerosol generating device is located within the consumable-receiving cavity 112. When a consumable is inserted into the consumable-receiving cavity 112, the heater may heat the consumable to generate an aerosol. The cap assembly 100 may be mounted on the aerosol generating device such that the cap assembly 100 can move relative to the heater such that the heater can move relative to the consumable-receiving cavity 112.

Claims

1. A cap assembly for an aerosol generating device, comprising an outer casing, the outer casing comprising polyphenylene oxide.

2. The cap assembly of claim 1 , wherein the aerosol generating device is configured to deliver an aerosol to a user for inhalation by the user.

3. The cap assembly of claim 1 or 2, wherein the aerosol-generating device is configured to generate an aerosol by heating an aerosol-forming substrate.

4. The cap assembly of claim 1 , further comprising an inner chassis, the inner chassis comprising polyetheretherketone, the inner chassis located within the outer casing.

5. The cap assembly of claim 1 , wherein the aerosol generating device further comprises a heater, and the inner chassis is configured to receive at least a portion of the heater.

6. 6. The cap assembly of claim 1, wherein the inner chassis is integrally formed from polyetheretherketone.

7. 7. The cap assembly of claim 1, wherein the outer casing is integrally formed from polyphenylene oxide.

8. The cap assembly of claim 1 , wherein the outer casing includes a consumable receiving aperture.

9. 9. The cap assembly of claim 8, further comprising a closure, said consumable-receiving aperture being selectably blocked by said closure.

10. 10. The cap assembly of claim 8, wherein the inner chassis includes a consumable-receiving cavity, and the consumable-receiving aperture is an entrance to the consumable-receiving cavity.

11. The cap assembly of claim 10 , wherein the inner chassis surface defining the consumable-receiving cavity comprises polyetheretherketone.

12. 12. The cap assembly of claim 1, further comprising one or more engagement mechanisms such that the inner chassis is retained within the outer casing by the one or more engagement mechanisms.

13. The cap assembly of claim 1 , wherein one or more layers of insulation are included between the inner chassis and the outer casing.

14. An aerosol generating device comprising a cap assembly according to any one of claims 1 to 13.

15. The aerosol generating device of claim 14, further comprising a heater when comprising a cap assembly as described in any one of claims 4 to 13, at least a portion of the heater being disposed within the inner chassis of the cap assembly.

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