Capsule containing an internal filter, heat-not-burn (HNB) aerosol generator, and aerosol generation method.

Abstract

To provide capsules, heat-not-burn (HNB) aerosol-generating devices, and methods of generating aerosol without involving a substantial pyrolysis of an aerosol-forming substrate.SOLUTION: A capsule 100 for an aerosol-generating device may include a housing, a filter 120, 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 so as to be adjacent to the gas-impermeable end. The aerosol-forming substrate may be disposed within the housing so as to be between the filter and the gas-permeable end. The housing may be configured to facilitate heating of the aerosol-forming substrate via conduction and / or convection so as to generate aerosol.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present disclosure relates to a capsule, a heat-not-burn (HNB) aerosol generating device, and an aerosol generating method that does not involve 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 components of the plant material while maintaining a temperature below the combustion point of the plant material so as to avoid substantial pyrolysis of the plant material. Such devices are sometimes referred to as aerosol generating devices (e.g., heat-not-burn aerosol generating devices), and the heated plant material may be tobacco. In some embodiments, the plant material may be introduced directly into a heating chamber of the aerosol generating device. In other embodiments, the plant material may be pre-packaged in individual containers to facilitate insertion into 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 arranged within the housing adjacent to the impermeable end. The aerosol-forming substrate may be arranged 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 one or both of conduction and convection to generate an aerosol.

[0004] At least one embodiment relates to a heat-not-burn (HNB) aerosol generator. In an exemplary embodiment, the aerosol generator may include a device body, a mouthpiece, and a heating assembly. The device body may define a compartment configured to receive a capsule containing 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 into the filter of the capsule. The heating assembly may be located within the device body. The heating assembly may be configured to heat the aerosol-forming substrate within the capsule via conduction and / or convection to generate an aerosol exiting the capsule through the conduit portion of the mouthpiece.

[0005] At least one embodiment relates to a method for generating an aerosol. In an exemplary embodiment, the method may include heating a capsule comprising 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 guiding an air intake flow along a meandering path through the capsule. The meandering path may include an entrained flow section and a filtered flow section. The entrained flow section may extend from the gas-permeable end of the housing through the aerosol-forming substrate to the filter. The filtered flow section may extend from the filter to the gas-permeable end of the housing. [Brief explanation of the drawing]

[0006] Various features and advantages of non-limiting embodiments of this specification will become more apparent by considering the detailed description in conjunction with the accompanying drawings. The accompanying drawings are provided for illustrative purposes only and should not be construed as limiting the claims. The accompanying drawings should not be considered to be drawn to scale unless expressly noted. For clarity, various dimensions in the drawings may be exaggerated.

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

[0008] [Figure 2] Figure 2 is a second perspective view of the capsule shown in Figure 1.

[0009] [Figure 3] Figure 3 is an exploded perspective view of the capsule shown in Figure 1.

[0010] [Figure 4] Figure 4 is an exploded perspective view of the capsule shown in Figure 2.

[0011] [Figure 5] Figure 5 is a cross-sectional view of the capsule from Figure 1 when it is engaged with the mouthpiece.

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

[0013] [Figure 7] Figure 7 is a second perspective view of the aerosol generating apparatus shown in Figure 6.

[0014] [Figure 8] Figure 8 is an exploded perspective view of the aerosol generator shown in Figure 6.

[0015] [Figure 9]Figure 9 is an exploded perspective view of the aerosol generator shown in Figure 7.

[0016] [Figure 10] Figure 10 is a cross-sectional view of the aerosol generating apparatus shown in Figure 6. [Modes for carrying out the invention]

[0017] Several detailed exemplary embodiments are disclosed herein. However, the specific structural and functional details disclosed herein are merely representative for the purpose of illustrating the exemplary embodiments. However, the exemplary embodiments may be embodied in many alternative forms and should not be construed as being limited only to the exemplary embodiments described herein.

[0018] Therefore, while the exemplary embodiments are subject to various modifications and alternative forms, they are illustrated in the drawings and will be described in detail here. However, it should be understood that the exemplary embodiments are not intended to be limited to any particular form disclosed, but rather, they cover all of its modifications, equivalents, and alternatives. Throughout the description of the figures, similar numbers refer to similar elements.

[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 on, connected to, coupled to, attached to, adjacent to, or covering the other element or layer, or one or more 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 present. In the present specification, the same reference numerals denote the same elements throughout. In the present specification, the term "and / or" includes any and all combinations and subcombinations of one or more of the relevant listed items.

[0020] While the terms first, second, third, etc. may be used herein to describe various elements, regions, layers and / or sections, it should be understood that these elements, regions, layers and / or sections are not to 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 discussed below could be termed a second element, region, layer or section without departing from the teachings of the exemplary embodiments.

[0021] In this specification, for ease of description, spatially relative terms (e.g., "beneath", "below", "lower", "above", "upper", etc.) may be used to describe the relationship between one element or feature and another element or feature as shown in the drawings. It should be understood that spatially relative terms are intended to encompass different orientations of the device during use and operation in addition to the orientation depicted in the drawings. For example, if the device in the drawings is turned over, an element described as "below" or "beneath" other elements or features would be oriented "above" the other elements or features. Therefore, the term "below" may encompass both upward and downward orientations. Furthermore, the device may be oriented in other directions (rotated 90 degrees or oriented in other directions), and the spatially relative descriptors used herein are to be interpreted accordingly.

[0022] The terminology used herein is for the purpose of describing various exemplary embodiments only and is not intended to limit the exemplary embodiments. As used herein, the singular forms "a", "an", and "the" are intended to include the plural forms as well, 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 the 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] Where the terms “about” and “substantially” are used in relation to a number in this specification, unless otherwise expressly defined, it is intended that the stated number includes a manufacturing or operational tolerance (e.g., ±10%). Furthermore, where the terms “generally” or “substantially” are used in relation to a geometric shape, precision of the geometric shape is not required, but the degree of freedom in the shape is intended to be within the scope of this disclosure. In addition, where a number or shape is expressed as “about,” “generally,” or “substantially,” it should be understood that these numbers and shapes should be interpreted as including a manufacturing or operational tolerance (e.g., ±10%) around the stated number or shape.

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

[0025] The hardware may be implemented using, but is not limited to, processing circuits or control circuits such as one or more processors, one or more CPUs (Central Processing Units), one or more microcontrollers, one or more ALUs (Arithmetic Logic Units), one or more DSPs (Digital Signal Processors), one or more microcomputers, one or more FPGAs (Field Programmable Gate Arrays), one or more SoCs (System-on-Chips), one or more programmable logic units (PLUs), one or more microprocessors, one or more ASICs (Application Specific Integrated Circuits), or other devices that can execute in response to instructions in a defined manner.

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

[0027] As shown in the figure, the capsule 100 may have a cylindrical shape. In such a shape, the capsule 100 may have a circular cross-section. However, it should be understood that other shapes and forms are also possible. For example, the capsule 100 may, as an alternative, have a shape similar to a triangular prism, a rectangular prism, a pentagonal prism, or a hexagonal prism. In a shape similar to a triangular prism, the capsule 100 may have a triangular cross-section (for example, an equilateral triangle). If it has a shape similar to a rectangular prism, the capsule 100 may have a square or rectangular cross-section. If it has a shape similar to a pentagonal prism, the capsule 100 may have a pentagonal cross-section. If it has a shape similar to a hexagonal prism, the capsule 100 may have a hexagonal cross-section.

[0028] The housing of capsule 100 has a gas-permeable end and a gas-impermeable end. As will be 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 aerosols to exit the capsule. A filter 120 (Figure 3) may be placed within the housing adjacent to the gas-impermeable end. Furthermore, the aerosol-forming substrate is placed within the housing between the filter 120 and the gas-permeable end.

[0029] In an 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 (Figure 3). The closed end 134 of the container 130 may have a rounded edge. However, it should be understood that other configurations are also possible (e.g., a chamfered edge). The container 130 is made of a conductive material. For example, the conductive material may be a metal, and the metal may include aluminum, its alloys, or stainless steel. As a result, the container 130 may facilitate the heating of the aerosol-forming substrate inside, at least by conduction.

[0030] During assembly, the end cap 110 is positioned on the open end 132 of the container 130 so as to enclose the aerosol-forming substrate and the filter 120 within it. For example, a large portion 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 achieved via an interference fit (sometimes also called a pressure fit or friction fit). In addition, 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) that is deemed food-safe or otherwise acceptable by regulatory authorities. The end cap 110 may be formed from 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 respect, the end cap 110 may be considered the gas-permeable end of the housing, and the closed end 134 of the container 130 may be considered the gas-impermeable end. As shown in the figure, the plurality of openings of the end cap 110 include an outlet opening 114 surrounded by an inlet opening 112. Although eight inlet openings 112 are shown in Figure 1, it should be understood that different numbers (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 exemplary embodiments, the quantity and size of the inlet openings 112 may be designed to result in a desired resistance to draw (RTD). For example, the capsule 100 may be designed to have an RTD between 90 and 110 mmHg.

[0032] The inlet openings 112 of the end cap 110 may be equidistant from each other by a first distance. In other words, each inlet opening 112 may be equidistant from an adjacent inlet opening 112 by a first distance. Furthermore, the inlet openings 112 may be equidistant from the center of the end cap 110 (e.g., the diametrical center) by a second distance. Exemplary embodiments are not limited thereto, but the first distance may be smaller than the second distance. For example, if the number of inlet openings 112 is reduced, the first distance may be larger than the second distance. During the operation of the aerosol generator, air enters the capsule 100 through the inlet openings 112, and the aerosol exits the capsule 100 through the outlet opening 114 (e.g., as a result of engagement with a mouthpiece such as the mouthpiece 310 in Figure 5). Each of the inlet openings 112 may be smaller than the outlet opening 114.

[0033] Figure 3 is an exploded perspective view of the capsule of Figure 1. Figure 4 is an exploded perspective view of the capsule of Figure 2. Referring to Figures 3 and 4, the filter 120 is configured to be inserted into the container 130 via the open end 132 during the assembly of the capsule 100. When fully seated in the container 130, the filter 120 is configured to be adjacent to or pressed against the inner end face corresponding to the closed end 134. To facilitate placement in the container 130, the bottom of the filter 120 may be shaped to conform to the inner surface corresponding to the closed end 134 (e.g., having a rounded edge). To provide a tight fit, the filter 120 may further be sized so 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 when the container 130 is inverted).

[0034] The filter 120 defines an orifice 122 configured to align with the outlet opening 114 in the end cap 110 when the capsule 100 is assembled. In exemplary embodiments, the orifice 122 in the filter 120 may be the same size as, or substantially the same size as, the outlet opening 114 in the end cap 110. Furthermore, 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 foamed material. In one embodiment, the fibrous material of the filter 120 may include cellulose acetate fibers. In another embodiment, the foamed material may include an open-cell foam. Furthermore, 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 materials for cigarette filters as known in the art.

[0036] Figure 5 is a cross-sectional view of the capsule of Figure 1 when engaged with the mouthpiece. Referring to Figure 5, the capsule 100 includes a chamber configured to receive the aerosol-forming substrate 160. As shown, the chamber may be defined by the inner sidewall of the container 130 and the 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 coincides with the longitudinal central axis of the container 130. Furthermore, as described above, the orifice 122 in the filter 120 may be oriented to coincide 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 coincide with the longitudinal central axis of the container 130. As will be described in more detail herein, the filter 120 and the aerosol-forming substrate 160 are arranged 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. Furthermore, the 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 aerosol through the filter 120 includes an inward, radial path toward the orifice 122.

[0037] In one example, the aerosol-forming substrate may be in a single, integrated form. This form is configured to maintain its shape so that the aerosol-forming substrate can be integrally placed within the container 130. In such an example, the single, integrated form of the aerosol-forming substrate may be cylindrical, while defining through-holes configured to align with the outlet opening 114 in the end cap 110 and the orifice 122 in the filter 120 (substantially corresponding to the volume of the chamber within the capsule 100).

[0038] In another example, the aerosol-forming substrate may be 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 disc defining a through-hole configured to align with the outlet opening 114 of the end cap 110 and the orifice 122 of the filter 120. Each of the plurality of combined forms may contain the same or different types of aerosol-forming substrate. As a result, various combinations of aerosol-forming substrates can be loaded into the container 130 to achieve the desired sensory appeal.

[0039] Alternatively, instead of, or in addition to, the combined form described above, the aerosol-forming substrate may be a loose form (e.g., particles, fibers, residue, fragments, shards) that does not have a set shape but rather takes the shape of a chamber within the capsule 100. In such an example, it should be understood that the loose form of the aerosol-forming substrate generally has an average size larger than the diameters of the openings in the end cap 110 (e.g., inlet opening 112, outlet opening 114) and the orifice 122 in the filter 120.

[0040] As discussed herein, an aerosol-forming substrate is a material or combination of materials capable of producing an aerosol. The aerosol relates to a substance produced or output by the disclosed apparatus, claims, and equivalents thereof. The material may contain a compound (e.g., nicotine, cannabinoid), and when the material is heated, an aerosol containing the compound is produced. The heating may be below the combustion temperature so as to produce the aerosol without substantial thermal decomposition of the aerosol-forming substrate or substantial production of combustion byproducts (if any). Thus, in exemplary embodiments, no thermal decomposition occurs between heating and the production of the resulting aerosol. In other embodiments, there may be some thermal decomposition and combustion byproducts, but to a relatively minor degree 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-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-based material such as tobacco, and the released compound may be nicotine. The term “tobacco” includes any tobacco plant-based 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. Furthermore, the tobacco material may include a blend of two or more different tobacco varieties. Examples of suitable types of tobacco material that may be used include, but are not limited to, smoke-hardened tobacco, Burley tobacco, Dark tobacco, Maryland tobacco, Oriental tobacco, rare tobacco, specialty tobacco, and blends thereof. The tobacco material may include, but is not limited to, processed tobacco material such as tobacco laminas, volume-expanded tobacco or puffed tobacco, processed tobacco stems such as cut rolling tobacco or cut puffed tobacco, reconstituted tobacco material, and blends thereof, and may be provided in any suitable form. In some exemplary embodiments, the tobacco material is in the form of substantially dried tobacco mass. Furthermore, in some exemplary embodiments, the tobacco material may be mixed and / or bonded with propylene glycol, glycerin, partial combinations thereof, or at least one of these combinations.

[0043] Furthermore, the compound may be a naturally derived component of a medicinal plant whose therapeutic effects have been recognized medically. For example, the medicinal plant may be a cannabis plant, and the compound may be a cannabinoid. Cannabinoids interact with receptors in the body to exert various effects. As a result, cannabinoids have been used for various medicinal purposes (e.g., pain, nausea, epilepsy, and mental illness). 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 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 tetrahydrocannabinol (THCA), tetrahydrocannabinol (THC), cannabidiolic acid (CBDA), cannabidiol (CBD), cannabinol (CBN), cannabicyclol (CBL), cannabichromene (CBC), and cannabigerol (CBG). Tetrahydrocannabinol (THCA) is a precursor of tetrahydrocannabinol (THC), and cannabidiolic acid (CBDA) is a precursor of cannabidiol (CBD). Tetrahydrocannabinol (THCA) and cannabidiolic acid (CBDA) can be converted to tetrahydrocannabinol (THC) and cannabidiol (CBD), respectively, through heating. In exemplary embodiments, heat from a heater (for example, the heating assembly 340 shown in Figure 8) may cause decarboxylation to convert tetrahydrocannabinol (THCA) in capsule 100 to tetrahydrocannabinol (THC), and / or cause decarboxylation to convert cannabidiolic acid (CBDA) in capsule 100 to cannabidiol (CBD).

[0045] In cases where both tetrahydrocannabinol (THCA) and tetrahydrocannabinol (THC) are present in capsule 100, decarboxylation and the resulting conversion will cause a decrease in tetrahydrocannabinol (THCA) and an increase in tetrahydrocannabinol (THC). At least 50% (e.g., at least 87%) of tetrahydrocannabinol (THCA) may be converted to tetrahydrocannabinol (THC) during heating of capsule 100. Similarly, in cases 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) may be converted to cannabidiol (CBD).

[0046] Furthermore, the compound may contain, or subsequently additionally, non-natural additives that are introduced into the fibrous material. In one example, the fibrous material may include at least one of the following: cotton, polyethylene, polyester, rayon, or a combination thereof (e.g., in the form of gauze). In another example, the fibrous material may be a cellulose material (e.g., a non-tobacco and / or non-cannabis material). In any example, the compound introduced may include nicotine, cannabinoids, and / or flavorings. The flavorings may be of natural origin, such as plant extracts (e.g., tobacco extract, cannabis extract), and / or artificial origin. In yet another example, if the fibrous material contains tobacco and / or cannabis, the compound may also contain, or additionally, one or more flavorings (e.g., menthol, mint, vanilla). Thus, the compound in the aerosol-forming substrate may contain naturally derived components and / or non-natural additives. In this regard, it should be understood that the level of naturally derived components in the aerosol-forming substrate can be increased by supplementation. For example, the amount of nicotine in tobacco may be increased by supplementation with a nicotine-containing extract. Similarly, the amount of one or more cannabinoids in cannabis may be increased by supplementation with an extract containing such cannabinoids.

[0047] Figure 6 is a first perspective view of an aerosol generator according to an exemplary embodiment. Figure 7 is a second perspective view of the aerosol generator of Figure 6. Referring to Figures 6-7, the aerosol generator 300 is configured to receive a capsule 200 (Figure 8) containing an aerosol-forming substrate. As illustrated, the aerosol generator 300 may have a cylinder-like form. In such a form, the aerosol generator 300 may have a circular cross-section. However, it should be understood that other forms and shapes are also possible. For example, the aerosol generator 300 may, as an alternative, have a form similar to a triangular prism, a rectangular parallelepiped, a pentagonal prism, or a hexagonal prism. In a triangular prism-like form, the aerosol generator 300 may have a triangular cross-section (e.g., an equilateral triangle). In a rectangular parallelepiped-like shape, the aerosol generator 300 may have a square or rectangular cross-section. In a pentagonal prism-like shape, the aerosol generator 300 may have a pentagonal cross-section. The aerosol generator 300 may have a hexagonal cross-section, similar in shape to a hexagonal prism.

[0048] As shown in the drawings, the form of the aerosol generator 300 may correspond to the form of the capsule 200 (for example, a cylindrical form for both the aerosol generator 300 and the capsule 200). However, in other embodiments, the form of the aerosol generator 300 may differ from the form of the capsule 200. For example, the capsule 200 may have a cylindrical form, while the aerosol generator 300 may have one of the different forms disclosed herein (for example, a rectangular parallelepiped form), or vice versa.

[0049] The aerosol generator 300 includes a device body 330, a mouthpiece 310 configured to engage with the device body 330, and a heating assembly 340 (Figure 8) within the device body 330. The mouthpiece 310 defines an aerosol outlet 312. The aerosol outlet 312 may be centrally located so as to coincide with the longitudinal central 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. Furthermore, the device body 330 defines a plurality of air inlets 334. The plurality of air inlets 334 may be arranged along the periphery of the surface of the upstream end of the device body 330 (e.g., in a circular arrangement). As used herein, “upstream” (and conversely “downstream”) is related to the aerosol flow, and “proximal” (and conversely “distal”) is related to the adult operator of the device during aerosol generation.

[0050] Each of the multiple air inlets 334 within the device body 330 may be larger than the aerosol outlet 312 within the mouthpiece 310. While Figure 7 shows 12 air inlets 334, it should be understood that different numbers may be implemented (e.g., 10 air inlets, 14 air inlets) based on the desired distribution of airflow within and through the aerosol generator 300. Furthermore, a gasket 320 may be placed between the mouthpiece 310 and the device body 330. The gasket 320 may help ensure a relatively airtight seal so that incoming air enters the aerosol generator 300 essentially only through the air inlets 334 within the device body 330.

[0051] Figure 8 is an exploded perspective view of the aerosol generator shown in Figure 6. Figure 9 is an exploded perspective view of the aerosol generator shown in Figure 7. Referring to Figures 8 and 9, the apparatus body 330 defines a compartment 332, in which a heating assembly 340 is located. The apparatus body 330 is configured to receive the capsule 200 into the compartment 332 so that the capsule 200 is in thermal contact with the heating assembly 340. The capsule 200 in Figures 8 and 9 may be the same as the capsule 100 in Figures 1 to 5. For example, the end cap 210, inlet opening 212, outlet opening 214, filter 220 (Figure 10), orifice 222 (Figure 10), and container 230 of the capsule 200 may be as described in relation to the end cap 110, inlet opening 112, outlet opening 114, filter 120, orifice 122, and container 130 of the capsule 100. Although not shown, it should be understood that capsule 200 may also contain an aerosol-forming substrate internally, such as the one described in relation to the aerosol-forming substrate of capsule 100. Consequently, the relevant disclosures above regarding 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 defines an internal channel that fluidly connects the aperture 318 to the aerosol outlet 312. The mouthpiece 310 is configured to engage with the apparatus body 330 to enclose the capsule 200 and the heating assembly 340 therein. Furthermore, a gasket 320 may be clamped between the mouthpiece 310 and the apparatus body 330. In particular, the gasket 320 may have an annular shape configured to be clamped between the head portion 314 of the mouthpiece 310 and the rim of the apparatus body 330.

[0053] In exemplary embodiments, the capsule 200 can be considered a consumable item that is removed and replaced with a new capsule before the operation of the aerosol generator 300 is restarted (for example, when the aerosol-forming substrate inside is depleted or deemed expired). In this respect, the capsule 200 can also be considered disposable. On the other hand, the mouthpiece 310, gasket 320, heating assembly 340, and device body 330 can be considered durable components of the aerosol generator 300 that are designed to be used multiple times (when it is not the end of the aerosol generator 300's lifespan). In this respect, the mouthpiece 310, gasket 320, heating assembly 340, and device body 330 can also be considered reusable.

[0054] The heating assembly 340 is configured to heat the aerosol-forming substrate within the capsule 200, causing aerosol generation via conduction, convection, or both. As shown, the heating assembly 340 may include a first heater 342 and a second heater 344. In exemplary embodiments, the first heater 342 and the second heater 344 are separate structures configured to allow independent operation. Alternatively, the first heater 342 and the second heater 344 may be a continuous structure configured to allow simultaneous operation. The first heater 342 may be responsible for heating the aerosol-forming substrate within the capsule 200 via conduction, while 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 arranged concentrically so as to form a spiral around the longitudinal central axis of the apparatus body 330. Furthermore, the wire diameter, pitch, coil angle, free length, and / or structural material of the first heater 342 may be the same as that of the second heater 344. However, exemplary embodiments are not limited thereto. Furthermore, the free lengths of the first heater 342 and the second heater 344 may be at least the height of the container 230 of the capsule 200. This allows for enhanced heating of the aerosol-forming substrate within during aerosol generation. In another embodiment, the first heater 342 and the second heater 344 may be in the form of ceramic heaters, silicon heaters, and / or flexible polymer heaters.

[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., compress) the container 230 of the capsule 200 when the capsule 200 is received into 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 side wall 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 located between the first heater 342 and the second heater 344. As a result, the air flowing into the main body of the device 330 via the air inlet 334 flows between the first heater 342 and the second heater 344, becoming a heating flow that enters the capsule 200 and heats the aerosol-forming substrate inside it via convection.

[0057] While the coil configuration has been described above, it should be understood that other configurations are also 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 waveforms configured to surround the capsule 200. In such an example, the first heater 342 and the second heater 344 may alternately extend toward the rim at the proximal end of the device body 330 and toward the distal end of the device body 330. In particular, the amplitude of the waveforms of the first heater 342 and the second heater 344 may be about half the height of the container 230 of the capsule 200, while the height of the waveforms of the first heater 342 and the second heater 344 may be about the height of the container 230 of the capsule 200. Heating of the aerosol-forming substrate within can be enhanced during aerosol generation.

[0058] The waveforms of the first heater 342 and the second heater 344 may be compressed amplitude or similar to a zigzag, and may have multiple parallel segments (e.g., extending longitudinally with respect to the apparatus body 330). In particular, the waveforms may include pulse waves (e.g., square waves), triangular waves, sawtooth waves, or sine waves. The waveform of the first heater 342 may be of the same type as the waveform of the second heater 344, but the illustrated embodiments are not limited thereto. In examples where the capsule 200 has a non-cylindrical shape (e.g., a shape similar to a triangular prism, cuboid, pentagonal prism, or hexagonal prism), it should be understood that the heater pattern (e.g., cut from a sheet material) may be bent as needed. This can result in suitable first and second heaters that can better accommodate the capsule 200 (e.g., improve thermal contact).

[0059] In exemplary embodiments, the first heater 342 and the second heater 344 are configured to undergo Joule heating (also known as ohmic / resistive heating) when an electric 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 an electric current passes through them. The electric 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 generator 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] Figure 10 is a cross-sectional view of the aerosol generator of Figure 6. Referring to Figure 10, in order to enable the operation of the aerosol generator 300, the capsule 200 is inserted into a compartment 332 of the device body 330 and made available to be received by the first heater 342. In the case of a resilient configuration of the first heater 342 as an internal coil, the first heater 342 may physically grip the capsule 200. This embodiment allows for improved thermal contact of the capsule 200 with the container 230 while holding the capsule 200 in a desired position. Once 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 in the diagram, the first heater 342 and the second heater 344 are located within this annular space, with the first heater 342 facing the outer side wall of the capsule 200 and the second heater 344 facing the inner side wall of the device body 330.

[0061] When the capsule 200 is seated, the mouthpiece 310 is configured to engage with the device body 330 and surround the capsule 200, with the conduit portion 316 extending through the outlet 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., dotted). This can further facilitate its insertion through the aerosol-forming substrate within the capsule 200.

[0062] As shown in Figure 10, when the capsule 200 is sealed 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 is embedded in the orifice 222 of the filter 220. In particular, the aperture 318 at the upstream end of the conduit portion 316 is also 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 also be a through-hole. In such a configuration, two inlets to the conduit portion 316 of the mouthpiece 310 can be provided. In some embodiments, the aperture 318 may be in the form of two intersecting through-holes (e.g., x configuration, cross configuration). This can provide four inlets to the conduit portion 316 of the mouthpiece 310.

[0063] As described above, the gasket 320 can help ensure a relatively airtight seal so that incoming air enters the aerosol generator 300 essentially only through the air inlet 334 in the device body 330. In one example, the gasket 320 may be a separate component located between the mouthpiece 310 and the device body 330. In another embodiment, the gasket 320 may be part of the mouthpiece 310 (for example, fixed to the underside of the head portion 314 of the mouthpiece 310). In yet another example, the gasket 320 may be part of the device body 330 (for example, fixed to the rim of the device body 330).

[0064] During the operation of the aerosol generator 300, incoming air (e.g., ambient air) is drawn into the device body 330 through a plurality of air inlets 334. The plurality of air inlets 334 located at the upstream end of the device body 330 help to disperse the incoming air around the capsule 200. The operation of the heating assembly 340 can include manual operation (e.g., button operation) and / or automatic operation (e.g., puff operation). Furthermore, the first heater 342 and the second heater 344 of the heating assembly 340 may be operated 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 activated simultaneously to begin heating. In another example, upon initial button activation, the first heater 342 may begin heating the capsule 200, and upon subsequent puff activation, 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 embodiment, the order may be reversed, for example, the second heater 344 may begin heating in response to the initial button activation, and the first heater 342 may begin heating in response to a subsequent puff activation. Furthermore, in each of the above embodiments, heating may include a preheating step including the first heater 342 and / or the second heater 344 (to reduce the time required to reach the target / aerosolizing temperature), followed by a main heating step including both the first heater 342 and the second heater 344. Here, the preheating step is performed, for example, by pressing a button to bring the temperature below the target temperature / aerosolization temperature, and the complete heating step is performed, for example, by puff activation to bring the temperature to the target temperature / aerosolization temperature. Appropriate temperature sensing may be achieved via thermocouples or by monitoring the resistance of the first heater 342 and the second heater 344.

[0066] Air flowing into the apparatus body 330 through multiple air inlets 334 is drawn into the internal annular space so as to flow between the first heater 342 and the second heater 344 (for example, in the first longitudinal direction), heating the incoming air in the heated airflow. When the heated air reaches the head portion 314 of the mouthpiece 310, its direction changes to an inward path relative to the inlet opening 212 of the end cap 210 (for example, a first radial path). The heated air entering the capsule 200 through the inlet opening 212 of the end cap 210 then flows (for example, in the second longitudinal direction) through the aerosol-forming substrate (which is located 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 generate an aerosol by being heated via conduction. Furthermore, as a result of both the first heater 342 and the second heater 344, the heated air entering the capsule 200 may further heat the aerosol-forming substrate via convection, thereby enhancing aerosol generation.

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

[0068] It should be understood that, although not shown, the aerosol generator 300 may include additional structures / components configured to provide desired aesthetics and / or functionality. For example, the aerosol generator 300 may include an external housing structure designed to be visually appealing, or an external housing structure that is portable and configured to be easy to handle (e.g., ergonomically shaped for one-handed operation). A power supply and control circuit may also be provided within the external housing structure. The power supply may include one or more batteries (e.g., a rechargeable battery arrangement). The control circuit may instruct the power supply to supply current to the first heater 342 and the second heater 344. The instruction to supply current from the power supply may be in response to manual operation (e.g., button operation) and / or automatic operation (e.g., puff operation). As a result of the current, the capsule 200 may be heated conductively and / or convectivally by the first heater 342 and the second heater 344 to generate an aerosol. The aerosol generated within the capsule 200 may be withdrawn from the aerosol generator 300 via the aerosol outlet 312 and optionally via an additional mouthpiece accessory.

[0069] Using the capsules and apparatus disclosed herein, an aerosol can be generated by conductively and / or convectively heating an aerosol-forming substrate. In exemplary embodiments, the method for generating the aerosol may include heating a capsule comprising 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 guiding an air intake flow along a meandering path through the capsule. The meandering path may include an entrained flow section and a filtered flow section. The entrained flow section may extend from the gas-permeable end of the housing through the aerosol-forming substrate to the filter. The filtered flow section may extend from the filter to the gas-permeable end of the housing.

[0070] In addition to the non-limiting embodiments described herein, further details of the substrates, capsules, devices, and methods discussed herein may also be found in U.S. applications 16 / 451,662, 16 / 252,951, 15 / 845,501, and 15 / 559,308. Each of these disclosures is incorporated herein by reference in its entirety. U.S. application 16 / 451,662 was filed on 25 June 2019, titled "CAPSULES, HEAT-NOT-BURN (HNB) AEROSOL-GENERATING DEVICES, AND METHODS OF GENERATING AN AEROSOL," with attorney number No. 24000NV-000522-US. U.S. Patent Application No. 16 / 252,951 was filed on January 21, 2019, and is titled "CAPSULES, HEAT-NOT-BURN (HNB) AEROSOL-GENERATING DEVICES, AND METHODS OF GENERATING AN AEROSOL." The attorney's case number is No. 24000NV-000521-US. U.S. Patent Application No. 15 / 845,501 was filed on December 18, 2017, and is titled "VAPORIZING DEVICES AND METHODS FOR DELIVERING A COMPOUND USING THE SAME." The attorney's case number is No. 24000DM-000012-US. U.S. Patent Application No. 15 / 559,308 was filed on 18 September 2017, with the title "VAPORIZER FOR VAPORIZING AN ACTIVE INGREDIENT," and the agent's case number is 24000DM-000003-US-NP.

[0071] While numerous exemplary embodiments are disclosed herein, it should be understood that other modifications are possible. Such modifications shall not be considered to deviate from the spirit and scope of this disclosure, and all such modifications that are obvious to those skilled in the art are intended to be included within the scope of the following claims.

Claims

1. A capsule for an aerosol generator, A housing having a gas-permeable end and a gas-impermeable end, Between the gas-impermeable end and the gas-permeable end, a filter is disposed within the housing, An aerosol-forming substrate is disposed within the housing between the filter and the gas-permeable end such that the air passage through the housing extends through the filter, Equipped with, The housing includes a container and an end cap, The container includes a chamber configured to receive the aerosol-forming substrate, The chamber is defined by the inner side wall of the container and the opposing inner surfaces of the filter and the end cap. The aerosol-forming substrate is configured to take the shape of the chamber. capsule.

2. In the capsule according to claim 1, The filter is a capsule adjacent to the gas-impermeable end.

3. In the capsule according to claim 1, The housing is configured to facilitate the heating of the aerosol-forming substrate via either conduction, convection, or both, in order to generate an aerosol.

4. In 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 aerosols to exit the capsule.

5. In the capsule according to claim 1, The container is a capsule having a closed end and an open end.

6. In the capsule according to claim 5, The end cap is the gas permeable end of the housing, A capsule in which the closed end of the container is the gas-impermeable end.

7. In the capsule according to claim 1, The majority of the end cap is a capsule inserted into the container.

8. In the capsule according to claim 1, The container is a capsule made of metal.

9. In the capsule according to claim 1, The end cap is a capsule having multiple openings.

10. In the capsule according to claim 1, The aforementioned filter defines an orifice, The aerosol-forming substrate is in a solidified form, and the solidified form of the aerosol-forming substrate defines a through hole. The end cap defines the outlet opening, A capsule in which the orifice, the through hole, and the exit opening are aligned.

11. In the capsule according to claim 10, The orifice, the through-hole, and the exit opening are aligned along the central axis of the capsule. capsule.

12. In the capsule according to claim 10, A capsule in which the orifice and the outlet opening are approximately the same size.

13. In the capsule according to claim 1, The aerosol-forming substrate is a capsule containing tobacco.

14. an aerosol generating device comprising a device body that defines a compartment, A capsule according to claim 1 received in the compartment, A mouthpiece including a conduit portion, wherein the conduit portion is configured to engage with the device body such that it extends through the aerosol-forming substrate of the capsule into the filter of the capsule, A heating assembly within the main body of the apparatus, configured to heat the aerosol-forming substrate within the capsule by conduction, convection, or both, so as to generate an aerosol that exits the capsule through the conduit portion of the mouthpiece, An aerosol generating device equipped with the following features.

15. In the aerosol generating apparatus according to claim 14, The aerosol-forming substrate and the filter are, The air entering the capsule passes through the aerosol-forming substrate before reaching the filter. The aerosol passes through the filter before leaving the capsule, An aerosol generating device, which is placed inside the aforementioned capsule.

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