Capsule containing an internal heater, heat-not-burn (HNB) aerosol generator, and method for generating aerosols

Abstract

A capsule for a heat-not-burn (HNB) aerosol generating device can include a housing and a heater within the housing. The housing has an inner surface defining a chamber configured to hold an aerosol-forming substrate. The housing further has an outer surface defining a first surface, an opposing second surface, and a side surface of the capsule. The first surface and the second surface of the capsule are permeable to the aerosol. The heater has a first end, a middle portion, and a second end. The first end and the second end of the heater can be outer segments that define a portion of the side surface of the capsule. The middle portion of the heater is an inner segment disposed within the chamber of the housing.

Description

[Technical field]

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

[0002] Some electronic devices are configured to heat the plant material to a temperature sufficient to release the plant material's components while maintaining a temperature below the plant material's combustion point to avoid substantial thermal decomposition of the plant material. Such devices may be referred to as aerosol generating devices (e.g., heat-not-burn aerosol generating devices), and the plant material to be heated may be tobacco. In some 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 prepackaged in individual containers for ease of 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 may include a housing and a heater within the housing. The housing has an interior surface defining a chamber configured to hold an aerosol-forming substrate. Additionally, the housing has an exterior surface constituting a first face, an opposing second face, and a side face of the capsule. The first face and the second face of the capsule are permeable to the aerosol. The heater has a first end, a middle portion, and a second end. The first end and the second end of the heater are exterior segments constituting a portion of the side face of the capsule. The middle portion of the heater is an interior segment disposed within the chamber of the housing.

[0004] At least one embodiment relates to a heat-not-burn (HNB) aerosol generating device. In an exemplary embodiment, the aerosol generating device may include a capsule and a device body. The capsule includes an aerosol-forming substrate. Additionally, the capsule includes a first permeable surface, an opposing second permeable surface, and a side surface. The device body may include a heating pad configured to heat the aerosol-forming substrate within the capsule by conduction to generate an aerosol. In such an example, the device body may be configured to receive the capsule such that the heating pad engages and covers the first permeable surface or the second permeable surface of the capsule.

[0005] At least one embodiment relates to a method of generating an aerosol. In an exemplary embodiment, the method may include engaging a capsule between a first pad and a second pad. The capsule includes an aerosol-forming substrate and includes a first permeable surface, an opposing second permeable surface, and a side surface. The method may further include heating the aerosol-forming substrate on at least one of the first pad or the second pad such that the generated aerosol passes through at least one of the first pad or the second pad. [Brief description of the drawings]

[0006] Various features and advantages of the non-limiting embodiments herein will become more apparent upon consideration of the detailed description in conjunction with the accompanying drawings. The accompanying drawings are provided merely for illustration purposes and should not be construed as limiting the scope of the claims. The accompanying drawings should not be considered as drawn to scale unless explicitly noted. For clarity, various dimensions of the drawings may be exaggerated.

[0007] [Figure 1] FIG. 1 is a perspective view of a first side of a capsule for an aerosol generating device according to an exemplary embodiment.

[0008] [Diagram 2]FIG. 2 is a perspective view showing a second opposing face of the capsule of FIG.

[0009] [Diagram 3] FIG. 3 is an exploded perspective view of the capsule of FIG.

[0010] [Figure 4] FIG. 4 is an exploded perspective view of the capsule of FIG.

[0011] [Diagram 5] FIG. 5 is an exploded perspective view of the heater and the third frame in FIG.

[0012] [Figure 6] FIG. 6 is an exploded perspective view of the heater and the third frame in FIG.

[0013] [Figure 7] FIG. 7 is a perspective view of a first side of another capsule for an aerosol generating device in accordance with an exemplary embodiment.

[0014] [Figure 8] FIG. 8 is a perspective view showing a second opposing side of the capsule of FIG.

[0015] [Figure 9] FIG. 9 is an exploded perspective view of the capsule of FIG.

[0016] [Figure 10] FIG. 10 is an exploded perspective view of the capsule of FIG.

[0017] [Figure 11] 11 is an exploded perspective view of the heater and the third frame in FIG.

[0018] [Figure 12] 12 is an exploded perspective view of the heater and the third frame in FIG. 10. FIG.

[0019] [Figure 13] FIG. 13 is a plan view of a patterned sheet associated with the fabrication of a heater according to an exemplary embodiment.

[0020] [Figure 14] FIG. 14 is a perspective view of a partially assembled capsule containing a heater resulting from the patterned sheet of FIG.

[0021] [Figure 15] FIG. 15 is a plan view of another patterned sheet associated with fabricating a heater according to an exemplary embodiment.

[0022] [Figure 16] FIG. 16 is a plan view of another patterned sheet associated with fabricating a heater according to an exemplary embodiment.

[0023] [Figure 17] FIG. 17 is a plan view of another patterned sheet associated with fabricating a heater according to an exemplary embodiment.

[0024] [Figure 18] FIG. 18 is a perspective view illustrating a method for manufacturing a capsule for an aerosol generating device according to an exemplary embodiment. [Figure 19] FIG. 19 is a perspective view illustrating a method for manufacturing a capsule for an aerosol generating device according to an exemplary embodiment. [Figure 20] FIG. 20 is a perspective view illustrating a method for manufacturing a capsule for an aerosol generating device according to an exemplary embodiment.

[0025] [Figure 21] FIG. 21 is a cross-sectional, schematic view of an aerosol generating device according to an exemplary embodiment.

[0026] [Figure 22] FIG. 22 is a perspective view of another capsule for an aerosol generating device according to an exemplary embodiment.

[0027] [Diagram 23] FIG. 23 is an internal perspective view of the capsule of FIG.

[0028] [Figure 24] FIG. 24 is a cross-sectional plan view of the capsule of FIG.

[0029] [Diagram 25] FIG. 25 is a cross-sectional side view of the capsule of FIG.

[0030] [Figure 26] FIG. 26 is a perspective, detached view of an engagement assembly for a capsule according to an exemplary embodiment.

[0031] [Figure 27] FIG. 27 is a perspective view of the engagement assembly of FIG. 26, shown partially engaged.

[0032] [Figure 28] 28 is a cross-sectional and engagement view of the engagement assembly of FIG. 26. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0033] 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.

[0034] Thus, while exemplary embodiments are susceptible to various modifications and alternative forms, exemplary embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It is to be understood, however, that there is no intention to limit the exemplary embodiments to the particular forms disclosed, but on the contrary, the exemplary embodiments are intended to cover all modifications, equivalents, and alternatives thereof. Like numbers refer to like elements throughout the description of the figures.

[0035] 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.

[0036] In this specification, terms such as first, second, third, etc. may be used to describe various elements, regions, layers, and / or sections, but it should be understood that these elements, regions, layers, and / or sections should not be limited by these terms. These terms are used only to distinguish one element, region, layer, or section from another region, layer, or section. Thus, a first element, region, layer, or section described below can be referred to as a second element, region, layer, or section without departing from the teachings of the exemplary embodiments.

[0037] For ease of description, spatially relative terms (e.g., "beneath," "below," "lower," "above," "upper," etc.) may be used herein to describe the relationship of one element or feature to another element or feature as depicted in the figures. It should be understood that the spatially relative terms are intended to encompass different orientations of the device during use and operation in addition to the orientation depicted in the figures. For example, if the device in the figures were turned over, elements described as "below" or "beneath" other elements or features would be oriented "above" the other elements or features. Thus, the term "below" may encompass both an orientation above and below. Also, the device may be otherwise oriented (rotated 90 degrees, oriented in other directions, etc.) and the spatially relative descriptors used herein would be interpreted accordingly.

[0038] The terms used herein are for the purpose of describing various exemplary embodiments only and are not intended to limit the exemplary embodiments. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms unless the context clearly indicates otherwise. It will be further understood that the terms "includes," "including," "comprises," and / or "comprising," as used herein, specify the presence of stated features, integers, steps, operations, and / or elements, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, and / or groups thereof.

[0039] In this specification, when the words "about" and "substantially" are used in connection with numerical values, unless expressly defined otherwise, the associated numerical value is intended to include a tolerance of ±10% around the stated numerical value. Additionally, when the terms "generally" or "substantially" are used in connection with geometric shapes, precision in the geometric shapes is not required, but degrees of freedom with respect to the shapes are intended to be within the scope of the present disclosure. Additionally, whether a numerical value or shape is modified "about," "generally," or "substantially," it will be understood that these numerical values ​​and shapes should be interpreted as including manufacturing or operating tolerances (e.g., ±10%) around the stated numerical value or shape.

[0040] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by a person of ordinary skill in the art to which the exemplary embodiments belong. Terms, including those defined in commonly used dictionaries, should be interpreted as having a meaning consistent with the meaning in the context of the relevant art, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0041] The hardware may be implemented using processing or control circuitry such as, but not limited to, one or more processors, one or more central processing units (CPUs), one or more microcontrollers, one or more arithmetic logic units (ALUs), one or more digital signal processors (DSPs), one or more microcomputers, one or more field programmable gate arrays (FPGAs), one or more system-on-chips (SoCs), one or more programmable logic units (PLUs), one or more microprocessors, one or more application specific integrated circuits (ASICs), or other devices capable of responding to and executing instructions in a defined manner.

[0042] FIG. 1 is a perspective view of a first side of a capsule for an aerosol generating device according to an exemplary embodiment. FIG. 2 is a perspective view of an opposing second side of the capsule of FIG. 1. Referring to FIGS. 1-2, a capsule 100 may be configured to be received within an aerosol generating device (e.g., a heat-not-burn aerosol generating device). In the drawings, the capsule 100 has a layered structure and a generally planar configuration. The proximal end of the capsule 100 may have a curved proximal edge and the opposing distal end may have a straight distal edge. Furthermore, a pair of straight side edges may connect the curved proximal edge and the straight distal edge. The pair of straight side edges may be parallel to each other. Furthermore, the junction of the linear side edge and the linear distal edge may be in the form of a rounded corner.

[0043] Although capsule 100 is shown in the figures as resembling a rectangle (e.g., elongated semicircle, semicircular) with semicircular ends, it should be understood that other configurations may be employed. For example, the shape may be circular such that capsule 100 has a disk-like appearance. In another example, capsule 100 may have an oval or racetrack-like shape. In other examples, capsule 100 may have a polygonal shape (regular or irregular), including a triangle, a rectangle (e.g., square), a pentagon, a hexagon, a heptagon, or an octagon. The layered structure and generally planar form of capsule 100 may facilitate stacking so that multiple capsules may be stored in an aerosol generating device or other receptacle for dispensing new capsules or receiving spent capsules. In an exemplary embodiment, capsule 100 has a thickness of between 1-4 mm (e.g., between 1-2 mm).

[0044] The capsule 100 may include a housing and a heater 170 (e.g., FIG. 5) within the housing. The housing of the capsule 100 has an inner surface that defines a chamber configured to hold an aerosol-forming substrate 160 (e.g., FIG. 5). Additionally, the housing of the capsule 100 has an outer surface that constitutes a first face, an opposing second face, and a side face of the capsule 100. The first face and the second face of the capsule 100 may be permeable to the aerosol. The side face of the capsule 100 is between the first face and the second face. The side face may be considered a periphery of the capsule 100.

[0045] The housing of the capsule 100 includes a first frame 130 and a second frame 140 (e.g., FIG. 3). The first frame 130 and the second frame 140 may be of the same shape and size (e.g., based on a plan view) and aligned such that the outer sidewalls are substantially flush with one another, although the exemplary embodiment is not so limited. The first frame 130 and the second frame 140 may be formed from a suitable polymer, such as polyetheretherketone (PEEK), liquid crystal polymer (LCP), and / or ultra-high molecular weight polyethylene (UHMWPE). The first frame 130 and the second frame 140 may be connected via a welding arrangement.

[0046] The first permeable structure 110 is fixed and exposed by the first frame 130. Similarly, the second permeable structure 120 is fixed and exposed by the second frame 140. As described in more detail herein, the third frame 150 is disposed between the first permeable structure 110 and the second permeable structure 120 (as well as between the first frame 130 and the second frame 140). The capsule 100 is configured to hold an aerosol-forming substrate 160, which may be present in the third frame 150 between the first permeable structure 110 and the second permeable structure 120. The first recess 133 (e.g., the first dimple portion) in the first frame 130 and the second recess 143 (e.g., the second dimple portion) in the second frame 140 may be by an injection molding process. In this regard, the size, location, and / or shape of the first recess 133 and the second recess 143 may vary (or may not exist at all) depending on the fabrication technique.

[0047] The first and second permeable structures 110 and 120 may be in the form of a mesh sheet, a perforated sheet, or a combination thereof. For example, both the first and second permeable structures 110 and 120 may be in the form of a mesh sheet. In another example, both the first and second permeable structures 110 and 120 may be in the form of a perforated sheet (e.g., 80, 100, or 250 mesh equivalent). The perforated sheet may be mechanically or chemically perforated (e.g., via photochemical machining / etching). In yet another example, one of the first and second permeable structures 110 and 120 may be in the form of a mesh sheet, and the other of the first and second permeable structures 110 and 120 may be in the form of a perforated sheet. The first transparent structure 110 and the second transparent structure 120 (as well as the first frame 130 and the second frame 140) may be substantially the same size (e.g., ±10% of a given dimension) based on a planar view.

[0048] As shown in FIG. 1, the combination of the exposed surface of the first transmissive structure 110 and the adjacent (e.g., substantially coplanar / parallel) surface of the first frame 130 may be considered a first surface of the capsule 100. Similarly, as shown in FIG. 2, the combination of the exposed surface of the second transmissive structure 120 and the adjacent (e.g., substantially coplanar / parallel) surface of the second frame 140 may be considered a second surface of the capsule 100. In one embodiment, the first surface, the second surface, or both may include a perforated sheet. In another embodiment, the first surface, the second surface, or both may include a mesh sheet. In yet another example, one of the first surface or the second surface may include a perforated sheet and the other of the first surface or the second surface may include a mesh sheet.

[0049] As mentioned above and discussed in more detail herein, a heater 170 (e.g., FIG. 5 ) may be disposed within the capsule 100 to heat the aerosol-forming substrate 160. The heater 170 may include, among other things, a first end 172 and a second end 176 configured to receive electrical current from a power source during activation of the heater 170. When the heater 170 is activated, the temperature of the aerosol-forming substrate 160 increases and an aerosol may be generated and released through the first permeable structure 110 and / or the second permeable structure 120 of the capsule 100.

[0050] 1-2, the combination of the exposed surface of the third frame 150 and the adjacent side walls of the first frame 130 and second frame 140 may be considered a side wall of the capsule 100. Additionally, the first end 172 and the second end 176 may be exterior segments of the heater 170 that also form part of the side of the capsule 100. The outwardly facing surfaces of the first end 172 and the second end 176 of the heater 170 may be coplanar, although an exemplary embodiment is not limited thereto.

[0051] As discussed herein, an aerosol-forming substrate is a material or combination of materials that can result in an aerosol. Aerosol refers to a substance that is generated or output by the disclosed device, 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 generated. The heating may be below combustion temperatures to generate the aerosol without substantial thermal decomposition of the aerosol-forming substrate or substantial generation 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.

[0052] 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, molded tobacco, or powdered tobacco, and combinations thereof from one or more tobacco plants, such as Nicotiana rustica and Nicotiana tabacum.

[0053] In some exemplary embodiments, the tobacco material may include material from any member of the Nicotiana genus. Additionally, the tobacco material may include a blend of two or more different tobacco varieties. Examples of suitable types of tobacco materials that may be used include, but are not limited to, flue-cured tobacco, burley tobacco, dark tobacco, Maryland tobacco, Oriental tobacco, rare tobacco, specialty tobacco, blends thereof, and the like. The tobacco material may be provided in any suitable form, including, but not limited to, tobacco lamina, processed tobacco materials such as volume-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. Additionally, 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.

[0054] The compound may also be a naturally occurring component of a medicinal plant that has been medically recognized for its 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 a variety of 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.

[0055] 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 the precursor of tetrahydrocannabinol (THC), and cannabidiol acid (CBDA) is the precursor of cannabidiol (CBD). Tetrahydrocannabinolic acid (THCA) and cannabidiol acid (CBDA) can be converted to tetrahydrocannabinol (THC) and cannabidiol (CBD), respectively, via heating. In an exemplary embodiment, decarboxylation may occur via heat from a heater (e.g., heater 170 shown in FIG. 5 ) to convert tetrahydrocannabinolic acid (THCA) in capsule 100 to tetrahydrocannabinol (THC) and / or to convert cannabidiol acid (CBDA) in capsule 100 to cannabidiol (CBD).

[0056] In an example where both tetrahydrocannabinolic acid (THCA) and tetrahydrocannabinol (THC) are present in the 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 the capsule 100. Similarly, in an example where both cannabidiolic acid (CBDA) and cannabidiol (CBD) are present in the capsule 100, decarboxylation and the resulting conversion will cause a decrease in cannabidiol acid (CBDA) and an increase in cannabidiol (CBD). At least 50% (e.g., at least 87%) of the cannabidiol acid (CBDA) may be converted to cannabidiol (CBD) during heating of the capsule 100.

[0057] Furthermore, the compound may include or may additionally include non-naturally occurring additives that are then introduced into the fibrous material. In one example, the fibrous material may include synthetic materials. In another example, the fibrous material may include natural materials such as cellulosic materials (e.g., non-tobacco and / or non-cannabis materials). In either example, the compound introduced may include nicotine, cannabinoids, and / or flavorants. The flavorants may be obtained from natural sources such as plant extracts (e.g., tobacco extracts, cannabis extracts), and / or artificial sources. In yet another example, when the fibrous material includes tobacco and / or cannabis, the compound may be or may additionally include one or more flavoring agents (e.g., menthol, mint, vanilla). Thus, the compound 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 of the aerosol-forming substrate may be increased by supplementation. For example, the existing level of nicotine contained in a quantity of tobacco may be increased through supplementation with an extract containing nicotine. Similarly, the existing levels of one or more cannabinoids in bulk cannabis may be increased through supplementation with an extract containing such cannabinoids.

[0058] FIG. 3 is an exploded perspective view of the capsule of FIG. 1. FIG. 4 is an exploded perspective view of the capsule of FIG. 2. Referring to FIGS. 3-4, the first frame 130 has a first inner peripheral surface and a first outer peripheral surface. Furthermore, the first frame 130 defines a first opening 131. In an exemplary embodiment, the sidewall of the first opening 131 has opposing straight portions and optionally opposing curved portions, one curved portion may be adjacent to a proximal end of the first frame 130 and the other curved portion may be adjacent to an opposing distal end of the first frame 130. The first permeable structure 110 may be fixed to a first inner surface of the first frame 130 to be exposed by the first opening 131. Also, from the difference, the first permeable structure 110 may be considered to cover the first opening 131. Furthermore, the first permeable structure 110 may define a first aperture 112. The first aperture 112 may be positioned and sized to accommodate the first protrusion 135 when the first transmissive structure 110 is secured to the first frame 130 .

[0059] The second frame 140 has a second inner peripheral surface and a second outer peripheral surface. Furthermore, the second frame 140 defines a second opening 141. In an exemplary embodiment, the sidewalls of the second opening 141 have opposing straight portions and, optionally, opposing curved portions, where one curved portion may be adjacent to a proximal end of the second frame 140 and the other curved portion may be adjacent to an opposing distal end of the second frame 140. The second transparent structure 120 may be fixed to a second inner surface of the second frame 140 to be exposed by the second opening 141. From another perspective, the second transparent structure 120 may be considered to cover the second opening 141. The size and shape of the second opening 141 may correspond to the size and shape of the first opening 131 (e.g., may be a mirror surface). Furthermore, the second transparent structure 120 may define a second aperture 122. The second aperture 122 may be positioned and sized to accommodate the second protrusion 145 when the second transmissive structure 120 is secured to the second frame 140 .

[0060] The third frame 150 defines a cavity 151 (e.g., FIG. 5 ) configured to receive the aerosol-forming substrate 160. The combination of the sidewalls of the cavity 151 and the inner surfaces of the first and second permeable structures 110, 120 (covering the cavity 151) may be considered to define a chamber. In an exemplary embodiment, the sidewalls of the cavity 151 have opposing straight portions and opposing curved portions, one curved portion adjacent a proximal end of the third frame 150 and the other curved portion adjacent an opposing distal end of the third frame 150. The third frame 150 may be substantially the same size (e.g., ±10% of a given dimension) as the first and second permeable structures 110, 120 based on a plan view. The third frame 150 may also define apertures 152a and 152b adjacent its distal ends. In addition to the structural materials of the first frame 130 and the second frame 140, the third frame 150 may be formed from other suitable materials, such as ceramic, sintered glass, and / or interlocking fibers (e.g., cardboard).

[0061] The heater 170 is configured to extend through the third frame 150 into the cavity 151. Furthermore, the heater 170 can be considered to be supported by the third frame 150. The heater 170 includes a first end 172, a middle portion 174, and a second end 176. The first end 172 and the second end 176 of the heater 170 are external segments that also form part of the side of the capsule 100. The middle portion 174 of the heater 170 is an internal segment that is disposed within the capsule 100 (e.g., within the chamber of the housing that contains the aerosol-forming substrate 160). The first end 172, the middle portion 174, and the second end 176 of the heater 170 are sections of a continuous structure. In an exemplary embodiment, the middle portion 174 of the heater 170 has a planar and wound configuration.

[0062] The aerosol-forming substrate 160 may be disposed within the cavity 151 of the third frame 150 such that it is on either side of the intermediate portion 174 of the heater 170. In one example, the aerosol-forming substrate 160 may be in an interlocking form (e.g., a sheet, a pallet, a tablet) configured to maintain its shape such that the aerosol-forming substrate 160 can be integrally disposed within the cavity 151 of the third frame 150. In such an example, one mass of the aerosol-forming substrate 160 may be disposed on one side of the intermediate portion 174 of the heater 170 and another mass of the aerosol-forming substrate 160 may be disposed on the other side of the intermediate portion 174 of the heater 170 (e.g., so as to substantially fill the cavity 151 of the third frame 150 and sandwich / embed the intermediate portion 174 of the heater 170 therebetween). Alternatively, the aerosol-forming substrate 160 may not have a set shape, but rather a loose shape (e.g., particles, fibers, debris, pieces, flakes) configured to take the shape of the cavity 151 of the third frame 150 when introduced.

[0063] The first and second transparent structures 110, 120 may be secured to the first and second frames 130, 140, respectively, via various attachment techniques. For example, the attachment technique may include injection molding (e.g., insert molding, overmolding). In another example, the attachment technique may include ultrasonic welding. In another example, the attachment technique may include an adhesive (e.g., tape, glue) deemed food safe or otherwise acceptable by a regulatory agency. Alternatively, instead of a separate attachment technique, the first and second transparent structures 110, 120 may be clamped (or otherwise restrained) to the third frame 150 by the first and second frames 130, 140, respectively.

[0064] The first frame 130 includes at least one first connector that protrudes from the first inner surface of the first frame 130. The at least one first connector of the first frame 130 may be in the form of a first connector 138. In an exemplary embodiment, the first connector 138 may extend along the edge of the first inner peripheral surface of the first frame 130 in the form of a ridge (e.g., a first ridge). The ridge may define a trench that extends along its entire length to resemble an elevated trench or a recessed / shaggy ridge. Additionally or alternatively, the ridge may have a tapered ridge, and thus may be referred to as a tapered ridge. Although the first connector 138 is shown as being separated into a plurality of discrete structures (e.g., four discrete structures), it should be understood that the exemplary embodiment is not limited thereto. For example, alternatively, the first connector 138 may be a single continuous structure that extends along the edge to completely surround the first inner surface of the first frame 130.

[0065] Similarly, the second frame 140 includes at least one second connector protruding from the second inner surface of the second frame 140. The at least one second connector of the second frame 140 may be in the form of a second connector 148. The second connector 148 of the second frame 140 and the first connector 138 of the first frame 130 are complementary structures configured to mate with one another. In an exemplary embodiment, the second connector 148 may extend along an edge of the second inner peripheral surface of the second frame 140 in the form of a ridge (e.g., a second ridge). The ridge may define a trench extending along its entire length to resemble an elevated trench or a recessed / shaggy ridge. Additionally or alternatively, the ridge may have a tapered ridge and may thus be referred to as a tapered ridge. While the second connector 148 is shown as being separated into a plurality of discrete structures (e.g., four discrete structures), it should be understood that the exemplary embodiment is not so limited. For example, the second connector 148 may alternatively be a single continuous structure that extends circumferentially completely around the second inner surface of the second frame 140 .

[0066] In the non-limiting embodiment shown in FIGS. 3-4 where the first connector 138 of the first frame 130 is separated into four discrete structures, two of the structures may be elevated trenches while the other two structures may be tapered ridges. Conversely, the second connector 148 of the second frame 140 may be separated into four discrete structures, two of the structures are tapered ridges while the other two structures are elevated trenches. The mixed set of elevated trenches and tapered ridges of the first frame 130 are configured to mate with the mixed set of tapered ridges and elevated trenches of the second frame 140, respectively, during assembly of the capsule 100. It should be understood that various combinations of elevated trenches and tapered ridges are possible for the first frame 130 and the second frame 140. Further, each of the first transparent structure 110 and the second transparent structure 120 may have a tab-like extension (e.g., four tab-like extensions) disposed between the discrete structures of the first connector 138 and the second connector 148, respectively, when the capsule 100 is assembled.

[0067] The tapered ridges of the first connector 138 and / or the second connector 148 may have a shoulder portion and a sloped portion rising from the shoulder portion to form the tapered ridges. The tapered ridges may act as energy directors during assembly (e.g., to facilitate welding). The corresponding elevated trenches of the first connector 138 and / or the second connector 148 may have a rim portion and a trench bottom. As shown in FIGS. 3-4, the trench bottoms of the elevated trenches may be planar bottoms. Alternatively, the trench bottoms of the elevated trenches may be V-shaped bottoms. In an exemplary embodiment of the connection between the first frame 130 and the second frame 140, the sloped portion of the tapered ridges is configured to contact the trench bottoms of the corresponding elevated trenches, and the shoulder portion of the tapered ridges interfaces with the rim portion of the elevated trench. Accordingly, the mating surfaces of the first connector 138 and the second connector 148 may be configured in an inverted or complementary manner to facilitate mating.

[0068] As shown in Figures 3-4, the first frame 130 and the second frame 140 may be the same part if the mixed set of elevated grooves and tapered ridges in each frame are assembled such that the elevated grooves are on one straight side edge and the tapered ridges are on the other straight side edge. In such an example, the first frame 130 and the second frame 140 are oriented toward each other for mating purposes, resulting in a complementary arrangement. As a result, a single part can be used interchangeably as the first frame 130 or the second frame 140, simplifying the manufacturing process.

[0069] To assemble the capsule 100, the first frame 130 may be connected to the second frame 140 after the aerosol-forming substrate 160 is placed in the cavity 151 of the third frame 150 (e.g., on both sides of the middle portion 174 of the heater 170). In such an example, the third frame 150 will be sandwiched between the first and second permeable structures 110 and 120 when the first frame 130 is coupled to the second frame 140. During assembly, at least one first connector of the first frame 130 is configured to engage with at least one second connector of the second frame 140 to form at least one connection (e.g., four connections). For example, the elevated trench (and / or tapered ridge) of the first connector 138 is configured to mate with a corresponding tapered ridge (and / or elevated trench) of the second connector 148. Additionally, the bond between the first connector 138 of the first frame 130 and the second connector 148 of the second frame 140 may be accomplished via a welded arrangement (e.g., ultrasonic welding). Additionally, the outer sidewall of the first frame 130 may be substantially flush with the outer sidewall of the second frame 140 when the capsule 100 is assembled, although exemplary embodiments are not limited thereto. Once assembled, the capsule 100 is difficult or impractical to open without damaging the connectors, the frames, and / or other sides of the capsule 100. As a result, the capsule 100 is relatively tamper-resistant to unauthorized actions by third parties.

[0070] The capsule 100 has been described as including, among other things, a first frame 130 that is separate from the second frame 140. Alternatively, in some embodiments, the first frame 130 and the second frame 140 may be fabricated as a single structure configured to fold during assembly such that the first connector 138 engages the second connector 148. For example, the first frame 130 and the second frame 140 may resemble a clamshell structure, where a linear distal edge of the first frame 130 is connected to a linear distal edge of the second frame 140 with an integral portion of reduced thickness that serves as a fold line. In another example, a straight side edge of the first frame 130 may be connected to a straight side edge of the second frame 140 with an integral portion of reduced thickness that serves as a fold line. It should be understood that in a clamshell structure, one or more connections (e.g., along the fold line) may be omitted from the capsule 100.

[0071] FIG. 5 is an exploded view of the heater and the third frame in FIG. 3. FIG. 6 is an exploded perspective view of the heater and the third frame in FIG. 4. Referring to FIGS. 5-6, the heater 170 includes a first end portion 172, a first arm portion 173, a middle portion 174, a second arm portion 175, and a second end portion 176. The first arm portion 173 and the second arm portion 175 may define apertures 178a and 178b, respectively, although the exemplary embodiment is not limited thereto. In one example, the first end portion 172 and the second end portion 176 may be coplanar. Additionally, the first arm portion 173, the middle portion 174, and the second arm portion 175 may be coplanar. In such an example, a plane corresponding to first end 172 and second end 176 may be orthogonal to a plane corresponding to first arm portion 173, intermediate portion 174, and second arm portion 175. Additionally, heater 170 may be symmetrical about its longitudinal axis. The longitudinal axis of heater 170 may lie in a plane corresponding to first arm portion 173, intermediate portion 174, and second arm portion 175, such that it bisects intermediate portion 174, and may extend (e.g., equidistantly) between first end 172 and second end 176.

[0072] In an exemplary embodiment, the heater 170 is configured to undergo Joule heating (also known as Ohmic / resistive heating) when a current is applied thereto. More specifically, the heater 170 may be formed of one or more conductors and is configured to generate heat when a current is passed therethrough. The current may be provided to the first end 172 and the second end 176 of the heater 170 from a power source (e.g., a battery) within the aerosol generating device. Suitable conductors for the heater 170 include iron-based alloys (e.g., stainless steel, iron alumina), nickel-based alloys (e.g., nichrome), and / or ceramics (e.g., ceramics coated with metal). The middle portion 174 of the heater 170 may have a thickness of about 0.1-0.3 mm (e.g., 0.15-0.25 mm) and a resistance of about 0.5-2.5 Ω (e.g., 1-2 Ω).

[0073] Current from a power source within the aerosol generating device may be transferred through electrodes configured to electrically contact the first end 172 and the second end 176 of the heater 170 when the capsule 100 is inserted into the aerosol generating device. In a non-limiting embodiment, the electrodes may be spring loaded to enhance engagement of the capsule 100 with the heater 170. The spring loading of the electrodes may be along the longitudinal axis of the heater 170 and perpendicular to the plane corresponding to the first end 172 and the second end 176. In addition to or instead of spring loading, movement (e.g., engagement, disengagement) of the electrodes may be accomplished by mechanical actuation. Furthermore, the supply of current from the aerosol generating device to the capsule 100 may be manually (e.g., button-activated) or automatically (e.g., puff-activated).

[0074] The third frame 150 may be a monolithic structure. In an exemplary embodiment, the heater 170 may be embedded within the third frame 150. For example, the heater 170 may extend through the third frame 150 via the slots 154a and 154b. In such an example, the middle portion 174 of the heater 170 is within the cavity 151 of the third frame 150, the first arm portion 173 and the second arm portion 175 of the heater 170 are within a distal portion of the third frame 150, and the first end portion 172 and the second end portion 176 of the heater 170 are outside the cavity 151 and against a distal sidewall of the third frame 150. Additionally, the apertures 178a and 178b of the heater 170 may be aligned with the apertures 152a and 152b of the third frame 150, respectively. The apertures 178a and 178b may already be formed (e.g., preformed) in the heater 170 before the heater 170 is embedded within the third frame 150. Alternatively, the apertures 178a and 178b in the heater 170 may be subsequently formed along with the apertures 152a and 152b in the third frame 150 after the heater 170 is embedded within the third frame 150. Embedding of the heater 170 within the third frame 150 may be accomplished via injection molding.

[0075] The intermediate portion 174 of the heater 170 may be in the form of a pattern that spans a majority of the open area in the cavity 151. For example, the intermediate portion 174 of the heater 170 may be in a pattern that meanders or undulates around the center of the cavity 151 of the third frame 150. In such an example, the intermediate portion 174 of the heater 170 may alternate between extending toward the center of the cavity 151 and extending away from the center of the cavity 151. As shown in FIGS. 5-6, the undulations of the intermediate portion 174 of the heater 170 may be in the form of five protrusions (e.g., lobes, wings, fingers) that do not contact the sidewalls of the cavity 151 of the third frame 150, although example embodiments are not limited thereto.

[0076] FIG. 7 is a perspective view of a first side of another capsule for an aerosol generating device according to an exemplary embodiment. FIG. 8 is a perspective view of an opposing second side of the capsule of FIG. 7. Referring to FIGS. 7-8, capsule 200 may be configured to be received within an aerosol generating device (e.g., a heat-not-burn aerosol generating device). Capsule 200 of FIGS. 7-8 may be similar to capsule 100 of FIGS. 1-2, but differs with respect to the configuration of the heater and third frame, which will be discussed in more detail herein. As a result, the above related disclosure of common features should be understood to apply to this section and may not be repeated for brevity. In the drawings, capsule 200 has a layered structure and a generally planar configuration. The proximal end of capsule 200 may have a curved proximal edge, and the opposing distal end may have a straight distal edge. Additionally, a pair of straight side edges may connect the curved proximal edge and the straight distal edge. The pair of straight side edges may be parallel to each other. Additionally, the junction of the linear lateral edge and the linear distal edge may be in the form of a rounded corner.

[0077] Although capsule 200 is shown in the figures as resembling a rectangle (e.g., elongated semicircle, semicircular) with semicircular ends, it should be understood that other configurations may be employed. For example, the shape may be circular such that capsule 200 has a disk-like appearance. In another embodiment, capsule 200 may be oval or racetrack-like in shape. In other examples, capsule 200 may have a polygonal shape (regular or irregular), including a triangle, a rectangle (e.g., square), a pentagon, a hexagon, a heptagon, or an octagon. The layered structure and generally planar form of capsule 200 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.

[0078] The capsule 200 may include a housing and a heater 270 (e.g., FIG. 11) within the housing. The housing of the capsule 200 has an inner surface that defines a chamber configured to hold an aerosol-forming substrate. Additionally, the housing of the capsule 200 has an outer surface that constitutes a first face, an opposing second face, and a side face of the capsule 200. The first face and the second face of the capsule 200 may be permeable to the aerosol. The side face of the capsule 200 is between the first face and the second face. The side face may be considered a periphery of the capsule 200.

[0079] The housing of the capsule 200 includes a first frame 230 and a second frame 240. The first frame 230 and the second frame 240 may be of the same shape and size (e.g., based on a plan view) and are aligned such that the outer sidewalls are substantially flush with one another, although the exemplary embodiment is not so limited. The first frame 230 and the second frame 240 may be formed of a suitable polymer, such as polyetheretherketone (PEEK), liquid crystal polymer (LCP), and / or ultra-high molecular weight polyethylene (UHMWPE). The first frame 230 and the second frame 240 may be connected via a welding arrangement.

[0080] The first permeable structure 210 is fixed and exposed by the first frame 230. Similarly, the second permeable structure 220 is fixed and exposed by the second frame 240. As described in more detail herein, the third frame 250 is disposed between the first permeable structure 210 and the second permeable structure 220 (as well as between the first frame 230 and the second frame 240). The capsule 200 is configured to hold an aerosol-forming substrate, which may be present in the third frame 250 and between the first permeable structure 210 and the second permeable structure 220. The first recess 233 (e.g., the first dimple portion) of the first frame 230 and the second recess 243 (e.g., the second dimple portion) of the second frame 240 may be by an injection molding process. In this regard, the size, location, and / or shape of the first recess 233 and the second recess 243 may vary (or may not exist at all) depending on the fabrication technique.

[0081] The first and second transparent structures 210 and 220 may be in the form of a mesh sheet, a perforated sheet, or a combination thereof. For example, both the first and second transparent structures 210 and 220 may be in the form of a mesh sheet. In another example, both the first and second transparent structures 210 and 220 may be in the form of a perforated sheet (e.g., 80, 100, or 250 mesh equivalent). The perforated sheet may be mechanically or chemically perforated (e.g., via photochemical machining / etching). In yet another example, one of the first and second transparent structures 210 and 220 may be in the form of a mesh sheet, and the other of the first and second transparent structures 210 and 220 may be in the form of a perforated sheet. The first transparent structure 210 and the second transparent structure 220 (as well as the first frame 230 and the second frame 240) may be substantially the same size (e.g., ±10% of a given dimension) based on a planar view.

[0082] As shown in FIG. 7, the combination of the exposed surface of the first transmissive structure 210 and the adjacent (e.g., substantially coplanar / parallel) surface of the first frame 230 may be considered a first surface of the capsule 200. Similarly, as shown in FIG. 8, the combination of the exposed surface of the second transmissive structure 220 and the adjacent (e.g., substantially coplanar / parallel) surface of the second frame 240 may be considered a second surface of the capsule 200. In one embodiment, the first surface, the second surface, or both may include a perforated sheet. In another embodiment, the first surface, the second surface, or both may include a mesh sheet. In yet another embodiment, one of the first surface or the second surface may include a perforated sheet and the other of the first surface or the second surface may include a mesh sheet.

[0083] As mentioned above and discussed in more detail herein, a heater 270 (e.g., FIG. 11 ) may be disposed within the capsule 200 to heat the aerosol-forming substrate. The heater 270 may include, among other things, a first end 272 and a second end 276 configured to receive electrical current from a power source during activation of the heater 270. When the heater 270 is activated, the temperature of the aerosol-forming substrate increases and an aerosol may be generated and released through the first permeable structure 210 and / or the second permeable structure 220 of the capsule 200.

[0084] As shown in FIGS. 7-8, the combination of the exposed surface of the third frame 250 and the adjacent side walls of the first frame 230 and the second frame 240 can be considered a side wall of the capsule 200. The first end 272 and the second end 276 can be exterior segments of the heater 270 that protrude beyond the housing (e.g., side) of the capsule 200 (e.g., to facilitate electrical connection to a power source). The first end 272 and the second end 276 of the heater 270 can be coplanar, although exemplary embodiments are not limited thereto. Additionally, the first end 272 and the second end 276 of the heater 270 can define apertures 278a and 278b, respectively. In another example, the first end 272 and the second end 276 of the heater 270 can be configured similarly to the first end 172 and the second end 176 of FIG. 2 to form part of the side of the capsule 200. In such an example, first end 172 and second end 176 in FIG. 2 may form part of a side surface at a distal end of capsule 100, while first end 272 and second end 276 in FIG. 7 may form part of a side surface at a proximal end of capsule 200.

[0085] FIG. 9 is an exploded perspective view of the capsule of FIG. 7. FIG. 10 is an exploded perspective view of the capsule of FIG. 8. Referring to FIGS. 9-10, the first frame 230 has a first inner peripheral surface and a first outer peripheral surface. Furthermore, the first frame 230 defines a first opening 231. In an exemplary embodiment, the sidewall of the first opening 231 has opposing straight portions and, optionally, opposing curved portions, one curved portion may be adjacent to a proximal end of the first frame 230 and the other curved portion may be adjacent to an opposing distal end of the first frame 230. The first permeable structure 210 may be fixed to a first inner surface of the first frame 230 so as to be exposed by the first opening 231. Also, from another perspective, the first permeable structure 210 may be considered to cover the first opening 231. Additionally, the first transmissive structure 210 may define a first aperture 212. The first aperture 212 may be positioned and sized to accommodate the first protrusion 235 when the first transmissive structure 210 is secured to the first frame 230.

[0086] The second frame 240 has a second inner peripheral surface and a second outer peripheral surface. Additionally, the second frame 240 defines a second opening 241. In an exemplary embodiment, the sidewalls of the second opening 241 have opposing straight portions and, optionally, opposing curved portions, one curved portion may be adjacent to a proximal end of the second frame 240 and the other curved portion may be adjacent to an opposing distal end of the second frame 240. The second transparent structure 220 may be fixed to a second inner surface of the second frame 240 to be exposed by the second opening 241. From another perspective, the second transparent structure 220 may be considered to cover the second opening 241. The size and shape of the second opening 241 may correspond to the size and shape of the first opening 231 (e.g., may be mirror-like). Additionally, the second transmissive structure 220 may define a second aperture 222. The second aperture 222 may be positioned and sized to accommodate the second protrusion 245 when the second transmissive structure 220 is secured to the second frame 240.

[0087] The third frame 250 defines a cavity 251 configured to receive an aerosol-forming substrate. As described in more detail herein, the third frame 250 may be formed from components 250a and 250b. The combination of the sidewalls of the cavity 251 and the inner surfaces of the first and second permeable structures 210 and 220 (covering the cavity 251) may be considered to define a chamber. In an exemplary embodiment, the sidewalls of the cavity 251 have opposing straight portions and opposing curved portions, one curved portion adjacent a proximal end of the third frame 250 and the other curved portion adjacent an opposing distal end of the third frame 250. The third frame 250 may be substantially the same size (e.g., ±10% of a given dimension) as the first and second permeable structures 210 and 220 based on a plan view. In addition to the materials of construction of the first frame 230 and the second frame 240, the third frame 250 may be formed from other suitable materials, such as ceramic, sintered glass, and / or interlocking fibers (e.g., cardboard).

[0088] The heater 270 is configured to extend through the third frame 250 into the cavity 251. Additionally, the heater 270 can be considered to be supported by the third frame 250. The heater 270 includes a first end 272, a middle portion 274, and a second end 276. The first end 272 and the second end 276 of the heater 270 are exterior segments disposed outside the capsule 200. The first end 272 and the second end 276 of the heater 270 may also define apertures 278a and 278b, respectively, although the exemplary embodiment is not limited thereto. The middle portion 274 of the heater 270 is an interior segment disposed within the capsule 200 (e.g., within a chamber of a housing containing an aerosol-forming substrate). The first end 272, the middle portion 274, and the second end 276 of the heater 270 are sections of a continuous structure. In the exemplary embodiment, the intermediate portion 274 of the heater 270 has a planar and winding configuration.

[0089] The first and second transparent structures 210 and 220 may be secured to the first and second frames 230 and 240, respectively, via various attachment techniques. For example, the attachment technique may include injection molding (e.g., insert molding, overmolding). In another example, the attachment technique may include ultrasonic welding. In another example, the attachment technique may include an adhesive (e.g., tape, glue) deemed food safe or otherwise acceptable by a regulatory agency. Alternatively, instead of a separate attachment technique, the first and second transparent structures 210 and 220 may be clamped (or otherwise restrained) to the third frame 250 by the first and second frames 230 and 240, respectively.

[0090] The first frame 230 includes at least one first connector protruding from the first inner surface of the first frame 230. The at least one first connector of the first frame 230 may be in the form of a first connector 238. In an exemplary embodiment, the first connector 238 may extend along the edge of the first inner peripheral surface of the first frame 230 in the form of a ridge (e.g., a first ridge). The ridge may define a trench extending along its entire length to resemble an elevated trench or a recessed / shaggy ridge. Additionally or alternatively, the ridge may have a tapered ridge, and thus may be referred to as a tapered ridge. Although the first connector 238 is shown as being separated into a plurality of discrete structures (e.g., four discrete structures), it should be understood that the exemplary embodiment is not limited thereto. For example, alternatively, the first connector 238 may be a single continuous structure extending along the edge to completely surround the first inner surface of the first frame 230.

[0091] Similarly, the second frame 240 includes at least one second connector protruding from the second inner surface of the second frame 240. The at least one second connector of the second frame 240 may be in the form of a second connector 248. The second connector 248 of the second frame 240 and the first connector 238 of the first frame 230 are complementary structures configured to mate with one another. In an exemplary embodiment, the second connector 248 may extend along an edge of the second inner peripheral surface of the second frame 240 in the form of a ridge (e.g., a second ridge). The ridge may define a trench extending along its entire length to resemble an elevated trench or a recessed / sharp ridge. Additionally or alternatively, the ridge may have a tapered edge, and may thus be referred to as a tapered ridge. Although the second connector 248 is shown as being separated into a number of discrete structures (e.g., four discrete structures), it should be understood that the exemplary embodiment is not limited in this respect. For example, the second connector 248 may alternatively be a single continuous structure that extends circumferentially to completely surround the second inner surface of the second frame 240.

[0092] In the non-limiting embodiment shown in FIGS. 9-10 where the first connector 238 of the first frame 230 is separated into four discrete structures, two of the structures may be elevated trenches while the other two structures may be tapered ridges. Conversely, the second connector 248 of the second frame 240 may be separated into four discrete structures, two of the structures are tapered ridges while the other two structures are elevated trenches. The mixed set of elevated trenches and tapered ridges of the first frame 230 are configured to mate with the mixed set of tapered ridges and elevated trenches of the second frame 240, respectively, during assembly of the capsule 200. It should be understood that various combinations of elevated trenches and tapered ridges are possible for the first frame 230 and the second frame 240. Further, each of the first transparent structure 210 and the second transparent structure 220 may have a tab-like extension (e.g., four tab-like extensions) disposed between the discrete structures of the first connector 238 and the second connector 248, respectively, when the capsule 200 is assembled.

[0093] The tapered ridges of the first connector 238 and / or the second connector 248 may have a shoulder portion and a sloped portion rising from the shoulder portion to form the tapered ridges. The tapered ridges may act as energy directors during assembly (e.g., to facilitate welding). The corresponding elevated trenches of the first connector 238 and / or the second connector 248 may have a rim portion and a trench bottom. As shown in Figures 9-10, the trench bottoms of the elevated trenches may be planar bottoms. Alternatively, the trench bottoms of the elevated trenches may be V-shaped bottoms. In an exemplary embodiment of the connection between the first frame 230 and the second frame 240, the sloped portion of the tapered ridges is configured to contact the trench bottoms of the corresponding elevated trenches, and the shoulder portion of the tapered ridges interfaces with the rim portion of the elevated trench. Accordingly, the mating surfaces of the first connector 238 and the second connector 248 may be configured in an inverted or complementary manner to facilitate mating.

[0094] As shown in Figures 9-10, the first frame 230 and the second frame 240 may be the same part if a mixed set of elevated grooves and tapered ridges for each frame are assembled such that the elevated grooves are on one straight side edge and the tapered ridges are on the other straight side edge. In such an example, the first frame 230 and the second frame 240 are oriented toward each other for mating purposes, resulting in a complementary arrangement. As a result, a single part can be used interchangeably as the first frame 230 or the second frame 240, simplifying the manufacturing process.

[0095] To assemble the capsule 200, the first frame 230 may be connected to the second frame 240 after the aerosol-forming substrate is placed in the cavity 251 of the third frame 250 (e.g., on both sides of the middle portion 274 of the heater 270). In such an example, the third frame 250 will be sandwiched between the first and second transparent structures 210 and 220 when the first frame 230 is connected to the second frame 240. During assembly, at least one first connector of the first frame 230 is configured to engage with at least one second connector of the second frame 240 to form at least one connection (e.g., four connections). For example, the elevated trench (and / or tapered ridge) of the first connector 238 is configured to mate with a corresponding tapered ridge (and / or elevated trench) of the second connector 248. Additionally, the bond between the first connector 238 of the first frame 230 and the second connector 248 of the second frame 240 may be accomplished via a welded arrangement (e.g., ultrasonic welding). Additionally, the outer sidewall of the first frame 230 may be substantially flush with the outer sidewall of the second frame 240 when the capsule 200 is assembled, although exemplary embodiments are not limited thereto. Once assembled, the capsule 200 is difficult or impractical to open without damaging the connectors, the frames, and / or other sides of the capsule 200. As a result, the capsule 200 is relatively tamper-resistant to unauthorized actions by third parties.

[0096] The capsule 200 has been described as including, among other things, a first frame 230 that is separate from the second frame 240. Alternatively, in some embodiments, the first frame 230 and the second frame 240 may be fabricated as a single structure configured to fold during assembly such that the first connector 238 engages the second connector 248. For example, the first frame 230 and the second frame 240 may resemble a clamshell structure, where a linear distal edge of the first frame 230 is connected to a linear distal edge of the second frame 240 with an integral portion of reduced thickness that serves as a fold line. In another example, a straight side edge of the first frame 230 may be connected to a straight side edge of the second frame 240 with an integral portion of reduced thickness that serves as a fold line. It should be understood that in a clamshell structure, one or more connections (e.g., along a fold line) may be omitted from the capsule 200.

[0097] FIG. 11 is an exploded view of the heater and the third frame in FIG. 9. FIG. 12 is an exploded perspective view of the heater and the third frame in FIG. 10. Referring to FIGS. 11-12, the heater 270 includes a first end 272, a first arm portion 273, a middle portion 274, a second arm portion 275, and a second end portion 276. As described above, the first end 272 and the second end 276 of the heater 270 may define apertures 278a and 278b, respectively. Additionally, the first arm portion 273 and the second arm portion 275 may define apertures 278c and 278d, respectively, although the exemplary embodiment is not limited thereto. In one example, the heater 270 may have a planar shape. As a result, the first end 272, the first arm portion 273, the middle portion 274, the second arm portion 275, and the second end 276 may be coplanar. Alternatively, the heater 270 may have a configuration in which the first end 272 and the second end 276 are similar to the first end 172 and the second end 176 of the heater 170 (e.g., the folded configuration shown in Figures 5-6). Additionally, the heater 270 may be symmetric about its longitudinal axis. The longitudinal axis of the heater 270 may lie in a plane corresponding to the heater 270 such that it bisects the middle portion 274 and extends (e.g., equidistantly) between the first end 272 and the second end 276.

[0098] In an exemplary embodiment, the heater 270 is configured to undergo Joule heating (also known as Ohmic / resistive heating) when a current is applied thereto. More specifically, the heater 270 may be formed of one or more conductors and is configured to generate heat when a current is passed therethrough. The current may be provided to the first end 272 and the second end 276 of the heater 270 from a power source (e.g., a battery) within the aerosol generating device. Suitable conductors for the heater 270 include iron-based alloys (e.g., stainless steel, iron alumina), nickel-based alloys (e.g., nichrome), and / or ceramics (e.g., ceramics coated with metal). The middle portion 274 of the heater 270 may have a thickness of about 0.1-0.3 mm (e.g., 0.15-0.25 mm) and a resistance of about 0.5-2.5 Ω (e.g., 1-2 Ω).

[0099] Current from a power source in the aerosol generating device may be transmitted through electrodes configured to electrically contact the first end 272 and the second end 276 of the heater 270 when the capsule 200 is inserted into the aerosol generating device. In a non-limiting embodiment, the electrodes in the aerosol generating device may be spring loaded to enhance engagement with the heater 270 of the capsule 100. For example, a spring-loaded first electrode in the aerosol generating device may have a rounded or beveled engagement portion configured to electrically contact the first end 272 of the heater 270 such that the engagement portion seats within an aperture 278a in the first end 272. Similarly, a spring-loaded second electrode in the aerosol generating device may have a rounded or beveled engagement portion configured to electrically contact the second end 276 of the heater 270 such that the engagement portion seats within an aperture 278b in the second end 276. In such an embodiment, engagement of the first and second electrodes of the aerosol generating device with the first and second ends 272 and 276 of the heater 270, respectively, can produce a confirming click. The spring loading of the electrodes can be in a direction perpendicular to the plane of the heater 270. In addition to or instead of the spring loading, movement (e.g., engagement, disengagement) of the electrodes can be accomplished by mechanical actuation. Furthermore, the supply of electrical current from the aerosol generating device to the capsule 200 can be manually (e.g., button actuated) or automatically (e.g., puff actuated).

[0100] The third frame 250 may be structured as or comprised of components 250a and 250b configured to engage and clamp the heater 270 therebetween. For example, the components 250a and 250b may define corresponding openings 251a and 251b, respectively, that form the cavity 251 of the third frame 250. In such an example, when assembled, the middle portion 274 of the heater 270 is within the cavity 251 of the third frame 250, the first arm portion 273 and the second arm portion 275 of the heater 270 are within at least the proximal and lateral portions of the third frame 250, and the first end 272 and the second end 276 of the heater 270 are outside the cavity 251 and extend beyond the proximal end of the third frame 250.

[0101] In an exemplary embodiment, component 250b may include a ridge portion 257, and component 250a may define a corresponding groove portion 254 configured to receive ridge portion 257 when components 250a and 250b are engaged (or vice versa). In such an embodiment, ridge portion 257 may be between and insulate first end 272 and second end 276 of heater 270 from one another when heater 270 is clamped by components 250a and 250b of third frame 250. Additionally, component 250b may include protrusions 255a and 255b, and component 250a may define corresponding apertures 252a and 252b (or vice versa) configured to receive protrusions 255a and 255b, respectively, when components 250a and 250b are engaged. Additionally, protrusions 255a and 255b of component 250b may extend through first arm portion 273 and second arm portion 275 of heater 270 via apertures 278c and 278d, respectively.

[0102] Component 250a is configured to be received by component 250b to form third frame 250. In an exemplary embodiment, component 250a is dimensioned to seat within a corresponding recess in component 250b. In such an embodiment, an outer sidewall of component 250a can engage with an inner sidewall of component 250b. Such engagement can occur via an interference fit (which may also be referred to as a press fit or friction fit). Additionally, the thickness of component 250a and / or the depth of the corresponding recess in component 250b may be dimensioned such that an outer surface of component 250a is substantially flush with a rim of component 250b when heater 270 is clamped between components 250a and 250b. Although third frame 250 is disclosed as being comprised of components 250a and 250b, it should be understood that in other embodiments, third frame 250 may be a monolithic structure. In such an embodiment, heater 270 may be embedded within third frame 250 via injection molding.

[0103] The intermediate portion 274 of the heater 270 may be in the form of a pattern that spans a majority of the open area in the cavity 251. For example, the intermediate portion 274 of the heater 270 may be patterned such that it meanders or undulates near the center of the cavity 251 of the third frame 250. In such an example, the intermediate portion 274 of the heater 270 may alternate between extending toward and away from the center of the cavity 251. As shown in FIGS. 11-12, the undulations of the intermediate portion 274 of the heater 270 may be in the form of five protrusions (e.g., lobes, wings, fingers) that do not contact the sidewalls of the cavity 251 of the third frame 250, although example embodiments are not limited thereto.

[0104] FIG. 13 is a plan view of a patterned sheet associated with the manufacture of a heater according to an exemplary embodiment. Referring to FIG. 13, the sheet material may be cut or otherwise processed (e.g., stamped, electrochemically etched, die cut, laser cut) to produce a patterned sheet 370'. The sheet material is formed of one or more conductors configured to undergo Joule heating (also known as Ohmic / resistive heating). Suitable conductors for the sheet material are iron-based alloys (e.g., stainless steel, iron aluminide), nickel-based alloys (e.g., nichrome), and / or ceramics (e.g., ceramics coated with metal). For example, the stainless steel may be of a type known in the art as SS316L, although exemplary embodiments are not limited thereto. The sheet material may have a thickness of about 0.1-0.3 mm (e.g., 0.15-0.25 mm).

[0105] Patterned sheet 370' includes a heater having a first end 372, a middle portion 374, and a second end 376. First end 372 and second end 376 may define apertures 378a and 378b, respectively. Sheet portion 309 is connected to first end 372, middle portion 374, and second end 376 via breakout portions 311. In a subsequent step of the manufacturing process, breakout portions 311 are cut to allow first end 372, middle portion 374, and second end 376 of heater 370 (FIG. 14) to be separated from sheet portion 309. Although six breakout portions 311 are illustrated, it should be understood that the exemplary embodiment is not so limited.

[0106] FIG. 14 is a perspective view of a partially assembled capsule including a heater obtained from the patterned sheet of FIG. 13. The partially assembled capsule of FIG. 14 may be similar to the corresponding embodiment of the capsule 200 of FIGS. 7-12. For example, the second permeable structure 320, the second frame 340, and the second connector 348 of FIG. 14 may be as described in connection with the second permeable structure 220, the second frame 240, and the second connector 248 of FIG. 9, respectively. As a result, the above relevant disclosure of common features should be understood to apply in this section and may not be repeated for brevity.

[0107] In the exemplary embodiment, the proximal portion of the third frame 350 defines a recess or channel configured to accommodate the heater 370. Each of the segments of the heater 370 seated in the channel of the third frame 350 may be wider than the segments of the heater 370 within the cavity of the third frame 350 (e.g., the middle portion 374). Each of these wider segments of the heater 370 will have a lower resistance than the narrower segments of the heater 370 and therefore may function as thermal relief segments.

[0108] The intermediate portion 374 of the heater 370 may be in the form of a pattern that spans a majority of the open area within the cavity of the third frame 350. For example, the intermediate portion 374 of the heater 370 may be in a pattern that meanders or undulates about the center of the cavity of the third frame 350. In such an example, the intermediate portion 374 of the heater 370 may alternate between extending toward and away from the center of the cavity. As shown in FIG. 14, the undulations of the intermediate portion 374 of the heater 370 may be in the form of six protrusions (e.g., lobes, wings, fingers) that do not contact the sidewalls of the cavity of the third frame 350, although example embodiments are not limited thereto.

[0109] Although not shown in FIG. 14, it should be understood that a first frame and a first permeable structure (discussed herein) may be provided along with an inner frame (complementary to the third frame 350) to surround the aerosol-forming substrate to complete assembly of the capsule. The complementary inner frame may mimic the third frame 350 while omitting the channel for the heater 370. In such an example, the complementary inner frame may have inner and outer surfaces that are completely planar. Alternatively, the complementary inner frame may include a ridge portion configured to seat between wider segments of the heater 370 in the channel of the third frame 350 when the capsule is assembled.

[0110] FIG. 15 is a plan view of another patterned sheet associated with the manufacture of a heater according to an exemplary embodiment. Referring to FIG. 15, a sheet material may be cut or otherwise processed (e.g., stamped, electrochemically etched, die cut, laser cut) to produce a patterned sheet 470'. The patterned sheet 470' may be as described in connection with the patterned sheet 370' of FIG. 13, except for the presence of the arm portions. As a result, the above related disclosure of common features should be understood to apply to this section and may not be repeated for brevity. As shown, the patterned sheet 470' includes a heater having a first end 472, a first arm portion 473, a middle portion 474, a second arm portion 475, and a second end 476. The first end 472 and the second end 476 may define apertures 478a and 478b, respectively. The first arm portion 473 and the second arm portion 475 may function as thermal relief segments as well as support structures. The sheet portion 409 is connected to the first end 472, the first arm portion 473, the second arm portion 475, and the second end 476 via the breakout portion 411. In a subsequent step of the fabrication process, the breakout portion 411 is cut to allow the first end 472, the first arm portion 473, the second arm portion 475, and the second end 476 of the heater to be separated from the sheet portion 409. Although six breakout portions 411 are shown, it should be understood that the exemplary embodiment is not so limited. Additionally, the first arm portion 473 and the second arm portion 475 may include alignment tabs (e.g., six alignment tabs) adjacent the breakout portion 411 to facilitate placement of the heater during assembly of the capsule.

[0111] FIG. 16 is a plan view of another patterned sheet associated with the manufacture of a heater according to an exemplary embodiment. Referring to FIG. 16, a sheet material may be cut or otherwise processed (e.g., stamped, electrochemically etched, die cut, laser cut) to produce a patterned sheet 570'. The patterned sheet 570' may be as described in connection with the patterned sheet 470' of FIG. 15, except for the configuration of the middle portion of the heater. As a result, the above related disclosure of common features should be understood to apply to this section and may not be repeated for brevity. As shown, the patterned sheet 570' includes a heater having a first end 572, a first arm portion 573, a middle portion 574, a second arm portion 575, and a second end 576. The first end 572 and the second end 576 may define apertures 578a and 578b, respectively. The first arm portion 573 and the second arm portion 575 may function as a thermal relief segment as well as a support structure. The middle portion 574 may have a winding configuration that includes loops, swirls, and / or arches, resembling a maze or a fingerprint. The sheet portion 509 is connected to the first end 572, the first arm portion 573, the second arm portion 575, and the second end 576 via breakout portions 511. In a subsequent step of the fabrication process, the breakout portions 511 are cut to allow the first end 572, the first arm portion 573, the second arm portion 575, and the second end 576 of the heater to be separated from the sheet portion 509. Although six breakout portions 511 are illustrated, it should be understood that the exemplary embodiment is not so limited. Additionally, the first arm portion 573 and the second arm portion 575 may include alignment tabs (e.g., six alignment tabs) adjacent the breakout portions 511 to facilitate placement of the heater during assembly of the capsule.

[0112] FIG. 17 is a plan view of another patterned sheet associated with the manufacture of a heater according to an exemplary embodiment. Referring to FIG. 17, a sheet material may be cut or otherwise processed (e.g., stamped, electrochemically etched, die cut, laser cut) to produce a patterned sheet 670'. The patterned sheet 670' may be as described in connection with the patterned sheet 470' of FIG. 15, except for the configuration of the middle portion of the heater. As a result, the above related disclosure of common features should be understood to apply to this section and may not be repeated for brevity. As shown, the patterned sheet 670' includes a heater having a first end 672, a first arm portion 673, a middle portion 674, a second arm portion 675, and a second end 676. The first end 672 and the second end 676 may define apertures 678a and 678b, respectively. The first arm portion 673 and the second arm portion 675 may function not only as a support structure but also as a thermal relief segment. The middle portion 674 may have a compression oscillation or zigzag-like winding shape with multiple parallel segments (e.g., 8-12 parallel segments). The sheet portion 609 is connected to the first end 672, the first arm portion 673, the second arm portion 675, and the second end 676 via a breakout portion 611. In a subsequent step of the fabrication process, the breakout portion 611 is cut to allow the first end 672, the first arm portion 673, the second arm portion 675, and the second end 676 of the heater to be separated from the sheet portion 609. It should be understood that while six breakout portions 611 are illustrated, the exemplary embodiment is not so limited. Additionally, the first arm portion 673 and the second arm portion 675 may include alignment tabs (e.g., six alignment tabs) adjacent the breakout portion 611 to facilitate placement of the heater during assembly of the capsule.

[0113] 18-20 are perspective views of a method of manufacturing a capsule for an aerosol generating device according to an exemplary embodiment. Referring to FIG. 18, the partially assembled capsule may resemble the corresponding aspects of the capsule 200 of FIGS. 7-12. For example, the second permeable structure 620, the second frame 640, and the second connector 648 of FIG. 18 may be as described in connection with the second permeable structure 220, the second frame 240, and the second connector 248 of FIG. 9, respectively. As a result, the above relevant disclosure of common features should be understood to apply in this section and may not be repeated for brevity.

[0114] After the second permeable structure 620, the third frame 650, and the aerosol-forming substrate (not shown) are placed on the second frame 640, the patterned sheet 670' may be placed such that the intermediate portion 674 is aligned with the opening defined by the third frame 650 to hold the aerosol-forming substrate. In an exemplary embodiment, the inner contours of the first arm portion 673 and the second arm portion 675 correspond to the shape and size of the opening defined by the third frame 650. The intermediate portion 674 of the heater may be in the form of a pattern that spans a majority of the opening in the opening of the third frame 650. For example, the pattern may be such that the intermediate portion 674 of the heater is rocked above the opening of the third frame 650. In such an example, the intermediate portion 674 of the heater may alternate between extending toward the proximal end of the second frame 640 and extending toward the distal end of the second frame 640.

[0115] As shown in FIG. 18, when the second connector 648 of the second frame 640 is separated into four discrete structures (e.g., two elevated trenches and two tapered ridges), four spaces are defined therebetween. In an exemplary embodiment, the four spaces include a proximal end space, a distal end space, and two opposing side spaces. During assembly, the patterned sheet 670' is positioned on the second frame 640 such that an outer segment of the heater, including a first end 672 and a second end 676, extends through the proximal end space of the second frame 640. Additionally, the positioning of the patterned sheet 670' is such that the three pairs of alignment tabs on the first arm portion 673 and the second arm portion 675 seat in the distal end space and the two opposing side spaces. Further, the outer contours of the first arm portion 673 and the second arm portion 675 substantially correspond to the shape and size of the inner surfaces of the third frame 650 and the second frame 640 to provide a relatively close fit.

[0116] 19, a first insert 602 is seated on a proximal portion of the third frame 650 between the first arm portion 673 and the second arm portion 675. Additionally, a second insert 604 is seated on a distal portion of the third frame 650 between the first arm portion 673 and the second arm portion 675. In an exemplary embodiment, each of the first insert 602 and the second insert 604 is in the form of a strip (e.g., silicone) having a thickness substantially corresponding to the thickness of the patterned sheet 670' and a width substantially corresponding to the gap between the first arm portion 673 and the second arm portion 675. The first insert 602 and the second insert 604 may also be aligned with a longitudinal axis of the patterned sheet 670', the longitudinal axis bisecting the middle portion 674 and extending (e.g., equidistantly) between the first arm portion 673 and the second arm portion 675. The first insert 602 and the second insert 604 may act as plugs to improve airflow (e.g., cross-flow) through the first permeable structure 610 (FIG. 20) and the second permeable structure 620. Additionally, the first insert 602 and the second insert 604 may act as insulating spacers to prevent or reduce the occurrence of electrical shorts.

[0117] 20, an inner frame (e.g., identical to the third frame 650) defining an opening is placed on the patterned sheet 670' with additional aerosol-forming substrate within the opening of the inner frame, followed by the first permeable structure 610 and the first frame 630, particularly to enclose the aerosol-forming substrate therein. The first permeable structure 610 and the first frame 630 may be as described in relation to the first permeable structure 210 and the first frame 230 of FIG. 7, respectively. Furthermore, the first recess 633 may be as described in relation to the first recess 233 of FIG. 7. As a result, the relevant disclosure above should be understood to apply to this section and may not be repeated for brevity. The first frame 630 and the second frame 640 may be connected via a welding arrangement. After the connection of the first frame 630 and the second frame 640, the breakout portion 611 is cut (e.g., die cut, laser cut) to separate the sheet portion 609 from the capsule.

[0118] FIG. 21 is a cross-sectional, schematic diagram of an aerosol generating device according to an exemplary embodiment. Referring to FIG. 21, an aerosol generating device 1000 (e.g., a heat-not-burn aerosol generating device) includes a mouthpiece 1015 and a device body 1025. A power source 1035 and a control circuit 1045 may be disposed within the device body 1025 of the aerosol generating device 1000. The power source 1035 may include one or more batteries (e.g., a rechargeable dual battery arrangement). The aerosol generating device 1000 is configured to receive a capsule 700, which may be as described in connection with any of the embodiments herein. The aerosol generating device 1000 also includes an engagement assembly 1055 configured to electrically contact the capsule 700. In an exemplary embodiment, the engagement assembly 1055 includes a first electrode and a second electrode configured to electrically contact a first end and a second end of a heater of the capsule 700, respectively.

[0119] When the capsule 700 is inserted into the aerosol generating device 1000, the control circuit 1045 may instruct the power source 1035 to supply current to the first electrode and the second electrode of the engagement assembly 1055. The supply of current from the power source 1035 may be in response to manual operation (e.g., button activation) or automatic operation (e.g., puff activation). As a result of the current, the capsule 700 may be heated to generate an aerosol. Furthermore, changes in the resistance of the heater may be used to monitor and control the aerosolization temperature. The generated aerosol may be inhaled from the aerosol generating device 1000 via the mouthpiece 1015.

[0120] FIG. 22 is a perspective view of another capsule for an aerosol generating device according to an exemplary embodiment. FIG. 23 is an internal perspective view of the capsule of FIG. 22. FIG. 24 is a cross-sectional plan view of the capsule of FIG. 22. FIG. 25 is a cross-sectional side view of the capsule of FIG. 22. Referring to FIGS. 22-25, a capsule 800 may be configured to be received in an aerosol generating device (e.g., a heat-not-burn aerosol generating device). The proximal end (e.g., the top end of FIG. 22) of the capsule 800 may have a curved proximal end, and the opposing distal end (e.g., the bottom end of FIG. 22) may have a straight distal end. Furthermore, a pair of linear side edges may connect the curved proximal edge and the linear distal edge. The pair of linear side edges may be parallel to each other. Furthermore, the junction of the linear side edge and the linear distal edge may have a rounded corner configuration.

[0121] Although the capsule 800 is shown in the figures as resembling a rectangle with a curved handle, it should be understood that other configurations may be employed. For example, the shape may be circular, such that the capsule 800 has a disk-like appearance. In another example, the shape of the capsule 800 may be oval or racetrack-like. In other examples, the capsule 800 may have a polygonal shape (regular or irregular), including a triangle, a rectangle (e.g., a square), a pentagon, a hexagon, a heptagon, or an octagon. The generally planar form of the capsule 800 may facilitate stacking, allowing multiple capsules to be stored in an aerosol generating device or other receptacle for dispensing new capsules or receiving spent capsules.

[0122] The capsule 800 includes a housing and a heater within the housing. The housing of the capsule 800 has an inner surface that defines a chamber configured to hold an aerosol-forming substrate. Additionally, the housing of the capsule 800 has an outer surface that constitutes a first surface, an opposing second surface, and a side surface of the capsule 800. The first surface and the second surface of the capsule 800 may be permeable to the aerosol. The side surface of the capsule 800 is between the first surface and the second surface. The side surface may be considered a periphery of the capsule 800.

[0123] The housing of the capsule 800 includes a first frame 830 and a second frame 840. The exterior surface of the first frame 830 may be considered a first surface of the capsule 800. Similarly, the exterior surface of the second frame 840 may be considered a second surface of the capsule 800. The first frame 830 and the second frame 840 may be of the same shape and size (e.g., based on a plan view) and are aligned such that the outer sidewalls are substantially flush with one another, although the exemplary embodiment is not so limited. The first frame 830 and the second frame 840 may be formed of a suitable polymer, such as polyetheretherketone (PEEK), liquid crystal polymer (LCP), and / or ultra-high molecular weight polyethylene (UHMWPE). The first frame 830 and the second frame 840 may be connected via a welding arrangement (e.g., ultrasonic welding) or with an adhesive (e.g., tape, glue) deemed food safe or otherwise acceptable by a regulatory agency.

[0124] The second frame 840 may be in the form of a container that defines a cavity or containment space. In an exemplary embodiment, the sidewalls of the cavity defined by the second frame 840 include opposing straight portions and, optionally, opposing curved portions, where one curved portion may be adjacent to a proximal end of the second frame 840 and the other curved portion may be adjacent to an opposing distal end of the second frame 840. The first frame 830 may be in the form of a lid configured to engage with the second frame 840 to close the cavity. The combination of the cavity of the second frame 840 and the corresponding inner surface of the first frame 830 (covering the cavity) may be considered to define a chamber.

[0125] As shown in FIG. 22, the first frame 830 defines first perforations 832 that coincide with the cavity of the second frame 840, while the peripheral area of ​​the first frame 830 that coincides with the rim of the second frame 840 is not perforated. Similarly, as shown in FIGS. 23-24, the second frame 840 defines second perforations 842 in the cavity. The pattern and size of the first perforations 832 may mimic the pattern and size of the second perforations 842 (e.g., staggered and 80, 100, or 250 mesh equivalent), although exemplary embodiments are not limited thereto. The first perforations 832 and second perforations 842 may be achieved mechanically or chemically (e.g., via photochemical machining / etching).

[0126] A heater is disposed within the capsule 800 for heating the aerosol-forming substrate. In an exemplary embodiment, the heater extends through the second frame 840 into the cavity. For example, the heater may be embedded within the second frame 840 via injection molding. The heater may be in the form of a ribbon-like strip having a length, a width, and a thickness, the width being a dimension greater than the thickness, and the width direction being perpendicular to the first and second faces of the capsule 800. The heater includes a first end 872, a middle portion 874, and a second end 876. The first end 872, the middle portion 874, and the second end 876 of the heater are sections of a continuous structure. At least the middle portion 874 of the heater has a winding (e.g., serpentine) form. The winding form of the middle portion 874 may include a plurality of parallel and equally spaced segments (e.g., eight such segments).

[0127] The heater intermediate portion 874 may be in the form of a pattern that spans a majority of the open area within the cavity of the second frame 840. For example, the pattern may be such that the heater intermediate portion 874 zigzags within the cavity of the second frame 840. In such an example, the heater intermediate portion 874 may alternate between extending toward the proximal end of the second frame 840 and extending toward the distal end of the second frame 840. As shown in FIGS. 23-24, the undulations of the heater intermediate portion 874 may be in the form of three to four protrusions (e.g., fingers) that do not contact the sidewalls of the cavity of the second frame 840, although exemplary embodiments are not limited thereto.

[0128] The first and second ends 872, 876 of the heater are outer segments configured to receive electrical current from a power source during heater activation. The middle portion 874 of the heater is an inner segment disposed within the capsule 800 (e.g., within a chamber of a housing containing the aerosol-forming substrate). When the heater is activated, the temperature of the aerosol-forming substrate increases (due to the aerosol-forming substrate being in thermal contact with the middle portion 874), and an aerosol may be generated and released through the first perforation 832 and / or the second perforation 842 of the capsule 800.

[0129] The combination of the sidewalls of the first frame 830 and the second frame 840 may be considered the sidewall of the capsule 800. Additionally, the first end 872 and the second end 876 may be exterior segments of the heater that also form part of the side of the capsule 800. For example, as shown in FIGS. 23-24, the first end 872 and the second end 876 of the heater may extend through the distal end of the second frame 840 and wrap around the proximal end while conforming to the peripheral contour of the second frame 840, although example embodiments are not limited in this respect.

[0130] To assemble the capsule 800, the first frame 830 may be connected to the second frame 840 after the aerosol-forming substrate is placed in the cavity of the second frame 840. The aerosol-forming substrate may not have a set shape, but rather may be a loose form (e.g., particles, fibers, dregs, pieces, strips) configured to fill the space between the winding shape of the intermediate portion 874 of the heater and take the shape of the cavity of the second frame 840. Based on the ribbon-like form of the heater, the intermediate portion 874 may be considered to form a channel or partition in the cavity of the second frame 840 for receiving the aerosol-forming substrate. Furthermore, as described above, the bond between the first frame 830 and the second frame 840 may be achieved via a welded arrangement or with an adhesive deemed food safe or otherwise acceptable by a regulatory agency. Additionally, the outer sidewall of first frame 830 may be substantially flush with the outer sidewall of second frame 840 when capsule 800 is assembled, although example embodiments are not limited thereto. Once assembled, capsule 800 is difficult or impractical to open without damaging first frame 830, second frame 840, and / or other sides of capsule 800. As a result, capsule 800 is relatively tamper-resistant to unauthorized actions by third parties.

[0131] In an exemplary embodiment, the heater is configured to undergo Joule heating (also referred to as Ohmic / resistive heating) upon passage of electrical current therethrough. More specifically, the heater may be formed of one or more conductors and configured to generate heat when electrical current is passed therethrough. Electrical current may be provided to a first end 872 and a second end 876 of the heater from a power source (e.g., a battery) within the aerosol generating device. Suitable conductors for the heater include iron-based alloys (e.g., stainless steel, iron alumina), nickel-based alloys (e.g., nichrome), and / or ceramics (e.g., ceramics coated with metal). The middle portion 874 of the heater may have a resistance of about 0.5-2.5 Ω (e.g., 1-2 Ω).

[0132] Electrical current from a power source within the aerosol generating device may be transferred through electrodes configured to electrically contact the first end 872 and the second end 876 of the heater when the capsule 800 is inserted into the aerosol generating device. In a non-limiting embodiment, the electrodes may be spring-loaded to enhance the engagement of the capsule 800 with the heater. Additionally, the first end 872 and the second end 876 of the heater may provide a relatively large contact surface for the electrodes to facilitate a proper and consistent electrical connection. The spring loading of the electrodes may be in a direction perpendicular to the side of the capsule 800. In addition to or instead of the spring loading, movement (e.g., engagement, disengagement) of the electrodes may be accomplished by mechanical actuation. Additionally, the supply of electrical current from the aerosol generating device to the capsule 800 may be manually (e.g., button-activated) or automatically (e.g., puff-activated).

[0133] FIG. 26 is a perspective view of an engagement assembly for a capsule according to an exemplary embodiment, with a breakaway view. Referring to FIG. 26, an aerosol generating device may include a device body having an engagement assembly configured to engage a capsule 900 including an aerosol-forming substrate. The capsule 900 includes a first permeable surface, an opposing second permeable surface, and a side surface. The engagement assembly of the device body may include at least one heating pad configured to heat the aerosol-forming substrate in the capsule 900 by conduction to generate an aerosol. For example, the device body may be configured to receive the capsule 900 such that the heating pad(s) engage and cover the first permeable surface and / or the second permeable surface of the capsule 900. In another example, the engagement assembly of the device body may further include a sealing pad in combination with the heating pad. In such an example, the device body may be configured to receive the capsule 900 such that the capsule 900 is sandwiched between the heating pad and the sealing pad.

[0134] The capsule 900 may be similar to corresponding aspects of the capsule 100 and / or capsule 200 discussed herein. For example, the first frame 930, the second frame 940, the second permeable structure 920, and the second recess 943 of FIG. 26 may be as described in connection with the first frame 230, the second frame 240, the second permeable structure 220, and the second recess 243 of FIG. 8, respectively. Furthermore, the third frame 950 in FIG. 26 may be as described in connection with the third frame 150 in FIG. 2 and / or the third frame 250 in FIG. 8. As a result, the above relevant disclosure of common features should be understood to apply in this section and may not be repeated for brevity.

[0135] The device body engagement assembly may include a first pad 1110, a second pad 1120, and / or a holder 1150. The first pad 1110 may include a plateau portion 1114 that defines a plurality of first perforations 1112 (e.g., a 5×6 array). The dimensions of the plateau portion 1114 of the first pad 1110 may correspond to the first opening of the first frame 930 (through which the first transparent structure is exposed). Although hidden in FIG. 26, the first opening and the first transparent structure may be as described in connection with the first opening 231 and the first transparent structure 210 of FIG. 10. The first pad 1110 may include a ridge portion (e.g., a sealing ridge) surrounding the plateau portion 1114. The height of the ridge portion may be less than the height of the plateau portion 1114. As shown, the ridge portion substantially follows the shape of the plateau portion 1114 and extends along at least the distal and side edges of the first pad 1110, although the exemplary embodiment is not limited in this respect.

[0136] Additionally, hidden in FIG. 26 (but shown in FIG. 28), the second pad 1120 may include a plateau portion defining a plurality of second perforations 1122 (e.g., a 5×5 array). The dimensions of the plateau portion of the second pad 1120 may correspond to the second opening of the second frame 940 (through which the second transparent structure 920 is exposed). Although not labeled in FIG. 26, the second opening may be as described in connection with the second opening 241 of FIG. 10. The second pad 1120 may also include a ridge portion (e.g., a sealing ridge) surrounding the plateau portion (as described in connection with the first pad 1110).

[0137] The first pad 1110 and / or the second pad 1120 may be formed of silicone or other heat-resistant polymers. In an exemplary embodiment, the first pad 1110 may be a heating pad configured to heat the aerosol-forming substrate in the capsule 900 by conduction to generate an aerosol, and the second pad 1120 may be a sealing pad. In another example, both the first pad 1110 and the second pad 1120 may be heating pads. When configured as heating pads, the first pad 1110 and / or the second pad 1120 may include an integrated heating element, as known in the art. Furthermore, in some implementations, when a heating pad is used to heat the aerosol-forming substrate, the capsule 900 may not include a heater. Thus, the first pad 1110 and / or the second pad 1120 as heating pads may function as a first aspect for heating the aerosol-forming substrate in the capsule 900. Alternatively, the first pad 1110 and / or the second pad 1120 as heating pads may function as a secondary mode for heating the aerosol-forming substrate within the capsule 900, where the primary mode is via a heater as described herein (e.g., heater 170).

[0138] The holder 1150 is configured to receive and support the capsule 900. As shown, the holder 1150 includes a rim 1152 and a shelf 1154. The shelf 1154 may extend around the entire lower portion (e.g., lower half) of the inner sidewall of the holder 1150, although the exemplary embodiment is not limited thereto. The shelf 1154 is configured to support the capsule 900 when received within the holder 1150. The holder 1150 may be a fixed or moving part of an engagement assembly of the device body. If configured as a moving part, the holder 1150 may be configured to slide outward (e.g., laterally) from the device body to allow the capsule 900 to seat within the holder 1150.

[0139] FIG. 27 is a perspective view of the engagement assembly of FIG. 26, partially engaged. Referring to FIG. 27, the capsule 900 is partially engaged with the engagement assembly. In particular, as shown, the capsule 900 is received to seat within the holder 1150. In an exemplary embodiment, the opening defined by the holder 1150 substantially corresponds to the shape and size of the capsule 900 (e.g., based on a plan view). As a result, when the capsule 900 is within the opening defined by the holder 1150 and rests on the shelf 1154, there is only a relatively small degree of freedom for movement (e.g., rotation and / or lateral shift in the plane of the capsule 900). Furthermore, the depth of the opening defined by the holder 1150 for the capsule 900 may substantially correspond to the thickness of the first frame 930. The depth of the opening defined by the holder 1150 may be the distance along the inner sidewall from the rim 1152 to the shelf 1154.

[0140] FIG. 28 is a cross-sectional view and engagement diagram of the engagement assembly of FIG. 26. Referring to FIG. 28, the capsule 900 is fully engaged with the engagement assembly. In particular, as shown, the capsule 900 is supported by the shelf 1154 of the holder 1150 and sandwiched between the first pad 1110 and the second pad 1120. The first pad 1110 and the second pad 1120 may be configured to move axially (e.g., along the longitudinal axis of the device body) to clamp the capsule 900. In an exemplary embodiment, the plateau portion 1114 of the first pad 1110 interfaces with the first permeable structure of the capsule 900, while the adjacent portion (e.g., including the sealing ridge) interfaces with the first frame 930 to establish a seal. Similarly, a plateau portion of the second pad 1120 interfaces with the second permeable structure 920 of the capsule 900, while an adjacent portion (e.g., including the sealing ridge) interfaces with the second frame 940 to establish a seal.

[0141] The plurality of first perforations 1112 of the first pad 1110 may be staggered or otherwise offset with the plurality of second perforations 1122 of the second pad 1120 when the first pad 1110 and the second pad 1120 engage the capsule 900. In such an example, air flowing through the plurality of first perforations 1112 and entering the capsule 900 will have a longer residence time or dwell time within the aerosol-forming substrate within the capsule 900 (e.g., compared to a scenario in which the first perforations 1112 are aligned with the second perforations 1122). A longer residence time or dwell time within the aerosol-forming substrate within the capsule 900 may increase the amount of volatile material entrapped by the air flowing therethrough. As a result, the quantity and / or quality of aerosol exiting the capsule 900 (via the second permeable structure 920) and exiting through the plurality of second perforations 1122 of the second pad 1120 may be improved.

[0142] The capsules and devices disclosed herein may be used to generate an aerosol by heating an aerosol-forming substrate. In an exemplary embodiment, a method of generating an aerosol may include engaging a capsule 900 between a first pad 1110 and a second pad 1120 of an aerosol generating device. As described above, the capsule 900 includes an aerosol-forming substrate and includes a first permeable surface, an opposing second permeable surface, and a side surface. The method may additionally include heating the aerosol-forming substrate on at least one of the first pad 1110 or the second pad 1120 such that the generated aerosol exits the permeable surface of the capsule 900 and passes through at least one of the first pad 1110 or the second pad 1120. The generated aerosol may be drawn from the aerosol generating device through a mouthpiece (e.g., mouthpiece 1015 of FIG. 21). Alternatively, instead of or in addition to external heating by the first pad 1110 and / or the second pad 1120, the aerosol-forming substrate within the capsule 900 may be subjected to internal heating by one or more of the internal heaters disclosed herein.

[0143] In addition to the non-limiting embodiments described herein, additional details of the substrates, capsules, devices, and methods discussed herein are discussed below, the disclosures of each of which are incorporated herein by reference in their entirety. No. 16 / 451,662, filed June 25, 2019, entitled "CAPSULES, HEAT-NOT-BURN (HNB) AEROSOL-GENERATING DEVICES, AND METHODS OF GENERATING AN AEROSOL" (Atty. Dkt. No. 24000NV-000522-US); No. 16 / 252,951, filed January 21, 2019, entitled "CAPSULES, HEAT-NOT-BURN (HNB) AEROSOL-GENERATING DEVICES, AND METHODS OF GENERATING AN AEROSOL" (Atty. Dkt. No. 24000NV-000521-US); No. 15 / 845,501, filed December 18, 2017 (Atty. Dkt. No. 24000DM-000012-US), entitled "A VAPORIZER FOR VAPORIZING AN ACTIVE INGREDIENT"; and U.S. Application No. 15 / 559,308, filed September 18, 2017 (Atty. Dkt. No. 24000DM-000003-US-NP), entitled "VAPORIZER FOR VAPORIZING AN ACTIVE INGREDIENT."

[0144] 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 apparent 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: The device includes a housing and a heater, the housing has an inner surface defining a chamber configured to hold an aerosol-forming substrate; the housing has an exterior surface that defines a first surface, an opposing second surface, and a side surface of the capsule, the first surface and the second surface being permeable to an aerosol; the housing includes a first frame, a second frame, and a third frame; the third frame is between the first frame and the second frame; the heater has a first end, a middle portion, and a second end, the first end and the second end being outer segments that form a portion of the side of the capsule; The intermediate portion is an interior segment disposed within the chamber of the housing.

2. 2. The capsule according to claim 1, The capsule, wherein the first surface, the second surface, or both, comprise a perforated sheet.

3. 2. The capsule according to claim 1, The capsule, wherein the first surface, the second surface, or both, comprise a mesh sheet.

4. 2. The capsule according to claim 1, The side surface is between the first surface and the second surface of the capsule.

5. 2. The capsule according to claim 1, The side surface is a periphery of the capsule.

6. 2. The capsule according to claim 1, The third frame defines a cavity.

7. 7. The capsule according to claim 6, The heater extends through the third frame into the cavity.

8. 7. The capsule according to claim 6, The third frame is structured as two components configured to engage and clamp the heater therebetween.

9. 9. The capsule according to claim 8, The two components define corresponding openings that form the cavity of the third frame, a capsule.

10. 9. The capsule according to claim 8, A capsule, wherein one of the two components includes a ridge portion and the other of the two components defines a corresponding groove portion configured to receive the ridge portion when the two components are engaged.

11. The capsule according to claim 10, The ridge portion is between the first end and the second end of the heater when the heater is clamped by the two components of the third frame, encapsulating the heater.

12. 2. The capsule according to claim 1, The first end, the middle section, and the second end of the heater are sections of a continuous structure.

13. 2. The capsule according to claim 1, The intermediate portion of the heater has a planar and wound configuration.

14. 2. The capsule according to claim 1, The intermediate portion of the heater has a resistance of 0.5 to 2.5 Ω.

15. 2. The capsule according to claim 1, The heater is a ribbon-like strip having a length, a width, and a thickness, the width being a dimension greater than the thickness, and the width direction is perpendicular to the first surface and the second surface of the capsule.

16. 2. The capsule according to claim 1, The capsule has a thickness of 1 to 4 mm.

17. 2. The capsule according to claim 1, A capsule, wherein the aerosol-forming substrate comprises a plant material.

18. 18. The capsule of claim 17, The plant material comprises tobacco.

19. An aerosol generating device, comprising: The device includes a capsule and a device body. The capsule includes a housing and a heater. the housing has an inner surface defining a chamber configured to hold an aerosol-forming substrate; the housing has an exterior surface that defines a first surface, an opposing second surface, and a side surface of the capsule, the first surface and the second surface being permeable to an aerosol; the housing includes a first frame, a second frame, and a third frame; the third frame is between the first frame and the second frame; the heater has a first end, a middle portion, and a second end, the first end and the second end being outer segments that form a portion of the side of the capsule; the intermediate portion being an interior segment disposed within the chamber of the housing; the device body includes a heating pad configured to heat the aerosol-forming substrate within the capsule via conduction to generate an aerosol; An aerosol generating device, wherein the device body is configured to receive the capsule such that the heating pad engages and covers the first surface or the second surface of the capsule.

20. 20. The aerosol generating device according to claim 19, the device body further includes a sealing pad; An aerosol generating device, wherein the device body is configured to receive the capsule such that the capsule is sandwiched between the heating pad and the sealing pad.

21. 1. A method for generating an aerosol, comprising: The method includes an engagement step and a heating step, the engaging step includes engaging a capsule between a first pad and a second pad; The capsule includes a housing and a heater. the housing has an inner surface defining a chamber configured to hold an aerosol-forming substrate; the housing has an exterior surface that defines a first surface, an opposing second surface, and a side surface of the capsule, the first surface and the second surface being permeable to an aerosol; the housing includes a first frame, a second frame, and a third frame; the third frame is between the first frame and the second frame; the heater has a first end, a middle portion, and a second end, the first end and the second end being outer segments that form a portion of the side of the capsule; the intermediate portion being an interior segment disposed within the chamber of the housing; The method, wherein the heating step is to heat the aerosol-forming substrate on at least one of the first pad and the second pad such that the generated aerosol passes through at least one of the first pad and the second pad.

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