Capsule with an integrated mouthpiece, heat-not-burn (HNB) aerosol generator, and aerosol generation method.

Abstract

A capsule for a heat-not-burn (HNB) aerosol generating device may include a base portion, a first cover, a second cover, an aerosol-forming substrate, and a heater. The base portion includes an engagement assembly configured to mate with the first cover and the second cover. The first cover defines a first recess and the second cover defines a second recess. When assembled, the first cover is aligned with the second cover such that the first recess and the second recess collectively form a chamber. The aerosol-forming substrate is within the chamber. The heater is configured to heat the aerosol-forming substrate to generate an aerosol. The heater includes a first end, a middle portion, and a second end. The heater extends through the base portion such that the middle portion is within the chamber, and the first end and the second end are exterior segments.

Description

Technical Field

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

Background Art

[0002] Some electronic devices are configured to heat a plant material to a temperature sufficient to release the components of the plant material while maintaining a temperature below the combustion point of the plant material to avoid substantial pyrolysis of the plant material. Such devices may be referred to as aerosol generators (e.g., heat-not-burn aerosol generators), 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 generator. In other embodiments, the plant material may be pre-packaged in individual containers to facilitate insertion and removal into the aerosol generator.

Summary of the Invention

[0003] 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 base portion, a first cover, a second cover, an aerosol-forming substrate, and a heater. The base portion includes an engagement assembly. The first cover is engaged with the base portion via the engagement assembly. The first cover includes a first inner surface and a first outer surface. The first inner surface defines a first recess. The second cover is engaged with the base portion and the first cover via the engagement assembly. The second cover includes a second inner surface and a second outer surface. The second inner surface defines a second recess. The first cover is aligned with the second cover such that the first recess and the second recess collectively form a chamber. The aerosol-forming substrate is within the chamber. The heater is configured to heat the aerosol-forming substrate to generate an aerosol. The heater includes a first end portion, an intermediate portion, and a second end portion. The heater extends from the base portion such that the intermediate portion is within the chamber.

[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 a housing containing an aerosol-forming substrate and a heater configured to heat the aerosol-forming substrate. The housing includes a base portion, a first cover, and a second cover. The first cover and the second cover jointly define a chamber, an aerosol channel, and an aerosol outlet therebetween. The aerosol-forming substrate is disposed within the chamber. The heater is supported by the base portion and extends into the chamber. The device body is configured to connect to the capsule. The device body includes a power source configured to supply an electric current to the heater.

[0005] At least one embodiment relates to a method of generating an aerosol. In an exemplary embodiment, the method may include supplying an electric current to a capsule that includes a housing containing an aerosol-forming substrate and a heater. The heater is subject to resistive heating. The housing includes a base portion, a first cover, and a second cover. The first cover and the second cover together define a chamber, an aerosol channel, and an aerosol outlet therebetween. The aerosol-forming substrate is disposed within the chamber. The heater is supported by the base portion and extends into the chamber. The method may optionally include drawing the aerosol generated by resistive heating out of the chamber through the aerosol channel and the aerosol outlet.

Brief Description of the Drawings

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

[0007]

Figure 1

[0008]

Figure 2

[0009]

Figure 3

[0010]

Figure 4

[0011]

Figure 5

[0012]

Figure 6

[0013]

Figure 7

[0014]

Figure 8

[0015]

Figure 9

[0016]

Figure 10

[0017]

Figure 11

[0018]

Figure 12

[0019]

Figure 13

[0020]

Figure 14

[0021]

Figure 15

[0022]

Figure 16

[0023]

Figure 17

[0024]

Figure 18

Mode for Carrying Out the Invention

[0025] Some detailed exemplary embodiments are disclosed herein. However, the specific structural and functional details disclosed herein are merely representative for the purpose of explaining the exemplary embodiments. However, the exemplary embodiments may be embodied in many alternative forms and should not be construed as limited to only the exemplary embodiments described herein.

[0026] Therefore, the exemplary embodiments are capable of various modifications and alternative forms, and the exemplary embodiments are illustrated in the drawings and will be described in detail herein. However, it is not intended to limit the exemplary embodiments to the specific forms disclosed, and conversely, it should be understood that the exemplary embodiments cover all modifications, equivalents, and alternatives thereof. The same reference numerals refer to like elements throughout the description of the figures.

[0027] When an element or layer is said to be "on," "connected to," "coupled to," "attached to," "adjacent to," or "covering" another element or layer, it should be understood that it may be directly on, connected to, coupled to, attached to, adjacent to, or covering the other element or layer, or intervening elements or layers may be present. On the other hand, when an element is said to be "directly on," "directly connected to," or "directly coupled to" another element or layer, there are no intervening elements or layers. In this specification, the same number means the same element. In this specification, the term "and / or" includes any and all combinations or sub-combinations of one or more of the related listed items.

[0028] 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 only used to distinguish one element, region, layer, or section from another region, layer, or section. Thus, a first element, region, layer, or section described hereinafter may be referred to as a second element, region, layer, or section without departing from the teachings of the exemplary embodiments.

[0029] In this specification, for ease of explanation, spatially relative terms (such as "beneath", "below", "lower", "above", "upper", etc.) may be used to describe the relationship between an element or function and another element or function as shown in the figures. It should be understood that spatially relative terms are intended to encompass different orientations of the device in use and operation in addition to the orientation depicted in the figures. For example, if the device in the figure is turned over, elements described as "below" or "beneath" other elements or features will face "above" the other elements or features. Thus, the term "below" can potentially encompass both upward and downward orientations. Also, the device may be oriented in other directions (it may be rotated 90 degrees or oriented in other directions), and the spatially relative descriptors used in this specification will be interpreted accordingly.

[0030] The terms used in this specification are for the purpose of describing various exemplary embodiments only and are not intended to limit the exemplary embodiments. The singular forms "a", "an", and "the" used in this specification are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "includes", "including", "comprises", and / or "comprising" as used in this specification identify the presence of the described features, integers, steps, operations, and / or elements, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, and / or groups thereof.

[0031] In this specification, when the terms "about" and "substantially" are used in connection with a numerical value, unless otherwise explicitly defined, it is intended to include manufacturing or operational tolerances (e.g., ±10%) around the recited numerical value. Further, when the terms "generally" or "substantially" are used in connection with a geometric shape, precision of the geometric shape is not required, but the freedom with respect to the shape is intended to be within the scope of the present disclosure. Further, when a numerical value or a shape is expressed in any of "about", "generally", or "substantially", it should be understood that these numerical values and shapes are to be interpreted as including manufacturing or operational tolerances (e.g., ±10%) around the recited numerical value or shape.

[0032] Unless otherwise defined, all terms (including technical and scientific terms) used in this specification have the same meaning as commonly understood by one of ordinary skill in the art to which the exemplary embodiments belong. Terms defined in commonly used dictionaries are to be interpreted as having a meaning that coincides with the meaning in the context of the relevant art and are not to be interpreted in an idealized or overly formal sense unless explicitly so defined herein.

[0033] The processing circuit may be hardware including a logic circuit; a combination of hardware / software such as a processor that executes software; or a combination thereof. For example, more specifically, the processing circuit may be, but is not limited to, a central processing unit (CPU), an arithmetic logic unit (ALU), a digital signal processor, a microcomputer, a field programmable gate array (FPGA), a system on chip (SoC), a programmable logic unit, a microprocessor, an application specific integrated circuit (ASIC), etc.

[0034] FIG. 1 is a first perspective view of a capsule for an aerosol generating device according to an exemplary embodiment. FIG. 2 is a second perspective view of the capsule of FIG. 1. Referring to FIGS. 1-2, capsule 100 includes a housing configured to hold an aerosol-forming substrate and to house a heater configured to heat the aerosol-forming substrate to generate an aerosol. The housing of capsule 100 includes a base portion 130, a first cover 110, and a second cover 120. The base portion 130 includes an engagement assembly 136 configured to facilitate connection with the first cover 110 and the second cover 120. When connected to the base portion 130, the first cover 110 and the second cover 120 are configured to be received by an end cap 170. The end cap 170 defines at least one aerosol outlet 174. As a result, the end cap 170 can be regarded as a mouthpiece integrated with the housing for manufacturing the capsule 100 having a four-piece structure.

[0035] Further, when connected, the base portion 130 and the first cover 110 define a first air inlet 152 therebetween. Similarly, when the base portion 130 and the second cover 120 are connected, they define a second air inlet 154 therebetween. The first air inlet 152 and the second air inlet 154 are in fluid communication with the aerosol outlet 174. As a result, air drawn into the first air inlet 152 and the second air inlet 154 flows through the capsule 100 to the aerosol outlet 174. The heater is configured to extend through the base portion 130 such that when the capsule 100 is assembled, an intermediate portion of the heater is hidden from view while a first end 142 and a second end 146 are visible. The heater will be described in more detail in connection with subsequent drawings.

[0036] FIG. 3 is a partial exploded perspective view of the capsule of FIG. 1. FIG. 4 is a partial exploded perspective view of the capsule of FIG. 2. Referring to FIGS. 3-4, the first cover 110 and the second cover 120 are configured to engage with each other and with the base portion 130 such that their adjacent surfaces are substantially coplanar. For example, when engaged, the main outer surface of the first cover 110 can be at the same height as the front surface of the base portion 130 (e.g., FIG. 3). Similarly, in another embodiment, the main outer surface of the second cover 120 may be at the same height as the rear surface of the base portion 130 (e.g., FIG. 4). Further, in another example, the opposing side surfaces of the base portion 130 may be at the same height as the adjacent side surfaces of the first cover 110 and the second cover 120. Further, in another embodiment, the downstream end surface of the first cover 110 may be at the same height as the downstream end surface of the second cover 120.

[0037] When the first cover 110, the second cover 120, and the base portion 130 are joined together, the resulting structure (e.g., the housing) may have a shape similar to a rectangular parallelepiped having a front surface, an opposing rear surface, a first side surface, an opposing second side surface, an upstream end surface, and an opposing downstream end surface. As used herein, "upstream" (and conversely "downstream") is related to the flow of the aerosol, and "proximal" (and conversely "distal") is related to the adult operator of the device during aerosol generation. The structure obtained (from the joining of the first cover 110, the second cover 120, and the base portion 130) in the shape of a rectangular parallelepiped can have a rectangular cross-section. Alternatively, in other embodiments, the rectangular parallelepiped form of the resulting structure may have a square cross-section. However, it should be understood that the exemplary embodiments are not limited thereto. For example, instead of the rectangular parallelepiped form, the resulting structure may have a shape similar to a cylinder (e.g., an oval cylinder, a circular cylinder). In the case of an elliptical cylinder, the resulting structure can have an elliptical cross-section. On the other hand, in the case of a cylinder, the resulting structure may have a circular cross-section.

[0038] As shown in the drawings, with respect to the rectangular parallelepiped form resulting from the combination of the first cover 110, the second cover 120, and the base portion 130, the main outer surface of the first cover 110 and the front surface of the base portion 130 can be regarded as a common front surface (the front surface defines, for example, the first air inlet 152). Similarly, the main outer surface of the second cover 120 and the rear surface of the base portion 130 may be regarded as a common opposing rear surface (the opposing rear surface defines, for example, the second air inlet 154). Further, the opposing side surfaces of the base portion 130 and the corresponding side surfaces of the first cover 110 and the second cover 120 may be regarded as the first side surface and the opposing second side surface of the housing. Further, the lower part or bottom of the base portion 130 may be regarded as the upstream end surface (the upstream end surface is, for example, from which the first end 142 and the second end 146 of the heater extend). Further, the downstream end surface of the first cover 110 and the corresponding downstream end surface of the second cover 120 may be regarded as a common downstream end surface of the housing.

[0039] As shown in FIG. 3, the downstream end surface of the housing defines a passage 166. The passage 166 is in fluid communication with the first air inlet 152 and the second air inlet 154. As a result, when the capsule 100 is fully assembled, the air drawn into the first air inlet 152 and the second air inlet 154 will flow through the passage 166 along the path to the aerosol outlet 174. In an exemplary embodiment, the first air inlet 152, the second air inlet 154, and the passage 166 are dimensioned to be large enough to allow sufficient inflow of air through the first air inlet 152 and the second air inlet 154 and sufficient outflow of aerosol through the passage 166, while being small enough to hold the aerosol-forming substrate within the housing.

[0040] The drawings illustrate the end cap 170 as defining four aerosol outlets 174, but it should be understood that the exemplary embodiments are not limited thereto. For example, the end cap 170 can define less than four (e.g., 1 - 3) aerosol outlets 174. In another example, the end cap 170 may define more than four (e.g., 5 - 8) aerosol outlets 174. The form of the end cap 170 may correspond to the form of the housing formed by the first cover 110, the second cover 120, and the base portion 130 (e.g., a rectangular parallelepiped form for both the end cap 170 and the housing). Alternatively, the form of the end cap 170 may be different from the form of the housing formed by the first cover 110, the second cover 120, and the base portion 130 (e.g., a rectangular parallelepiped form for the end cap 170 and a cylindrical form for the housing, or vice versa). Further, the aerosol outlets 174 can be arranged linearly / continuously, radially, or in rows and columns, depending not only on the number of aerosol outlets 174 but also on the form of the end cap 170 and the available space. Additionally, the shape of each of the aerosol outlets 174 can be circular, an elongated shape (e.g., oval), polygonal (e.g., rounded rectangle), or another suitable shape.

[0041] As shown in FIG. 4, end cap 170 defines a cavity 172 configured to receive first cover 110 and second cover 120 of the housing during assembly of capsule 100. In an exemplary embodiment, when capsule 100 is assembled, the major outer surfaces of first cover 110 and second cover 120 will interface with the corresponding major inner surfaces of end cap 170. Instead of (or in addition to) such interfacial engagement, the outer side surfaces of first cover 110 and second cover 120 may interface with the corresponding inner side surfaces of end cap 170. Such interfacial engagement may be via an interference fit (sometimes also referred to as a press fit or friction fit). However, it should be understood that other attachment techniques may also be utilized. For example, the attachment technique can include adhesives (e.g., tapes, adhesives) considered acceptable by regulatory authorities for food safety or otherwise. In another example, the attachment technique can include ultrasonic welding.

[0042] FIG. 5 is a further exploded perspective view of the capsule of FIG. 3. FIG. 6 is a further exploded perspective view of the capsule of FIG. 4. Referring to FIGS. 5 - 6, first cover 110 defines a first notch 112, a first recess 114, and a first downstream rim 116. Similarly, second cover 120 defines a second notch 122, a second recess 124, and a second downstream rim 126. In some embodiments, first cover 110 and second cover 120 may be the same part. In such an example, when first cover 110 and second cover 120 are oriented towards each other to mate with base portion 130, they will be in a complementary arrangement. As a result, one part can be used interchangeably as either first cover 110 or second cover 120, simplifying the manufacturing process.

[0043] In an exemplary embodiment, the first notch 112 may be defined as a pair of notches at the upstream corner of the first cover 110, each notch being adjacent / exposed to the upstream end surface of the first cover 110 and may also be adjacent / exposed to the side surface of the first cover 110 (e.g., FIG. 6). Similarly, the second notch 122 may be defined as a pair of notches at the upstream corner of the second cover 120, each notch being adjacent / exposed to the upstream end surface of the second cover 120 and may also be adjacent / exposed to the side surface of the second cover 120 (e.g., FIG. 5). During assembly, the first notch 112 and the second notch 122 collectively form a T-shaped notch configured to fit with the engagement assembly 136 when the first cover 110 and the second cover 120 are coupled to the base portion 130.

[0044] Furthermore, the first recess 114 of the first cover 110 and the second recess 124 of the second cover 120 collectively form a chamber (e.g., chamber 164 in FIG. 7) configured to accommodate the middle portion 144 of the heater 140 when the first cover 110 and the second cover 120 are coupled to the base portion 130. As shown in FIGS. 5-6, the first aerosol-forming substrate 160a and the second aerosol-forming substrate 160b may be housed in the chamber so as to be in thermal contact with the middle portion 144 of the heater 140 when the capsule 100 is assembled.

[0045] In one example, each of the first aerosol-forming substrate 160a and the second aerosol-forming substrate 160b may be in a connected form (e.g., a sheet, a pallet, a tablet) configured to maintain its shape so as to be integrally disposed within the first recess 114 of the first cover 110 and the second recess 124 of the second cover 120. In such an example, the first aerosol-forming substrate 160a may be disposed on one side of the intermediate portion 144 of the heater 140 (e.g., the side facing the first cover 110), and the second aerosol-forming substrate 160b may be disposed on the other side of the intermediate portion 144 of the heater 140 (e.g., the side facing the second cover 120) so as to substantially fill the first recess 114 of the first cover 110 and the second recess 124 of the second cover 120 respectively, thereby sandwiching / embedding the intermediate portion 144 of the heater 140 therebetween. Alternatively, one or both of the first aerosol-forming substrate 160a and the second aerosol-forming substrate 160b may not have a set shape, but rather be in a loose form (e.g., particles, fibers, shells, fragments, pieces) configured to take the shape of the first recess 114 of the first cover 110 and / or the second recess 124 of the second cover 120 when introduced.

[0046] As discussed herein, an aerosol-forming substrate is a material or combination of materials that has the potential to produce an aerosol. An aerosol is related to the substances generated or output by the disclosure, claims, and their equivalents. The material may include a compound (e.g., nicotine, cannabinoid), and when the material is heated, an aerosol containing the compound is generated. The heating may be below the combustion temperature so as to generate an aerosol without substantial thermal decomposition of the aerosol-forming substrate or substantial generation of combustion by-products (if any). Thus, in an exemplary embodiment, thermal decomposition does not occur during the heating of the aerosol and the resulting generation. In other examples, thermal decomposition and combustion by-products may be present, but to a relatively minor extent and / or may be considered merely incidental.

[0047] The aerosol-forming substrate may be a fibrous material. For example, the fibrous material may be a plant-based 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, shaped tobacco, or powdered tobacco from one or more of tobacco plants such as Nicotiana rustica and Nicotiana tabacum, and combinations thereof.

[0048] In some exemplary embodiments, the tobacco material can include material from any member of the Nicotiana genus. Further, the tobacco material can include a blend of two or more different tobacco varieties. Examples of suitable types of tobacco materials that can be used include, but are not limited to, pipe-cured tobacco, burley tobacco, dark tobacco, Maryland tobacco, oriental tobacco, rare tobacco, special tobacco, blends thereof, and the like. The tobacco material may be provided in any suitable form including, but not limited to, processed tobacco materials such as tobacco lamina, volume-expanded tobacco or cased tobacco, processed tobacco stems such as cut rolled stems or cut cased stems, reconstituted tobacco materials, blends thereof, and the like. In some exemplary embodiments, the tobacco material is in the form of a substantially dry tobacco mass. Further, in some exemplary embodiments, the tobacco material can be mixed and / or combined with at least one of propylene glycol, glycerin, sub-combinations thereof, or combinations thereof.

[0049] Alternatively, the compound may be a naturally occurring component of a medicinal plant that has been medically proven to have a therapeutic effect. For example, the medicinal plant may be a cannabis plant, and the compound may be a cannabinoid. Cannabinoids interact with receptors in the body to exert various effects. As a result, cannabinoids are used for various medicinal purposes (e.g., treatment of pain, nausea, epilepsy, mental disorders). The fibrous material may include leaves and / or floral materials from one or more cannabis plants such as Cannabis sativa, Cannabis indica, and Cannabis ruderalis. In some examples, the fibrous material is a mixture of 60 - 80% (e.g., 70%) Cannabis sativa and 20 - 40% (e.g., 30%) Cannabis indica.

[0050] Examples of cannabinoids include tetrahydrocannabinolic acid (THCA), tetrahydrocannabinol (THC), cannabidiolic acid (CBDA), cannabidiol (CBD), cannabinol (CBN), cannabinocyclol (CBL), cannabichromene (CBC), cannabigerol (CBG), etc. Tetrahydrocannabinolic acid (THCA) is a precursor of tetrahydrocannabinol (THC), and cannabidiolic acid (CBDA) is a precursor of cannabidiol (CBD). Tetrahydrocannabinolic acid (THCA) and cannabidiolic acid (CBDA) can be converted to tetrahydrocannabinol (THC) and cannabidiol (CBD), respectively, via heating. In an exemplary embodiment, heat from a heater (e.g., heater 140 shown in FIG. 5) causes decarboxylation to convert tetrahydrocannabinolic acid (THCA) in capsule 100 to tetrahydrocannabinol (THC), and / or convert cannabidiolic acid (CBDA) in capsule 100 to cannabidiol (CBD).

[0051] In an example where both tetrahydrocannabinolic acid (THCA) and tetrahydrocannabinol (THC) are present in capsule 100, decarboxylation and the resulting conversion cause a decrease in tetrahydrocannabinolic acid (THCA) and an increase in tetrahydrocannabinol (THC). During heating of capsule 100, at least 50% (e.g., at least 87%) of tetrahydrocannabinolic acid (THCA) can be converted to tetrahydrocannabinol (THC). Similarly, in an example where both cannabidiolic acid (CBDA) and cannabidiol (CBD) are present in capsule 100, decarboxylation and the resulting conversion will cause a decrease in cannabidiolic acid (CBDA) and an increase in cannabidiol (CBD). During heating of capsule 100, at least 50% (e.g., at least 87%) of cannabidiolic acid (CBDA) can be converted to cannabidiol (CBD).

[0052] Furthermore, the compound may be a non-naturally occurring additive that is subsequently introduced into the fibrous material, or may additionally be included. In one example, the fibrous material can include a synthetic material. In another example, the fibrous material may include a natural material such as a cellulose material (e.g., a non-tobacco and / or non-cannabis material). In any example, the compound introduced can include nicotine, cannabinoids, and / or flavorants. The flavorants may be 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 can include naturally occurring components and / or non-naturally occurring additives. In this regard, it should be understood that the existing levels of the naturally occurring components of the aerosol-forming substrate can be increased by supplementation. For example, the existing level of nicotine contained in the amount of tobacco can be increased through supplementation with an extract containing nicotine. Similarly, the existing level of one or more cannabinoids contained in the amount of cannabis can be increased by supplementation with an extract containing such cannabinoids.

[0053] The first downstream rim 116 of the first cover 110 and the second downstream rim 126 of the second cover 120 jointly define a passage 166 (e.g., FIG. 3) when the first cover 110 and the second cover 120 are coupled to the base portion 130. The first downstream rim 116 of the first cover 110 and the second downstream rim 126 of the second cover 120 are small enough or narrow enough to hold the first aerosol-forming substrate 160a and the second aerosol-forming substrate 160b within the chamber, but large enough or wide enough for aerosol to pass through when the first aerosol-forming substrate 160a and the second aerosol-forming substrate 160b are heated by the heater 140.

[0054] As described above, the base portion 130 includes an engagement assembly 136 configured to facilitate connection with the first cover 110 and the second cover 120 via the first notch 112 and the second notch 122, respectively. The engagement assembly 136 may be an integrally formed part of the base portion 130. In an exemplary embodiment, the engagement assembly 136 of the base portion 130 includes a pair of fitting members. The pair of fitting members of the engagement assembly 136 may be adjacent to opposite edges of the base portion 130. Each of the pair of fitting members of the engagement assembly 136 may have a head portion and a body portion, and the head portion may be wider than the body portion. For example, each of the pair of fitting members of the engagement assembly 136 may have a T-shape corresponding to a T-shaped notch collectively formed by the first notch 112 of the first cover 110 and the second notch 122 of the second cover 120.

[0055] As shown in FIGS. 5 to 6, the base portion 130 defines a first recess 132 and a second recess 134. As a result, when assembled, the surface of the base portion 130 that defines the first recess 132 and the corresponding surface of the first cover 110 jointly define a first air inlet 152 (e.g., FIG. 3). Similarly, the surface of the base portion 130 that defines the second recess 134 and the corresponding surface of the second cover 120 jointly define a second air inlet 154 (e.g., FIG. 4). The first air inlet 152 and the second air inlet 154 are in fluid communication with a chamber (e.g., chamber 164 in FIG. 7) in which the first aerosol-forming substrate 160a and the second aerosol-forming substrate 160b are disposed together with the intermediate portion 144 of the heater 140.

[0056] The sheet material may be cut or otherwise processed (e.g., stamping, electrochemical etching, die cutting, laser cutting) to manufacture the heater 140. The sheet material may be formed of one or more conductors configured to receive Joule heating (which is also known as ohmic / resistive heating). Suitable conductors for the sheet material 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). For example, the stainless steel may be of a type known as SS316L in the art, although the exemplary embodiments are not limited thereto. The sheet material can have a thickness of about 0.1 - 0.3 mm (e.g., 0.15 - 0.25 mm).

[0057] The heater 140 has a first end 142, an intermediate portion 144, and a second end 146. The first end 142 and the second end 146 are configured to receive current from a power source during activation of the heater 140. When the heater 140 is activated (e.g., to receive Joule heating), the temperature of the first aerosol-forming substrate 160a and the second aerosol-forming substrate 160b increases, and an aerosol may be generated and drawn through the aerosol outlet 174 of the capsule 100 or otherwise released. The first end 142 and the second end 146 may each define an opening to facilitate electrical connection with a power source, although the exemplary embodiments are not limited thereto. Further, since the heater 140 may be manufactured from a sheet material, the first end 142, the second end 146, and the intermediate portion 144 may be in the same plane. Further, the intermediate portion 144 of the heater 140 may have a compressed vibration or zigzag-like planar and winding configuration having a plurality of parallel segments (e.g., 8 - 12 parallel segments). However, it should be understood that other configurations for the intermediate portion 144 of the heater 140 are possible (e.g., spiral configuration, flower-like configuration).

[0058] In an exemplary embodiment, the heater 140 extends through the base portion 130. In such an example, the first end 142 and the second end 146 may be regarded as external segments of the heater 140 disposed on the opposite side of the base portion 130 from the engagement assembly 136. In particular, the intermediate portion 144 of the heater 140 may be downstream of the base portion 130, while the terminus of each of the first end 142 and the second end 146 may be upstream of the base portion 130. During manufacture, the heater 140 may be embedded within the base portion 130 via injection molding (e.g., insert molding, overmolding). For example, the heater 140 may be embedded such that the intermediate portion 144 is between a pair of mating members of the engagement assembly 136.

[0059] The first end 142 and the second end 146 of the heater 140 are shown in the drawings as protrusions extending from the upstream side of the base portion 130, but it should be understood that in some exemplary embodiments, the first end 142 and the second end 146 of the heater 140 may be configured to form part of the upstream end face of the capsule 100. For example, the exposed portions of the first end 142 and the second end 146 of the heater 140 may be dimensioned and oriented to be positioned / folded (e.g., substantially coplanar) with respect to the lower or bottom surface of the base portion 130. As a result, the first end 142 and the second end 146 may each form the first electrical contact pad and the second electrical contact pad, as well as part of the upstream end face of the capsule 100.

[0060] FIG. 7 is a cross-sectional view of the capsule of FIG. 1. Referring to FIG. 7, when the capsule 100 is assembled, the upstream portions of the first cover 110 and the second cover 120 are coupled to the base portion 130, and the downstream portions of the first cover 110 and the second cover 120 are received by the end cap 170. In addition to defining the aerosol outlet 174 (e.g., FIG. 1), the end cap 170 also defines a cavity 172. The cavity 172 is downstream of the chamber 164 via the passage 166 and is in fluid communication with the chamber 164. Specifically, the first air inlet 152, the second air inlet 154, the chamber 164, the passage 166, the cavity 172, and the aerosol outlet 174 (e.g., FIG. 1) are all in fluid communication with each other to allow air / aerosol flow therethrough.

[0061] As a result, when current is supplied to the heater 140 and air is drawn into the capsule 100, the air can enter the capsule 100 through the first air inlet 152 and the second air inlet 154 (e.g., through the front and rear surfaces of the capsule 100). After being drawn into the capsule 100, the air flows longitudinally along the middle portion 144 of the heater 140 and may pass through the aerosol-forming substrate (e.g., the first aerosol-forming substrate 160a and the second aerosol-forming substrate 160b of FIGS. 5-6) in the chamber 164. Inside the chamber 164, volatiles are released by the aerosol-forming substrate heated by the middle portion 144 of the heater 140 to generate an aerosol, and this aerosol is entrained by the air flowing through the chamber 164, the passage 166, and the cavity 172 and then exits the capsule 100 through the aerosol outlet 174.

[0062] In an exemplary embodiment, at least one of the filter or the flavor medium may be optionally disposed within the cavity 172 of the end cap 170. In such an example, the filter and / or the flavor medium is disposed within the cavity 172 of the end cap 170 downstream of the first cover 110 and the second cover 120 such that aerosol generated within the chamber 164 passes through at least one of the filter or the flavor medium within the cavity 172 before exiting through at least one aerosol outlet 174. The filter can reduce or prevent particles from the aerosol-forming substrate from being inadvertently drawn out of the capsule 100, while the flavor medium may release a flavorant when the aerosol passes therethrough so as to impart a desired flavor to the aerosol. The flavorant may be the same as that described above in connection with the aerosol-forming substrate. Further, the filter and / or the flavor medium can have a connected form or a loose form as described above in connection with the aerosol-forming substrate.

[0063] FIG. 8 is a first perspective view of another capsule for an aerosol generating device according to an exemplary embodiment. FIG. 9 is a second perspective view of the capsule of FIG. 8. Referring to FIGS. 8-9, the capsule 200 includes a housing configured to hold an aerosol-forming substrate and containing a heater configured to heat the aerosol-forming substrate to generate an aerosol. The housing of the capsule 200 includes a base portion 230, a first cover 210, and a second cover 220. The base portion 230 includes an engagement assembly (e.g., engagement assembly 236 in FIG. 10) configured to facilitate connection with the first cover 210 and the second cover 220. When connected to the base portion 230, the first cover 210 and the second cover 220 together define an aerosol outlet 274 therebetween. As a result, the capsule 200 can be considered to have a three-piece structure.

[0064] Further, when connected, the base portion 230 and the first cover 210 define a first air inlet 252 therebetween. Similarly, the base portion 230 and the second cover 220 define a second air inlet 254 therebetween when connected. The first air inlet 252 and the second air inlet 254 are in fluid communication with the aerosol outlet 274. As a result, the air drawn into the first air inlet 252 and the second air inlet 254 will flow through the capsule 200 to the aerosol outlet 274. In an exemplary embodiment, the downstream sector of the capsule 200 may taper towards a mouth end (e.g., a cylindrical end) that defines the aerosol outlet 274. The heater is configured to extend through the base portion 230 such that when the capsule 200 is assembled, the middle portion of the heater is hidden from view while the first end 242 and the second end 246 are visible. The heater will be described in further detail in connection with the subsequent drawings.

[0065] In the drawings, the aerosol outlet 274 is illustrated as a single outlet, but it should be understood that the exemplary embodiments are not limited thereto. For example, the aerosol outlet 274 may be defined as a plurality of outlets (e.g., two to four outlets). The aerosol outlet 274 may be defined by the first cover 210 and the second cover 220 or, alternatively, by a separate insert or end cap. Further, when the aerosol outlet 274 is provided as a plurality of outlets, they may be arranged in a linear / continuous manner, a radial manner, or an array of rows and columns. Further, the shape of the aerosol outlet 274 (or each outlet when a plurality are provided) may be circular, elongate (e.g., elliptical), polygonal (e.g., rounded rectangle), or another suitable shape.

[0066] FIG. 10 is a partial exploded perspective view of the capsule of FIG. 8. FIG. 11 is a partial exploded perspective view of the capsule of FIG. 9. Referring to FIGS. 10-11, the first cover 210 and the second cover 220 are configured to engage with each other and with the base portion 230 during the assembly of the capsule 200. In an exemplary embodiment, to facilitate the engagement between the first cover 210 and the second cover 220, the first cover 210 includes a first protrusion 213, defines a first orifice 215, the second cover 220 includes a second protrusion 223, and defines a second orifice 225. As a result, during assembly, the first protrusion 213 of the first cover 210 fits into the second orifice 225 of the second cover 220, and the second protrusion 223 of the second cover 220 fits into the first orifice 215 of the first cover 210. As a result, the engagement between the first cover 210 and the second cover 220 can be through interference fit.

[0067] As shown, the first cover 210 also defines one or more of a first notch 212, a first recess 214, a first groove 216, and a first channel 218. Similarly, the second cover 220 defines one or more of a second notch 222, a second recess 224, a second groove 226, and a second channel 228. In some embodiments, the first cover 210 and the second cover 220 may be the same part. In such an example, when the first cover 210 and the second cover 220 are oriented towards each other for mating (and also for connection with the base portion 230), they are in a complementary arrangement. As a result, one part can be used interchangeably as the first cover 210 or the second cover 220, and the manufacturing method can be simplified.

[0068] When the capsule 200 is assembled, the first recess 214 of the first cover 210 and the second recess 224 of the second cover 220 collectively form a chamber 264 (e.g., FIG. 12) configured to accommodate both the aerosol-forming substrate and the intermediate portion 244 of the heater 240. Further, the first inner surface of the first cover 210 further defines a first channel 218 downstream from the first recess 214, and the second inner surface of the second cover 220 further defines a second channel 228 downstream from the second recess 224. The first channel 218 and the second channel 228 are configured to collectively form an aerosol channel 268 (e.g., FIG. 12). Further, the first inner surface of the first cover 210 further defines a first groove 216 connecting the first recess 214 to the first channel 218, and the second inner surface of the second cover 220 further defines a second groove 226 connecting the second recess 224 to the second channel 228. The first groove 216 and the second groove 226 are aligned and dimensioned to collectively form a passage 266 (e.g., FIG. 12) configured to hold the aerosol-forming substrate within the chamber 264 while allowing the generated aerosol to pass through the aerosol channel 268. The number of passages 266 may be in the range of 4 to 8 (e.g., 6), although the exemplary embodiments are not limited thereto.

[0069] The first notch 212 of the first cover 210 may be defined as a pair of notches at the upstream corner of the first cover 210, each notch being adjacent to / and thereby exposed by the upstream end surface of the first cover 210 while being bounded / prevented by the corresponding side surface of the first cover 210 (e.g., FIG. 11). Similarly, the second notch 222 may be defined as a pair of notches at the upstream corner of the second cover 220, each notch being adjacent to / and thereby exposed by the upstream end surface of the second cover 220 while being bounded / prevented by the corresponding side surface of the second cover 220 (e.g., FIG. 10). Alternatively, the first notch 212 and the second notch 222 may be provided such that they are respectively exposed by the corresponding side surfaces of the first cover 210 and the second cover 220, as discussed in connection with the first notch 112 (e.g., FIG. 6) and the second notch 122 (e.g., FIG. 5). During assembly, the first notch 212 and the second notch 222 collectively form a T-shaped notch configured to mate with the engagement assembly 236 when the first cover 210 and the second cover 220 are coupled to the base portion 230.

[0070] The engagement assembly 236 may be an integrally formed part of the base portion 230. In an exemplary embodiment, the engagement assembly 236 of the base portion 230 includes a pair of mating members. The pair of mating members of the engagement assembly 236 may be adjacent to and slightly spaced apart from corresponding opposing edges of the base portion 230. As a result, the engagement assembly 236 may be hidden / blocked from view by the first cover 210 and the second cover 220 when the capsule 200 is assembled. Alternatively, the pair of mating members of the engagement assembly 236 may be disposed (e.g., on the same plane) relative to corresponding opposing edges of the base portion 230, as disclosed in connection with the engagement assembly 136 of the capsule 100 (e.g., FIG. 5). In such an example, the engagement assembly 236 will still be partially visible when the capsule 200 is assembled. Each of the pair of mating members of the engagement assembly 236 can have a head portion and a body portion, and the head portion is wider than the body portion. For example, each of the pair of mating members of the engagement assembly 236 may have a T-shape corresponding to a T-shaped notch collectively formed by the first notch 212 of the first cover 210 and the second notch 222 of the second cover 220.

[0071] As shown in FIGS. 10-11, the base portion 230 defines a first recess 232 and a second recess 234. As a result, when the capsule 200 is assembled, the surface of the base portion 230 that defines the first recess 232 and the corresponding surface of the first cover 210 jointly define a first air inlet 252 (e.g., FIG. 8). Similarly, the surface of the base portion 230 that defines the second recess 234 and the corresponding surface of the second cover 220 jointly define a second air inlet 254 (e.g., FIG. 9). The first air inlet 252 and the second air inlet 254 are in fluid communication with a chamber (e.g., chamber 264 of FIG. 12) in which an aerosol-forming substrate is disposed together with the intermediate portion 244 of the heater 240. An aerosol-forming substrate (not shown) for the capsule 200 may be as described in connection with either form / format for the first aerosol-forming substrate 160a and / or the second aerosol-forming substrate 160b of the capsule 100 (e.g., FIG. 5). As a result, the above related disclosure regarding the aerosol-forming substrate should be understood to apply to this section and may not have been repeated for the sake of brevity.

[0072] The sheet material may be cut or otherwise processed (e.g., stamping, electrochemical etching, die cutting, laser cutting) to manufacture the heater 240. The sheet material may be formed of one or more conductors configured to receive Joule heating (also known as ohmic / resistive heating). Conductors suitable for the sheet material 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). For example, the stainless steel may be of a type known as SS316L in the art, although exemplary embodiments are not limited thereto. The sheet material can have a thickness of about 0.1 - 0.3 mm (e.g., 0.15 - 0.25 mm).

[0073] The heater 240 has a first end 242, an intermediate portion 244, and a second end 246. The first end 242 and the second end 246 are configured to receive current from a power source during activation of the heater 240. When the heater 240 is activated (e.g., to receive Joule heating), the temperature of the aerosol-forming substrate rises, and an aerosol may be generated and drawn through the aerosol outlet 274 of the capsule 200 or otherwise released. The first end 242 and the second end 246 may each define an opening for facilitating electrical connection to a power source, although the exemplary embodiments are not limited thereto. Further, since the heater 240 may be manufactured from a sheet material, the first end 242, the second end 246, and the intermediate portion 244 may be in the same plane. Further, the intermediate portion 244 of the heater 240 may have a compressed vibration or a zigzag-like planar and winding configuration having a plurality of parallel segments (e.g., 8 to 12 parallel segments). However, it should be understood that other configurations for the intermediate portion 244 of the heater 240 are possible (e.g., a helical configuration, a flower-like configuration).

[0074] In an exemplary embodiment, the heater 240 extends through the base portion 230. In such an example, the first end 242 and the second end 246 may be regarded as external segments of the heater 240 disposed on the opposite side of the base portion 230 from the engagement assembly 236. In particular, the intermediate portion 244 of the heater 240 may be downstream of the base portion 230, while the terminus of each of the first end 242 and the second end 246 may be upstream of the base portion 230. During manufacture, the heater 240 can be seated within a slot that extends through the base portion 230. To enhance seating (e.g., via an interference fit), the heater 240 can include a base insert that covers segments of the heater 240 between the intermediate portion 244 and the terminus of each of the first end 242 and the second end 246. As a result, when the heater 240 is introduced through the slot in the base portion 230, the base insert is between the heater 240 and the base portion 230 to create a relatively snug arrangement, and thus the base portion 230 can grip the heater 240 in a relatively secure manner. Alternatively, the heater 240 may be embedded within the base portion 230 via injection molding (e.g., insert molding, overmolding). For example, the heater 240 may be embedded such that the intermediate portion 244 is between a pair of mating members of the engagement assembly 236.

[0075] The first end 242 and the second end 246 of the heater 240 are shown in the drawings as protrusions extending from the upstream side of the base portion 230, but it should be understood that in some exemplary embodiments, the first end 242 and the second end 246 of the heater 240 may be configured to form part of the upstream end face of the capsule 200. For example, the exposed portions of the first end 242 and the second end 246 of the heater 240 may be dimensioned and oriented to be positioned (e.g., substantially coplanar) with respect to the lower or bottom portion of the base portion 230 / to be folded. As a result, the first end 242 and the second end 246 can each form the first electrical contact pad and the second electrical contact pad, as well as part of the upstream end face of the capsule 200.

[0076] In an exemplary embodiment, the first cover 210 and the second cover 220 are configured to engage with each other and with the base portion 230 such that their adjacent surfaces are substantially coplanar. For example, when engaged, the main outer surface of the first cover 210 may be at the same height as the front surface of the base portion 230 (e.g., FIG. 8). Similarly, in another example, the main outer surface of the second cover 220 may be at the same height as the rear surface of the base portion 230 (e.g., FIG. 9). Further, in another example, the opposing side surfaces of the base portion 230 may be coplanar with the adjacent side surfaces of the first cover 210 and the second cover 220. Further, in another embodiment, the downstream end surface of the first cover 210 may be at the same height as the downstream end surface of the second cover 220.

[0077] When the first cover 210, the second cover 220, and the base portion 230 are joined together, the resulting structure (e.g., housing) of the capsule 200 may have an upstream sector having a shape similar to a rectangular parallelepiped having a front face, an opposing rear face, a first side face, an opposing second side face, and an upstream end face. In the form of a rectangular parallelepiped, the upstream sector of the capsule 200 may have a rectangular cross-section. Alternatively, in other embodiments, the rectangular parallelepiped form of the upstream sector of the capsule 200 may have a square cross-section. However, it should be understood that the exemplary embodiments are not limited thereto. For example, instead of the rectangular parallelepiped form, the upstream sector of the capsule 200 may have a shape similar to a cylinder (e.g., an elliptical cylinder, a cylinder). In the case of an elliptical cylinder, the upstream sector of the capsule 200 may have an elliptical cross-section. On the other hand, in the case of a circular cylinder, the upstream sector of the capsule 200 may have a circular cross-section.

[0078] As shown in the drawings, with respect to the upstream sector of the cuboid resulting from the combination of the first cover 210, the second cover 220, and the base portion 230, the main outer surface of the first cover 210 and the front surface of the base portion 230 may together be regarded as the front surface (e.g., defining the first air inlet 252). Similarly, the main outer surface of the second cover 220 and the rear surface of the base portion 230 may together be regarded as the opposing rear surface (e.g., defining the second air inlet 254). Further, the opposing side surfaces of the base portion 230 and the corresponding side surfaces of the first cover 210 and the second cover 220 may together be regarded as the first side surface and the opposing second side surface of the housing. Additionally, the lower surface or bottom surface of the base portion 230 may be regarded as the upstream end surface (e.g., from which the first end 242 and the second end 246 of the heater extend). With respect to the entire housing, the downstream end surface of the first cover 210 and the corresponding downstream end surface of the second cover 220 may together be regarded as the downstream end surface.

[0079] As shown, the downstream sector of the capsule 200 may be tapered (narrower) to a cylindrical end defining the aerosol outlet 274. However, it should be understood that the exemplary embodiments are not limited thereto. For example, instead of a cylindrical end having a circular or elliptical cross-section, the downstream sector of the capsule 200 may be tapered to a polygonal end, which may be a cuboid end having a rectangular or square cross-section. In another example, the downstream sector of the capsule 200 may be tapered to a flattened end, which may be an end similar to a wedge, chisel, or duckbill shape.

[0080] FIG. 12 is a cross-sectional view of the capsule of FIG. 8. Referring to FIG. 12, when the capsule 200 is assembled, the upstream portions / ends of the first cover 210 and the second cover 220 are coupled / engaged with the base portion 230, and the downstream portions / ends of the first cover 210 and the second cover 220 form a mouth end that defines the aerosol channel 268 and the aerosol outlet 274 (e.g., FIG. 8). The aerosol channel 268 is downstream of the chamber 264 via the passage 266 and is in fluid communication with the chamber 264. Specifically, the first air inlet 252, the second air inlet 254, the chamber 264, the passage 266, and the aerosol channel 268 are all in fluid communication with each other to allow the flow of air / aerosol therethrough.

[0081] As a result, when current is supplied to the heater 240 and air is drawn into the capsule 200, the air can enter the capsule 200 through the first air inlet 252 and the second air inlet 254 (e.g., through the front and rear surfaces of the capsule 200). After being drawn into the capsule 200, the air flows longitudinally along the middle portion 244 of the heater 240 and can pass through an aerosol-forming substrate (not shown) in the chamber 264. Inside the chamber 264, volatile substances are released by the aerosol-forming substrate heated by the middle portion 244 of the heater 240, generating an aerosol that is entrained by the air flowing through the chamber 264, the passage 266, and the aerosol channel 268 before exiting the capsule 200 through the aerosol outlet 274.

[0082] FIG. 13 is a first perspective view of another capsule for an aerosol generating device according to an exemplary embodiment. FIG. 14 is a second perspective view of the capsule of FIG. 13. The capsules 300 of FIGS. 13-14 are similar to the capsules 200 of FIGS. 8-9, while differing in terms of an internal slot defined by a first cover 310 and a second cover 320, and corresponding external protrusions, 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 have been repeated for the sake of brevity.

[0083] The capsule 300 includes a housing configured to hold an aerosol-forming substrate described herein and to accommodate a heater configured to heat the aerosol-forming substrate to generate an aerosol. The housing of the capsule 300 includes a base portion 330, a first cover 310, and a second cover 320. The base portion 330 includes an engagement assembly (e.g., the engagement assembly 336 of FIG. 15) configured to facilitate connection with the first cover 310 and the second cover 320. When connected to the base portion 330, the first cover 310 and the second cover 320 together define an aerosol outlet 374 therebetween. As a result, the capsule 300 can be considered to have a three-piece structure.

[0084] Further, when connected, the base portion 330 and the first cover 310 define a first air inlet 352 therebetween. Similarly, the base portion 330 and the second cover 320 define a second air inlet 354 therebetween when connected. The first air inlet 352 and the second air inlet 354 are in fluid communication with the aerosol outlet 374. As a result, the air drawn into the first air inlet 352 and the second air inlet 354 will flow through the capsule 300 to the aerosol outlet 374. In an exemplary embodiment, the downstream sector of the capsule 300 may taper towards a mouth end (e.g., a cylindrical end) that defines the aerosol outlet 374. The heater is configured to extend through the base portion 330 such that when the capsule 300 is assembled, the middle portion 344 of the heater 340 (e.g., FIG. 15) is hidden from view while the first end portion 342 and the second end portion 346 are visible. The aerosol outlet 374, the first air inlet 352, the second air inlet 354, the base portion 330, the first end portion 342, and the second end portion 346 of FIGS. 13-14 may be similar to those described in relation to the aerosol outlet 274, the first air inlet 252, the second air inlet 254, the base portion 230, the first end portion 242, and the second end portion 246 of FIGS. 8-9. As a result, the above related disclosure of common features should be understood to apply to this section and may not be repeated for the sake of brevity.

[0085] FIG. 15 is a partial exploded perspective view of the capsule of FIG. 13. FIG. 16 is a partial exploded perspective view of the capsule of FIG. 14. Referring to FIGS. 15-16, the first inner surface of the first cover 310 defines a first slot 317 oriented perpendicular to the first channel 318, and the second inner surface of the second cover 320 defines a second slot 327 oriented perpendicular to the second channel 328. Each of the first slot 317 and the second slot 327 may be, although the exemplary embodiments are not limited thereto, a semi-disk-shaped recess. Further, the first cover 310 may have a first external protrusion corresponding to the first slot 317. Similarly, the second cover 320 may have a second external protrusion corresponding to the second slot 327. Alternatively, it should be understood that the thicknesses of the first cover 310 and the second cover 320 may be increased so that the depths of the first slot 317 and the second slot 327 do not result in corresponding external protrusions of the first cover 310 and the second cover 320.

[0086] When the first cover 310 and the second cover 320 are engaged, the first slot 317 and the second slot 327 collectively form a compartment (e.g., compartment 367 in FIG. 17). The compartment is configured to accommodate at least one of the filters or flavor media described herein. The compartment may be a disk-shaped recess. However, it should be understood that other shaped compartments (and thus other shaped slots) may be provided. For example, the compartment may be a polygonal (e.g., square, hexagonal, octagonal) recess configured to accommodate filters and / or flavor media of a similar shape.

[0087] Unless otherwise specifically described and / or illustrated with respect to the differentiating features, other aspects of the first cover 310 and the second cover 320 of FIGS. 15 - 16 may be the same as those described in connection with the first cover 210 and the second cover 220 of FIGS. 10 - 11. In particular, the first notch 312, the first protrusion 313, the first recess 314, the first orifice 315, the first groove 316, and the first channel 318 of FIG. 16 may be the same as those described in connection with the first notch 212, the first protrusion 213, the first recess 214, the first orifice 215, the first groove 216, and the first channel 218 of FIG. 11. Similarly, the second notch 322, the second protrusion 323, the second recess 324, the second orifice 325, the second groove 326, and the second channel 328 of FIG. 15 may be the same as those described in connection with the second notch 222, the second protrusion 223, the second recess 224, the second orifice 225, the second groove 226, and the second channel 228 of FIG. 10.

[0088] In some embodiments, the first cover 310 and the second cover 320 may be the same component. In such a case, when the first cover 310 and the second cover 320 are oriented to face each other (also for connection with the base portion 330) for fitting, they will be in a complementary arrangement. As a result, one component can be used interchangeably as the first cover 310 or the second cover 320, and the manufacturing method can be simplified.

[0089] Furthermore, the base portion 330 and the heater 340 of FIGS. 15-16 may be the same as those described in relation to the base portion 230 and the heater 240 of FIGS. 10-11. In particular, the first recess 332, the second recess 334, and the engagement assembly 336 of the base portion 330 of FIGS. 15-16 may be the same as those described in relation to the first recess 232, the second recess 234, and the engagement assembly 236 of the base portion 230 of FIGS. 10-11. Similarly, the first end portion 342, the middle portion 344, and the second end portion 346 of the heater 340 of FIGS. 15-16 may be the same as those described in relation to the first end portion 242, the middle portion 244, and the second end portion 246 of the heater 240 of FIGS. 10-11. As a result, the above related disclosures of the common features should be understood to apply to this section and may not have been repeated for the sake of brevity.

[0090] FIG. 17 is a cross-sectional view of the capsule of FIG. 13. Referring to FIG. 17, when the capsule 300 is assembled, the upstream portion / end of the first cover 310 and the second cover 320 is coupled / engaged with the base portion 330, and the downstream portion / end of the first cover 310 and the second cover 320 forms a mouth end that defines the aerosol channel 368 and the aerosol outlet 374 (e.g., FIG. 13). The aerosol channel 368 is downstream of the section 367 and is in fluid communication with the section 367. The section 367 is in fluid communication with the chamber 364 via the passage 366 in turn. Specifically, the first air inlet 352, the second air inlet 354, the chamber 364, the passage 366, the section 367, and the aerosol channel 368 are all in fluid communication with each other to allow the flow of air / aerosol therethrough.

[0091] As a result, when current is supplied to the heater 340 and air is drawn into the capsule 300, the air can enter the capsule 300 through the first air inlet 352 and the second air inlet 354 (e.g., through the front and rear surfaces of the capsule 300). After being drawn into the capsule 300, the air can flow longitudinally along the middle portion 344 of the heater 340 and pass through an aerosol-forming substrate (not shown) within the chamber 364. The aerosol-forming substrate of the capsule 300 may be as described in any of the forms / formats for the first aerosol-forming substrate 160a and / or the second aerosol-forming substrate 160b of the capsule 100 (e.g., FIG. 5). As a result, the above-related disclosure regarding the aerosol-forming substrate is to be understood as being applicable to this section and may not have been repeated for the sake of brevity.

[0092] Inside the chamber 364, volatiles are released by the aerosol-forming substrate heated by the middle portion 344 of the heater 340, generating an aerosol that is taken up by the air flowing through the chamber 364, the passage 366, the compartment 367, and the aerosol channel 368 before exiting the capsule 300 through the aerosol outlet 374. Optionally, at least one of the filter or flavor medium described herein may be provided within the compartment 367 such that the aerosol generated within the chamber 364 passes through at least one of the filter or flavor medium before flowing through the aerosol channel 368.

[0093] FIG. 18 is a front view of an aerosol generating device according to an exemplary embodiment. Referring to FIG. 18, the aerosol generating device 1000 (e.g., a heat non-combustible aerosol generating device) may include a capsule 400 and a device body 1025. In a non-limiting aspect, the capsule 400 may be the same as those described in connection with capsule 100, capsule 200, and / or capsule 300 to cover various combinations of the disclosed features. For example, the capsule 400 may include a housing containing an aerosol-forming substrate and a heater that undergoes resistive heating when activated. The housing may include a base portion, a first cover, and a second cover. The first cover and the second cover can jointly define a chamber, an aerosol channel, and an aerosol outlet therebetween, and the aerosol-forming substrate is disposed within the chamber. The heater is supported by the base portion and extends into the chamber.

[0094] The device body 1025 may define a socket or recess configured to receive the capsule 400 such that the device body 1025 engages the capsule 400 mechanically and electrically. For example, the socket or recess of the device body 1025 may be configured to grip at least two opposing outer surfaces (e.g., opposing side walls) of the capsule 400. Alternatively, the device body 1025 and / or the capsule 400 may include magnets configured to establish a magnetic arrangement such that the device body 1025 attracts and holds the capsule 400. Further, the device body 1025 may include a first electrode and a second electrode configured to electrically contact the first end and the second end of the heater of the capsule 400, respectively, within the socket or recess.

[0095] The power source 1035 and the control circuit 1045 may be disposed within the device main body 1025 of the aerosol generator 1000. The power source 1035 may include one or more batteries (e.g., rechargeable batteries). When the capsule 400 is engaged with the device main body 1025, the control circuit 1045 can instruct the power source 1035 to supply current to the capsule 400 via the first electrode and the second electrode of the device main body 1025. The supply of current from the power source 1035 may be responsive to a manual operation (e.g., button actuation) or an automatic operation (e.g., puff actuation). As a result of the current, the aerosol-forming substrate within the capsule 400 can be heated to generate an aerosol. Further, the change in the resistance value of the heater may be used by the control circuit 1045 to monitor and control the aerosolization temperature. The generated aerosol may be drawn out from the aerosol generator 1000 through the aerosol outlet at the mouth end of the capsule 400.

[0096] Accordingly, during operation of the aerosol generator 1000, the method of generating an aerosol may include supplying current to the capsule 400 so as to heat the aerosol-forming substrate therein (e.g., via resistive heating). The method may further include drawing the aerosol generated within the chamber of the capsule 400 such that the aerosol flows through the aerosol channel and exits the aerosol outlet of the capsule 400.

[0097] In addition to the non-limiting embodiments described herein, additional details of the substrates, capsules, devices, and methods discussed herein are also provided in U.S. Application No. 16 / 909,131, filed June 23, 2020, titled "CAPSULES INCLUDING INTERNAL HEATERS, HEAT-NOT-BURN (HNB) AEROSOL-GENERATING DEVICES, AND METHODS OF GENERATING AN AEROSOL", Attorney Docket No. 24000NV-000603-US, U.S. Application No. 16 / 451,662, filed June 25, 2019, titled "CAPSULES, HEAT-NOT-BURN (HNB) AEROSOL-GENERATING DEVICES, AND METHODS OF GENERATING AN AEROSOL", Attorney Docket No. 24000NV-000522-US, and U.S. Application No. 16 / 252,951, filed January 21, 2019, titled "CAPSULES, HEAT-NOT-BURN (HNB) AEROSOL-GENERATING DEVICES, AND METHODS OF GENERATING AN AEROSOL", Attorney Docket No. 24000NV-000521-US, the disclosures of each of which are hereby incorporated by reference in their entirety.

[0098] Although numerous exemplary embodiments are disclosed herein, it should be understood that other variations are possible. Such variations are not to be regarded as departing from the spirit and scope of the present disclosure, and all such modifications as would be apparent to one of ordinary skill in the art are intended to be included within the scope of the following claims.

Claims

1. A capsule for an aerosol generating device, comprising: a base portion, a first cover, a second cover, an aerosol forming substrate, and a heater, wherein the base portion includes an engagement assembly, the engagement assembly includes a pair of fitting members, each of the pair of fitting members having a head portion and a body portion, the head portion being wider than the body portion, the first cover, is engaged with the base portion via the engagement assembly, including a first inner surface and a first outer surface, wherein the first inner surface defines a first recess, the second cover, is engaged with the base portion and the first cover via the engagement assembly, including a second inner surface and a second outer surface, wherein the second inner surface defines a second recess, the first cover is aligned with the second cover such that the first recess and the second recess collectively form a chamber, the aerosol forming substrate is within the chamber, the heater, is configured to heat the aerosol forming substrate to generate an aerosol, including a first end portion, an intermediate portion, and a second end portion, extending from the base portion such that the intermediate portion is within the chamber.

2. The capsule according to claim 1, wherein the engagement assembly is a portion integrally formed with the base portion.

3. The capsule according to claim 1, wherein each of the pair of fitting members has a T-shape.

4. The capsule according to claim 1, wherein the pair of fitting members are adjacent to opposite edges of the base portion.

5. The capsule according to claim 1, wherein the intermediate portion of the heater is between the pair of fitting members.

6. The capsule according to claim 1, wherein the first cover and the base portion define a first air inlet therebetween, the second cover and the base portion define a second air inlet therebetween, the first air inlet and the second air inlet are in fluid communication with the chamber.

7. The capsule according to claim 6, wherein the base portion defines a first indentation and a second indentation as part of the first air inlet and the second air inlet, respectively.

8. The capsule according to claim 1, further comprising an end cap. The end cap is configured to receive the first cover and the second cover, and define at least one aerosol outlet in fluid communication with the chamber. **Claim 9** The capsule according to claim 8, further comprising at least one of a filter and a flavor medium, wherein at least one of the filter and the flavor medium is located within the end cap and downstream of the first cover and the second cover such that the generated aerosol passes through at least one of the filter and the flavor medium before exiting from the at least one aerosol outlet. **Claim 10** The capsule according to claim 1, wherein the first inner surface of the first cover further defines a first channel downstream from the first recess, the second inner surface of the second cover further defines a second channel downstream from the second recess, and the first channel and the second channel converge to form an aerosol channel, or each of the first cover and the second cover has an upstream end and a downstream end, the upstream ends of the first cover and the second cover engage the base portion, and the downstream ends of the first cover and the second cover form tapered ends that define an aerosol outlet. **Claim 11** The capsule according to claim 10, wherein the first inner surface of the first cover further defines a first groove connecting the first recess to the first channel, the second inner surface of the second cover further defines a second groove connecting the second recess to the second channel, or the first inner surface of the first cover further defines a first slot oriented in a direction orthogonal to the first channel, the second inner surface of the second cover further defines a second slot oriented in a direction orthogonal to the second channel, and the first slot and the second slot converge to form a partition. **Claim 12** The capsule according to claim 11, wherein the first groove and the second groove are aligned and dimensioned to hold the aerosol-forming substrate within the chamber and allow the generated aerosol to pass through the aerosol channel. **Claim 13** The capsule according to claim 11, Furthermore, it includes at least one of a filter and a flavor medium, wherein at least one of the filter and the flavor medium within the compartment is such that the aerosol generated within the chamber passes through at least one of the filter and the flavor medium before flowing through the aerosol channel. **Claim 14** In the capsule according to claim 1, the aerosol-forming substrate includes plant material. **Claim 15** In the capsule according to claim 14, the plant material includes tobacco. **Claim 16** In the capsule according to claim 1, the heater extends through the base portion. **Claim 17** In the capsule according to claim 1, the first end portion and the second end portion are outer segments of the heater, where the heater is disposed on the side opposite to the engagement assembly of the base portion. **Claim 18** In the capsule according to claim 1, the intermediate portion of the heater has a planar and coiled shape. **Claim 19** An aerosol generating device, including a capsule and a device body, wherein the capsule includes a housing containing an aerosol-forming substrate and a heater configured to heat the aerosol-forming substrate to generate an aerosol, the heater including a first end portion, an intermediate portion, and a second end portion, the housing includes a base portion, a first cover, and a second cover, the base portion includes an engagement assembly, the engagement assembly includes a pair of fitting members, each of the pair of fitting members having a head portion and a body portion, and the head portion is wider than the body portion, the first cover is engaged with the base portion via the engagement assembly and includes a first inner surface and a first outer surface, where the first inner surface defines a first recess, the second cover is engaged with the base portion and the first cover via the engagement assembly and includes a second inner surface and a second outer surface, where the second inner surface defines a second recess, the first cover and the second cover jointly define a chamber, an aerosol channel, and an aerosol outlet therebetween, the aerosol-forming substrate is disposed within the chamber, the heater is supported by the base portion and extends into the chamber such that the intermediate portion is within the chamber. The apparatus main body is configured to be connected to the capsule and has a power source for supplying current to the heater. The apparatus main body is configured to be connected to the capsule and has a power source for supplying current to the heater. The apparatus main body is configured to be connected to the capsule and has a power source for supplying current to the heater. **Claim 20** A method for generating an aerosol, the method comprising the step of supplying current to a capsule including a housing, where the housing includes an aerosol-forming substrate and a heater, the heater being subject to resistive heating, the heater including a first end, an intermediate portion, and a second end. A method for generating an aerosol, the method comprising the step of supplying current to a capsule including a housing, where the housing includes an aerosol-forming substrate and a heater, the heater being subject to resistive heating, the heater including a first end, an intermediate portion, and a second end. The housing includes a base portion, a first cover, and a second cover. The base portion includes an engagement assembly, the engagement assembly including a pair of fitting members, each of the pair of fitting members having a head portion and a body portion, the head portion being wider than the body portion. The first cover is engaged with the base portion via the engagement assembly and includes a first inner surface and a first outer surface, where the first inner surface defines a first recess. The second cover is engaged with the base portion and the first cover via the engagement assembly and includes a second inner surface and a second outer surface, where the second inner surface defines a second recess. The first cover and the second cover jointly define a chamber, an aerosol channel, and an aerosol outlet therebetween. The aerosol-forming substrate is disposed in the chamber. The heater is supported by the base portion and extends into the chamber such that the intermediate portion is within the chamber.

Images