Capsule, heat-not-burn (HNB) aerosol-generating device, and aerosol-generating method

Abstract

A capsule, a heat-not-burn (HNB) aerosol-generating device and a method of generating an aerosol without substantial thermal decomposition of an aerosol-forming substrate.SOLUTION: A capsule 300 for a heat-not-burn (HNB) aerosol-generating device may include a base of thermally conductive material, the base defining a first cavity therein, the base comprising a first surface, the first surface defining an opening to the second cavity, the first surface comprising a first plurality of apertures through the first surface. The capsule may further comprise a cover 310 coupled to and overlying the base, the cover comprising a second plurality of apertures in a middle portion of the cover, wherein the first plurality of apertures and the second plurality of apertures may define an air flow path through the base and the cover.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present disclosure relates to a capsule, a heat-not-burn (HNB) aerosol generator, and a method for generating an aerosol without substantial thermal decomposition of the aerosol-forming substrate. [Background technology]

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

[0003] [Summary] At least one embodiment relates to a capsule for a heat-not-burn (HNB) aerosol generating device. In an exemplary embodiment, the capsule includes a base of a thermally conductive material, the base defining a first cavity therein, the base having a first surface, the first surface defining an opening to a second cavity, the first surface having a first plurality of apertures therethrough, a cover coupled to and disposed on the base, the cover having a second plurality of apertures in an intermediate portion of the cover, and the first and second plurality of apertures may define air flow paths through the base and the cover.

[0004] In at least one exemplary embodiment, the base further comprises a first wall and a second wall, the first surface connecting the first wall and the second wall, and the first surface, the first wall, and the second wall defining a first cavity.

[0005] In at least one exemplary embodiment, the width of the first cavity increases as the first wall and the second wall extend from the first surface.

[0006] In at least one exemplary embodiment, the width increases continuously from the base to the top.

[0007] In at least one exemplary embodiment, the width is at most about 2 mm.

[0008] In at least one exemplary embodiment, the first wall, the second wall, and the first surface are unitary.

[0009] In at least one exemplary embodiment, the first plurality of apertures is in a circular pattern.

[0010] In at least one exemplary embodiment, the first plurality of apertures lies on a single circular line.

[0011] In at least one exemplary embodiment, the cover comprises a second surface and a third surface, the second surface and the third surface being at different heights, and the second plurality of apertures being in the third surface.

[0012] In at least one exemplary embodiment, the third surface is elevated relative to the second surface.

[0013] In at least one exemplary embodiment, the cover includes an overhang coupled to the base.

[0014] In at least one exemplary embodiment, the width of the first cavity increases along the first direction and the width of the second cavity decreases along the first direction.

[0015] In at least one exemplary embodiment, the first direction is the longitudinal direction of the capsule.

[0016] In at least one exemplary embodiment, the second plurality of apertures is on an inner wall of the base, the inner wall defining an end of the second cavity.

[0017] In at least one exemplary embodiment, the capsule further comprises an aerosol-forming substrate within the first cavity.

[0018] In at least one exemplary embodiment, the aerosol-forming substrate comprises tobacco.

[0019] In at least one exemplary embodiment, the second plurality of apertures is a circular pattern including at least two circles.

[0020] At least one exemplary embodiment provides an aerosol generating device including a capsule having a base made of a thermally conductive material, the base defining a first cavity therein, the base having a first surface, the first surface defining an opening to a second cavity, the first surface having a first plurality of apertures therethrough, a cover coupled to and disposed on the base, the cover having a second plurality of apertures in an intermediate portion thereof, the first plurality of apertures and the second plurality of apertures defining an air flow path through the base and the cover, and further including a heating system configured to heat the base of the capsule.

[0021] In at least one exemplary embodiment, the heating system includes a heater and a heater sleeve covering a portion of the heater.

[0022] In at least one exemplary embodiment, the heater sleeve is mounted to generally fit against the wall of the second cavity.

[0023] In at least one exemplary embodiment, the aerosol generating device further comprises a biasing element that applies a force to the capsule so that the capsule contacts the heater sleeve.

[0024] In at least one exemplary embodiment, the aerosol-generating device further comprises an aerosol-forming substrate within the first cavity. [Brief explanation of the drawings]

[0025] Various features and advantages of the non-limiting embodiments herein will become more apparent from a 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 should not be considered to be drawn to scale unless explicitly noted. Various dimensions of the drawings may be exaggerated for clarity.

[0026] [Figure 1] FIG. 1 is a diagram illustrating an aerosol generating device in accordance with at least one exemplary embodiment.

[0027] [Figure 2] FIG. 2 is a perspective view of a second section of the aerosol generating device of FIG.

[0028] [Figure 3] FIG. 3 is a cross-sectional view showing the aerosol generating device of FIG.

[0029] [Figure 4] FIG. 4 is a cross-sectional view of an aerosol generation portion in accordance with at least one exemplary embodiment.

[0030] [Figure 5A] FIG. 5A is a diagram illustrating a capsule and heater in accordance with at least one example embodiment. [Figure 5B] FIG. 5B is a diagram illustrating a capsule and heater in accordance with at least one example embodiment. [Figure 5C] FIG. 5C is an illustration of a capsule and heater in accordance with at least one example embodiment.

[0031] [Figure 6] FIG. 6 is a cross-sectional view of a capsule in accordance with at least one exemplary embodiment.

[0032] [Figure 7] FIG. 7 is a diagram illustrating multiple stacked capsules in accordance with at least one exemplary embodiment.

[0033] [Figure 8] FIG. 8 is a diagram illustrating a capsule in accordance with at least one exemplary embodiment; and

[0034] [Figure 9A] FIG. 9A is an illustration of a capsule in accordance with at least one exemplary embodiment. [Figure 9B] FIG. 9B is an illustration of a capsule in accordance with at least one exemplary embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0035] [Detailed explanation] Several detailed exemplary embodiments are disclosed herein. However, the specific structural and functional details disclosed herein are merely representative for purposes of describing the exemplary embodiments. However, the exemplary embodiments may be embodied in many alternative forms and should not be construed as being limited to only the exemplary embodiments set forth herein.

[0036] Thus, while exemplary embodiments are susceptible to various modifications and alternative forms, such exemplary embodiments have been shown by way of example in the drawings and will be described in detail herein. It should 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.

[0037] When an element or layer is referred to as being "on," "connected to," "coupled to," "attached to," "adjacent to," or "covering" another element or layer, it should be understood that it may be directly connected to, coupled to, attached to, adjacent to, or covering the other element or layer, or that intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly connected to," or "directly coupled to" another element or layer, there are no intervening elements or layers. As used herein, like numbers refer to like elements. As used herein, the term "and / or" includes any and all combinations or subcombinations of one or more of the associated listed items.

[0038] Terms such as "first," "second," and "third" may be used herein to describe various elements, regions, layers, and / or sections; however, it should be understood that these elements, regions, layers, and / or sections are not 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 could be referred to as a second element, region, layer, or section without departing from the teachings of the exemplary embodiments.

[0039] For ease of description, spatially relative terms (e.g., "beneath," "below," "lower," "above," "upper," etc.) may be used herein to describe the relationship of one element or feature to another, as illustrated in the figures. It should be understood that spatially relative terms are intended to encompass different orientations of the device during use and operation in addition to the orientation depicted in the figures. For example, if a device in the figures were turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the term "below" can encompass both an orientation of above and below. Additionally, a device may be otherwise oriented (rotated 90 degrees, oriented in other directions, etc.), and the spatially relative descriptors used herein would be interpreted accordingly.

[0040] The terminology used herein is for the purpose of describing various exemplary embodiments only and is not intended to limit the exemplary embodiments. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms unless the context clearly dictates otherwise. It will be further understood that the terms "includes," "including," "comprises," and / or "comprising," as used herein, specify the presence of stated features, integers, steps, operations, and / or elements, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, and / or groups thereof.

[0041] As used herein, when the words "about" and "substantially" are used in connection with numerical values, unless expressly defined otherwise, the associated numerical value is intended to include a tolerance of ±10% around the stated numerical value.

[0042] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the illustrated embodiment belongs. Furthermore, terms, including those defined in commonly used dictionaries, should be interpreted as having a meaning consistent with the meaning in the context of the relevant art, and will not be interpreted in an idealized or overly formal sense unless explicitly defined herein.

[0043] The hardware may be implemented using processing or control circuitry such as, but not limited to, one or more processors, one or more CPUs (Central Processing Units), one or more microcontrollers, one or more ALUs (Arithmetic Logic Units), one or more DSPs (Digital Signal Processors), one or more microcomputers, one or more FPGAs (Field Programmable Gate Arrays), one or more SoCs (System-on-Chips), one or more Programmable Logic Units (PLUs), one or more microprocessors, one or more ASICs (Application Specific Integrated Circuits), or other devices capable of responding to and executing instructions in a defined manner.

[0044] FIG. 1 is a diagram illustrating an aerosol generating device in accordance with at least one exemplary embodiment.

[0045] 1, the aerosol generating device 100 includes a first section 105 and a second section 150. The first section 105 is at a distal end 110. The sections 105, 150 may be coupled together at complementary interfaces 107, 109 of the respective sections 105, 150. Both the first section 105 and the second section 150 may be reusable.

[0046] The complementary interfaces 107, 109 may be any type of connector. Alternatively, the sections 105, 150 may be a single housing without the need for interfaces 107, 109. In some exemplary embodiments, the interfaces 107, 109 are threaded connectors. It should be understood that the interfaces 107, 109 may be any type of connector, including but not limited to, snug fit, detent, clamp, bayonet, slide fit, sleeve fit, alignment fit, threaded connector, magnetic, clasp, or any other type of connection, and / or combinations thereof. In some embodiments, the sections 105 and 150 may be part of the same piece without the need for interfaces 107, 109.

[0047] The second section 150 includes a first housing 160, a chimney 170, and a mouthpiece 180. The mouthpiece 180 is disposed at the proximal end 155.

[0048] As will be explained in more detail below, the heater in first section 105 generates an aerosol from the capsules containing the plant material, which flows out of the chimney 170 and out of the mouthpiece 180 when negative pressure is applied to the mouthpiece 180.

[0049] FIG. 2 is a perspective view showing a second section of the aerosol generating device of FIG. 1. A mouthpiece 180 is disposed at the end of the chimney 170. The mouthpiece 180 includes N outlet ports 182, which can be located on-axis and / or off-axis from the longitudinal axis of the device 100. In FIG. 2, N is 4, but N may be greater or less than 4. The outlet ports 182 may be angled outward relative to the longitudinal axis of the device 100. The outlet ports 182 may be positioned with respect to the mouthpiece 180 so as to align with the chimney 170. Thus, when the aerosol is drawn through the outlet ports 182, the dispersion may travel in different directions.

[0050] FIG. 3 is a cross-sectional view of the aerosol generating device of FIG. 1 taken along line 3-3'.

[0051] As shown in FIG. 3 , the second section 150 includes a first housing 160, a chimney 170, and a mouthpiece 180. A first portion 170a of the chimney 170 is located in the first housing 160, and a second portion 170b of the chimney 170 protrudes from the first housing 160. The second portion 170b is coupled to the mouthpiece 180. The chimney 170 includes an inner wall 172 that defines an annular space 174 having a first portion 174a and a second portion 174b. The diameter of the first portion 174a is larger than the diameter of the second portion 174b, allowing aerosol from the capsule 300 to enter a channel at the first portion 174a. The chimney 170 may be pressed against the edge of the cover 310 of the capsule 300 to prevent the aerosol from flowing into other portions of the first housing 160.

[0052] A spring 171 may be disposed in the gap between the chimney 170 and the first housing 160. The spring 171 allows the chimney 170 and the capsule 300 to maintain contact and applies a force that ensures that the capsule 300 maintains contact with the heater sleeve 450. The spring 171 reduces and / or eliminates an air gap between the capsule 300 and the heater sleeve, improving heat transfer to the aerosol-forming substrate 220.

[0053] Additionally, mouthpiece 180 includes at least one interior wall 181 that defines a space 185 through mouthpiece 180. Annular space 174 and space 185 are for an air flow path 190 for aerosol to travel from capsule 300 to the outside of mouthpiece 180. Filter material (to reduce the temperature of the aerosol) or flavoring materials to enhance the flavor experience may be present in space 185. Flavoring materials may include crushable capsules to alter the flavor of the aerosol entering space 185.

[0054] In some exemplary embodiments, the mouthpiece 180 is inserted into two slots in the chimney 170 and then twisted 90 degrees. When the mouthpiece 180 is twisted, two tabs 184 on the bottom of the mouthpiece may lock into place. The interference fit may force the mouthpiece 180 toward the chimney 170, forming a seal between the mouthpiece 180, the sealing element 183 (e.g., silicone), and the chimney 170.

[0055] First section 105 includes housing 255, control system 260, electrical leads 226, heater 400, and heater sleeve 450. Housing 255 includes one or more air inlets 280 that allow air to flow along air flow path 282.

[0056] In the exemplary embodiment, the control system 260 includes a controller 290 operably connected to a power source 294 and at least one sensor 292, such as a pressure sensor, a flow sensor, and / or a temperature sensor. The sensor(s) 292 may be located in the first section 105 or the second section 150. In the exemplary embodiment, the at least one sensor 292 is operably configured to measure one or more of a resistance of the heater 400, a temperature of the heater 400, and / or an airflow draw through the aerosol generation device 100. In the exemplary embodiment, the controller 290 receives input signal(s) from the sensor(s) 292, and the controller 290 controls operation of the aerosol generation device 100, including providing current from the power source 294 to the heater 100 to heat the aerosol-forming substrate, based at least in part on the signal from the sensor(s) 292. In the exemplary embodiment, control system 260 is operatively and electrically connected to heater 400 via electrical leads 226 that enable control system 260 to selectively send electrical current to heater 400 .

[0057] The aerosol thus formed is exhausted outside the device 100 through the mouthpiece 180 .

[0058] In an exemplary embodiment, one or more air inlets 280 are included in either the first section 105 and / or the second section 150 of the device 100. In an exemplary embodiment, the air inlet(s) 280 are used to establish an air flow path through the device 100 that can exit the mouthpiece 180, where the heater 400 and capsule 300 are within or otherwise exposed to the air flow path. The location of the one or more air inlets is not limited thereto. Depending on the placement of the air inlet location relative to the heater 400, the heater 400 can preheat the air before it enters the capsule air inlet.

[0059] In the exemplary embodiment, the control system 260 is in fluid communication with the air flow path.

[0060] In an exemplary embodiment, second section 150 is detachable from first section 105 to allow a capsule to be placed over heater 400 and heater sleeve 450. For example, second section 150 can be separated from first section 105 by threading second section 150.

[0061] In another embodiment, the capsule 300 is temporarily held by the heater sleeve 450 and the chimney 170 such that the capsule 300 is removable and replaceable, and the first section 105 and the second section 150 are non-disposable and / or can be reused with the capsule 300.

[0062] In the exemplary embodiment, heater 400 is in thermal communication with capsule 300 .

[0063] In the exemplary embodiment, heater 400 heats aerosol-forming substrate 220 within capsule 300 to generate aerosol 222 that flows through airflow path 190 exiting mouthpiece 180. In the exemplary embodiment, heater sleeve 450 contacts capsule 300 such that heat generated by heater 400 is transferred to capsule 300 through heater sleeve 450. Capsule 300 is made of a thermally conductive material and uses the heat generated by heater 400 to heat aerosol-forming substrate 220.

[0064] In the exemplary embodiment, mouthpiece 180 is permanently affixed within chimney 170, or alternatively, mouthpiece 180 is removable.

[0065] In some exemplary embodiments, the heater 400 heats the aerosol-forming substrate 220, but the heater 400 does not burn and / or combust the aerosol-forming substrate 220. Thus, the aerosol-forming substrate 220 in some exemplary embodiments is non-combustible. Because the device 100 includes the heater 400 that vaporizes the aerosol-forming substrate 220 but does not otherwise combust any materials, the device 100 may be referred to as a "non-combustible device."

[0066] For example, heater 400 may heat aerosol-forming substrate 220 to a temperature of 125°C to 320°C, more preferably to a temperature of 250°C to 280°C. However, exemplary embodiments are not limited thereto. For example, heater 400 may be controlled to heat to a desired temperature based on the type of aerosol-forming substrate 220 in capsule 300, the density of the aerosol-forming substrate in capsule 300, the additives in the aerosol-forming substrate, a subcombination thereof, or a combination thereof.

[0067] In exemplary embodiments, power supply 294 is a battery, such as a lithium-ion battery. The battery may be a lithium-ion battery or one of its variations, such as a lithium-ion polymer battery. Alternatively, the battery may be a nickel-metal hydride battery, a nickel-cadmium battery, a lithium-manganese battery, a lithium-cobalt battery, a fuel cell, or a solar cell. Any other power source or battery technology may be used. In exemplary embodiments, first section 105 may be usable until the energy in power supply 294 of control system 260 is depleted and / or falls below a certain threshold. Alternatively, power supply 294 of control system 260 may be rechargeable and reusable, may include circuitry that allows the battery to be charged by an external charging device, or may be rechargeable via solar power. In some exemplary embodiments, the circuitry of control system 260, once charged, may provide power for a desired (or alternatively, determined) number of draws until the energy in power supply 294 is depleted and / or falls below a certain threshold, after which the circuitry must be reconnected to the external charging device.

[0068] In some examples, air flow through device 100 may be caused by air being drawn into air inlet(s) 280 and through first section 105. As described in further detail below, the air flows along flow path 282, enters capsule 300, and may become entrained (dissolved) by an aerosol that may be generated by heater 400 heating aerosol-forming substrate 220.

[0069] In exemplary embodiments, airflow through device 100 activates device 100. Sensor(s) 292 may be configured to generate an output indicative of the airflow, the magnitude of the airflow, and / or the direction of the airflow, and controller 290 may receive an output from sensor(s) 292 output to determine whether the following internal conditions exist: (1) the direction of the airflow indicates airflow drawing through device 100 (vs. airflow blowing through device 100), and / or (2) the magnitude of the airflow exceeds a threshold. In some exemplary embodiments, only one condition may be sufficient to activate the heater, while in other instances, two or all conditions may need to be met before activating the heater. If these internal conditions of device 100 are met, controller 290 electrically connects power source 294 to heater 400, thereby activating heater 400. In an exemplary embodiment, the sensor(s) 292 generate a variable output signal that correlates at least in part with the magnitude of the pressure drop sensed by the sensor(s) 292. In an exemplary embodiment, the controller 290 may send a variable current to the heater 400 based on the variable output signal from the sensor(s) 292. The sensor(s) 292 may be a sensor disclosed in "Electronic Smoke Apparatus" (U.S. Patent Application No. 14 / 793,453, filed July 7, 2015) or "Electronic Smoke" (U.S. Patent No. 9,072,321, issued July 7, 2015), each of which is incorporated by reference in its entirety. Other types of sensors that detect air flow may also be used.

[0070] FIG. 4 is a cross-sectional view of an aerosol generation portion in accordance with at least one exemplary embodiment.

[0071] 4, air along air flow path 282 enters device 100 through inlet 280 upon application of negative pressure to mouthpiece 180. Air follows air flow path 282 into channel 281 upstream of heater 400.

[0072] Air along the air flow path travels around the heater sleeve 450 at gap 284. Gap 284 is the space between the housing 255 and the heater sleeve 450. As shown in FIG. 4 , the heater sleeve 450 includes a circular base 452. The diameter of the circular base 452 may be larger than the diameter of the continuous wall 480 of the heater sleeve 450. The continuous wall 480 may extend from the circular base 452 at a normal angle or at an angle less than 90 degrees. Due to the difference in diameter between the circular base 452 and the continuous wall 480, air along the air flow path 282 exits into region 286 of the channel 281 between the housing 255 and the heater sleeve 450. As the air passes along the continuous wall 480 and through region 286, the air may be heated by the heater sleeve 450 because the heater sleeve 450 conducts heat generated by the heater 400.

[0073] From region 286, air flows through gap 285. Housing 255 includes protrusion 266. Protrusion 266 protrudes into the interior of housing 255, narrowing channel 281. Gap 285 is between protrusion 266 and heater sleeve 450 and may be smaller than gap 284. More specifically, the distance between housing 255 and circular base 452 may be greater than the distance between protrusion 266 and continuous wall 480.

[0074]

[0074] In other exemplary embodiments, protrusion 266 may be an alignment tab and may be larger than the gap between protrusion 266 and heater sleeve 450 and gap 284 .

[0075] The air exits the gap 284 and enters the capsule 300 through the aperture 324. The heater 400 is capable of heating the aerosol-forming substrate 220 to an extent that the flavoring, nicotine and / or ingredients within the aerosol-forming substrate 220 are at least partially extracted (e.g., aerosolized) to produce an aerosol 222 that is extracted from the aerosol-forming substrate 220. The heater 400 heats the capsule 300 and the aerosol-forming substrate 220 to an extent that the aerosol-forming substrate 220 and the flavoring, nicotine and / or other materials of the aerosol-forming substrate 220 remain below their combustion temperature.

[0076] As a result, the air mixes with the aerosol-forming substrate 220 to produce an aerosol 222 that exits the capsule 300 through the aperture 358 into the first portion 174 a and then the second portion 174 b of the chimney 170 .

[0077] Figure 5A is a cross-sectional view of a capsule and heater according to at least one exemplary embodiment. Figures 5B-5C are perspective views of the capsule and heater of Figure 5A according to at least one exemplary embodiment.

[0078] While capsule 300 is shown resembling a cylinder with elevated portions, it should be understood that other configurations may be employed. For example, the shape may be disc-like, such that capsule 300 has a disc-like appearance. In another embodiment, capsule 300 may be box-like in shape. In other embodiments, capsule 300 may have a polygonal shape (regular or irregular), including a triangle, rectangle (e.g., square), pentagon, hexagon, heptagon, or octagon. The structure of capsule 300 may facilitate stacking so that multiple capsules can be stored in an aerosol generating device or other receptacle for dispensing new capsules or receiving spent capsules.

[0079] The capsule 300 includes a base 305 and a cover 310. The base 305 and the cover 310 may comprise a suitable thermally conductive material, such as aluminum, an aluminum alloy, stainless steel, a copper alloy, or a combination thereof. The base 305 and the cover 310 may be made of the same material or different materials. For example, the base 305 may be made of a thermally conductive material, while the cover 310 is made of a non-conductive material. The base 305 and the cover 310 are connected via a connection interface 311. The connection interface 311 may be along an outer surface 312 of the base 305 and / or along an inner surface 360 ​​of the cover 310. The connection interface 311 may be, for example, a snap-fit ​​connection or a friction-fit connection. In other exemplary embodiments, the base 305 and cover 310 may be connected by "rolling" the overhang 350 of the cover 310 onto the base 305 or by welding the base 305 and cover 310 together.

[0080] In some exemplary embodiments, the base 305 and cover 310 form a unitary piece to reduce tampering by rolling the overhang 350 of the cover 310 onto the base 310 in such a way that any attempt to remove the cover 310 would damage the base 305.

[0081] The base 305 includes an outer surface 312, a bottom surface 314, and an inner surface 316. The outer surface 312, the bottom surface 314, and the inner surface 316 may be one piece, or may be separate and connected pieces. The inner surface 316 extends from the bottom surface 314 to an interior top surface 318. The interior surface 316 and the interior top surface 318 define a cavity 320. The interior surface 316 wraps around to define the diameter of the cavity and is angled such that the diameter of the cavity 320 decreases from the bottom surface 314 to the top surface 318. When describing the base 305 and the cover 310 in the exemplary embodiment, the sides may also be referred to as walls.

[0082] 5A, cavity 320 may be annular. However, inner surface 316 may have different shapes and angles, such that cavity 320 may have different shapes. Inner surface 316 is shaped to allow a cover from another capsule to fit into at least a portion of cavity 320, such that multiple capsules can be stacked.

[0083] The outer surface 312 , the bottom surface 314 and the inner surface 316 define a cavity 322 for receiving the aerosol-forming substrate 220 .

[0084] The inner surface 316 is angled away from the outer surface 312 from the bottom surface 314 to the top surface 318 so that the width of the cavity 322 increases continuously from the bottom surface 314 to the top surface 318. In an exemplary embodiment, the wall thickness of the inner surface 316 is 0.2 mm. Thus, a portion of the aerosol-forming substrate 220 may be 0.2 mm away from the heater sleeve 450.

[0085] The cross-section of the aerosol-forming substrate cavity 322 relative to the heater contact area is kept thin and uniform. In some exemplary embodiments, the widest part of the cavity 322 is between 1 and 2 mm. This allows for consistent and uniform heating of the aerosol-forming substrate 220.

[0086] The inner surface 316 may be angled to provide uniform contact with the tapered surface 460 of the heater sleeve 450 .

[0087] In some exemplary embodiments, the width W is 50% greater at the top surface 318 than at the bottom surface 314. For example, the width W at the bottom surface 314 may be 1 mm, and the width W at the top surface may be 1.5 mm.

[0088] However, the illustrated embodiment is not so limited. For example, cavity 322 may have a constant width W, and outer surface 312 may be parallel to inner surface 316. Outer surface 312 and inner surface 316 enclose cavity 320 such that width W is constant at each distance along height H.

[0089] In some exemplary embodiments, the same cross-sectional profile of the aerosol-forming substrate 220 is achieved when the outer surface 312 and the inner surface 316 are parallel, but the wall thickness of the inner surface 316 constantly varies along the height H.

[0090] In some exemplary embodiments, the exterior surface 312 is anodized to reduce heat loss and improve energy efficiency. Alternatively or additionally, the bottom surface 314 may be anodized. Alternatively or additionally, a portion of the cap 310 may be anodized.

[0091] 5A and 5C, the bottom surface 314 includes a plurality of apertures 324 disposed about the periphery of the bottom surface 314. The apertures 324 may be equidistantly spaced apart. However, example embodiments are not limited in this regard. The number of apertures may be determined based on computational fluid dynamics analysis.

[0092] Aperture 324 allows air to enter capsule 300. More specifically, air enters through aperture 324 and flows through aerosol-forming substrate 220 within cavity 322.

[0093] Aperture 324 is sized such that the aerosol-forming substrate cannot fall through the aperture and be pulled out of the capsule. In some exemplary embodiments, aperture 324 has a diameter of 0.3 mm. In other exemplary embodiments, aperture 324 may have a larger or smaller diameter depending on the particle size of the aerosol-forming substrate 220 in capsule 300.

[0094] As discussed herein, an aerosol-forming substrate is a material or combination of materials capable of producing an aerosol. Aerosol refers to a substance produced or output by the disclosed devices, claims, and equivalents. The material may include a compound (e.g., nicotine, cannabinoids), and when the material is heated, an aerosol containing the compound is produced. The heating may be below combustion temperatures to produce the aerosol without substantial thermal decomposition of the aerosol-forming substrate or substantial production of combustion by-products (if any). Thus, in exemplary embodiments, no thermal decomposition occurs during the heating and resulting production of the aerosol. In other examples, there may be thermal decomposition and combustion by-products, but the extent may be relatively minor and / or may be considered merely incidental.

[0095] The aerosol-forming substrate may be a fibrous material. For example, the fibrous material may be a plant material. The fibrous material is configured to release a compound when heated. The compound may be a naturally occurring component of the fibrous material. For example, the fibrous material may be a plant material such as tobacco, and the released compound may be nicotine. The term "tobacco" includes any tobacco plant material, including tobacco leaves, tobacco plugs, reconstituted tobacco, compressed tobacco, formed tobacco, or powdered tobacco, and combinations thereof from one or more tobacco plants, such as Nicotiana rustica and Nicotiana tabacum.

[0096] In some exemplary embodiments, the tobacco material may include material from any member of the Nicotiana genus. Furthermore, the tobacco material may include a blend of two or more different tobacco varieties. Examples of suitable types of tobacco material that may be used include, but are not limited to, flue-cured tobacco, burley tobacco, dark tobacco, Maryland tobacco, Oriental tobacco, rare tobacco, specialty tobacco, blends thereof, and the like. The tobacco material may be provided in any suitable form, including, but not limited to, tobacco lamina, processed tobacco materials such as expanded tobacco or puffed tobacco, processed tobacco stems such as cut cigarette tobacco or cut puffed tobacco, reconstituted tobacco materials, blends thereof, and the like. In some exemplary embodiments, the tobacco material is in the form of a substantially dried tobacco mass. Furthermore, in some exemplary embodiments, the tobacco material may be mixed and / or combined with at least one of propylene glycol, glycerin, subcombinations thereof, or combinations thereof.

[0097] The compound may also be a naturally occurring component of a medicinal plant with recognized medical therapeutic effects. For example, the medicinal plant may be a cannabis plant, and the compound may be a cannabinoid. Cannabinoids interact with receptors in the body to exert various effects. As a result, cannabinoids have been used for a variety of medicinal purposes (e.g., treating pain, nausea, epilepsy, and psychiatric disorders). The fibrous material may include leaves and / or flower material from one or more cannabis plants, such as Cannabis sativa, Cannabis indica, and Cannabis ruderalis. In some embodiments, the fibrous material is a mixture of 60-80% (e.g., 70%) Cannabis sativa and 20-40% (e.g., 30%) Cannabis indica.

[0098] Examples of cannabinoids include tetrahydrocannabinolic acid (THCA), tetrahydrocannabinol (THC), cannabidiol acid (CBDA), cannabidiol (CBD), cannabinol (CBN), cannabicyclol (CBL), cannabichromene (CBC), cannabigerol (CBG), etc. Tetrahydrocannabinolic acid (THCA) is a precursor of tetrahydrocannabinol (THC), and cannabidiol acid (CBDA) is a precursor of cannabidiol (CBD). Tetrahydrocannabinolic acid (THCA) and cannabidiol acid (CBDA) can be converted to tetrahydrocannabinol (THC) and cannabidiol (CBD), respectively, by heating. In exemplary embodiments, heat from first heater 110 and / or second heater 120 may cause decarboxylation to convert tetrahydrocannabinolic acid (THCA) in capsule 100 to tetrahydrocannabinol (THC) and / or convert cannabidiolic acid (CBDa) in capsule 100 to cannabidiol (CBD).

[0099] In instances where both tetrahydrocannabinolic acid (THCA) and tetrahydrocannabinol (THC) are present in capsule 100, decarboxylation and the resulting conversion will cause a decrease in tetrahydrocannabinolic acid (THCA) and an increase in tetrahydrocannabinol (THC). At least 50% (e.g., at least 87%) of the tetrahydrocannabinolic acid (THCA) may be converted to tetrahydrocannabinol (THC) during heating of capsule 100. Similarly, in instances where both cannabidiolic acid (CBDA) and cannabidiol (CBD) are present in capsule 100, decarboxylation and the resulting conversion will cause a decrease in cannabidiolic acid (CBDA) and an increase in cannabidiol (CBD). At least 50% (e.g., at least 87%) of the cannabidiolic acid (CBDA) may be converted to cannabidiol (CBD) during heating of capsule 300.

[0100] Furthermore, the compound may include, or may additionally include, non-naturally occurring additives that are 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 introduced compound may include nicotine, cannabinoids, and / or flavorants. The flavorants may be derived from natural sources, such as plant extracts (e.g., tobacco extract, cannabis extract), and / or artificial sources. In yet another example, if the fibrous material includes tobacco and / or cannabis, the compound may be, or may additionally include, one or more flavorants (e.g., menthol, mint, vanilla). Thus, the compound within 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 levels of naturally occurring components in the aerosol-forming substrate can be increased by supplementation. For example, the existing level of nicotine in a quantity of tobacco may be increased through supplementation with an extract containing nicotine, and similarly, the existing level of one or more cannabinoids in a quantity of cannabis may be increased through supplementation with an extract containing such cannabinoids.

[0101] In an exemplary embodiment, cavity 322 can contain 200-300 mg of tobacco, preferably 200-230 mg of tobacco.

[0102] Returning to FIG. 5A, the cover 310 may include an overhang portion 350 that provides a connection at a connection interface 311 to the base 305 .

[0103] In some exemplary embodiments, the overhang portion 350 provides a press fit between the cover 310 and the base 305. The overhang portion 350 allows the cover 310 to be removed from the base 305.

[0104] In another exemplary embodiment, the overhang 350 of the cover 310 is rolled onto the base 305 in such a way that any attempt to remove the cover 310 will damage the base 305 .

[0105] Overhang 350 extends from a midsection of base 305 in a curved line 352 that transitions to a lower plane 354. When cover 310 is placed on base 305, lower plane 354 extends inward from the curved line above cavity 322. Lower plane 354 transitions to an elevated plane 356. When cover 310 is placed on base 305, elevated plane 356 is higher (at a greater distance from base 305) than lower plane 354 and is above top surface 318 of base 305. Furthermore, lower plane 354 transitions to elevated plane 356 above cavity 322.

[0106] The elevated plane 356 includes a plurality of apertures 358 in a middle portion 359 of the elevated plane 356. The number of apertures 358 may be based on empirical data and / or computational fluid dynamics analysis. The apertures 358 are sized to prevent the aerosol-forming substrate from falling through the apertures and being pulled out of the capsule. In some exemplary embodiments, the diameter of the aerosol exit aperture 358 is 0.3 mm. In other exemplary embodiments, the diameter of the aperture 358 may be larger or smaller depending on the particle size of the aerosol-forming substrate 220 in the capsule 300. The apertures 358 allow the aerosol generated by heating the aerosol-forming substrate 220 to exit the capsule 300. In some exemplary embodiments, the size and number of the apertures 358 are the same as the size and number of the apertures 324. The size of the apertures 324 and 358 is sized to prevent the aerosol-forming substrate from exiting the capsule 300.

[0107] The heater 400 may be a ceramic cartridge heater that heats the capsule 300 by conduction. The heater is cylindrical and is connected to the electrical wires 226a, 226b and receives power from the power supply 294 via the controller 290.

[0108] The heater 400 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.

[0109] In exemplary embodiments, the heater 400 is configured to undergo Joule heating (also known as ohmic / resistive heating) when an electric current is applied thereto. More specifically, the heater 400 may be formed of a conductor (same or different) and configured to generate heat when an electric current passes through the conductor. The electric current may be supplied from a power source 294 within the aerosol generating device. Suitable conductors for the heater 400 include iron-based alloys (e.g., stainless steel) and / or nickel-based alloys (e.g., nichrome). In some exemplary embodiments, the heater 400 is cylindrical. The resistance of the heater 400 may be 1 Ω, and the diameter of the heater 400 is approximately 2 mm and the length is approximately 15 mm. Furthermore, while the heater 400 is shown in FIGS. 5A-5C, it should be understood that in some exemplary embodiments, the heater 400 may have a different shape.

[0110] In addition, the current from the power source may be transmitted via electrodes / wires 226a, 226b connected to the heater 400. Furthermore, the supply of current from the aerosol generating device to the heater 400 may be manual (e.g., button operation) or automatic (e.g., puff operation).

[0111] Heater sleeve 450 covers a portion of heater 400 and is designed to be inserted into cavity 320. In some exemplary embodiments, heater sleeve 450 may be made of aluminum. More specifically, heater sleeve 450 has an upper diameter 455 that is smaller than the diameter of upper surface 318 of base 305 of capsule 300. Heater sleeve 450 includes a tapered section 460 that extends from upper surface 465 to lower portion 470 of heater sleeve 450. Tapered section 460 is angled such that the diameter increases continuously from upper surface 465 to lower portion 470. Thus, diameter 475 is larger than diameter 455.

[0112] The outer surface of tapered portion 460 is tapered at the same angle as inner surface 316. This allows tapered portion 460 to come into contact with inner surface 316 when heater 400 and heater sleeve 450 are inserted into cavity 320. In addition, the application of spring pressure from above promotes contact between tapered surface 460 and inner surface 316.

[0113] Lower portion 470 includes a continuous wall 480 that defines a cavity 485. Lower portion 470 includes a constant diameter.

[0114] Heater sleeve 450 further includes a bore 490 extending from top surface 465 to cavity 485. Bore 490 is sized to allow heater 400 to be inserted into bore 490 such that heater 400 is exposed at top surface 465 when inserted into bore 490.

[0115] Additionally, heater sleeve 450 includes slots 495 extending from upper surface 465 into lower surface 470. The number of slots 495 is three as shown in Figures 5A-5C, but the exemplary embodiment is not limited thereto. Slots 495 allow heater sleeve 450 to expand to accommodate insertion of heater 400, such that pressure applied to heater 400 can maintain heater 400 in place.

[0116] The sleeve 450 acts as a collet for the heater 400. When the heater 400 is inserted into the heater sleeve 450, slots 495 cut into the heater sleeve 450 can expand to accept the heater 400 while applying light pressure to the heater 400, facilitating contact and heat transfer between the heater sleeve 450 and the heater 400.

[0117] 6 is a cross-sectional view of a capsule according to at least one exemplary embodiment. As shown in FIG. 6, the depth h1 of the cavity 320 may be 7.95 mm. More specifically, the depth h1 extends from the top surface 318 to a common plane 600 between the cavity 320 and the bottom surface 314. The depth h2 is the distance between the lower plane 354 and the bottom surface 314. The depth h2 may be 8.00 mm.

[0118] The width w1 (i.e., diameter) of the cover 310 may be 12.30 mm, and the width w2 of the elevated plane 356, including the transition to the lower plane 354, may be 9.31 mm. The design of the transition from the lower plane 354 to the elevated plane 356 guides the aerosol back toward the central axis of the chimney 170.

[0119] Width w3 is the diameter of top surface 318 and may be 6.61 mm. Width w3 may also be considered the smallest diameter of cavity 320. Width w4 is the diameter of cavity 320 defined by bottom surface 314. Width w4 may be 8.39 mm and may be considered the largest diameter of cavity 320. Width w5 is the width of base 305 and is the diameter on the outer surface side. Width w5 may be 12.00 mm.

[0120] Width w6 is the thickness of the sides and surfaces of the walls of base 305 and cover 310, such as outer surface 312, inner surface 316, bottom surface 314, lower plane 354, and elevated plane 356. Width w6 may be 0.15 mm. In some exemplary embodiments, all walls of capsule 300 have a uniform thickness, allowing for simplified manufacturing.

[0121] FIG. 7 illustrates multiple stacked capsules in accordance with at least one exemplary embodiment. As shown in FIG. 7 , an initial transition 710 between the lower plane 354 and the elevated plane 356 may be the same shape as a transition 715 between the bottom surface 314 and the inner surface 316. Thus, when multiple capsules are stacked, the initial transition 710 of a first capsule 720 may coincide with the transition 715 of a second capsule 730. The initial transition 710 and the transition 715 may contact each other, and the lower plane 354 of the first capsule 720 may contact the bottom surface 314 of the second capsule 730. Furthermore, the elevated plane 356 of the first capsule 720 may protrude into the cavity 320 of the second capsule 730.

[0122] As a result, when multiple capsules are stacked, the stacked capsules can form a tessellation.

[0123] FIG. 8 illustrates at least one exemplary embodiment of a cavity of a capsule.

[0124] 8, capsule base 805 may include multiple partitions 810 within cavity 822. Similar to the capsules described in FIGS. 3-7, cavity 822 is defined by a bottom surface 814, an outer surface 812, and an inner surface 816. Bottom surface 814, outer surface 812, and inner surface 816 may be walls of cavity 822.

[0125] The dividers 810 may extend between the outer surface 812 and the inner surface 816, and to the bottom surface 814. The dividers 810 may be spaced equidistantly or may be positioned according to the desired airflow through the cavity 822.

[0126] In some exemplary embodiments, plate 830 may extend across and over multiple partitions 810. Plate 830 may include apertures 835. In FIG. 8 , plate 830 is shaped like a trapezoid, but the shape of plate 830 is not limited thereto. For example, the shape of the plate may be any shape and may be based on the desired air flow through cavity 822.

[0127] 9A-9B illustrate a capsule according to at least one exemplary embodiment.

[0128] 9A is a cross-sectional plan view of capsule 900. Capsule 900 is similar to capsule 300. Therefore, differences between capsule 900 and capsule 300 will be described. Capsule 900 includes a base 905 and a cover 910. Unlike cover 310, cover 910 may have a completely flat surface 920. Base 905 defines a cavity 922 (similar to how cavity 322 is defined). Cavity 922 is wider than cavity 322 and has a depth h9 that is less than the depth of cavity 322. Depth h9 may be 2 mm, and cavity 922 may have a depth of 0.43 cm to hold the aerosol-forming substrate. 3 has a total volume of

[0129] An aperture 930 extends through the cover 910 and overlies the cavity 922. The base 905 and cover 910 may be spot welded at 940. In other exemplary embodiments, the cover 910 and base 905 may be joined at 940 by other joining methods.

[0130] 9B is a bottom view of capsule 900. As shown in FIG. 9B, base 905 includes a plurality of apertures 945 extending through bottom surface 950. The width h of bottom surface 950 10 may be greater than the width of the bottom surface 314.

[0131] While a number of exemplary embodiments are disclosed herein, it should be understood that other variations are possible. Such variations are not to be regarded as a departure from the spirit and scope of the present disclosure, and all such modifications as 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: a base made of a thermally conductive material and a cover; the base defining a first cavity therein; the base comprises a first surface; the first surface defines an opening to a second cavity; the first surface comprising a first plurality of apertures through the first surface; the cover is coupled to the base and disposed on the base; the cover includes a second plurality of apertures disposed in a medial portion of the cover; The capsule, wherein the first plurality of apertures and the second plurality of apertures define an air flow path through the base and the cover.

2. The capsule of claim 1, the base further comprises a first wall and a second wall; the first surface connects the first wall and the second wall; The first surface, the first wall, and the second wall define the first cavity.

3. The capsule according to claim 2, The capsule, wherein the width of the first cavity increases as the first wall and the second wall extend from the first surface.

4. The capsule according to claim 3, The capsule wherein the width increases continuously from the base to the apex.

5. The capsule according to claim 4, The capsule has a width of up to about 2 mm.

6. The capsule according to claim 2, The capsule, wherein the first wall, the second wall and the first surface are integral.

7. The capsule of claim 1, The capsule, wherein the first plurality of apertures is in a circular pattern.

8. 8. The capsule of claim 7, The capsule, wherein the first plurality of apertures are on a single circular line.

9. The capsule of claim 1, the cover has a second surface and a third surface; The capsule, wherein the second surface and the third surface are at different heights and the second plurality of apertures are in the third surface.

10. 10. The capsule of claim 9, The third surface is elevated relative to the second surface of the capsule.

11. The capsule of claim 1, The capsule, wherein the cover comprises an overhang coupled to the base.

12. The capsule of claim 1, A capsule, wherein the width of the first cavity increases along a first direction and the width of the second cavity decreases along the first direction.

13. 13. The capsule of claim 12, The capsule, wherein the first direction is a longitudinal direction of the capsule.

14. The capsule of claim 1, the second plurality of apertures are on an inner wall of the base; The interior wall defines an end of the second cavity.

15. The capsule of claim 1, The capsule further comprises an aerosol-forming substrate within the first cavity.

16. 16. The capsule of claim 15, The aerosol-forming substrate comprises tobacco.

17. The capsule of claim 1, The capsule, wherein the second plurality of apertures is a circular pattern including at least two circles.

18. An aerosol generating device, comprising: a capsule and a heating system, the capsule comprises a base of a thermally conductive material and a cover; the base defining a first cavity therein; the base comprises a first surface; the first surface defines an opening to a second cavity; the first surface comprising a first plurality of apertures through the first surface; the cover is coupled to the base and disposed on the base; a second plurality of apertures disposed in an intermediate portion of the cover; the first plurality of apertures and the second plurality of apertures define air flow paths through the base and the cover; The aerosol generating device, wherein the heating system is configured to heat the base of the capsule.

19. 19. The aerosol generating device according to claim 18, The aerosol generating device, wherein the heating system comprises a heater and a heater sleeve covering a portion of the heater.

20. 20. The aerosol generating device according to claim 19, The heater sleeve is attached to the aerosol generating device so as to generally fit against the wall of the second cavity.

21. The aerosol generating device according to claim 20, The aerosol generating device further comprises a biasing element that applies a force to the capsule so that the capsule contacts the heater sleeve.

22. 19. The aerosol generating device according to claim 18, The aerosol generating device further comprises an aerosol-forming substrate within the first cavity.

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