Capsule containing an internal filter, heat-not-burn (HNB) aerosol generating device, and aerosol generating method

Abstract

A capsule for an aerosol-generating device may include a housing, a filter, and an aerosol-forming substrate. The housing may have a gas-permeable end and a gas-impermeable end. The filter may be disposed within the housing adjacent to the gas-impermeable end. The aerosol-forming substrate may be disposed within the housing between the filter and the gas-permeable end. The housing may be configured to promote heating of the aerosol-forming substrate via either or both conduction and convection to generate an aerosol.

Description

[Technical field]

[0001] The present disclosure relates to capsules, heat-not-burn (HNB) aerosol generators, and methods of 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 components of the plant material while maintaining a temperature below the combustion point of the plant material 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, a filter, and an aerosol-forming substrate. The housing may have a gas permeable end and a gas impermeable end. The filter may be disposed within the housing adjacent the impermeable end. The aerosol-forming substrate may be disposed within the housing between the filter and the gas permeable end. The housing may be configured to facilitate heating of the aerosol-forming substrate via either or both of conduction and convection to generate an aerosol.

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

[0005] At least one embodiment relates to a method of generating an aerosol. In an exemplary embodiment, the method may include heating a capsule including a housing, a filter, and an aerosol-forming substrate. The housing may have a gas permeable end and a gas impermeable end. The method may further include directing an aspirated flow of air along a tortuous path through the capsule. The tortuous path may include an entrained flow section and a filtered flow section. The entrained flow section may be from the gas permeable end of the housing through the aerosol-forming substrate to the filter. The filtered flow section may be from the filter to the gas permeable end of the housing. [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 first perspective view of a capsule for an aerosol generating device according to an exemplary embodiment.

[0008] [Diagram 2] FIG. 2 is a second perspective view 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 a cross-sectional view of the capsule of FIG. 1 when engaged with a mouthpiece.

[0012] [Figure 6] FIG. 6 is a first perspective view of an aerosol generating device according to an exemplary embodiment.

[0013] [Figure 7] FIG. 7 is a second perspective view of the aerosol generating device of FIG.

[0014] [Figure 8] FIG. 8 is an exploded perspective view of the aerosol generating device of FIG.

[0015] [Figure 9]FIG. 9 is an exploded perspective view of the aerosol generating device of FIG.

[0016] [Figure 10] FIG. 10 is a cross-sectional view of the aerosol generating device of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] 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.

[0018] Thus, while exemplary embodiments are susceptible to various modifications and alternative forms, exemplary embodiments thereof have been 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.

[0019] 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.

[0020] In this specification, terms such as first, second, third, etc. may be used to describe various elements, regions, layers, and / or sections, but it should be understood that these elements, regions, layers, and / or sections should not be limited by these terms. These terms are 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.

[0021] 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.

[0022] 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.

[0023] In this specification, when the words "about" and "substantially" are used in connection with numerical values, unless otherwise expressly defined, it is intended to include manufacturing or operating tolerances (e.g., ±10%) around the stated numerical values. Furthermore, when the terms "generally" or "substantially" are used in connection with geometric shapes, it is intended that precision of the geometric shapes is not required, but that freedom in the shapes is within the scope of the present disclosure. Furthermore, when numerical values ​​or shapes are expressed as either "about," "generally," or "substantially," it is understood that these numerical values ​​and shapes should be interpreted as including manufacturing or operating tolerances (e.g., ±10%) around the stated numerical values ​​or shapes.

[0024] Unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by a person of ordinary skill in the art to which the illustrated embodiment belongs. Furthermore, terms, including those defined in commonly used dictionaries, should be interpreted as having a meaning consistent with the meaning in the context of the relevant art, and should not be interpreted in an idealized or overly formal sense unless expressly defined herein.

[0025] 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.

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

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

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

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

[0030] During assembly, the end cap 110 is placed on the open end 132 of the container 130 to enclose the aerosol-forming substrate and filter 120 therein. For example, a majority of the end cap 110 may be inserted into the container 130. The engagement between the end cap 110 and the container 130 may be via an interference fit (sometimes also referred to as a pressure fit or friction fit). Furthermore, instead of or in addition to an interference fit, the end cap 110 may be secured to the container 130 using an adhesive (e.g., glue) deemed food safe or otherwise acceptable by a regulatory agency. The end cap 110 may be formed of a suitable plastic (e.g., via molding). Exemplary embodiments are not limited thereto.

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

[0032] The inlet openings 112 of the end caps 110 may be equidistant from each other by a first distance. Stated differently, each of the inlet openings 112 may be equidistant from an adjacent inlet opening 112 by a first distance. Additionally, the inlet openings 112 may be equidistant from a center (e.g., a diametric center) of the end caps 110 by a second distance. Although exemplary embodiments are not limited thereto, the first distance may be smaller than the second distance. For example, if the quantity of the inlet openings 112 is reduced, the first distance may be larger than the second distance. During operation of the aerosol generating device, air enters the capsule 100 through the inlet openings 112 and aerosol exits the capsule 100 through the exit openings 114 (e.g., as a result of engagement with a mouthpiece, such as the mouthpiece 310 in FIG. 5). Each of the inlet openings 112 may be smaller than the exit openings 114.

[0033] FIG. 3 is an exploded perspective view of the capsule of FIG. 1. FIG. 4 is an exploded perspective view of the capsule of FIG. 2. Referring to FIGS. 3 and 4, the filter 120 is configured to be inserted into the container 130 via the open end 132 during assembly of the capsule 100. When fully seated in the container 130, the filter 120 is configured to abut or press against an inner end surface corresponding to the closed end 134. To facilitate placement in the container 130, the bottom of the filter 120 may be shaped (e.g., with rounded edges) to match the inner surface corresponding to the closed end 134. To provide a tight fit, the filter 120 may further be sized such that its outer sidewall interfaces with the inner sidewall of the container 130. In such an example, the filter 120 may grip the inner sidewall of the container 130 sufficiently to maintain its seated position (e.g., sufficient to overcome gravity if the container 130 is turned upside down).

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

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

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

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

[0038] In another example, the aerosol-forming substrate may be in a plurality of combined forms configured to allow each combined form to be placed in an individual manner within the container 130. In such an example, each of the plurality of combined forms may resemble a round tablet or disk defining a through hole configured to align with the exit opening 114 of the end cap 110 and the orifice 122 of the filter 120. Each of the plurality of combined forms may include the same or different types of aerosol-forming substrate. As a result, various combinations of aerosol-forming substrates may be loaded into the container 130 to achieve a desired organoleptic appeal.

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

[0040] 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 temperature 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 heating and the resulting generation of the aerosol. In other examples, there may be some thermal decomposition and combustion by-products, but the extent may be relatively minor and / or may be considered merely incidental.

[0041] The aerosol-forming substrate may be a fibrous material. For example, the fibrous material may be a plant 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 of one or more tobacco plants, such as Nicotiana rustica and Nicotiana tabacum.

[0042] In some exemplary embodiments, the tobacco material may include material from any member of the 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, partial combinations thereof, or combinations thereof.

[0043] The compound may also be a naturally derived 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.

[0044] 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, heat from a heater (e.g., of the heating assembly 340 shown in FIG. 8) may cause decarboxylation to convert tetrahydrocannabinolic acid (THCA) in the capsule 100 to tetrahydrocannabinol (THC) and / or may cause decarboxylation to convert cannabidiol acid (CBDA) in the capsule 100 to cannabidiol (CBD).

[0045] 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.

[0046] Furthermore, the compound may include or may subsequently additionally include non-naturally occurring additives that are subsequently introduced into the fibrous material. In one example, the fibrous material may include at least one of cotton, polyethylene, polyester, rayon, combinations thereof, and the like (e.g., in the form of gauze). In another example, the fibrous material may be a cellulosic material (e.g., a non-tobacco and / or non-cannabis material). In either example, the compound introduced may include nicotine, cannabinoids, and / or flavorings. The flavorings may be naturally occurring, such as plant extracts (e.g., tobacco extracts, cannabis extracts), and / or artificially occurring. In yet another example, when the fibrous material includes tobacco and / or cannabis, the compound may be or may additionally include one or more flavorings (e.g., menthol, mint, vanilla). Thus, the compound in the aerosol-forming substrate may include naturally occurring components and / or non-naturally occurring additives. In this regard, it should be understood that the level of naturally occurring components present in the aerosol-forming substrate may be increased by supplementation. For example, the amount of nicotine in tobacco may be increased by supplementation with an extract containing nicotine, and similarly, the amount of one or more cannabinoids in cannabis may be increased by supplementation with an extract containing such cannabinoids.

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

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

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

[0050] Each of the multiple air inlets 334 in the device body 330 may be larger than the aerosol outlet 312 in the mouthpiece 310. Although twelve air inlets 334 are shown in FIG. 7, it should be understood that a different amount may be implemented (e.g., ten air inlets, fourteen air inlets) based on the desired distribution of air flow in and through the aerosol generation device 300. Additionally, a gasket 320 may be disposed between the mouthpiece 310 and the device body 330. The gasket 320 may help ensure a relatively airtight seal such that incoming air enters the aerosol generation device 300 essentially only through the air inlets 334 in the device body 330.

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

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

[0053] In an exemplary embodiment, the capsule 200 may be considered a consumable item that is removed and replaced with a new capsule (e.g., when the aerosol-forming substrate therein is depleted or deemed expired) before operation of the aerosol generating device 300 is resumed. In this regard, the capsule 200 may also be considered disposable. Meanwhile, the mouthpiece 310, the gasket 320, the heating assembly 340, and the device body 330 may be considered durable parts of the aerosol generating device 300 that are designed for multiple uses (if not for the life of the aerosol generating device 300). In this regard, the mouthpiece 310, the gasket 320, the heating assembly 340, and the device body 330 may also be considered reusable.

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

[0055] The first heater 342 may be in the form of an inner coil, and the second heater 344 may be in the form of an outer coil surrounding the inner coil. In such an example, the first heater 342 and the second heater 344 may be concentrically arranged to spiral around the longitudinal central axis of the device body 330. Furthermore, the wire diameter, pitch, coil angle, free length, and / or material of construction of the first heater 342 may be the same as the wire diameter, pitch, coil angle, free length, and / or material of construction of the second heater 344. However, the exemplary embodiment is not so limited. Furthermore, the free length of the first heater 342 and the second heater 344 may have a dimension that is at least the height of the container 230 of the capsule 200. This may enhance heating of the aerosol-forming substrate therein during aerosol generation. In another example, the first heater 342 and the second heater 344 may be in the form of a ceramic heater, a silicon heater, and / or a flexible polymer heater.

[0056] In the coil configuration, the inner diameter of the first heater 342 may substantially correspond to the outer diameter of the capsule 200. As a result, the first heater 342 may physically contact (e.g., press against) the container 230 of the capsule 200 when the capsule 200 is received in the compartment 332 of the device body 330. Furthermore, the outer diameter of the second heater 344 may substantially correspond to the inner diameter of the device body 330. As a result, the second heater 344 may contact (e.g., press against) the inner sidewall of the device body 330. Furthermore, based on the position of the heating assembly 340 in the compartment 332 of the device body 330, the air inlet 334 may be between the first heater 342 and the second heater 344. As a result, air entering the device body 330 via the air inlet 334 flows between the first heater 342 and the second heater 344, becoming a heated flow that enters the capsule 200 and heats the aerosol-forming substrate therein via convection.

[0057] Although a coil configuration is described above, it should be understood that other configurations are possible for the first heater 342 and the second heater 344. For example, the first heater 342 and the second heater 344 may be structured as a corrugation configured to surround the capsule 200. In such an example, the first heater 342 and the second heater 344 may alternate between extending toward a rim at the proximal end of the device body 330 and extending toward the distal end of the device body 330. In particular, the amplitude of the corrugation of the first heater 342 and the second heater 344 may have a magnitude that is approximately half the height of the container 230 of the capsule 200, while the height of the corrugation of the first heater 342 and the second heater 344 may have a magnitude that is approximately the height of the container 230 of the capsule 200. Heating of the aerosol-forming substrate therein during aerosol generation can be enhanced.

[0058] The waveforms of the first heater 342 and the second heater 344 may resemble a compressed amplitude or a zigzag, and may have multiple parallel segments (e.g., extending longitudinally relative to the device body 330). In particular, the waveforms may include pulse waves (e.g., square waves), triangular waves, sawtooth waves, or sinusoidal waves. The waveform of the first heater 342 may be of the same type as the waveform of the second heater 344, although the illustrated embodiment is not limited thereto. In examples where the capsule 200 has a non-cylindrical shape (e.g., a shape resembling a triangular prism, a rectangular prism, a pentagonal prism, or a hexagonal prism), it should be understood that the heater pattern (e.g., may be cut from a sheet material) may be curved as necessary. This may result in suitable first and second heaters that can better accommodate the capsule 200 (e.g., improve thermal contact).

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

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

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

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

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

[0064] During operation of the aerosol generating device 300, incoming air (e.g., ambient air) is drawn into the device body 330 via the multiple air inlets 334. The multiple air inlets 334 at the upstream end of the device body 330 help to disperse the incoming air around the capsule 200. Activation of the heating assembly 340 can include manual operation (e.g., button activation) and / or automatic operation (e.g., puff activation). Furthermore, the first heater 342 and the second heater 344 of the heating assembly 340 may be activated simultaneously or sequentially. Furthermore, since the first heater 342 and the second heater 344 are configured to allow independent operation, the first heater 342 and the second heater 344 may have different heating profiles and therefore may be at different temperatures at a given time.

[0065] For example, in response to manual or automatic operation, both the first heater 342 and the second heater 344 may be simultaneously activated to begin heating. In another example, upon a first button actuation, the first heater 342 may begin heating the capsule 200, and upon a subsequent puff actuation, the second heater 344 (in combination with the first heater 342) may begin heating the incoming air to generate a heated airflow. In yet another example, the order may be reversed, for example, the second heater 344 begins heating in response to a first button actuation, and the first heater 342 begins heating in response to a subsequent puff actuation. Furthermore, in each of the above examples, the heating may include a pre-heating step involving the first heater 342 and / or the second heater 344 (to reduce the time required to reach the target / aerosolization temperature), followed by a main heating step involving both the first heater 342 and the second heater 344. Here, the pre-heat step is below the target temperature / aerosolization temperature, e.g., by button activation, and the full heating step is at the target temperature / aerosolization temperature, e.g., by puff activation. Suitable temperature sensing may be achieved via thermocouples or by monitoring the resistance of the first heater 342 and the second heater 344.

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

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

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

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

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

[0071] 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: a housing having a gas permeable end and a gas impermeable end, the housing comprising a vessel and an end cap, the end cap defining a plurality of openings, the plurality of openings including an outlet opening surrounded by an inlet opening; a filter disposed within the housing adjacent the gas impermeable end; an aerosol-forming substrate disposed within the housing such that the aerosol-forming substrate is between the filter and the gas permeable end; wherein the housing is configured to facilitate heating of the aerosol-forming substrate via either or both of conduction and convection to generate an aerosol. thing.

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

3. 2. The capsule according to claim 1, The container has a closed end and an open end.

4. The capsule according to claim 3, the end cap is disposed at the open end of the container; thing.

5. The capsule according to claim 3, the end cap being the gas permeable end of the housing; the closed end of the container is the gas impermeable end; thing.

6. 2. The capsule according to claim 1, A majority of the end cap is inserted into the container. thing.

7. 2. The capsule according to claim 1, The container is made of metal. thing.

8. The capsule according to claim 7, The metal includes aluminum. thing.

9. 2. The capsule according to claim 1, Each of the inlet openings is smaller than the outlet openings. thing.

10. 2. The capsule according to claim 1, The amount and size of the inlet openings are configured to provide the capsule with a resistance to draw (RTD) of between 90 and 110 mmHg. thing.

11. 2. The capsule according to claim 1, The outlet opening is aligned with a central longitudinal axis of the container. thing.

12. 2. The capsule according to claim 1, the filter includes an orifice aligned with the outlet opening of the end cap; thing.

13. 13. The capsule according to claim 12, the orifice in the filter is configured such that the passage of the aerosol through the filter includes a radial path toward the orifice. thing.

14. 13. The capsule according to claim 12, the orifice in the filter is a central through hole; thing.

15. 2. The capsule according to claim 1, The aerosol-forming substrate comprises a plant material; thing.

16. 16. The capsule of claim 15, The plant material comprises tobacco. thing.

17. An aerosol generating device, comprising: a device body defining a compartment configured to receive the capsule of claim 1; a mouthpiece including a conduit portion, the mouthpiece configured to engage with the device body such that the conduit portion extends through the aerosol-forming substrate and into the filter of the capsule; a heating assembly within the device body, the heating assembly configured to heat the aerosol-forming substrate within the capsule via either or both of conduction and convection to generate an aerosol that exits the capsule via the conduit portion of the mouthpiece; Equipped with thing.

18. 18. The aerosol generating device according to claim 17, The aerosol-forming substrate and the filter are air entering the capsule passes through the aerosol-forming substrate before reaching the filter; such that the aerosol passes through the filter before exiting the capsule. Disposed within the capsule, thing.

19. 1. A method for generating an aerosol, comprising: heating a capsule comprising a housing, a filter and an aerosol-forming substrate; directing an aspirated flow of air along a serpentine path through the capsule. the housing has a gas permeable end and a gas impermeable end and includes a container and an end cap, the end cap having a plurality of openings, the plurality of openings including an outlet opening surrounded by an inlet opening; the filter is disposed within the housing adjacent the gas impermeable end; the aerosol-forming substrate is disposed within the housing such that it is between the filter and the gas permeable end, the housing being configured to facilitate heating of the aerosol-forming substrate via either or both of conduction and convection to generate an aerosol; the serpentine path includes an entrained flow section and a filtered flow section; the entrainment flow path portion extending from the gas permeable end of the housing through the aerosol-forming substrate to the filter; the filtered flow path portion is from the filter to the gas permeable end of the housing. method.

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