Aerosol-forming substrate and encapsulated flavoring agent

Abstract

A capsule for an aerosol generating device comprises a housing and an aerosol forming substrate. The housing defines an inlet opening, an outlet opening, and a chamber between the inlet opening and the outlet opening. The aerosol forming substrate is located inside the housing. The aerosol forming substrate comprises tobacco, an encapsulated flavoring agent, and an aerosol forming agent. The encapsulated flavoring agent comprises a matrix and a flavoring agent within the matrix. The capsule has an inhalation resistance ranging from 30 mmH2O to 130 mmH2O.

Description

Technology Field

[0001] The present disclosure relates to a non-combustion heating (HNB) aerosol generating device configured to generate an aerosol without substantial thermal decomposition of the aerosol-forming substrate, an aerosol-forming substrate such as one intended for use in capsules, and an encapsulated flavoring agent.

[0002] Cross-reference of related technologies

[0003] This application claims the benefit of U.S. Provisional Application No. 63 / 599,111 filed on November 15, 2023, the entire disclosure of said application incorporated herein by reference. Background Technology

[0004] Some electronic devices are configured to heat an aerosol-forming substrate, such as plant material, to a temperature sufficient to release the components of the plant material, while maintaining the temperature below the combustion point of the plant material to prevent substantial thermal decomposition of the plant material. Such devices are called aerosol generating devices (e.g., non-combustion heating aerosol generating devices), and the plant material being heated may be tobacco and / or hemp. In some cases, the plant material may be introduced directly into the heating chamber of the aerosol generating device. In other cases, the plant material may be pre-packaged in individual containers to allow for easy insertion and removal from the aerosol generating device. The problem to be solved

[0005] At least one exemplary embodiment relates to a capsule for an aerosol generating device. means of solving the problem

[0006] In at least one exemplary embodiment, the capsule comprises a housing and an aerosol-forming substrate. The housing defines an inlet opening, an outlet opening, and a chamber between the inlet opening and the outlet opening. The aerosol-forming substrate is located within the housing. The aerosol-forming substrate comprises tobacco, an encapsulated flavoring agent, and an aerosol-forming agent. The encapsulated flavoring agent comprises a matrix and a flavoring agent within the matrix. The capsule has an inhalation resistance in the range of 30 mmH2O to 130 mmH2O.

[0007] In at least one exemplary embodiment, the tobacco is 150 It is a particle form with an average particle size ranging from µm to 1250 µm.

[0008] In at least one exemplary embodiment, the average particle size is in the range of 270 μm to 415 μm.

[0009] In at least one exemplary embodiment, the aerosol-forming substrate is 0.2 g / cm³ 3 At 1.2 g / cm² 3 It has a range of apparent density (bulk density).

[0010] In at least one exemplary embodiment, the flavoring agent is present in an amount ranging from 0.5 weight percent to 85 weight percent within the encapsulated flavoring agent.

[0011] In at least one exemplary embodiment, the aerosol-forming agent comprises propylene glycol, glycerol, butylene glycol, or any combination thereof.

[0012] In at least one exemplary embodiment, the matrix comprises methyl cellulose, ethyl cellulose, hydroxypropyl methyl cellulose, starch, pectin, gelatin, sodium alginate, maltodextrin, pullulan, xanthan, gum arabic, sodium carboxymethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose, polyethylene oxide, polyvinyl alcohol, polyvinyl pyrrolidone, low-density polyethylene, polyethylene glycol, polyurethane, poly(methyl methacrylate), ethylene vinyl acetate, sugar alcohols thickened by polymers, waxes, fatty acid esters, copolymers thereof, or any combination thereof.

[0013] In at least one exemplary embodiment, the encapsulated flavor further comprises a plasticizer, a crosslinking agent, a foaming agent, or any combination thereof.

[0014] In at least one exemplary embodiment, the flavoring comprises menthol, peppermint, spearmint, wintergreen, cinnamon, chocolate, vanillin, licorice, clove, anise, sandalwood, geranium, rose, vanilla, lemon, cassia, fennel, ginger, ethyl acetate, isoamyl acetate, propyl isobutyrate, isobutyrate, ethyl butyrate, ethyl valerate, benzyl formate, limonene, cymene, pinene, linalool, geraniol, citronellol, citral, orange, coriander, borneol, fruit extract, coffee, tea, cacao, mint, terpene, or any combination thereof.

[0015] In at least one exemplary embodiment, the encapsulated flavor agent further comprises a carrier. The flavor agent is absorbed into the carrier. The carrier is dispersed within a matrix.

[0016] In at least one exemplary embodiment, the carrier comprises cellulose, silica, pectin, or a combination thereof.

[0017] In at least one exemplary embodiment, the carrier comprises cellulose. The cellulose comprises microcrystalline cellulose.

[0018] In at least one exemplary embodiment, the carrier comprises cellulose. The cellulose comprises tobacco.

[0019] In at least one exemplary embodiment, the encapsulated flavoring agent is in the form of a plurality of particles, granules, cuts, shreds, flakes, or any combination thereof.

[0020] In at least one exemplary embodiment, the encapsulated flavoring agent is mixed with tobacco and an aerosol-forming agent.

[0021] In at least one exemplary embodiment, the encapsulated flavor agent is on the surface of the housing.

[0022] In at least one exemplary embodiment, the surface is an inner surface that allows the encapsulated flavor agent to be inside the chamber.

[0023] At least one exemplary embodiment relates to an aerosol generating device.

[0024] In at least one exemplary embodiment, the aerosol generating device comprises a capsule, a heater, and a device body. The capsule comprises a housing and an aerosol forming substrate within the housing. The aerosol forming substrate comprises tobacco and an aerosol forming agent. The heater is in thermal communication with the aerosol forming substrate. The device body comprises a lid, a mouthpiece, and an encapsulated flavoring agent. The lid is configured to open to allow insertion of the capsule and to close to engage the capsule within the device body. The encapsulated flavoring agent is configured to be in fluid communication with the aerosol path of the aerosol generating device. The encapsulated flavoring agent comprises a matrix and a flavoring agent within the matrix. The capsule has an inhalation resistance in the range of 30 mmH2O to 130 mmH2O.

[0025] In at least one exemplary embodiment, the encapsulated flavoring agent is disposed on the surface of the mouthpiece. In at least one exemplary embodiment, the encapsulated flavoring agent is disposed inside the mouthpiece. The encapsulated flavoring agent is in the form of a plurality of particles, granules, cut pieces, crushed pieces, flakes, or any combination thereof.

[0026] At least one exemplary embodiment relates to a replaceable mouthpiece for an aerosol generating device. The replaceable mouthpiece comprises a wall and an encapsulated flavoring agent. The wall defines an inlet, an outlet, and a channel fluidly communicating with the inlet and the outlet. The encapsulated flavoring agent is disposed on the surface of the wall that fluidly communicates with the channel. The encapsulated flavoring agent comprises a matrix and a flavoring agent within the matrix.

[0027] At least one exemplary embodiment relates to a method for manufacturing a flavor sheet for an aerosol generating device.

[0028] In at least one exemplary embodiment, the method comprises the step of preparing a first film-forming solution by dissolving a first film-forming material in a first solvent. The method further comprises the step of mixing a flavoring agent with the first film-forming solution. The method further comprises the step of preparing a film precursor by casting the first film-forming solution onto a surface. The method further comprises the step of preparing a flavor sheet by drying the film precursor. The flavor sheet contains the flavoring agent in an amount ranging from 0.5% by weight to 90% by weight.

[0029] In at least one exemplary embodiment, the flavor sheet contains the flavor agent in an amount ranging from 10 weight% to 35 weight%.

[0030] In at least one exemplary embodiment, the mixing step comprises the step of preparing a flavoring solution by dissolving the flavoring agent in a second solvent. The mixing step further comprises the step of mixing the first film-forming solution and the flavoring solution.

[0031] In at least one exemplary embodiment, the mixing step includes the step of dissolving the flavor agent in the first solvent.

[0032] In at least one exemplary embodiment, the step of preparing the first film-forming solution and the step of mixing are performed simultaneously.

[0033] In at least one exemplary embodiment, the mixing step includes the step of dispersing the flavor agent in the first film-forming solution.

[0034] In at least one exemplary embodiment, the mixing step includes lowering the temperature of the first film-forming solution and the flavor agent.

[0035] In at least one exemplary embodiment, the flavoring agent is in powder form.

[0036] In at least one exemplary embodiment, the mixing step comprises the step of preparing a flavoring solution by dissolving the flavoring agent and the second film-forming material in a second solvent. The flavoring agent is a flavoring agent that is insoluble in water. The mixing step further comprises the step of dispersing the flavoring solution within the first film-forming solution.

[0037] In at least one exemplary embodiment, the method further includes the step of absorbing the flavor agent onto a carrier prior to the mixing step.

[0038] In at least one exemplary embodiment, the absorbing step comprises the step of preparing a flavoring solution by dissolving the flavoring agent in a second solvent. The absorbing step further comprises the step of absorbing the flavoring solution onto the carrier. The absorbing step further comprises the step of removing the second solvent from the carrier.

[0039] In at least one exemplary embodiment, the method further comprises the step of forming a second film. The second film is in contact with the flavor sheet.

[0040] In at least one exemplary embodiment, the method further comprises the step of forming a pair of second films comprising the second film. The flavor sheet is positioned between the pair of second films.

[0041] In at least one exemplary embodiment, the mixing step includes the step of stirring the first film-forming solution for a desired period.

[0042] In at least one exemplary embodiment, the step of preparing the film precursor includes moving a blade across the first film-forming solution on the surface so that the flavor sheet has a desired thickness.

[0043] In at least one exemplary embodiment, the step of manufacturing the flavor sheet includes the step of drying the film precursor in a vacuum oven.

[0044] In at least one exemplary embodiment, the method further comprises the step of subdividing the flavor sheet to form a plurality of particles, granules, cut pieces, crushed pieces, flakes, or any combination thereof.

[0045] In at least one exemplary embodiment, the first solvent comprises ethanol, water, or both ethanol and water.

[0046] At least one exemplary embodiment relates to a method for manufacturing a flavor sheet for an aerosol generating device.

[0047] In at least one exemplary embodiment, the method comprises the step of melting a polymer to produce a polymer melt. The method further comprises the step of producing a mixture comprising said polymer and a flavoring agent. The method further comprises the step of forming an encapsulated flavoring agent precursor comprising said polymer melt and said flavoring agent. The forming step comprises extrusion, blow molding, or a combination of extrusion and blow molding. The method further comprises the step of cooling said encapsulated flavoring agent precursor to form said encapsulated flavoring agent.

[0048] In at least one exemplary embodiment, the step of preparing the mixture is performed prior to the step of preparing the polymer melt.

[0049] In at least one exemplary embodiment, the step of preparing the polymer melt is performed prior to the step of preparing the mixture.

[0050] In at least one exemplary embodiment, the step of forming the flavor sheet precursor includes the extrusion. The extrusion is performed using a screw extruder and a ribbon die.

[0051] In at least one exemplary embodiment, the method further includes the step of absorbing the flavor agent onto a carrier prior to the step of preparing the mixture.

[0052] In at least one exemplary embodiment, the absorbing step comprises the step of preparing a flavoring solution by dissolving the flavoring agent in a solvent. The absorbing step further comprises the step of absorbing the flavoring solution onto the carrier. The absorbing step further comprises the step of removing the solvent from the carrier.

[0053] At least one exemplary embodiment relates to a method for manufacturing an encapsulated flavor agent for an aerosol generating device.

[0054] In at least one exemplary embodiment, the method comprises the step of melting a polymer to produce a polymer melt. The method further comprises the step of producing a mixture comprising said polymer and a flavoring agent. The method further comprises the step of extruding said mixture to form an encapsulated flavoring agent precursor. The method further comprises the step of cooling said encapsulated flavoring agent precursor to form said encapsulated flavoring agent.

[0055] In at least one exemplary embodiment, the step of preparing the mixture is performed prior to the step of preparing the polymer melt.

[0056] In at least one exemplary embodiment, the step of preparing the mixture includes mixing a plurality of solid polymer particles with a plurality of solid flavoring particles.

[0057] In at least one exemplary embodiment, the step of forming the encapsulated flavoring precursor is performed using a screw extruder.

[0058] In at least one exemplary embodiment, the method is performed in the absence of a solvent.

[0059] In at least one exemplary embodiment, the method further comprises the step of preparing a plurality of particles of the encapsulated flavor agent.

[0060] In at least one exemplary embodiment, the step of manufacturing the plurality of particles includes grinding, pelletizing, cutting, crushing, or any combination thereof.

[0061] In at least one exemplary embodiment, the method further includes the step of mixing the plurality of particles with tobacco.

[0062] In at least one exemplary embodiment, the step of preparing the mixture includes mixing solid ethyl cellulose particles and solid menthol particles.

[0063] In at least one exemplary embodiment, the method further includes the step of absorbing the flavor agent onto a carrier prior to the step of preparing the mixture.

[0064] In at least one exemplary embodiment, the absorbing step comprises the step of preparing a flavoring solution by dissolving the flavoring agent in a solvent. The absorbing step further comprises the step of absorbing the flavoring solution onto the carrier. The absorbing step further comprises the step of removing the solvent from the carrier. Brief explanation of the drawing

[0065] Various features and advantages of the non-limiting embodiments in this specification may become more apparent upon review of the detailed description in conjunction with the accompanying drawings. The accompanying drawings are provided for illustrative purposes only and should not be construed as limiting the scope of such purposes. The accompanying drawings should not be construed as being drawn to scale unless expressly stated otherwise. For clarity, various dimensions in the drawings may be exaggerated. FIG. 1 is a perspective view of an exemplary aerosol-forming substrate in a consolidated form according to at least one exemplary embodiment. FIG. 2 is a perspective view of another exemplary aerosol-forming substrate in a molded form according to at least one exemplary embodiment. FIG. 3 is a perspective view of another exemplary aerosol-forming substrate in a loose form according to at least one exemplary embodiment. FIG. 4 is a perspective view of a rod-shaped aerosol-forming substrate according to at least one exemplary embodiment. FIG. 5 is an upper right perspective view of a capsule according to at least one exemplary embodiment. FIG. 6 is a cross-sectional view of the capsule cut along line XI-XI of FIG. 5 according to at least one exemplary embodiment. FIG. 7 is an exploded view of the capsule of FIG. 5 according to at least one exemplary embodiment. FIG. 8 is a perspective view of an aerosol generating device having a cover in a closed position according to at least one exemplary embodiment. FIG. 9 is a partial perspective view of an aerosol generating device of FIG. 8 having a cover in an open position and a capsule of FIG. 5 inside, according to at least one exemplary embodiment. FIG. 10 is a cross-sectional view of the mouthpiece and capsule of the aerosol generating device of FIG. 8, which is without a heater, according to at least one exemplary embodiment. FIG. 11 is a flowchart illustrating a method for manufacturing an encapsulated flavor agent according to at least one exemplary embodiment. FIG. 12 is a flowchart illustrating another method for manufacturing an encapsulated flavor agent according to at least one exemplary embodiment. FIG. 13A is a schematic diagram illustrating a method for preparing a flavor agent encapsulated by hot melt extrusion (HME) according to at least one exemplary embodiment. FIG. 13B is a schematic diagram showing a portion of an encapsulated flavor agent formed by the method of FIG. 13A according to at least one exemplary embodiment. FIG. 14 is a graph showing the distribution of menthol in aerosols by puff block for first and second aerosol-forming substrates according to at least one exemplary embodiment. Specific details for implementing the invention

[0066] Some detailed embodiments are disclosed in this specification. However, the specific structural and functional details disclosed herein are merely representative for the purpose of describing the embodiments. However, the embodiments may be implemented in many alternative forms and should not be construed as being limited only to the embodiments presented herein.

[0067] Accordingly, various modifications and alternative forms of the embodiments are possible, but such embodiments are presented as examples in the drawings and will be described in detail in this specification. However, there is no intention to limit the embodiments to the specific forms disclosed; on the contrary, the embodiments should be understood to cover all modifications, equivalents, and alternatives that fall within the scope of the embodiments. Throughout the description of the drawings, similar reference numerals refer to similar components.

[0068] When one component or layer is referred to as being "on" another component or layer, or being "connected," "combined," or "covering" it, it should be understood that this is directly on, directly connected to, directly combined with, or directly covered by, or that there may be an interposed component or layer. In contrast, when one component is referred to as being "directly on," "directly connected to," or "directly combined" with another component or layer, there is no interposed component or layer. Throughout the specification, similar reference numerals refer to similar components. As used herein, the term "and / or" includes any and all combinations of one or more of the items listed in association.

[0069] While terms such as first, second, third, etc., may be used in this specification to describe various components, regions, layers, and / or sections, it should be understood that such components, regions, layers, and / or sections are not to be limited by these terms. These terms are used solely to distinguish one component, region, layer, or section from another. Accordingly, the first component, component, region, layer, or section discussed below may be referred to as the second component, region, layer, or section without departing from the technical spirit of the embodiments.

[0070] As illustrated in the drawings, spatially relative terms (e.g., "below," "under," "lower," "above," "upper," etc.) may be used herein to facilitate the description of the relationship between one component or feature and other component(s) or feature(s). It should be understood that spatially relative terms are intended to encompass different orientations of the device in use or operation, in addition to the orientations depicted in the drawings. For example, if the device in the drawings is inverted, components described as being "below" or "under" another component or feature will be positioned in the "above" direction of that other component or feature. Thus, the term "below" may encompass both the up and down directions. The device may be oriented in other directions (rotated 90 degrees or in other directions), and the spatially relative terms used herein should be interpreted accordingly.

[0071] The terms used herein are for the purpose of describing various embodiments only and are not intended to limit the embodiments. As used herein, the singular form is intended to include the plural form unless the context clearly indicates otherwise. It will also be understood that the terms “comprising,” “comprising,” “composing,” and / or “composing” specify the presence of the mentioned features, integers, steps, operations, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, components, and / or groups thereof.

[0072] When the terms “about” or “substantially” are used in combination with a numerical value in this specification, it is intended that the associated numerical value includes a manufacturing or operating tolerance (e.g., ±10%) around the mentioned numerical value. Additionally, when the terms “generally” or “substantially” are used in combination with a geometric shape, it is intended that the tolerance for the shape is within the scope of this disclosure, rather than requiring precision of the geometric shape. Furthermore, it will be understood that, regardless of whether a numerical value or shape is modified by “about,” “generally,” or “substantially,” such numerical value and shape should be interpreted as including a manufacturing or operating tolerance around the mentioned numerical value or shape.

[0073] Unless otherwise defined, all terms used herein have the same meaning as commonly understood by those skilled in the art to which the embodiments pertain. Terms including those defined in commonly used dictionaries should be interpreted as having a meaning consistent with the contextual meaning of the relevant technology, and it will also be understood that, unless explicitly defined in this specification, they should not be interpreted in an ideal or overly formal sense.

[0074] At least one exemplary embodiment relates to an aerosol-forming substrate for use in an aerosol generating device.

[0075] An aerosol-forming substrate is a substance or a combination of substances capable of generating an aerosol. The aerosol relates to a substance generated or output by the disclosed and claimed device and equivalents thereof. The substance may include a compound (e.g., nicotine, cannabinoid), and an aerosol containing said compound is generated when said substance is heated. Heating may be below the combustion temperature to generate an aerosol without entailing substantial thermal decomposition of the aerosol-forming substrate or substantial generation of combustion byproducts (if any). Thus, in at least one exemplary embodiment, thermal decomposition does not occur during heating and the subsequent aerosol generation. In other examples, some thermal decomposition and combustion byproducts may be present, but to a relatively minor extent and / or may be considered merely incidental.

[0076] The aerosol-forming substrate can be a fibrous material. For example, the fibrous material can be a plant material. The fibrous material is configured to release a compound when heated. The compound can be a naturally occurring component of the fibrous material. For example, the fibrous material can be a plant material such as tobacco, and the released compound can be nicotine. The term tobacco Nicotiana rustica (Nicotiana Rustica) and Nicotiana tabacum It includes any tobacco plant material comprising tobacco leaves, tobacco plugs, sheet tobacco, compressed tobacco, molded tobacco, or powdered tobacco derived from one or more tobacco plant species such as (Nicotiana tabacum), and combinations thereof.

[0077] In some embodiments, the tobacco material may comprise a material derived from any member of the genus Nicotiana. Additionally, the tobacco material may comprise 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, yellow tobacco, Burley tobacco, dark tobacco, Maryland tobacco, Oriental tobacco, rare tobacco, specialty tobacco, blends thereof. The tobacco material may be provided in any suitable form, including, but not limited to, tobacco lamina, processed tobacco material such as volume-expanded or puffed tobacco, processed tobacco stem such as cut-rolled or cut-pugged stem, reconstituted tobacco material, blends thereof, etc. In some embodiments, the tobacco material is in the form of substantially dry tobacco mass.

[0078] Aerosol-forming substrates may contain naturally occurring components of medicinal plants that possess medically recognized therapeutic effects. For example, the medicinal plant may be cannabis, and the compound may be a cannabinoid. Cannabinoids exert a wide range of effects by interacting with receptors in the body. As a result, cannabinoids have been used for various medical purposes (e.g., the treatment of pain, nausea, epilepsy, and mental disorders). Fibrotic materials Cannabis sativa (Cannabis Sativa), Indian cannabis (Cannabis Indica), and Cannabis ruderalis It may include leaf and / or flower material of one or more cannabis plant species, such as (Cannabis ruderalis). In some examples, the fibrous material is a mixture of 50% to 80% (e.g., 70%) cannabis sativa and 20% to 50% (e.g., 30%) cannabis indica.

[0079] Examples of cannabinoids include tetrahydrocannabinol (THCA), tetrahydrocannabinol (THC), cannabidiol (CBDA), cannabidiol (CBD), cannabinol (CBN), cannabicyclol (CBL), cannabicromene (CBC), and cannabigerol (CBG). Tetrahydrocannabinol (THCA) is a precursor of tetrahydrocannabinol (THC), and cannabidiol (CBDA) is a precursor of cannabidiol (CBD). Tetrahydrocannabinol (THCA) and cannabidiol (CBDA) can be activated into tetrahydrocannabinol (THC) and cannabidiol (CBD), respectively, through heating. In at least one exemplary embodiment, heat from a heating device may induce a decarboxylation reaction to convert tetrahydrocannabinol (THCA).

[0080] If both tetrahydrocannabinol (THCA) and tetrahydrocannabinol (THC) are present within the capsule, the decarboxylation reaction and subsequent conversion will result in a decrease in tetrahydrocannabinol (THCA) and an increase in tetrahydrocannabinol (THC). During heating in a heating device, at least 50 percent (e.g., at least 87 percent) of tetrahydrocannabinol (THCA) may be converted to tetrahydrocannabinol (THC). Similarly, if both cannabidiol (CBDA) and cannabidiol (CBD) are present within the aerosol-forming substrate, the decarboxylation reaction and subsequent conversion will result in a decrease in cannabidiol (CBDA) and an increase in cannabidiol (CBD). While heating the aerosol-forming substrate, at least 50 percent (e.g., at least 87 percent) of cannabidiol acid (CBDA) can be converted to cannabidiol (CBD).

[0081] Furthermore, the aerosol-forming substrate may additionally or alternatively include an unnaturally occurring additive that is intentionally introduced into the fibrous material. In at least one exemplary embodiment, the unnaturally occurring additive may include a non-nicotine alkaloid (e.g., caffeine), a vitamin, an amino acid (e.g., theanine), a sedative (e.g., melatonin), a concentration enhancer (e.g., ginkgo biloba extract), a mineral, a dietary supplement, a health functional food, a chemical sensitizer, a plant-based ingredient, or any combination thereof. In one example, the fibrous material may include at least one of cotton, polyurethane, polyester, rayon, inulin, psyllium husk, a plant-based material, a combination thereof, etc. (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-hemp cellulose material). In another example, the aerosol-forming substrate material may contain nicotine, cannabinoids, flavoring agents, and / or other additives (e.g., non-naturally occurring additives). The aerosol-forming substrate may be free of tobacco, nicotine, cannabis, and / or cannabinoids. Flavoring agents may be encapsulated and will be described in more detail below. Flavoring agents may be derived from natural sources, e.g., plant extracts (e.g., tobacco extract, cannabis extract), and / or artificial sources. In another example, if the fibrous material contains tobacco and / or cannabis, the mixture may contain one or more flavoring agents (e.g., menthol mass, vanilla) or additionally contain them. Thus, the compounds within the aerosol-forming substrate may contain naturally occurring components and / or non-naturally occurring additives. In this regard, it should be understood that the existing level of the naturally occurring components of the aerosol-forming substrate may be increased through supplementation. For example, the existing level of nicotine present in a certain amount of tobacco can be increased by supplementing with a nicotine-containing extract.Similarly, existing levels of one or more cannabinoids present in a certain amount of cannabis can be increased by supplementing with an extract containing such cannabinoids.

[0082] In at least one exemplary embodiment, the aerosol-forming substrate comprises an aerosol-forming agent. The aerosol-forming agent may be mixed and / or blended with a plant material and / or a fibrous material. The aerosol-forming agent may comprise propylene glycol, glycerol, butylene glycol, water, or any combination thereof. The aerosol-forming agent may be present in an amount of at least about 10 weight percent (e.g., at least about 15 weight percent, at least about 20 weight percent, at least about 25 weight percent, at least about 30 weight percent, at least about 35 weight percent, at least about 40 weight percent, or at least about 45 weight percent) of the aerosol-forming substrate. The aerosol-forming agent may be present in an amount of about 50 weight% or less of the aerosol-forming substrate (e.g., about 45 weight% or less, about 40 weight% or less, about 35 weight% or less, about 30 weight% or less, about 25 weight% or less, about 20 weight% or less, or about 15 weight% or less).

[0083] In at least one exemplary embodiment, the aerosol-forming substrate further comprises a humectant. The humectant may be mixed and / or combined with a plant material and / or a fibrous material. The humectant may comprise propylene glycol, glycerol, butylene glycol, or any combination thereof. The humectant may be present in an amount of at least 10 weight percent of the aerosol-forming substrate (e.g., at least 15 weight percent, at least 20 weight percent, at least 25 weight percent, at least 30 weight percent, at least 35 weight percent, at least 40 weight percent, or at least 45 weight percent). The humectant may be present in an amount of at least 50 weight percent of the aerosol-forming substrate (e.g., at least 45 weight percent, at least 40 weight percent, at least 35 weight percent, at least 30 weight percent, at least 25 weight percent, at least 20 weight percent, or at least 15 weight percent).

[0084] In at least one exemplary embodiment, the aerosol-forming substrate comprises an encapsulated flavor agent. The encapsulated flavor agent may comprise a matrix or an encapsulating agent and a flavor agent. The flavor agent may be partially or completely encapsulated within the matrix. The encapsulated flavor agent may comprise one or more flavor agent regions. The flavor agent regions may be continuous throughout the matrix, or the encapsulated flavor agent may comprise a plurality of discontinuous flavor agent regions. In at least one exemplary embodiment, the encapsulated flavor agent further comprises a flavor agent carrier material as described in more detail below. In at least one exemplary embodiment, the encapsulated flavor agent further comprises a plasticizer, a cross-linking agent, a foaming agent, a filler, or any combination thereof as described in more detail below.

[0085] In at least one exemplary embodiment, the encapsulated flavorant comprises a matrix material in an amount of at least 15 wt% of the encapsulated flavorant (e.g., at least 20 wt%, at least 25 wt%, at least 30 wt%, at least 35 wt%, at least 40 wt%, at least 45 wt%, at least 50 wt%, at least 55 wt%, at least 60 wt%, at least 65 wt%, at least 70 wt%, at least 75 wt%, at least 80 wt%, at least 85 wt%, at least 90 wt%, or at least 95 wt%). The encapsulated flavoring agent may contain a matrix material in an amount of about 99.5 wt% or less of the encapsulated flavoring agent (e.g., about 95 wt% or less, about 90 wt% or less, about 85 wt% or less, about 80 wt% or less, about 75 wt% or less, about 70 wt% or less, about 65 wt% or less, about 60 wt% or less, about 55 wt% or less, about 50 wt% or less, about 45 wt% or less, about 40 wt% or less, about 35 wt% or less, about 30 wt% or less, about 25 wt% or less, or about 20 wt% or less). In at least one exemplary embodiment, the matrix comprises a film-forming material and / or a polymer.

[0086] In at least one exemplary embodiment, the matrix material is selected to have a desired melting temperature. The melting temperature may be suitable for an aerosol generating device. For example, the desired melting temperature may be sufficiently low to melt the matrix material, thereby allowing the flavoring agent to be released during the use of the aerosol generating device. The desired melting temperature may be sufficiently high to facilitate delayed release over the duration of use of the device, rather than releasing substantially all the flavoring agent immediately at once. In at least one exemplary embodiment, the flavoring agent may be released for a time of about 1 minute or more (e.g., about 2 minutes or more, about 3 minutes or more, about 4 minutes or more, about 5 minutes or more, about 6 minutes or more, about 7 minutes or more, about 8 minutes or more, about 9 minutes or more, about 10 minutes or more, or about 11 minutes or more). The flavor agent may be released for a time of 12 minutes or less (e.g., about 11 minutes or less, about 10 minutes or less, about 9 minutes or less, about 8 minutes or less, about 7 minutes or less, about 6 minutes or less, about 5 minutes or less, about 4 minutes or less, about 3 minutes or less, or about 2 minutes or less).

[0087] In at least one exemplary embodiment, the matrix comprises materials comprising methylcellulose, ethylcellulose, hydroxypropylmethylcellulose, starch, modified starch, pectin, gelatin, sodium alginate, maltodextrin, pullulan, xanthan, gum arabic, sodium carboxymethylcellulose, hydroxypropylcellulose, hydroxyethylcellulose, polyethylene oxide, polyvinyl alcohol, polyvinylpyrrolidone, low-density polyethylene, polyethylene glycol, polyester, polymethyl methacrylate, ethylene vinyl acetate, polymer-thickened sugar alcohols, waxes, fatty acid esters, copolymers thereof, or any combination thereof. It should be understood that commercially available modified starch includes CAPSUL®, but that many other modified starch products exist, such as CAPSUL TA®, HI-CAP 100®, and N-LOK®.

[0088] In at least one exemplary embodiment, the encapsulated flavoring comprises the flavoring in an amount of at least about 0.5 wt% of the encapsulated flavoring (e.g., at least about 1 wt%, at least about 2 wt%, at least about 3 wt%, at least about 5 wt%, at least about 7 wt%, at least about 10 wt%, at least about 15 wt%, at least about 20 wt%, at least about 25 wt%, at least about 30 wt%, at least about 35 wt%, at least about 40 wt%, at least about 45 wt%, at least about 50 wt%, at least about 55 wt%, at least about 60 wt%, at least about 65 wt%, at least about 70 wt%, at least about 75 wt%, at least about 80 wt%, or at least about 85 wt%). The encapsulated flavoring agent may contain a flavoring agent in an amount of about 90 wt% or less (e.g., about 85 wt% or less, about 80 wt% or less, about 75 wt% or less, about 70 wt% or less, about 65 wt% or less, about 60 wt% or less, about 55 wt% or less, about 50 wt% or less, about 45 wt% or less, about 40 wt% or less, about 35 wt% or less, about 30 wt% or less, about 25 wt% or less, about 20 wt% or less, about 15 wt% or less, about 10 wt% or less, about 7 wt% or less, about 5 wt% or less, about 3 wt% or less, about 2 wt% or less, or about 1 wt% or less). In at least one exemplary embodiment, the flavoring agent comprises menthol, peppermint, spearmint, wintergreen, cinnamon, chocolate, vanillin, licorice, clove, anise, sandalwood, geranium, rose, vanilla, lemon, cassia, fennel, ginger, ethyl acetate, isoamyl acetate, propyl isobutyrate, isobutylbutyrate, ethyl butyrate, ethyl valerate, benzyl formate, limonene, cymene, pinene, linalool, geraniol, citronellol, citral, orange, coriander, borneol, fruit extract, coffee, tea, cocoa, mint, terpene(s), or any combination thereof.Terpenes may include 8-mysene, 8-caryophyllene, di-limonene, linalool, pulegone, 1,8-cineole, alpha-pinene, alpha-terpineol, terpinene-4-ol, para-cymene, or any combination thereof.

[0089] In at least one exemplary embodiment, the encapsulated flavoring agent comprises nicotine and / or cannabinoid(s). In at least one other embodiment, the encapsulated flavoring agent substantially does not contain nicotine and cannabinoid.

[0090] In at least one exemplary embodiment, the encapsulated flavor agent comprises a carrier material. The flavor agent may be absorbed, adsorbed, and / or coated onto the carrier material.

[0091] A carrier material having a flavor agent within and / or on it may be embedded within the matrix and / or dispersed throughout. The encapsulated flavor agent may comprise the carrier material in an amount of at least about 0.01 wt% of the encapsulated flavor agent (e.g., at least about 0.1 wt%, at least about 1 wt%, at least about 5 wt%, at least about 10 wt%, at least about 15 wt%, at least about 20 wt%, at least about 25 wt%, at least about 30 wt%, at least about 35 wt%, at least about 40 wt%, at least about 45 wt%, at least about 50 wt%, at least about 55 wt%, at least about 60 wt%, at least about 65 wt%, at least about 70 wt%, at least about 75 wt%, at least about 80 wt%, at least about 85 wt%, or at least about 90 wt%). The encapsulated flavoring agent may contain a carrier material in an amount of about 95% by weight or less of the encapsulated flavoring agent (e.g., about 90% by weight or less, about 85% by weight or less, about 80% by weight or less, about 75% by weight or less, about 70% by weight or less, about 65% by weight or less, about 60% by weight or less, about 55% by weight or less, about 50% by weight or less, about 45% by weight or less, about 40% by weight or less, about 35% by weight or less, about 30% by weight or less, about 25% by weight or less, about 20% by weight or less, about 15% by weight or less, about 10% by weight or less, about 5% by weight or less, about 1% by weight or less, about 0.1% by weight or less, or about 1% by weight or less). The carrier may be in the form of a plurality of particles, granules, cut pieces, shreds, fibers, flakes, or any combination thereof. In at least one exemplary embodiment, the carrier material comprises cellulose, a cellulose derivative, silica, pectin, starch, modified starch, a starch derivative, or a combination thereof. In at least one exemplary embodiment, the cellulose comprises microcrystalline cellulose. In at least one exemplary embodiment, the cellulose comprises tobacco.

[0092] In at least one exemplary embodiment, the encapsulated flavoring comprises a plasticizer. The plasticizer may be combined with and / or dispersed throughout the matrix material so that the plasticizer becomes part of the matrix. The plasticizer may be present in the encapsulated flavoring in an amount of at least about 0.5 wt% of the encapsulated flavoring (e.g., at least about 1 wt%, at least about 5 wt%, at least about 10 wt%, at least about 15 wt%, at least about 20 wt%, at least about 25 wt%, or at least about 30 wt%). The plasticizer may be present in the encapsulated flavoring in an amount of at least about 35 wt% of the encapsulated flavoring (e.g., at least about 30 wt%, at least about 25 wt%, at least about 20 wt%, at least about 15 wt%, at least about 10 wt%, at least about 5 wt%, or at least about 1 wt%). The plasticizer may comprise water, propylene glycol, butanediol, glycerin, sugar alcohol(s), vegetable oil(s), triglyceride(s) (e.g., short-chain, medium-chain, and / or long-chain triglycerides), phthalate(s), ester(s) of polycarboxylic acids having medium-chain straight-chain or branched-chain aliphatic alcohols, or any combination thereof. In at least one exemplary embodiment, in addition to the plasticizer or as an alternative, other components within the encapsulated flavoring agent, e.g., nicotine, cannabinoid(s), and / or flavoring agent(s) may additionally function as plasticizers. In at least one other embodiment, the encapsulated flavoring agent does not contain a plasticizer.

[0093] In at least one exemplary embodiment, the encapsulated flavor agent comprises a crosslinking agent. The crosslinking agent may be combined with and / or dispersed throughout the matrix material so that the crosslinking agent becomes part of the matrix. The crosslinking agent may be present in the encapsulated flavor agent in an amount of at least about 0.01 wt% of the encapsulated flavor agent (e.g., at least about 0.1 wt%, at least about 1 wt%, at least about 5 wt%, at least about 10 wt%, at least about 15 wt%, at least about 20 wt%, or at least about 25 wt%). The crosslinking agent may be present in the encapsulated flavor agent in an amount of at least about 30 wt% of the encapsulated flavor agent (e.g., at least about 25 wt%, at least about 20 wt%, at least about 15 wt%, at least about 10 wt%, at least about 5 wt%, at least about 1 wt%, or at least about 0.1 wt%). The crosslinking agent may include calcium ions (Ca2+), sodium ions (Na+), polyol(s), polyacid(s), epichlorohydrin, or any combination thereof. In at least one other embodiment, the encapsulated flavor agent does not contain a crosslinking agent.

[0094] In at least one exemplary embodiment, the encapsulated flavor agent comprises a foaming agent. The foaming agent may be combined with and / or dispersed throughout the matrix material so that the foaming agent becomes part of the matrix. The foaming agent may be present in the encapsulated flavor agent in an amount of at least about 0.5 wt% of the encapsulated flavor agent (e.g., at least about 1 wt%, at least about 5 wt%, at least about 10 wt%, at least about 15 wt%, at least about 20 wt%, at least about 25 wt%, at least about 30 wt%, at least about 35 wt%, at least about 40 wt%, at least about 45 wt%, at least about 50 wt%, at least about 55 wt%, at least about 60 wt%, or at least about 65 wt%). The foaming agent may be present in the encapsulated flavoring agent in an amount of about 70 weight percent or less (e.g., about 65 weight percent or less, about 60 weight percent or less, about 55 weight percent or less, about 50 weight percent or less, about 45 weight percent or less, about 40 weight percent or less, about 35 weight percent or less, about 30 weight percent or less, about 25 weight percent or less, about 20 weight percent or less, about 15 weight percent or less, about 10 weight percent or less, about 5 weight percent or less, or about 1 weight percent or less). The foaming agent may comprise bicarbonate, liquid CO2, gelatin, alginic acid, sodium alginate, potassium alginate, ammonium alginate, calcium alginate, propane-1,2-diol alginate, xanthan gum, mono and diglycerides of fatty acids, acetic acid esters of mono and diglycerides of fatty acids, lactic acid esters of mono and diglycerides of fatty acids, sucrose esters of fatty acids, polyglycerol esters of fatty acids, propane-1,2-diol fatty acid esters, sodium stearoyl-2-lactylate, calcium stearoyl-2-lactylate, quillaya extract, or any combination thereof. In at least one other embodiment, the encapsulated flavor agent does not contain a foaming agent.

[0095] In at least one exemplary embodiment, the encapsulated flavoring agent comprises a filler. The filler may be combined with and / or dispersed throughout the matrix material so that the filler becomes part of the matrix. The filler material may be a solid, such as a powder, ground tobacco, microcrystalline cellulose, cellulose nanocrystals, cellulose material(s), starch(s), modified starch(s), starch derivative(s), titanium dioxide, calcium carbonate, natural mineral(s), or any combination thereof. The filler may be present in the encapsulated flavoring in an amount of about 0.5 weight% or more of the encapsulated flavoring (e.g., about 1 weight% or more, about 5 weight% or more, about 10 weight% or more, about 15 weight% or more, about 20 weight% or more, about 25 weight% or more, about 30 weight% or more, about 35 weight% or more, about 40 weight% or more, about 45 weight% or more, about 50 weight% or more, about 55 weight% or more, about 60 weight% or more, about 65 weight% or more, or about 70 weight% or more). The filler material may be present in the encapsulated flavoring agent in an amount of about 75 weight percent or less of the encapsulated flavoring agent (e.g., about 70 weight percent or less, about 65 weight percent or less, about 60 weight percent or less, about 55 weight percent or less, about 50 weight percent or less, about 45 weight percent or less, about 40 weight percent or less, about 35 weight percent or less, about 30 weight percent or less, about 25 weight percent or less, about 20 weight percent or less, about 15 weight percent or less, about 10 weight percent or less, about 5 weight percent or less, or about 1 weight percent or less).

[0096] In at least one exemplary embodiment, the encapsulated flavoring is in the form of a plurality of pellets, particles, granules, cut pieces, crushed pieces, flakes, or any combination thereof. The encapsulated flavoring may have an average particle size of about 5 μm or more (e.g., about 10 μm or more, about 15 μm or more, about 20 μm or more, about 25 μm or more, about 50 μm or more, approximately 100 μm or more, approximately 150 μm or more, approximately 200 μm or more, approximately 250 μm or more, up to about 300 μm or more, approximately 350 μm or more, approximately 400 μm or more, up to about 450 μm or more, approximately 0.5 mm or more, approximately 0.75 mm or more, approximately 1 mm or more, approximately 1.25 mm or more, approximately 1.5 mm or more, approximately 1.75 mm or more, or approximately 2 mm or more, or approximately 2.25 mm or more). The encapsulated flavoring agent may have an average particle size of about 2.5 mm or less (e.g., about 2.25 mm or less, about 2 mm or less, about 1.75 mm or less, about 1.5 mm or less, about 1.25 mm or less, about 1 mm or less, about 0.75 mm or less, about 0.5 mm or less, about 450 μm or less, about 400 μm or less, about 350 μm or less, about 300 μm or less, about 250 μm or less, about 200 μm or less, about 150 μm or less, about 100 μm or less, about 50 μm or less, about 25 μm or less, about 20 μm or less, about 15 μm or less, or about 10 μm or less).

[0097] In at least one exemplary embodiment, the aerosol-forming substrate may comprise an encapsulated flavoring agent. The encapsulated flavoring agent may be dispersed throughout the aerosol-forming substrate. For example, the encapsulated flavoring agent may be mixed with a vegetable and / or fibrous material (e.g., tobacco). The distribution of the encapsulated flavoring agent throughout the aerosol-forming substrate may be non-uniform or substantially uniform.

[0098] Additionally or alternatively, the encapsulated flavor agent may be present as a coating on the surface of the capsule, as described in more detail in the following discussion accompanying FIG. 10. Additionally or alternatively, the encapsulated flavor agent may be present as a coating on a surface fluidly communicating with an aerosol passage. For example, the encapsulated flavor agent may be within the mouthpiece and fluidly communicating with an aerosol passage, and may be a coating on the surface of the mouthpiece of an aerosol generating device, as described in more detail in the following discussion accompanying FIG. 10, and / or in a molded or loose form within an area of ​​the mouthpiece. Additionally or alternatively, the encapsulated flavor agent may be embedded within the mouthpiece itself.

[0099] In at least one exemplary embodiment, the capsule has an inhalation resistance (RTD) of about 30 mmH2O or more (e.g., about 40 mmH2O or more, about 50 mmH2O or more, about 60 mmH2O or more, about 70 mmH2O or more, about 80 mmH2O or more, about 90 mmH2O or more, about 100 mmH2O or more, about 110 mmH2O or more, or about 120 mmH2O or more). In at least one exemplary embodiment, the inhalation resistance (RTD) is about 130 mmH2O or less (e.g., about 120 mmH2O or less, about 110 mmH2O or less, about 100 mmH2O or less, about 90 mmH2O or less, about 80 mmH2O or less, about 70 mmH2O or less, about 60 mmH2O or less, about 50 mmH2O or less, or about 40 mmH2O or less). In at least one exemplary embodiment, the resistance to inhalation (RTD) is in the range of about 60 mmH2O to about 80 mmH2O (e.g., about 65 mmH2O to about 75 mmH2O, about 67 mmH2O to about 73 mmH2O, or about 69 mmH2O to about 71 mmH2O). In at least one exemplary embodiment, the resistance to inhalation (RTD) is caused at least partially by an aerosol-forming substrate within the capsule.

[0100] In at least one exemplary embodiment, the aerosol-forming substrate is about 0.2 g / cm³ 3 Ideal (e.g., about 0.25 g / cm³) 3 Above, approximately 0.3 g / cm³ 3 Above, approximately 0.35 g / cm³ 3 Above, approximately 0.4 g / cm³ 3 Above, approximately 0.45 g / cm³ 3 Above, approximately 0.5 g / cm³ 3 Above, approximately 0.55 g / cm³ 3 Above, approximately 0.6 g / cm³ 3 Above, approximately 0.65 g / cm³ 3 Above, approximately 0.7 g / cm³ 3 Above, approximately 0.75 g / cm³3 Above, approximately 0.8 g / cm³ 3 Above, approximately 0.85 g / cm³ 3 Above, approximately 0.9 g / cm³ 3 Above, approximately 0.95 g / cm³ 3 Above, approximately 1 g / cm³ 3 Above, approximately 1.05 g / cm³ 3 Above, approximately 1.1 g / cm³ 3 Above, or about 1.15 g / cm³ 3 It has an apparent density of (above). In at least one exemplary embodiment, the apparent density is about 1.2 g / cm³. 3 Less than (e.g., about 1.15 g / cm³) 3 Below, approximately 1.1 g / cm³ 3 Below, approximately 1.05 g / cm³ 3 Below, approximately 1 g / cm³ 3 Below, approximately 0.95 g / cm³ 3 Below, approximately 0.9 g / cm³ 3 Below, approximately 0.8 g / cm³ 3 Below, approximately 0.75 g / cm³ 3 Below, approximately 0.7 g / cm³ 3 Below, approximately 0.65 g / cm³ 3 Below, approximately 0.6 g / cm³ 3 Below, approximately 0.55 g / cm³ 3 Below, approximately 0.5 g / cm³ 3 Below, approximately 0.45 g / cm³ 3 Below, approximately 0.4 g / cm³ 3 Below, approximately 0.35 g / cm³ 3 Below, approximately 0.3 g / cm³ 3 Less than, or about 0.25 g / cm³ 3 (Below). In at least one exemplary embodiment, the apparent density is about 0.2 g / cm³. 3 Up to about 1.2 g / cm³ 3 (e.g., about 0.3 g / cm³) 3 Up to about 0.5 g / cm³ 3 , approximately 0.35 g / cm³ 3 Up to about 0.45 g / cm³ 3, or about 0.37 g / cm³ 3 Up to about 0.43 g / cm³ 3 It is the range of ).

[0101] In at least one exemplary embodiment, the plant and / or fibrous material of the aerosol-forming substrate (e.g., tobacco) has a particulate form having an average particle size (e.g., diameter) of about 100 μm or more (e.g., about 125 μm or more, about 150 μm or more, about 200 μm or more, about 225 μm or more, about 250 μm or more, about 275 μm or more, about 280 μm or more, about 290 μm or more, about 300 μm or more, about 310 μm or more, about 320 μm or more, about 330 μm or more, about 340 μm or more, about 350 μm or more, about 360 μm or more, about 370 μm or more, about 380 μm or more, about 390 μm or more, about 400 μm or more, about 410 μm or more, about 425 μm or more, about 450 μm or more, approximately 475 μm or more, approximately 500 μm or more, approximately 600 μm or more, approximately 650 μm or more, approximately 700 μm or more, approximately 800 μm or more, approximately 900 μm or more, approximately 1000 μm or more, approximately 1100 μm or more, or approximately 1200 μm or more).In at least one exemplary embodiment, the average particle size is about 1250 μm or less (e.g., about 1200 μm or less, about 1100 μm or less, about 1000 μm or less, about 900 μm or less, about 800 μm or less, about 700 μm or less, about 650 μm or less, about 600 μm or less, about 550 μm or less, about 500 μm or less, about 475 μm or less, about 450 μm or less, about 425 μm or less, about 410 μm or less, about 400 μm or less, about 390 μm or less, about 380 μm or less, about 370 μm or less, about 360 μm or less, about 350 μm or less, about 340 μm or less, about 330 μm or less, about 320 μm or less, about 310 μm or less, about 300 μm or less, approximately 290 μm or less, approximately 280 μm or less, approximately 275 μm or less, approximately 250 μm or less, approximately 225 μm or less, approximately 200 μm or less, or approximately 150 μm or less).

[0102] In at least one exemplary embodiment, the aerosol-forming substrate has a 10th percentile diameter in the range of about 160 μm to about 225 μm. In at least one exemplary embodiment, the aerosol-forming substrate has a 50th percentile (or median) diameter in the range of about 200 μm to about 385 μm. In at least one exemplary embodiment, the aerosol-forming substrate has a 90th percentile diameter in the range of about 390 μm to about 635 μm.

[0103] FIG. 1 is a perspective view of a consolidated aerosol-forming substrate according to at least one exemplary embodiment.

[0104] In at least one exemplary embodiment, as illustrated in FIG. 1, the aerosol forming substrate (100) may comprise a first aerosol forming substrate (102a) and a second aerosol forming substrate (102b) to facilitate substrate loading during the assembly of the capsule. Each of the first aerosol forming substrate (102a) and the second aerosol forming substrate (102b) may be a molded form configured to maintain its shape to facilitate placement in an aligned manner within the chamber of the capsule. For example, the first aerosol forming substrate (102a) and the second aerosol forming substrate (102b) may be in the form of a rectangular sheet / slab of dimensions for insertion into the capsule.

[0105] FIG. 2 is a perspective view of another aerosol-forming substrate in a molded form according to at least one exemplary embodiment.

[0106] In at least one exemplary embodiment, as shown in FIG. 2, the aerosol forming substrate (200) may differ from the aerosol forming substrate (100) (shown in FIG. 1) in terms of its shape and dimensions. Otherwise, the aerosol forming substrate (200) may be the same as described in relation to the aerosol forming substrate (100). The aerosol forming substrate (200) may comprise a first aerosol forming substrate (202a) and a second aerosol forming substrate (202b), each of which may be in a molded form. For example, the first aerosol forming substrate (202a) and the second aerosol forming substrate (202b) may be in the form of a slab / pallet having a dimensioned semicircular cross-section for insertion into a capsule (e.g., the capsule (500) of FIG. 5 to 7).

[0107] FIG. 3 is a perspective view of a loose form aerosol-forming substrate according to at least one exemplary embodiment.

[0108] In at least one exemplary embodiment, as illustrated in FIG. 3, the aerosol forming substrate (300) may be in a loose form (e.g., particles, fibers, ground, fragments, crushed pieces) and is configured not to have a set shape but rather to take the shape of the available space within the chamber. When introduced into the capsule, specifically during assembly / loading, the loose form aerosol forming substrate (300) may partially or completely occupy the available space within the chamber of the capsule so as to be on each side of the intermediate section of the heater. For example, the loose form aerosol forming substrate (300) may be used to fill the gaps in the chamber (e.g., to fill a chamber already loaded with a molded form aerosol forming substrate). In another example, the loose form aerosol forming substrate (300) may be used to fill the entire chamber of the capsule. Furthermore, the aerosol forming substrate (300) may be loaded into the capsule via a vacuum-assisted process.

[0109] FIG. 4 is a perspective view of a rod-shaped aerosol-forming substrate according to at least one exemplary embodiment.

[0110] In at least one exemplary embodiment, as illustrated in FIG. 4, the aerosol-forming substrate (400) may be formed into the shape of a rod (402). The periphery of the aerosol-forming substrate (400) may be surrounded by a wrap (404). For example, the wrap (404) may be tipping paper. In at least one exemplary embodiment, the rod (402) may not be inside a capsule but may be used within an aerosol-generating device.

[0111] In at least one exemplary embodiment, the aerosol-forming substrate may be used within an aerosol-generating device, optionally within a capsule. The aerosol-forming substrate may comprise or be similar to an aerosol-forming substrate (100) (illustrated in FIG. 1), an aerosol-forming substrate (200) (illustrated in FIG. 2), and / or an aerosol-forming substrate (300) (illustrated in FIG. 3). The capsule may comprise an encapsulated flavoring agent as described above. The encapsulated flavoring agent may be present within the aerosol-forming substrate, on the surface of the capsule, within the mouthpiece, and / or elsewhere within the device (e.g., along the aerosol passage).

[0112] FIG. 5 is an upper right perspective view of a capsule according to at least one exemplary embodiment.

[0113] In at least one exemplary embodiment, as illustrated in FIG. 5, the capsule (500) has a housing (502) configured to accommodate an aerosol-forming substrate (e.g., the aerosol-forming substrate (200) of FIG. 2 and / or the aerosol-forming substrate (300) of FIG. 3). The downstream portion of the housing (502) may be in the form of a first end cap (506) (e.g., a downstream cap). The upstream portion of the housing (502) may be in the form of a second end cap (508) (e.g., an upstream cap, a connector cap). The main body portion of the housing may be in the form of a cover (510) (e.g., a shell, a box sleeve). The first end cap (506) may define a first opening (512). In the illustrated embodiment, the first opening (512) is in the form of a series of outflow openings (e.g., nine outflow openings).

[0114] FIG. 6 is a cross-sectional view of the capsule of FIG. 5 cut along line XI-XI according to at least one exemplary embodiment.

[0115] In at least one exemplary embodiment, as illustrated in FIG. 6, the housing (502) at least partially surrounds / encloses or accommodates the heater (600). The heater (600) is a conductive component comprising a first end section (602), an intermediate section (604), and a second end section (606). The intermediate section (604) is an inner segment configured to heat an aerosol-forming substrate within the capsule (500). The first end section (602) and the second end section (606) are outer segments configured to establish an electrical connection with a power source.

[0116] In at least one exemplary embodiment, the intermediate section (604) of the heater (600) has a planar and coiled shape similar to a compressed vibration or zigzag having a plurality of parallel segments (e.g., 8 to 16 parallel segments). However, it should be understood that other shapes for the intermediate section (604) of the heater (600) (e.g., spiral shape, flower shape) are also possible. The ends of the first end section (602) and the second end section (606) may be oriented to be orthogonal to the plane of the intermediate section (604). Each of the first end section (602) and the second end section (606) may also include a segment having a lateral J-shape. Consequently, the first end section (602) and the second end section (606) may be embedded relatively securely within the second end cap (508) while providing a pair of electrical contact surfaces.

[0117] The second end cap (508) may define a second opening (610). In the illustrated embodiment, the second opening (610) is in the form of a series of inlet openings (e.g., eight inlet openings). In at least one exemplary embodiment, the second end cap (508) may expose the first end section (602) and the second end section (606) of the heater (600). As illustrated, the second opening (610) may be located between the exposed portions of the first end section (602) and the second end section (606). The first end cap (506) and / or the second end cap (508) may be transparent to function as a window configured to allow observation of the contents / components (e.g., aerosol-forming substrate and / or heater) within the capsule (500).

[0118] In addition to the second opening (610), the second end cap (508) also defines a recess (612) and an inlet groove (614). The recess (612) and the inlet groove (614) may appear to be in a multi-level arrangement, wherein the base / inner end surface of the recess (612) exposing the first end section (602) and the second end section (606) may be considered to be in one level, while the base / inner end surface of the inlet groove (614) (or the grill-shaped surface of the second opening (610)) may be considered to be in another level. The recess (612) is configured to facilitate the placement of the capsule (500) during insertion into the device body of the aerosol generating device (e.g., the aerosol generating device (800) of FIGS. 8 and 9). In one embodiment, the alignment groove (612) has an inclined side wall that tapers inward toward the inlet groove (614). Due to the inclined side wall, the alignment groove (612) can be more easily and quickly coupled with a corresponding coupling member of the device body.

[0119] FIG. 7 is an exploded perspective view of the capsule of FIG. 5 according to at least one exemplary embodiment.

[0120] Referring to FIG. 7, the first end cap (506) includes a first sealing ridge (700), and the second end cap (508) includes a second sealing ridge (702). In one embodiment, the first sealing ridge (700) is in the form of a series of ribs (e.g., four ribs), and the second sealing ridge (702) is in the form of a series of ribs (e.g., four ribs). In some examples, each series of ribs may have different heights to ensure desired contact with the cover (510). When the capsule (500) is assembled, the first sealing ridge (700) of the first end cap (506) and the second sealing ridge (702) of the second end cap (508) are configured to interface with the inner surface of the cover (510) (e.g., via an interference fit) to provide an air seal. Consequently, when air is directed toward the capsule (500) during the operation of the aerosol generating device (e.g., the aerosol generating device (800) of FIGS. 8 and 9), the air will enter the capsule (500) through the inlet groove (614) and the second opening (610) in the second end cap (508) instead of entering the capsule (500) through the gap between the second end cap (508) and the cover (510) (wherein this air may essentially flow along the inner surface of the cover (510) to bypass the intermediate section (604) of the aerosol forming substrate and / or heater (600)). Similarly, by proper sealing, the aerosol generated within the chamber of the capsule (500) will flow out through the first opening (512) of the first end cap (506) instead of leaking out through the gap between the first end cap (506) and the cover (510).

[0121] FIG. 8 is a perspective view of an aerosol generating device having a cover in a closed position according to at least one exemplary embodiment.

[0122] In at least one exemplary embodiment, the aerosol generating device (800) (e.g., a non-combustion heating (HNB) aerosol generating device) has an overall elongated elliptical or pebble shape and has a replaceable mouthpiece (802) extending from the body of the aerosol generating device (800). For example, the aerosol generating device (800) may include a housing (804) that accommodates a capsule (e.g., a capsule (500) illustrated in FIGS. 5 through 7). The aerosol generating device (800) may further include a cover (806) configured to open and close with respect to the housing (804). The cover (806) may be configured to be coupled to the replaceable mouthpiece (802).

[0123] In at least one exemplary embodiment, the exterior of the housing (804) and / or cover (806) may be formed of metal (e.g., aluminum, stainless steel, etc.); aesthetic and food-contact grade plastic (e.g., polycarbonate (PC), acrylonitrile butadiene styrene (ABS) material, liquid crystal polymer (LCP), copolyester plastic, or any other suitable polymer and / or plastic); or any combination thereof. The replaceable mouthpiece (802) may similarly be formed of metal (e.g., aluminum, stainless steel, etc.); aesthetic and food-contact grade plastic (e.g., polycarbonate (PC), acrylonitrile butadiene styrene (ABS) material, liquid crystal polymer (LCP), copolyester plastic, or any other suitable polymer and / or plastic); and / or plant-based material (e.g., wood, bamboo, etc.). One or more inner surfaces of the housing (804) and / or cover (806) may be formed of or coated with a high-temperature plastic (e.g., polyetheretherketone (PEEK), liquid crystal polymer (LCP), etc.). The cover (806) and the housing (804) may be collectively considered as the main body of the aerosol generating device (800).

[0124] In at least one exemplary embodiment, the housing (804) encloses or accommodates a latch release mechanism, a power supply, and a processing or control circuit for the cover (806). The control circuit may be hardware including a logic circuit; a hardware / software combination such as a processor executing software; or a combination thereof. For example, the control circuit may include, 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 device, a microprocessor, an application-specific integrated circuit (ASIC), etc. The supply of current from the power supply may respond to manual actions (e.g., button activation) or automatic actions (e.g., puff activation). The power supply may include one or more batteries (e.g., a rechargeable dual battery array, a lithium-ion battery, and / or a fuel cell). In at least some embodiments, the control circuit may further include a haptic motor that may be placed on one side of the power supply.

[0125] FIG. 9 is a partial perspective view of an aerosol generating device of FIG. 8 comprising a cartridge of FIG. 5 having a cover in an open position, according to at least one exemplary embodiment.

[0126] In at least one exemplary embodiment, as illustrated in FIG. 9, the housing (804) surrounds the capsule connector (900). Additionally, in some examples, the capsule connector (900) may be mounted on a printed circuit board (PCB) within the housing (804) or secured in another manner. In at least one exemplary embodiment, the capsule connector (900) defines a capsule receiving cavity (902).

[0127] In at least some embodiments, the control / heating method and the related circuit and electrical contact (e.g., a capsule connector (900) having electrical contact) may be as described in U.S. Application No. 17 / 151,375, filed January 18, 2021, titled “Heat-Not-Burn (HNB) Aerosol-Generating Devices Including Energy Based Heater Control, And Methods Of Controlling A Heater”; and U.S. Application No. 17 / 151,409, filed January 18, 2021, titled “Heat-Not-Burn (HNB) Aerosol-Generating Devices Including Intra-Draw Heater Control, And Methods Of Controlling A Heater”, the entire contents of which are incorporated herein by reference.

[0128] The capsule (500) is initially loaded into the aerosol generating device (800) by inserting the capsule (500) into the capsule receiving cavity (902) defined by the capsule connector (900). In at least one exemplary embodiment, the capsule (500) makes contact (e.g., full contact) with the electrical contact within the capsule receiving cavity (902) only when a force (e.g., downward / inward force) is applied to the capsule (500). In at least one exemplary embodiment, a force is applied to the capsule (500) by closing and / or latching the cover (806). In another embodiment, a force is applied to the capsule (500) by an adult consumer. In yet another embodiment, a force is applied to the capsule (500) by a combination of pressure applied by an adult consumer and closing and / or latching the cover (806). For example, in each example, force is applied until resistance is felt and / or a clicking sound is heard, which signals complete coupling of the capsule (500) within the capsule receiving cavity (902).

[0129] Further details and / or alternatives regarding aerosol generating devices, capsules, and / or aerosol forming substrates are in U.S. Application No. 17 / 151,277, filed January 18, 2021, titled "Capsules Including Embedded Heaters And Heat-Not-Burn (HNB) Aerosol-Generating Devices"; U.S. Application No. 17 / 151,327, filed January 18, 2021, titled "Heat-Not-Burn (HNB) Aerosol Generating Devices And Capsules"; U.S. Application No. 17 / 151,556, filed January 18, 2021, titled "Heat-Not-Burn (HNB) Aerosol-Generating Devices And Capsules"; U.S. Application No. 17 / 151,340, filed January 18, 2021, titled "Heat-Not-Burn (HNB) Aerosol Generating Devices And Capsules"; U.S. Application No. 17 / 947,436, filed September 19, 2022, titled "Heat-Not-Burn (HNB) Aerosol-Generating Devices And Capsules"; U.S. Application No. 17 / 981,973, filed November 7, 2022, titled "Capsules Having Electrical Contact Pads With Surface Discontinuities And Heat-Not-Burn (HNB) Aerosol-Generating Devices Including The Same"; U.S. Application No. 29 / 859,073, filed November 7, 2023, titled "Aerosol-Generating Capsules"; U.S. Application No. 29 / 890,076, filed November 7, 2022, titled "Electrical Contact Pads";The subject matter is found in U.S. Application No. 29 / 853,736, filed September 19, 2022, titled "Heat-Not-Burn Aerosol Generating Device With A Flip-Top Lid"; and U.S. Application No. 17 / 982,138, filed November 7, 2022, titled "Heat-Not-Burn (Hnb) Aerosol Generating Devices And Capsules Having Electrical Contact Pads With Surface Discontinuities," the full contents of which are incorporated herein by reference.

[0130] FIG. 10 is a cross-sectional view of the mouthpiece and capsule of the aerosol generating device of FIG. 8, not showing a heater, according to at least one exemplary embodiment.

[0131] In at least one exemplary embodiment, as illustrated in FIG. 10, the mouthpiece (802) extends between a first or downstream end (1000) and a second or upstream end (1002). The first end (1000) defines a mouthpiece outlet (1004). In the illustrated embodiment, the mouthpiece outlet (1004) includes a series of openings (e.g., five openings). The second end (1002) defines an opening or depression (1006) and a mouthpiece inlet (1008). The mouthpiece outlet (1004) and the inlet (1008) are fluidly connected by a mouthpiece channel (1010). The mouthpiece channel (1010) may be defined by an inner mouthpiece wall (1012).

[0132] In at least one exemplary embodiment, the mouthpiece seal (1020) may be on and / or near the second end (1002) of the mouthpiece (802). At least a portion of the mouthpiece seal (1020) is within the opening (1006) in the second end (1002) of the mouthpiece (802). The mouthpiece seal (1020) may include a top ridge (1022) extending along the circumference of the mouthpiece seal (1020). The top ridge (1022) is at least partially fitted within the opening (1006) to keep the mouthpiece seal (1020) fixed in place relative to the mouthpiece (802). In at least one exemplary embodiment, as illustrated, the mouthpiece seal (1020) defines a sealing channel (1024) that is at least partially aligned with the mouthpiece channel (1010). The sealing channel (1024) and the mouthpiece channel (1010) are in fluid communication with and / or lead to the outlet (1004) of the mouthpiece (802).

[0133] The capsule (500) is in fluid communication with the sealing channel (1024) and the mouthpiece channel (1010). In at least one exemplary embodiment, the first end cap (506) of the capsule (500) is coupled with the mouthpiece seal (1020). During use of the aerosol generating device (800) (shown in FIGS. 8 and 9), air may enter the capsule (500) through the inlet groove (614) and the second opening (514). Air and aerosol (formed, for example, by heating the aerosol-forming substrate within the capsule (500) with a heater (600)) may exit the capsule (500) through the first opening (512).

[0134] In at least one exemplary embodiment, the encapsulated flavoring agent may be contained within a capsule (500) and / or an aerosol generating device (800) (illustrated in FIG. 8 and 9), for example, within a mouthpiece (802). Additionally or alternatively, the encapsulated flavoring agent may be contained within an aerosol forming substrate as described above. The encapsulated flavoring agent may be positioned to be in fluid communication with an airflow path and configured to be heated by a heater (600) (illustrated in FIG. 6). The encapsulated flavoring agent may be in the form of a substantially uniform film, a coating (e.g., a coating of particles, granules, cut pieces, crushed pieces, and / or flakes of the encapsulated flavoring agent), and / or loose pellets, particles, granules, cut pieces, crushed pieces, and / or flakes.

[0135] In at least one exemplary embodiment, a first coating or film (1030) of the encapsulated flavoring agent is on the inner cover surface (1032) of the cover (510) of the capsule (500). The first coating (1030) may cover a portion of the inner cover surface (1032) as illustrated, or may cover the entire inner cover surface (1032). Additionally or alternatively, a second coating or film (1034) may be on the first inner end cap surface (1036). The second coating (1034) may cover a portion of the first inner cap surface (1036) as illustrated, or may cover the entire first inner cap surface (1036). Additionally or alternatively, the coating or film may be on the second inner end cap surface (1038) and / or the surface(s) (1040) defining the first opening (512). In at least one exemplary embodiment, a third coating or film (1042) is on the inner mouthpiece surface (1044). The third coating (1042) may cover a portion of the inner mouthpiece surface (1044) as illustrated, or may cover the entire inner mouthpiece surface (1044). Additionally or alternatively, the coating may be present on the inner sealing surface (1046) and / or the surface(s) (1048) defining the mouthpiece outlet (1004). Accordingly, the encapsulated flavoring may be present as a coating on the inner cover surface (1032), the first inner cap surface (1036), the second inner cap surface (1038), the surface(s) (1040) defining the first opening (512), the inner mouthpiece surface (1044), the inner sealing surface (1046), and / or the surface(s) (1048) defining the mouthpiece outlet (1004).

[0136] In at least one exemplary embodiment, a coating comprising an encapsulated flavor agent (e.g., first, second, and / or third coating 1030, 1034, 1042) has a thickness of about 1 μm or more (e.g., about 5 μm or more, about 10 μm or more, about 15 μm or more, about 20 μm or more, about 25 μm or more, about 50 μm or more, about 100 μm or more, about 150 μm or more, about 200 μm or more, about 250 μm or more, about 300 μm or more, about 350 μm or more, about 400 μm or more, about 450 μm or more, about 0.5 mm or more, about 0.75 mm or more, about 1 mm or more, or about 1.25 mm or more). The thickness may be about 1.5 mm or less (e.g., about 1.25 mm or less, about 1 mm or less, about 0.75 mm or less, about 0.5 mm or less, about 400 μm or less, about 350 μm or less, about 300 μm or less, about 250 μm or less, about 200 μm or less, about 150 μm or less, about 100 μm or less, about 50 μm or less, about 25 μm or less, about 20 μm or less, about 15 μm or less, about 10 μm or less, or about 5 μm or less).

[0137] In at least one exemplary embodiment, in addition to being mixed with an aerosol-forming substrate and / or being in a coating, the encapsulated flavor agent may be embedded within the mouthpiece (e.g., adjacent to the mouthpiece inlet, adjacent to the mouthpiece outlet, and / or in the middle portion of the mouthpiece). Additionally or alternatively, the encapsulated flavor agent may be present within one of the walls defining the mouthpiece (e.g., the inner mouthpiece wall (1012)). For example, the flavor agent may be embedded within the polymer forming the walls.

[0138] FIG. 11 is a flowchart illustrating a method for manufacturing an encapsulated flavor agent according to at least one exemplary embodiment.

[0139] In at least one exemplary embodiment, as illustrated in FIG. 11, a method for preparing an encapsulated flavor agent comprises the step of preparing a first film-forming solution in S1100. The method further comprises the step of mixing the flavor agent with the first film-forming solution in S1104. The method further comprises the step of preparing a film precursor in S1108. The method further comprises the step of preparing a flavor film (i.e., an encapsulated flavor agent) in S1112. The method may optionally further comprise the step of forming a multilayer flavor film in S1116. The method may optionally comprise the step of preparing a plurality of particles, granules, cut pieces, crushed pieces, and / or flakes from the flavor film in S1120. Each of these steps is described in more detail below.

[0140] In S1100, the method may include the step of preparing a first film-forming solution. In at least one exemplary embodiment, the step of preparing the first film-forming solution includes the step of dissolving a first film-forming material in a first solvent. The first film-forming material may include methyl cellulose, ethyl cellulose, hydroxypropyl ethyl cellulose, starch, modified starch, polyvinylpyrrolidone, carrageenan, carboxymethylcellulose, gum arabic, pectin, pullulan, sodium alginate, xanthan gum, casein, whey protein, soy protein, cornein, gelatin, or any combination thereof. The solvent may be a polar solvent (e.g., water and / or ethanol) or a non-polar solvent. The step of preparing the first film-forming solution may further include the step of stirring or shaking the first film-forming solution for a desired (or alternatively, predetermined) time at a desired (or alternatively, predetermined) temperature.

[0141] In one example, the preparing step comprises dispersing a first film-forming material in a first solvent at a first temperature. The method may further comprise a step of hydrating the first film-forming material by lowering the temperature of the first solvent to a second temperature lower than the first temperature. The lowering step may include a step of adding an additional or different solvent(s) to the first solvent, wherein the additional or different solvent(s) are at a temperature lower than the first temperature. The method may further comprise a step of dissolving the first film-forming material in the first solvent at a second temperature.

[0142] In S1104, the method comprises the step of mixing a flavoring agent and a first film-forming solution. The mixing step may include stirring or shaking the first film-forming solution and the flavoring agent at a desired temperature (e.g., room temperature) for a desired (or alternatively, predetermined) time. In at least one exemplary embodiment, the mixing step comprises the step of making the film-forming material and the flavoring agent co-conjugate by dissolving the flavoring agent in a first solvent. The flavoring agent may be added after, simultaneously with, or before S1100. In another example, the flavoring agent may be dissolved in a second solvent to form a flavoring solution, and the flavoring solution may be mixed with and / or blended with the first film-forming solution. The second solvent may be the same as the first solvent or different from the first solvent.

[0143] In at least one other embodiment, the mixing step comprises the step of dispersing a flavoring agent in a first solvent. In one example, the dispersing step comprises the step of dispersing a flavoring agent powder in a first solvent.

[0144] In another example, the flavoring agent is in a second film-forming solution dispersed in a first film-forming solution. The method may include the step of preparing a second film-forming solution by dissolving the flavoring agent and a second film-forming material in a second solvent. The second solvent may have a polarity different from that of the first solvent. For example, the second film-forming solution may be an oil phase, which is dispersed in the first film-forming solution, which is an aqueous phase. The dispersing step may be performed in the absence or in the presence of a surfactant.

[0145] In another example, the flavor agent is in the form of flavor agent-carrier particles. The method may include the step of preparing flavor agent-carrier particles. The step of preparing flavor agent-carrier particles may include the step of absorbing, adsorbing, and / or coating the flavor agent into / on the carrier material. For example, a flavor solution may be prepared by dissolving the flavor agent in a solvent, and then a dispersion may be formed by combining and / or mixing the solution with the carrier material. The dispersion may be dried to reduce or remove the solvent, such as by casting the dispersion onto a surface and evaporating the solvent, with or without applying heat.

[0146] In S1108, the method comprises the step of preparing a film precursor. The step of preparing the film precursor may include the step of casting a film-forming solution having a flavoring agent inside onto a surface. The surface may be on a glass panel. The method may further include the step of moving a blade across the surface of the cast solution to achieve a desired (or alternatively, a predetermined) thickness and / or uniformity of the film precursor.

[0147] In S1112, the method comprises the step of preparing a flavor film (i.e., an encapsulated flavor agent). The step of preparing the flavor film may include the step of drying a film precursor. Drying may be performed for a desired (or alternatively, a predetermined) time. Drying may be performed at room temperature or by applying heat. Accordingly, drying may include the step of heating the film precursor to a desired (or alternatively, a predetermined) temperature. In one example, drying is performed in a vacuum oven.

[0148] In S1116, the method optionally includes the step of forming a multilayer film. The step of forming a multilayer film includes the step of forming one or more secondary films on the flavor film. The secondary film may be identical to the flavor film or different from the flavor film. The secondary film may differ in terms of the type of flavoring agent, the presence or absence of the flavoring agent (e.g., the absence of the flavoring agent), the amount of the flavoring agent, the thickness, and / or the film-forming material. The secondary film may be formed by repeating S1100, optionally S1104 (i.e., if the secondary film contains the flavoring agent), S1108, and S1112. In S1108, the surface may be the surface of the flavor film. In one example, the flavor film is sandwiched between two plain or flavor-free films.

[0149] In S1120, the method optionally includes the step of producing a plurality of particles, granules, cut pieces, shredded pieces, and / or flakes from a flavor film. In at least one exemplary embodiment, S1120 includes the step of grinding, milling, shredding, and / or cross-cutting the film to form a plurality of particles, granules, cut pieces, shredded pieces, and / or flakes.

[0150] FIG. 12 is a flowchart illustrating another method of manufacturing an encapsulated flavor agent according to at least one exemplary embodiment.

[0151] In at least one exemplary embodiment, as illustrated in FIG. 12, a method for manufacturing an encapsulated flavor agent comprises the step of preparing a polymer melt in S1200. The method further comprises the step of preparing a mixture comprising a polymer and a flavor agent in S1204. The method optionally comprises the step of blending a polymer and a filler in S1208. The method further comprises the step of forming an encapsulated flavor agent precursor in S1212. The method further comprises the step of forming an encapsulated flavor agent in S1216. The method may optionally further comprise the step of manufacturing a plurality of particles, granules, cut pieces, crushed pieces, and / or flakes from the encapsulated flavor agent in S1220. Each of these steps is described in more detail below.

[0152] In S1200, the method comprises the step of preparing a polymer melt. The step of preparing the polymer melt may include the step of heating the polymer to a desired (or alternatively, predetermined) temperature. The method may include the step of stirring and / or shaking the polymer while heating. In at least one exemplary embodiment, the polymer is substantially solvent-free. In at least one exemplary embodiment, the polymer melt comprises a polymer and a plasticizer. In at least one exemplary embodiment, such as a hot melt extrusion (HME) process, the polymer may be heated to a plurality of desired temperatures in a plurality of respective zones.

[0153] In S1204, the method further comprises the step of preparing a mixture comprising a polymer and a flavoring agent. The polymer may comprise the matrix materials described above. The polymer may comprise a thermoplastic polymer. In one example, the polymer comprises low-density polyethylene, polyethylene glycol, polyurethane, poly(methyl methacrylate), ethylene vinyl acetate, ethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methyl cellulose, or any combination thereof. The flavoring agent may be in the form of a liquid, solution, and / or a solid (e.g., powder, flavoring agent-carrier particles). The flavoring agent may comprise a plurality of flavoring agents, each flavoring agent being independently in the form of a liquid, solution, or solid.

[0154] Step S1204 of preparing the mixture may be performed after S1200, simultaneously with S1200, or before preparing the polymer melt in S1200. In at least one exemplary embodiment, Step S1204 of preparing the mixture is performed after Step S1200 of preparing the polymer melt by adding flavoring agents to the polymer melt (e.g., through one or more funnels in the extruder). In at least one exemplary embodiment, Step S1204 of preparing the mixture is performed simultaneously with Step S1200 of preparing the polymer melt by adding the flavoring agent to the extruder (e.g., through another funnel) at the same time as adding the polymer solid (e.g., resin, powder) to the extruder. In at least one exemplary embodiment, Step S1204 of preparing the mixture is performed simultaneously with Step S1200 of preparing the polymer melt by adding the flavoring agent to the extruder after adding the polymer solid to the extruder and before the polymer solid is completely melted. In at least one exemplary embodiment, the step S1204 of preparing the mixture is performed prior to the step S1200 of preparing the polymer melt by mixing the polymer solid with the flavoring agent to form a mixture before adding the obtained mixture to the extruder. In at least one exemplary embodiment, such as the HME process, a number of flavoring agents are added at different points within the process, for example, in different zones of the extruder. In another exemplary embodiment, a number of flavoring agents are combined with the polymer simultaneously.

[0155] In at least one exemplary embodiment, the flavor agent is in the form of flavor agent-carrier particles. The method may include the step of preparing flavor agent-carrier particles. The step of preparing flavor agent-carrier particles may include the step of absorbing, adsorbing, and / or coating the flavor agent into / on the carrier material. For example, a flavor solution may be prepared by dissolving the flavor agent in a solvent, and then a dispersion may be formed by combining and / or mixing the solution with the carrier material. The dispersion may be dried to reduce or remove the solvent, such as by casting the dispersion onto a surface and evaporating the solvent, with or without applying heat.

[0156] In S1208, the method optionally includes the step of combining a polymer and a filler. The filler may be in the form of a powder or other solid. In at least one exemplary embodiment, the filler comprises ground tobacco, microcrystalline cellulose, starch, modified starch, or any combination thereof. S1208 may be performed simultaneously with S1200 and / or S1204, or sequentially. In at least one exemplary embodiment, such as an HME process, the filler may be added in one section of the extruder.

[0157] In S1212, the method further comprises the step of forming an encapsulated flavor precursor. The step of forming the encapsulated flavor precursor may include the step of extruding or blow-molding the polymer and flavor melt. Extrusion may be performed using a single-screw extruder, a co-rotating twin-screw extruder, or a bi-rotating twin-screw extruder. The method may include the step of extruding the polymer and flavor melt through a die such as a ribbon die, a rod die, or a die having a desired cross-sectional shape such as an elliptical, square, star shape, or other shape. The die may include one or more openings having the desired shape. In at least one exemplary embodiment, the extruder is in the form of one or more thin rods or filaments, and such rods have a diameter of about 0.1 mm or more (e.g., about 0.5 mm or more, about 1 mm or more, about 5 mm or more, about 10 mm or more, about 15 mm or more, or about 20 mm or more). The rod may have a diameter of about 25 mm or less (e.g., about 20 mm or less, about 15 mm or less, about 15 mm or less, about 10 mm or less, about 5 mm or less, about 1 mm or less, or about 0.5 mm or less).

[0158] In S1216, the method further comprises the step of forming an encapsulated flavor agent. The step of forming an encapsulated flavor agent may include the step of cooling an encapsulated flavor agent precursor. In at least one exemplary embodiment, the encapsulated flavor agent precursor may be cooled at room temperature. The method may include the step of transferring the encapsulated flavor agent precursor through one or more fans and / or through a water bath. In at least one exemplary embodiment, cooling may be performed for a duration of about 5 seconds or more (e.g., about 10 seconds or more, about 15 seconds or more, about 30 seconds or more, about 45 seconds or more, about 1 minute or more, about 2 minutes or more, about 3 minutes or more, about 4 minutes or more, about 5 minutes or more, about 7.5 minutes or more, or about 10 minutes or more). The duration may be about 15 minutes or less (e.g., about 10 minutes or less, about 7.5 minutes or less, about 5 minutes or less, about 4 minutes or less, about 3 minutes or less, about 2 minutes or less, about 1 minute or less, about 45 seconds or less, about 30 seconds or less, about 15 seconds or less, or about 10 seconds or less).

[0159] In S1220, the method further comprises the step of producing a plurality of pellets, particles, granules, cut pieces, crushed pieces, and / or flakes from an optionally encapsulated flavoring agent. S1220 may be performed sequentially after S1216, before S1216, or simultaneously with S1215. In at least one exemplary embodiment, the grinding process is performed after the completion of S1212. In at least one other exemplary embodiment, a hot-face cutter is used to cut the extruder as it is discharged from the die. The hot extruder is then transferred to a receiving / cooling chamber for cooling (e.g., vacuum transfer) and then transferred to a collection chamber (e.g., drop) after a desired (or alternatively, predetermined) cooling or holding time.

[0160] In at least one exemplary embodiment, a plurality of pellets, particles, granules, cut pieces, crushed pieces, and / or flakes are mixed or blended with the remaining components of the aerosol-forming substrate (e.g., tobacco, cellulose, etc.). In at least one exemplary embodiment, the mixing step is performed in a tumbler mixer. The mixing step may be performed for a duration of at least one minute (e.g., at least two minutes, at least five minutes, at least ten minutes, at least fifteen minutes, at least twenty minutes, at least thirty minutes, at least fourty minutes, at least fifty minutes, at least sixty minutes, at least seventy minutes, at least eighty minutes, at least ninety minutes, at least tenty minutes, or at least tenty minutes, or at least tenty minutes). The duration may be about 120 minutes or less (e.g., about 110 minutes or less, about 100 minutes or less, about 90 minutes or less, about 80 minutes or less, about 70 minutes or less, about 60 minutes or less, about 50 minutes or less, about 40 minutes or less, about 30 minutes or less, about 20 minutes or less, about 10 minutes or less, about 5 minutes or less, or about 2 minutes or less).

[0161] FIG. 13A is a schematic diagram of a method for preparing a flavor agent encapsulated by HME according to at least one exemplary embodiment.

[0162] In at least one exemplary embodiment, steps S1200, S1204, S1208, S1212, S1216, and S1220 illustrated in FIG. 12 are performed as a continuous process using a single machine such as an HME process. As illustrated in FIG. 13A, in at least one exemplary embodiment, the HME process may generally include the step of feeding pellets and / or granules of a polymer (1320) into a feeder (1302) of an extruder (1304). These polymer pellets and / or granules (1320) may optionally be mixed with one or more first flavoring agents (1306) while or before being fed into the extruder (1304). The HME process further includes the step of melting and / or softening the polymer using heat and / or pressure. The above method may further include the step of passing a polymer (and an optional first flavor agent) through a plurality of zones, each zone having a desired (or alternatively, a predetermined) temperature. The number of zones may be about 2 or more (e.g., about 3 or more, about 4 or more, about 5 or more, about 6 or more, about 7 or more, about 8 or more, about 9 or more, or about 10 or more). The number of zones may be about 15 or fewer (e.g., about 10 or fewer, about 9 or fewer, about 8 or fewer, about 7 or fewer, about 6 or fewer, about 5 or fewer, about 4 or fewer, or about 3 or fewer).

[0163] In at least one other embodiment, the HME process may further include the step of adding one or more flavoring agents to the polymer in one or more desired zones of the extruder, for example, through a side feeder and / or an injector. The second and third flavoring agents may be added into the same or different barrels of the extruder. The second and third flavoring agents may be in different forms, for example, a second flavoring agent in powder form and a third flavoring agent in oil form. The HME process may optionally include the step of adding a filler to the extruder in a desired zone, such as through a side feeder.

[0164] Referring again to FIG. 13A, the HME process comprises the step of forming an encapsulated flavor precursor (or extrude) (1308) by extruding a mixture of a polymer, flavor(s), and an optional filler through a die (1310), such as a ribbon die, a rod die, or a die having other desired cross-sectional shapes, such as an elliptical, triangular, square, star shape, or other shapes. When discharged from the die (1310), the extrude (1308) may be transported by a conveyor (1312). While on the conveyor (1312), the extrude (1308) may be cooled, for example, by a plurality of fans (1314). The extrude (1308) may be transported into a grinder, a cutter, or a pelletizer (1316) to form a plurality of granules (1318). The granules (1318) may be discharged into a collection container (1320).

[0165] In at least one other embodiment, when discharged from the extruder (1304), a plurality of pellets may be formed using a hot-face cutter. The pellets may be transferred to a receiving / cooling chamber for cooling. After a desired duration, the cooled pellets of the encapsulated flavoring agent fall into a collection container.

[0166] FIG. 13B is a schematic diagram showing a portion of an encapsulated flavor agent formed by the method of FIG. 13A according to at least one exemplary embodiment.

[0167] As illustrated in FIG. 13B, in at least one exemplary embodiment, the encapsulated flavoring agent (1350) comprises a polymer (1352) and flavoring agent (1354). The flavoring agent (1354) is present in a plurality of zones (1356). During use, the polymer (1352) is configured to melt in order to gradually release the flavoring agent (1354).

[0168] The methods of FIG. 11 and / or FIG. 12 may further include the step of including the encapsulated flavoring agent into an aerosol generating device and / or a capsule. In at least one exemplary embodiment, the including step includes including the encapsulated flavoring agent into an aerosol forming substrate. For example, the encapsulated flavoring agent may be mixed with other components of the aerosol forming substrate (e.g., tobacco, aerosol forming agent, etc.). The mixture may be placed in a capsule (e.g., formed into a molded form as shown in FIG. 1 and 2, and / or a loose form as shown in FIG. 3, and / or formed into a rod as shown in FIG. 4), and in at least one exemplary embodiment, the including step includes coating the encapsulated flavoring agent onto a surface of a cartridge, a mouthpiece, and / or any other surface in fluid communication with an aerosol pathway. In one example, the coating step includes atomizing the encapsulated flavoring agent onto the surface using an atomizer. In another example, the coating step comprises the step of heat-sealing an encapsulated flavor agent onto a surface. In at least one exemplary embodiment, the containing step comprises the step of placing an encapsulated flavor agent in a region of the mouthpiece (e.g., in a molded and / or loose form). In at least one exemplary embodiment, the containing step comprises the step of manufacturing the mouthpiece, cartridge, and / or other part of the device such that the encapsulated flavor agent is embedded within the body of each mouthpiece, cartridge, and / or other part of the device.

[0169] Example 1

[0170] 2g of Aqualon® EC-N100 ethyl cellulose is dissolved in 40g of ethanol under vigorous stirring to form a cloudy solution. 1g of menthol is added to the solution and dissolved by stirring. The mixture is vigorously stirred for a long time and then cast onto a glass panel. A transparent menthol film is formed by moving a BYK-Gardner film casting knife over the viscous mixture at a set thickness, and then subjected to a drying step.

[0171] Example 2

[0172] Klucel® hydroxypropyl cellulose (HPC) is used as a film-forming material. Specifically, 10 g of HPC is first dissolved in 87.5 g of ethanol under stirring to form a clear and smooth solution. Then, 2.5 g of menthol is added to the viscous solution and stirred vigorously until completely dissolved. The mixture is then cast into a film.

[0173] Example 3

[0174] 4g of Benecel® E5 methylcellulose is dispersed in 16g of 80°C water. As the temperature of the dispersion is lowered to room temperature, the methylcellulose is hydrated and dissolved under gentle stirring to finally become a transparent viscous solution. 1.0g of ground menthol powder is dispersed in the solution. The dispersion is cast onto a glass panel and dried overnight in a vacuum oven at room temperature to form a flexible, rubbery transparent film with fine menthol crystals dispersed inside.

[0175] Example 4

[0176] First, 10g of HPC is hydrated in 60g of 55℃ hot water to form a slurry. After immersing for 10 minutes while shaking and mixing, 27.5g of cold water is added to the slurry. When the temperature of the system drops to room temperature, the slurry gradually turns into a transparent HPC solution under medium shear stirring. At this point, menthol powder is dispersed in the solution under high shear stirring. Subsequently, the dispersion is cast onto a glass panel to form a film.

[0177] Example 5

[0178] 8g of Aqualon® EC-N100 ethyl cellulose is dissolved in 21g of ethanol to form a cloudy solution, and then 2g of menthol crystals are dissolved in this viscous solution under high shear stirring. This solution is used as the oil phase. 7g of CAPSUL® modified starch granules are hydrated in 13g of cold water and then dissolved at 85°C, and this solution is used as the aqueous phase. Then, the oil phase is dispersed in the aqueous phase using high shear stirring to form an emulsion. Then, the emulsion is cast into a film. The dried film is hard and brittle and can easily break into pieces. The film can seal the menthol odor very well during storage.

[0179] Example 6

[0180] 30g of a 50wt% menthol ethanol solution is first mixed with 25g of ARBOCEL® A300 powdered cellulose and then dried to remove the ethanol. Subsequently, the dried mixture is dispersed in 100g of 25wt% methyl cellulose. The dispersion is then cast onto a glass panel to form a rubbery film after water evaporation. Menthol-impregnated cellulose powder may also be dispersed in an ethyl cellulose ethanol solution, an aqueous solution of isomalt, mannitol, and erythritol, and then cast onto a glass panel to form a film.

[0181] Example 7

[0182] A flavor solution is obtained by dissolving 8g of Aqualon® EC-N100 ethyl cellulose and 2g of menthol in 21g of ethanol. A plain solution is prepared by first hydrating 14g of CAPSUL TA® modified starch granules in 26g of water and then raising the temperature to 65°C under vigorous stirring. The plain solution is cast onto a glass panel to form a first plain film. After a short time, the flavor solution is cast onto the gel-like plain film to form an intermediate flavor layer. Finally, another plain layer is formed on top of the first two layers. The three-layer film is completely dried. The slightly yellowish film is somewhat brittle, but the CAPSUL TA® membrane is as strong as an ethyl cellulose membrane. It can be peeled off from the glass panel.

[0183] Example 8

[0184] 120g of LDPE and 40g of ground menthol are pre-mixed and then fed into a single-screw extruder equipped with a 0.8mm x 50mm ribbon die. The mixture is heated to 140°C and extruded at 110°C. The extruded ribbon passes through the die and moves to an air-cooled conveyor, then is wound on a film winder or blow-molded to form a flavor film. Tween 80 and PEG 300 may be used to increase process stability.

[0185] Example 9

[0186] 1333.34 g of a 50 wt% menthol ethanol solution is absorbed into 1000 g of ARBOCEL® A300 powdered cellulose. After evaporating the ethanol, the menthol-impregnated cellulose powder is mixed with one or more film-forming polymers and extruded into a film in the process described in Example 8.

[0187] Example 10

[0188] Four parts of low-density polyethylene (LLDPE) pellets or granules and one part of crushed menthol are mixed at room temperature and fed into a three-zone Brabender single-axis extruder. When all three zones and the die zone are heated to 140°C, the LDPE and menthol are melted inside the extruder and extruded into a 0.8 mm ribbon at a melting pressure of 100 psi. Once completely cooled, the ribbon is shredded to the desired size and mixed with tobacco-containing ingredients to produce a filler for consumables. When these consumables are used in a heated tobacco product (HTP) device, menthol is released in a controllable manner.

[0189] Example 11

[0190] Ethyl cellulose (EC) and menthol are fed from Zone 1 (the first zone adjacent to the feed zone) to Zone 7 (the discharge zone) into a Zone 7 Leistritz 18HP extruder with temperatures set to 60°C, 95°C, 125°C, 130°C, 130°C, 125°C, and 115°C. The mixture is melted inside the extruder, extruded through a rod die, and cooled into a solid rod on a conveyor equipped with a cooling fan. The rod is then ground into flakes of 0.3 to 2 mm, which are subsequently incorporated into consumables and / or capsules at 5% to 25% by weight. The release of menthol continues for the entire 7-minute session, and the consistency of menthol release across the puff is improved to a satisfactory level.

[0191] Example 12

[0192] Ethyl cellulose is fed into an extruder. Peppermint oil is injected into the extruder in zone 6 and mixed with the hot ethyl cellulose melt in the remaining zones. The extruder is processed into a consumable in a manner similar to that described in Example 11. The release of encapsulated peppermint oil across the puff is more consistent than that of the control specimen in which peppermint oil is applied directly without encapsulation.

[0193] Hydroxypropyl cellulose (HPC), hydroxyethyl cellulose (HEC), and methyl cellulose (MC) may also be used in HME to encapsulate flavoring agents without the use of solvents. For example, HPC is dried in an oven to remove moisture, and then 4 parts of HPC and 1 part of menthol are fed into a Zone 7 extruder with temperatures set to 95°C, 130°C, 155°C, 155°C, 145°C, 140°C, and 135°C from Zones 1 to 7. To increase brittleness, the extruded material is frozen at -20°C and then ground to the desired shape and size before being included in consumables.

[0194] Example 13

[0195] EC is fed into a Zone 7 extruder with zones 1 through 7 set to temperatures of 60°C, 95°C, 125°C, 130°C, 130°C, 125°C, and 115°C, respectively. Insoluble flavor-containing powder is fed into the extruder in Zone 3 by an auxiliary feeder. The resulting extruder undergoes a process similar to that described in the previous example before being included in consumables and / or capsules. In sensory evaluation, the encapsulated flavor agent is released in a more consistent manner across the puff compared to its unencapsulated counterpart.

[0196] Example 14

[0197] A first aerosol-forming substrate comprising tobacco and a menthol flavoring agent is prepared. A flavoring solution is prepared by combining the flavoring agent with a solvent (e.g., dissolving and / or dispersing). The flavoring solution is sprayed onto and / or dripped onto tobacco during blending.

[0198] A second aerosol-forming substrate is prepared comprising tobacco and an encapsulated flavoring agent. The encapsulated flavoring agent comprises ethyl cellulose as a matrix and menthol as a flavoring agent. The encapsulated flavoring agent is prepared by one of the methods of the above examples, for example, by forming a film with the flavoring agent and a polymer, or by extruding and then cutting into micro-pellets. The encapsulated flavoring agent is then blended with the aerosol-forming substrate. The blending process may include powder mixing or be similar.

[0199] FIG. 14 is a graph showing the amount of menthol released per puff block for first and second aerosol-forming substrates according to at least one exemplary embodiment.

[0200] The first and second aerosol-forming substrates are heated within their respective aerosol generating devices. In at least one exemplary embodiment, as illustrated in FIG. 14, the encapsulated flavoring is configured to release menthol more uniformly over 12 puffs than the sprayed flavoring. That is, the amount of menthol in each of the three puff blocks is relatively constant for the encapsulated flavoring, with the last puff block being only about 10% lower than the first puff block. In contrast, the sprayed flavoring has a large initial release and then decreases with each puff block, with the last puff block being about 25% less than the first puff block. Accordingly, encapsulating the flavoring provides controlled, gradual, and / or consistent flavoring release during use. Additionally, the encapsulated flavoring releases more menthol into the aerosol for use by adult consumers. As shown in Fig. 14, the encapsulated flavoring agent releases about 3.2 mg of menthol into the aerosol, whereas the sprayed flavoring agent releases about 1.0 mg of menthol into the aerosol.

[0201] While some embodiments have been disclosed in this specification, it should be understood that other variations may be possible. Such variations should not be construed as departing 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.

[0202] Although described with reference to specific examples and drawings, various modifications, additions, and substitutions of some embodiments may be made by those skilled in the art according to the present disclosure. For example, the described techniques may be performed in a different order than the described method, and / or elements such as the described system, architecture, device, circuit, etc. may be connected or combined differently from the described method, or may be appropriately achieved by other elements or equivalents.

Claims

Claim 1 A capsule for an aerosol generating device, wherein the capsule comprises: a housing defining an inlet opening, an outlet opening, and a chamber between the inlet opening and the outlet opening; an aerosol forming substrate comprising tobacco within the housing; an encapsulated flavoring agent comprising a matrix and a flavoring agent within the matrix; and an aerosol forming agent; wherein the capsule has an inhalation resistance in the range of 30 mm H2O to 130 mm H2O. Claim 2 In claim 1, the tobacco is a capsule in the form of particles having an average particle size in the range of 150 μm to 1250 μm. Claim 3 In paragraph 2, the capsule having an average particle size in the range of 270 μm to 415 μm. Claim 4 In claim 1, the aerosol-forming substrate is a capsule having an apparent density in the range of 0.2 g / cm³ to 1.2 g / cm³. Claim 5 A capsule according to claim 1, wherein the flavor agent is present in an amount ranging from 0.5% by weight to 85% by weight based on the total weight of the encapsulated flavor agent. Claim 6 A capsule according to claim 1, wherein the aerosol-forming agent comprises propylene glycol, glycerol, butylene glycol, or any combination thereof. Claim 7 A capsule according to claim 1, wherein the matrix comprises methyl cellulose, ethyl cellulose, hydroxypropyl methyl cellulose, starch, pectin, gelatin, sodium alginate, maltodextrin, pullulan, xanthan, gum arabic, sodium carboxymethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose, polyethylene oxide, polyvinyl alcohol, polyvinyl pyrrolidone, low-density polyethylene, polyethylene glycol, polyurethane, poly(methyl methacrylate), ethylene vinyl acetate, a sugar alcohol thickened with a polymer, wax, fatty acid ester, a copolymer thereof, or any combination thereof. Claim 8 A capsule according to claim 1, wherein the encapsulated flavor agent further comprises a plasticizer, a crosslinking agent, a foaming agent, or any combination thereof. Claim 9 A capsule according to claim 1, wherein the flavoring agent comprises menthol, peppermint, spearmint, wintergreen, cinnamon, chocolate, vanillin, licorice, clove, anise, sandalwood, geranium, rose, vanilla, lemon, cassia, fennel, ginger, ethyl acetate, isoamyl acetate, propyl isobutyrate, isobutyrate, ethyl butyrate, ethyl valerate, benzyl formate, limonene, cymene, pinene, linalool, geraniol, citronellol, citral, orange, coriander, borneol, fruit extract, coffee, tea, cacao, mint, terpene, or any combination thereof. Claim 10 In claim 1, the capsule further comprises a carrier, wherein the encapsulated flavoring agent is absorbed by the carrier and the carrier is dispersed within the matrix. Claim 11 In claim 10, a capsule in which the carrier comprises cellulose, silica, pectin, or a combination thereof. Claim 12 A capsule according to claim 11, wherein the carrier comprises the cellulose, and the cellulose comprises microcrystalline cellulose. Claim 13 In claim 11, a capsule in which the carrier comprises the cellulose, and the cellulose comprises tobacco. Claim 14 In claim 1, the capsule is in the form of a plurality of particles, granules, cut pieces, crushed pieces, flakes, or any combination thereof. Claim 15 In paragraph 14, a capsule in which the encapsulated flavoring agent is mixed with the tobacco and the aerosol-forming agent. Claim 16 A capsule according to claim 1, wherein the encapsulated flavor agent is on the surface of the housing. Claim 17 In paragraph 16, the above surface is a capsule that is an inner surface that allows the encapsulated flavor agent to be within the chamber. Claim 18 An aerosol generating device, wherein the aerosol generating device comprises a capsule, a heater, and a device body; wherein the capsule comprises a housing and an aerosol forming substrate within the housing; wherein the aerosol forming substrate comprises tobacco and an aerosol forming agent; wherein the heater is thermally connected to the aerosol forming substrate; wherein the device body comprises: a cover configured to open to allow insertion of the capsule and to close to combine the capsule within the device body; a mouthpiece; and an encapsulated flavoring agent configured to be fluidly connected to an aerosol path of the aerosol generating device; wherein the encapsulated flavoring agent comprises a matrix and a flavoring agent within the matrix, and the capsule has an inhalation resistance in the range of 30 mm H2O to 130 mm H2O. Claim 19 A replaceable mouthpiece for an aerosol generating device, wherein the replaceable mouthpiece comprises: a wall defining an inlet, an outlet, and a channel fluidly connecting the inlet and the outlet; and an encapsulated flavoring agent on the surface of the wall fluidly communicating with the channel; wherein the encapsulated flavoring agent comprises a matrix and a flavoring agent within the matrix. Claim 20 A method for manufacturing an encapsulated flavoring agent for an aerosol generating device, the method comprising: a step of preparing a polymer melt by melting a polymer; a step of preparing a mixture comprising said polymer and a flavoring agent; a step of forming an encapsulated flavoring agent precursor by extruding said mixture; and a step of forming said encapsulated flavoring agent by cooling said encapsulated flavoring agent precursor.

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