Capsules including internal heaters, heat-not-burn(HNB) aerosol-generating devices, and methods of generating an aerosol

Abstract

A capsule for a heat-not-burn (HNB) aerosol generating device may include a housing and a heater within the housing. The housing has inner surfaces defining a chamber configured to hold an aerosol-forming substrate. Additionally, the housing has outer surfaces constituting a first face, an opposing second face, and a side of the capsule. The first and second faces of the capsule are permeable to the aerosol. The heater has a first end section, an intermediate section, and a second end section. The first and second end sections of the heater may be outer segments constituting part of the side of the capsule. The intermediate section of the heater is an inner segment disposed within the chamber of the housing.

Description

Technology Field

[0001] The present invention relates to a capsule, a heat-not-burn (HNB) aerosol generating device, and a method for generating an aerosol without substantial thermal decomposition of an aerosol forming substrate. Background Technology

[0002] Some electronic devices are configured to heat plant material to a temperature sufficient to release its components while maintaining the temperature below the combustion point of the plant material to avoid substantial thermal decomposition of the plant material. Such devices may be referred to as aerosol generators (e.g., non-combustion heating aerosol generators), and the plant material being heated may be tobacco. In some cases, the plant material may be introduced directly into the heating chamber of the aerosol generator. In other cases, the plant material may be pre-packaged in individual containers to facilitate insertion and removal from the aerosol generator. means of solving the problem

[0003] At least one embodiment relates to a capsule for a heat-not-burn (HNB) aerosol generating device. In an exemplary embodiment, the capsule may comprise a housing and a heater within the housing. The housing has an inner surface defining a chamber configured to hold an aerosol-forming substrate. Additionally, the housing has an outer surface forming a first face, a second face opposite the first face, and a side of the capsule. The first and second faces of the capsule are permeable to the aerosol. The heater has a first end section, an intermediate section, and a second end section. The first and second end sections of the heater are outer segments forming part of the side of the capsule. The intermediate section of the heater is an inner segment disposed within the chamber of the housing.

[0004] At least one embodiment relates to a non-combustion heating aerosol generating device. In an exemplary embodiment, the aerosol generating device may include a capsule and a device body. The capsule includes an aerosol-forming substrate. Additionally, the capsule includes a first permeable surface, an opposing second permeable surface, and a side. The device body may include a heating pad configured to heat the aerosol-forming substrate within the capsule via conduction to generate an aerosol. In such a case, the device body may be configured to receive the capsule such that the heating pad engages with and covers the first permeable surface or the second permeable surface of the capsule.

[0005] At least one embodiment relates to a method for generating an aerosol. In an exemplary embodiment, the method may include the step of securing a capsule between a first pad and a second pad. The capsule comprises an aerosol-forming substrate and includes a first permeable surface, an opposing second permeable surface, and a side. The method may further include the step of heating the aerosol-forming substrate to at least one of the first pad or the second pad so that the generated aerosol passes through at least one of the first pad or the second pad. Brief explanation of the drawing

[0006] The various features and benefits of the non-limiting embodiments of this specification may become more apparent when the detailed description is reviewed in conjunction with the accompanying drawings. The accompanying drawings are provided for illustrative purposes only and should not be construed as limiting the claims. Unless expressly stated otherwise, the accompanying drawings are not to be drawn to scale. Various dimensions in the drawings may be exaggerated for clarity. FIG. 1 is a first side perspective view of a capsule for an aerosol generating device according to an exemplary embodiment. FIG. 2 is a perspective view of the opposing second side of the capsule of FIG. 1. Figure 3 is an exploded view of the capsule of Figure 1. Figure 4 is an exploded view of the capsule of Figure 1. Figure 5 is an exploded view of the heater and the third frame of Figure 3. Figure 6 is a separated view of the heater and the third frame of Figure 4. FIG. 7 is a perspective view of a first side of another capsule for an aerosol generating device according to an exemplary embodiment. 8 is a perspective view of the opposing second side of the capsule of Fig. 7. Figure 9 is an exploded view of the capsule of Figure 7. Figure 10 is an exploded view of the capsule of Figure 8. Figure 11 is an exploded view of the heater and the third frame of Figure 9. Fig. 12 is an exploded view of the heater and the third frame of Fig. 10. FIG. 13 is a plan view of a patterned sheet related to the manufacture of a heater according to an exemplary embodiment. FIG. 14 is a perspective view of a partially assembled capsule including a heater obtained from the patterned sheet of FIG. 13. FIG. 15 is a plan view of another patterned sheet related to the manufacture of a heater according to an exemplary embodiment. FIG. 16 is a plan view of another patterned sheet related to the manufacture of a heater according to an exemplary embodiment. FIG. 17 is a plan view of another patterned sheet related to the manufacture of a heater according to an exemplary embodiment. FIGS. 18 to 20 are perspective views of a method for manufacturing a capsule for an aerosol generating device according to an exemplary embodiment. FIG. 21 is a schematic cross-sectional view of an aerosol generating device according to an exemplary embodiment. FIG. 22 is a perspective view of another capsule for an aerosol generating device according to an exemplary embodiment. Fig. 23 is an internal view of the capsule of Fig. 22. Fig. 24 is a cross-sectional plan view of the capsule of Fig. 22. FIG. 25 is a side cross-sectional view of the capsule of FIG. 22. FIG. 26 is an uncoupled perspective view of a fastening assembly for a capsule according to an exemplary embodiment. FIG. 27 is a partially fastened perspective view of the fastening assembly of FIG. 26. FIG. 28 is a cross-sectional view of the fastening assembly of FIG. 26. Specific details for implementing the invention

[0007] Some exemplary embodiments are disclosed in detail in this specification. However, specific structural and functional details disclosed in this specification are provided only for the purpose of describing exemplary embodiments. However, exemplary embodiments may be implemented in many alternative forms and should not be construed as being limited to the exemplary embodiments described herein.

[0008] Accordingly, exemplary embodiments may have various modifications and alternative forms, but exemplary embodiments are illustrated by the drawings and will be described in detail herein. However, it should be understood that there is no intention to limit exemplary embodiments to the specific forms disclosed, and that exemplary embodiments encompass all modifications, equivalents, and alternatives. The same reference numerals refer to the same elements throughout the description of the drawings.

[0009] When an element or layer is referred to as "on," "connected," "combined," "attached," "adjacent," or "covering" with respect to another element or layer, it may be directly on, connected to, combined with, attached to, adjacent to, or covering said other element or layer, or intermediate elements or layers may exist. Conversely, when an element is referred to as "directly on," "directly connected," or "directly combined" with respect to another element or layer, it should be understood that no intermediate elements or layers exist. Throughout the specification, the same reference numerals refer to the same elements. As used herein, the term "and / or" includes any combination and non-combination of one or more of the listed items.

[0010] Although terms such as first, second, third, etc., may be used to describe various elements, regions, layers, and / or sections in the present invention, it should be understood that these elements, regions, layers, and / or sections are not limited by these terms. These terms are used merely to distinguish one element, region, layer, or section from another element, region, layer, or section. Accordingly, the first element, first region, first layer, or first section discussed below may be referred to as the second element, second region, second layer, or second section without departing from the teachings of the exemplary embodiments.

[0011] Spatially relative terms (e.g., "below," "under," "lower," "above," "upper," etc.) may be used for convenience of description to explain the relationship between one element or feature and another element(s) or feature(s) as illustrated in the drawings. It should be understood that spatially relative terms are intended to include not only the orientations illustrated in the drawings but also other orientations of the device in use or operation. For example, if the device in the drawings is inverted, elements described as "below" or "under" other elements or features will be oriented "above" other elements or features. Accordingly, the term "below" may include both upper and lower orientations. The device may be oriented differently (rotated 90 degrees or in a different orientation), and spatially relative descriptive terms used herein may be interpreted accordingly.

[0012] The terms used herein are merely for describing various exemplary embodiments and are not intended to limit the exemplary embodiments. Singular expressions or expressions where singularity is not specified, as used herein, are intended to include plural expressions unless the context clearly indicates otherwise. When terms such as “comprising,” “comprising,” and / or “comprising” are used herein, it will be understood that they specify the presence of the mentioned features, components, steps, operations, and / or elements, and do not exclude the presence or addition of one or more other features, components, steps, operations, elements, and / or groups thereof.

[0013] Where the words “about” or “substantially” are used in this specification with respect to figures, it should be understood that such figures include a manufacturing or operational tolerance (e.g., ±10%) for the figures mentioned. Additionally, where the words “generally” and “substantially” are used with respect to geometric shapes, it should be understood that while geometric accuracy is not required, the latitude of the shape is within the scope of disclosure. Furthermore, regardless of whether a figure or shape is limited by “about” or “substantially,” it should be understood that the figure and shape include a manufacturing or operational tolerance (e.g., ±10%) for the figures and shapes mentioned.

[0014] Unless otherwise defined, all terms used in the present invention (including technical and scientific terms) have the same meaning as generally understood by those skilled in the art to which the exemplary embodiments belong. Furthermore, terms, including those defined in commonly used dictionaries, should be interpreted as having a meaning consistent with that meaning in the context of the relevant technology, and should not be interpreted in an ideal or overly formal sense unless explicitly defined in the present invention.

[0015] Hardware may be implemented using processing or control circuits such as one or more processors, one or more central processing units (CPUs), one or more microcontrollers, one or more arithmetic logic units (ALUs), one or more digital signal processors (DSPs), one or more microcomputers, one or more field programmable gate arrays (FPGAs), one or more System-on-Chip (SoCs), one or more Programmable Logic Units (PLUs), one or more microprocessors, one or more Application Specific Integrated Circuits (ASICs), or other device(s) capable of responding to instructions and executing instructions in a limited manner, but is not limited to those listed herein.

[0016] FIG. 1 is a first side perspective view of a capsule for an aerosol generating device according to an exemplary embodiment. FIG. 2 is a second side perspective view of the capsule of FIG. 1. Referring to FIG. 1 and FIG. 2, the capsule (100) may be configured to be accommodated within an aerosol generating device (e.g., a heat-not-burn aerosol generating device). In the drawings, the capsule (100) has a layered structure and is generally planar in shape. The proximal end of the capsule (100) may have a curved proximal edge, and the opposing distal end may have a straight distal edge. Additionally, a pair of straight side edges may connect the curved proximal edge and the straight distal edge. The pair of straight side edges may be parallel to each other. Additionally, the joint between the straight side edge and the straight distal edge may be in the form of a curved edge.

[0017] Although the capsule (100) is illustrated in the drawings as being similar to a rectangular shape with semicircular ends (e.g., cage-shaped semicircular, semi-obround), it should be understood that other configurations may be employed. For example, the shape of the capsule (100) may be circular so that it has a disc-like appearance. In other examples, the shape of the capsule (100) may be elliptical or racetrack-shaped. In other cases, the capsule (100) may have a polygonal shape (regular or irregular) including a triangle, a rectangle (e.g., square), a pentagon, a hexagon, a heptagon, or an octagon. The layered structure and generally flat shape of the capsule (100) facilitate stacking, allowing multiple capsules to be stored in an aerosol generating device or other receiving device to dispense new capsules or receive used capsules. In an exemplary embodiment, the capsule (100) has a thickness of 1 to 4 mm (e.g., 1 to 2 mm).

[0018] The capsule (100) may include a housing and a heater (170) (e.g., FIG. 5) within the housing. The housing of the capsule (100) has interior surfaces that define a chamber configured to hold an aerosol-forming substrate (160) (e.g., FIG. 5). Additionally, the housing of the capsule (100) has exterior surfaces that constitute a first surface, an opposing second surface, and a side surface of the capsule (100). The first surface and the second surface of the capsule (100) are permeable to aerosols. The side surface of the capsule (100) is located between the first surface and the second surface. The side surface of the capsule (100) may be referred to as the periphery of the capsule (100).

[0019] The housing of the capsule (100) comprises a first frame (130) and a second frame (140) (see, for example, FIG. 3). The first frame (130) and the second frame (140) may have the same shape and size (when viewed in a planar view) and may be aligned so that their outer walls are substantially coplanar, but are not limited thereto. The first frame (130) and the second frame (140) may be formed from a suitable polymer material such as polyether ether ketone (PEEK), liquid crystal polymer (LCP), and / or ultra high molecular weight polyethylene (UHMWPE). The first frame (130) and the second frame (140) may be connected by a welded arrangement.

[0020] The first permeable structure (110) is fixed and exposed by the first frame (130). Similarly, the second permeable structure (120) is fixed and exposed by the second frame (140). As discussed in more detail herein, a third frame (150) is positioned between the first permeable structure (110) and the second permeable structure (120) (also between the first frame (130) and the second frame (140)). The capsule (100) is configured to hold an aerosol-forming substrate (160) that may be within the third frame (150) and between the first permeable structure (110) and the second permeable structure (120). The first concavity (133) (e.g., the first dimple portion) of the first frame (130) and the second concavity (143) (e.g., the second dimple portion) of the second frame (140) may be formed from an injection molding process. In this case, the size, location, and / or shape of the first concavity (133) and the second concavity (143) may vary depending on the manufacturing technology (or these concavities may not be formed).

[0021] The first permeable structure (110) and the second permeable structure (120) may be in the form of a mesh sheet, a perforated sheet, or a combination thereof. For example, both the first permeable structure (110) and the second permeable structure (120) may be in the form of a mesh sheet. In another example, both the first permeable structure (110) and the second permeable structure (120) may be in the form of a perforated sheet (e.g., 80, 100, or 250 mesh equivalent). The perforated sheet may be mechanically or chemically perforated (e.g., through photochemical processing / etching). As another example, either of the first permeable structure (110) and the second permeable structure (120) may be in the form of a mesh sheet, and the other of the first permeable structure (110) and the second permeable structure (120) may be in the form of a perforated sheet. The first permeable structure (110) and the second permeable structure (120) (also the first frame (130) and the second frame (140)) may be substantially the same size when viewed in a planar view (e.g., ±10% of a given dimension).

[0022] As illustrated in FIG. 1, the exposed surface of the first permeable structure (110) and the surface of the adjacent first frame (130) (e.g., substantially coplanar / parallel surfaces) can be considered together as the first surface of the capsule (100). Similarly, as illustrated in FIG. 2, the exposed surface of the second permeable structure (120) and the surface of the adjacent second frame (140) (e.g., substantially coplanar / parallel surfaces) can be considered together as the second surface of the capsule (100). In one example, the first surface, the second surface, or both may comprise a perforated sheet. In another example, the first surface, the second surface, or both may comprise a mesh sheet. In yet another example, one of the first surface and the second surface may comprise a perforated sheet, and the other of the first surface and the second surface may comprise a mesh sheet.

[0023] As described above and as discussed in more detail in this specification, a heater (170) (e.g., FIG. 5) may be placed within the capsule (100) to heat the aerosol-forming substrate (160). The heater (170) includes a first end section (172) and a second end section (176) configured to receive current from a power source, particularly during the activation (operation) of the heater (170). When the heater (170) is activated, the temperature of the aerosol-forming substrate (160) may rise, and an aerosol may be generated and released through the first permeable structure (110) and / or the second permeable structure (120) of the capsule (100).

[0024] As illustrated in FIGS. 1 and 2, the exposed surface of the third frame (150) and the adjacent side walls of the first frame (130) and second frame (140) can be viewed together as the side of the capsule (100). Additionally, the second end section (176) may also be an outer segment of the heater (170) that constitutes part of the side of the capsule (100). The outward surfaces of the first end section (172) and the second end section (176) of the heater (170) may form a coplanar plane, but exemplary embodiments are not limited thereto.

[0025] As stated herein, an "aerosol-forming substrate" is a material (or combination of materials) capable of generating an aerosol. An "aerosol" relates to a material generated or output by the devices and equivalents disclosed and claimed herein. The material may include a compound (e.g., nicotine, cannabinoid), and an aerosol containing this compound is generated when the material is heated. The heating may be lower than the combustion temperature so as to generate an aerosol without substantial thermal decomposition of the aerosol-forming substrate or substantial generation of combustion byproducts (if present). Thus, according to exemplary embodiments, thermal decomposition does not occur during heating and the subsequent generation of the aerosol. In other cases, some thermal decomposition and combustion byproducts may be present, but to a relatively minor and / or incidental extent.

[0026] The aerosol-forming substrate may be a fibrous material. For example, the fibrous material may be a plant material. The fibrous material is configured to release a compound when heated. The compound may be a naturally occurring component of the fibrous material. For example, the fibrous material may be a plant material such as tobacco, and the released compound may be nicotine. The term "tobacco" refers to tobacco leaves, tobacco plugs, recycled tobacco, compressed tobacco, shaped tobacco, powdered tobacco, and, for example, Nicotiana rustica and Nicotiana tabacum It includes all tobacco plant materials containing a combination of one or more tobacco plant species such as

[0027] In some exemplary embodiments, the tobacco material is Nicotiana The tobacco material may include any member of the genus. Additionally, the tobacco material may include a blend of two or more different tobacco varieties. Examples of suitable types of tobacco material that may be used include, but are not limited to, flue-cured tobacco, Burley tobacco, dark tobacco, Maryland tobacco, Oriental tobacco, rare tobacco, specialty tobacco, blends thereof, etc. The tobacco material may be provided in any suitable form, including, but not limited to, processed tobacco material such as tobacco sheets, bulk-expanded or puff tobacco, processed tobacco main veins such as cut-rolled or cut-puff stems, regenerated tobacco, and blends thereof. In some exemplary embodiments, the tobacco material is in the form of substantially dry tobacco chunks. Additionally, in some cases, the tobacco material may be mixed and / or combined with at least one of propylene glycol, glycerin, a sub-combination thereof, or a combination thereof.

[0028] The above compound may also be a naturally occurring component of a medicinal plant having medically acceptable therapeutic effects. The above medicinal plant may be a cannabis plant, and the above compound may be a cannabinoid. Cannabinoids interact with receptors in the body to produce a wide range of effects. As a result, cannabinoids have been used for various medical purposes (e.g., treatment of pain, vomiting, epilepsy, and psychiatric disorders). The above fibrous material is Cannabis sativa ( Cannabis sativa ), Cannabis Indica( Indian cannabis ), Cannabis ruderalis ( Cannabis ruderalis It may include one or more leaves and / or flowers of cannabis plant species such as ). In some examples, the fibrous material is a mixture of 60-80% (e.g. 70%) cannabis sativa and 20-40% (e.g. 30%) cannabis indica.

[0029] Examples of cannabinoids include tetrahydrocannabinolic acid (THCA), tetrahydrocannabinol (THC), cannabidiolic acid (CBDA), cannabidiol (CBD), cannabinol (CBN), cannabicyclol (CBL), cannabichromene (CBC), and cannabigerol (CBG). Tetrahydrocannabinolic acid (THCA) is a precursor of tetrahydrocannabinol (THC), and cannabidiolic acid (CBDA) is a precursor of cannabidiol (CBD). Tetrahydrocannabinol acid (THCA) and cannabidiol acid (CBDA) can be converted into tetrahydrocannabinol (THC) and cannabidiol (CBD), respectively, through heating. In one exemplary embodiment, heating by a heater (e.g., heater (170) shown in FIG. 5) causes decarboxylation to convert tetrahydrocannabinol acid (TCHA) of the capsule (100) into tetrahydrocannabinol (THC) and / or convert cannabidiol acid (CBDA) of the capsule (100) into cannabidiol (CBD).

[0030] If both tetrahydrocannabinol (THCA) and tetrahydrocannabinol (THC) are present in the capsule (100), decarboxylation and the resulting conversion cause a decrease in tetrahydrocannabinol (THCA) and an increase in tetrahydrocannabinol (THC). During heating of the capsule (100), at least 50% (e.g., at least 87%) of tetrahydrocannabinol (THCA) may be converted to tetrahydrocannabinol (THC). Likewise, if both cannabidiol (CBDA) and cannabidiol (CBD) are present in the capsule (100), decarboxylation and the resulting conversion will cause a decrease in cannabidiol (CBDA) and an increase in cannabidiol (CBD). During heating of the above capsule (100), at least 50% (e.g., at least 87%) of cannabidiol acid (CBDA) can be converted into cannabidiol (CBD).

[0031] Additionally, the compound may be a non-naturally occurring additive subsequently introduced into the fibrous material or may additionally include such additives. In one example, the fibrous material may include a synthetic material. In another example, the fibrous material may be a natural material, such as a cellulose material (e.g., a non-tobacco and / or non-cannabis material). In either case, the introduced compound may include nicotine, cannabinoids, and / or flavorings. The flavorings may be derived from natural sources and / or artificial sources, such as plant extracts (e.g., tobacco extract, cannabis extract). In yet another example, where the fibrous material includes tobacco and / or cannabis, the compound may be one or more flavorings (e.g., menthol, mint, vanilla) or additionally include such additives. Thus, the compound within the aerosol-forming substrate may include naturally occurring components and / or non-naturally occurring additives. In this regard, it should be understood that the existing levels of naturally occurring components of the aerosol-forming agent can be increased through supplementation. For example, the existing levels of nicotine in the amount of tobacco can be increased by supplementing with an extract containing nicotine. Similarly, the existing levels of one or more cannabinoids in the amount of cannabis can be increased by supplementing with an extract containing such cannabinoids.

[0032] FIG. 3 is an exploded view of the capsule of FIG. 1. FIG. 4 is an exploded view of the capsule of FIG. 2. Referring to FIG. 3 and FIG. 4, the first frame (130) has a first inner surface and a first outer surface. Additionally, the first frame (130) defines (is provided with) a first opening (131). In an exemplary embodiment, the side walls of the first opening (131) may have opposing straight sections and optionally opposing curved sections, one of the curved sections may be adjacent to the proximal end of the first frame (130) and the other of the curved sections may be adjacent to the distal end opposite the proximal end of the first frame (130). A first permeable structure (110) is fixed to the first inner surface of the first frame (130) so as to be exposed by the first opening (131). In another perspective, the first permeable structure (110) may also be considered to cover the first opening (131). Additionally, the first permeable structure (110) may define (provide) a first aperture (112). The position and size of the first aperture (112) may be determined to accommodate the first convex portion (135) when the first permeable structure (110) is fixed to the first frame (130).

[0033] The second frame (140) has a second inner surface and a second outer surface. Additionally, the second frame (140) defines a second opening (141). In an exemplary embodiment, the side walls of the second opening (141) have opposing straight sections and, optionally, opposing curved sections, one of the curved sections may be adjacent to the proximal end of the second frame (140) and the other of the curved sections may be adjacent to the distal end opposite the proximal end of the second frame (140). The second permeable structure (120) may be fixed to the second inner surface of the second frame (140) so as to be exposed by the second opening (141). In another aspect, the second permeable structure (120) may be considered to cover the second opening (141). The size and shape of the second opening (141) may correspond to the size and shape of the first opening (131) (e.g., mirror symmetry). Additionally, the second permeable structure (120) may define a second hole (122). The position and size of the second hole (122) may be determined to accommodate a second convex portion (145) when the second permeable structure (120) is fixed to the second frame (140).

[0034] The third frame (150) defines a cavity (151) (e.g., see FIG. 5) configured to accommodate an aerosol-forming substrate (160). The sidewalls of the cavity (151) and the first permeable structure (110) and the second permeable structure (120) (covering the cavity (151)) together may be considered to define a chamber. In an exemplary embodiment, the sidewalls of the cavity (151) have opposing straight sections and opposing curved sections, one of the curved sections is adjacent to the proximal end of the third frame (150), and the other of the curved sections is adjacent to the distal end opposite the proximal end of the third frame (150). The third frame (150), when viewed in a plan view, may be substantially the same size as the first transparent structure (110) and the second transparent structure (120) (e.g., ±10% of the given dimensions). The third frame (150) may also define holes (152a, 152b) adjacent to its distal end. In addition to the constituent materials for the first frame (130) and the second frame (140), the third frame (150) may also be formed of other suitable materials such as ceramic, sintered glass and / or reinforcing fiber (e.g., cardboard).

[0035] The heater (170) is configured to extend into the cavity (151) through the third frame (150). Additionally, the heater (170) may be considered to be supported by the third frame (150). The heater (170) comprises a first end section (172), an intermediate section (174), and a second end section (176). The first end section (172) and the second end section (176) of the heater (170) are outer segments that form part of the side of the capsule (100). The intermediate section (174) of the heater (170) is an inner segment disposed within the capsule (100) (e.g., within the chamber of the housing containing the aerosol-forming substrate (160)). The first end section (172), the intermediate section (174), and the second end section (176) of the heater (170) are sections of a continuous structure. In an exemplary embodiment, the middle section (174) of the heater (170) is planar and has a winding shape.

[0036] The aerosol-forming substrate (160) may be placed within the cavity (151) of the third frame (150) so as to be on both sides of the intermediate section (174) of the heater (170). The aerosol-forming substrate (160) may be a consolidated form (e.g., sheet, pallet, plate) configured to maintain its shape so that it can be placed in a unified manner within the cavity (151) of the third frame (150). (e.g., to substantially fill the cavity (151) of the third frame (150) and sandwich / insert the intermediate section (174) of the heater (170) between them), for example, one aerosol-forming substrate (160) may be placed on one side of the intermediate section (174) of the heater (170), while the other aerosol-forming substrate (160) may be placed on the other side of the intermediate section (174) of the heater (170). Alternatively, the aerosol-forming substrate (160) may not have a fixed shape and may be a loose form (e.g., particles, fibers, grounds, fragments, pieces) configured to take the shape of the cavity (151) of the third frame (150) when introduced.

[0037] The first permeable structure (110) and the second permeable structure (120) may be fixed to the first frame (130) and the second frame (140), respectively, through various attachment techniques. For example, the attachment technique may include injection molding (e.g., insert molding, overmolding). In other examples, the attachment technique may include ultrasonic welding. In other cases, the attachment technique may include an adhesive (e.g., tape, glue) that is considered food-safe or permitted by regulatory authorities. Alternatively, instead of separate attachment techniques, the first permeable structure (110) and the second permeable structure (120) may be clamped (or otherwise restrained) to the third frame (150) by the first frame (130) and the second frame (140), respectively.

[0038] The first frame (130) includes at least one first connection protruding from its first inner surface. At least one first connection of the first frame (130) may be in the form of a first connection (138). In an exemplary embodiment, the first connection (138) may extend along the edge of the first inner surface of the first frame (130) in the form of a ridge (e.g., a first ridge). The ridge may define a trench extending along the entire length to resemble a raised trench or a concave / furrowed ridge. Additionally or alternatively, the ridge may have a tapering ridgeline and may be referred to as a tapered ridgeline. It should be understood that although the first connecting portion (138) is depicted as being separated into a plurality of individual structures (e.g., four individual structures), exemplary embodiments are not limited thereto. For example, alternatively, the first connecting portion (138) may be a single continuous structure extending along the edge to completely surround the first inner surface of the first frame (130).

[0039] Similarly, the second frame (140) includes at least one second connecting portion protruding from its second inner surface. At least one second connecting portion of the second frame (140) may be in the form of a second connecting portion (148). The second connecting portion (148) of the second frame (140) and the first connecting portion (138) of the first frame (130) are complementary structures configured to fit together. In an exemplary embodiment, the second connecting portion (148) may extend along the edge of the second inner surface of the second frame (140) in the form of a ridge (e.g., a second ridge). The ridge may define a trench extending along the entire length to resemble a raised trench or a concave / furrowed ridge. Additionally or alternatively, the ridge may have a tapering ridge line and, as a result, may be referred to as a tapered ridge. It should be understood that although the second connecting portion (148) is depicted as being separated into a plurality of individual structures (e.g., four individual structures), exemplary embodiments are not limited thereto. For example, alternatively, the second connecting portion (148) may be a single continuous structure extending along the periphery to completely surround the second inner surface of the second frame (140).

[0040] In the non-limiting embodiment illustrated in FIGS. 3 and 4, where the first connecting portion (138) of the first frame (130) is separated into four individual structures, two of the four separated structures may be raised trenches, while the other two may be tapered ridges. Conversely, the second connecting portion (148) of the second frame (140) may be separated into four individual structures, where two of the four separated structures are tapered ridges and the other two are raised trenches. A mixed set of raised trenches and tapered ridges of the first frame (130) is configured to be combined, respectively, with a mixed set of tapered ridges and raised trenches of the second frame (140) during the assembly of the capsule (100). It should be understood that various combinations of raised trenches and tapered ridges are possible for the first frame (130) and the second frame (140). Additionally, each of the first permeable structure (110) and the second permeable structure (120) may have tab-like extensions (e.g., four tab-like extensions), and these tab-like extensions are placed between the separated structures of the first connection (138) and between the separated structures of the second connection (148), respectively, when the capsule (100) is assembled.

[0041] The tapered ridge of the first connection (138) and / or the second connection (148) may have a shoulder portion and an inclined portion rising from the shoulder to form a tapered ridge. The tapered ridge may function as an energy detector during assembly (e.g., to facilitate welding). The raised trench of the first connection (138) and / or the second connection (148) corresponding to the tapered ridge may have a rim portion and a trench bottom. As illustrated in FIGS. 3 and 4, the trench bottom of the raised trench may be a flat bottom. Alternatively, the trench bottom of the raised trench may be a V-shaped bottom. In an exemplary embodiment of the connection between the first frame (130) and the second frame (140), the inclined portion of the tapered ridge is configured to contact the bottom of the corresponding raised trench, while the shoulder portion of the tapered ridge interfaces with the edge portion. Accordingly, the fastening (interlocking) surfaces of the first connecting portion (138) and the second connecting portion (148) may be configured in reverse or complementarily to facilitate alignment.

[0042] When a mixed set of raised trenches and tapered ridges of each frame is grouped such that the raised trenches are on one straight side edge and the tapered ridges are on another straight side edge, the first frame (130) and the second frame (140) may be the same part, as illustrated in FIGS. 3 and 4. In such a case, if the first frame (130) and the second frame (140) are oriented to face each other for alignment, it will lead to a mutually complementary arrangement. As a result, either part can be used interchangeably as the first frame (130) or the second frame (140), thereby simplifying the manufacturing method.

[0043] To assemble the capsule (100), after the aerosol-forming substrate (160) is placed within the cavity (151) of the third frame (150) (e.g., placed on both sides of the middle section (174) of the heater (170), the first frame (130) can be connected to the second frame (140). In this case, the third frame (150) will be sandwiched between the first permeable structure (110) and the second permeable structure (120) when the first frame (130) is connected to the second frame (140). During assembly, at least one first connection of the first frame (130) will be joined to at least one connection of the second frame (140) to form at least one connection (e.g., four connections). For example, the raised trench (and / or tapered ridge) of the first connecting portion (138) is configured to align with the corresponding tapered ridge (and / or raised trench) of the second connecting portion (148). Additionally, the connection between the first connecting portion (138) of the first frame (130) and the second connecting portion (148) of the second frame (140) can be achieved by welding (e.g., ultrasonic welding). Furthermore, the outer wall of the first frame (130) may be substantially flat with the outer wall of the second frame (140) when the capsule (100) is assembled, but is not limited thereto. Once assembled, the capsule (100) is difficult or impossible to open without damaging the connecting portion, the frame, and / or other components of the capsule (100).

[0044] The above capsule (100) has been described as including, in particular, a first frame (130) which is a separate component from the second frame (140). Alternatively, in some examples, the first frame (130) and the second frame (140) may be manufactured as a single structure configured to be folded during assembly so that the first connecting part (138) is joined to the second connecting part (148). For example, the first frame (130) and the second frame (140) may resemble a clamshell structure, such as a door that opens on both sides, and the straight distal edge of the first frame (130) may be connected to the straight distal edge of the second frame (140) by an integral section of reduced thickness that functions as a folding line. In other examples, the straight side edge of the first frame (130) may be connected to the straight side edge of the second frame (140) by an integral section of reduced thickness that functions as a folding line. It should be understood that, in a clamshell structure, one or more connections (e.g., along the fold lines) may be omitted from the capsule (100).

[0045] FIG. 5 is an exploded view of the heater and the third frame of FIG. 3. FIG. 6 is an exploded view of the heater and the third frame of FIG. 4. As illustrated in FIG. 5 and FIG. 6, the heater (170) includes a first end section (172), a first arm section (173), an intermediate section (174), a second arm section (175), and a second end section (176). The first arm section (173) and the second arm section (175) each define a hole (178a) and a hole (178b), respectively, but the present invention is not limited thereto. For example, the first end section (172) and the second end section (176) may be on the same plane. Also, the first arm section (173), the intermediate section (174), and the second arm section (175) may be on the same plane. In such a case, the plane corresponding to the first end section (172) and the second end section (176) may be orthogonal to the plane corresponding to the first arm section (173), the middle section (174), and the second arm section (175). Additionally, the heater (170) may be symmetric with respect to its longitudinal axis. The longitudinal axis of the heater (170) lies within the plane corresponding to the first arm section (173), the middle section (174), and the second arm section (175), and may bisect the middle section (174) and extend between the first end section (172) and the second end section (176) (e.g., at an equal distance).

[0046] In an exemplary embodiment, the heater (170) is configured to receive Joule heating (also known as ohmic / resistance heating) when current is applied. Specifically, the heater (170) may be formed of one or more conductors and may be configured to generate heat when current flows. Current may be supplied to the first end section (172) and the second end section (176) of the heater (170) from a power source (e.g., a battery) within the aerosol generating device. Conductors suitable for the heater (170) include iron-based alloys (e.g., stainless steel, iron aluminide), nickel-based alloys (e.g., nichrome), and / or ceramics (e.g., metal-coated ceramics). The middle section (174) of the heater (170) may have a thickness of about 0.1 to 0.3 mm (e.g., 0.15 to 0.25 mm) and a resistance of about 0.5 to 2.5 ohms (e.g., 1 to 2 ohms).

[0047] Current from the power source within the aerosol generating device may be delivered through electrodes configured to make electrical contact with the first end section (172) and the second end section (176) of the heater (170) when the capsule (100) is inserted into the aerosol generating device. In a non-limiting embodiment, the electrodes may be spring-loaded to enhance the coupling of the capsule (100) with the heater (170). The spring loading of the electrodes may be in a direction along the longitudinal axis of the heater (170) and perpendicular to the plane corresponding to the first end section (172) and the second end section (176). In addition to or instead of spring loading, movement of the electrodes (e.g., engaging, disengaging) may be achieved by mechanical operation. Additionally, the supply of current from the aerosol generating device to the capsule (100) may be manual (e.g., button operation) or automatic (e.g., puff operation).

[0048] The third frame (150) may be a monolithic structure. In an exemplary embodiment, the heater (170) may be embedded within the third frame (150). For example, the heater (170) may extend through the third frame (150) through slots (154a, 154b). In such an example, the middle section (174) of the heater (170) is within the cavity (151) of the third frame (150), while the first arm (173) and second arm (175) of the heater (170) are within the distal portion of the third frame (150), and the first end section (172) and second end section (176) of the heater (170) are outside the cavity (151) and in contact with the distal side wall of the third frame (150). The holes (178a, 178b) may already be formed (e.g., pre-formed) in the heater (170) before the heater (170) is embedded within the third frame (150). Alternatively, the holes (178a, 178b) of the heater (170) may be formed together with the holes (152a, 152b) of the third frame (150) after the heater (170) is embedded within the third frame (150). The embedding of the heater (170) within the third frame (150) may be achieved through injection molding.

[0049] The intermediate section (174) of the heater (170) may be in the form of a pattern extending across most of the open area of ​​the cavity (151). For example, such a pattern may be a pattern in which the intermediate section (174) of the heater (170) meanders or flows around the center of the cavity (151) of the third frame (150). In such a case, the intermediate section (174) of the heater (170) may alternate between extending toward the center of the cavity (151) and extending away from the center of the cavity (151). As illustrated in FIGS. 5 and 6, the wavy shape of the middle section (174) of the heater (170) may be in the form of five protrusions (e.g., lobe, wing, finger) that do not come into contact with the side wall of the cavity (151) of the third frame (150), but the embodiments are not limited thereto.

[0050] FIG. 7 is a first-side perspective view of another capsule for an aerosol generating device according to an exemplary embodiment. FIG. 8 is a second-side perspective view of the capsule of FIG. 7. As illustrated in FIG. 7 and 8, the capsule (200) may be configured to be housed within an aerosol generating device (e.g., a non-combustion heating aerosol generating device). The capsule (200) of FIG. 7 and 8 may be similar to the capsule (100) of FIG. 1 and 2, except for the shape of the heater and the third frame, which will be described in more detail later. Consequently, the above related disclosures regarding common features should be understood to apply to this section and may not be repeated for brevity. In the drawings, the capsule (200) has a layered structure and is generally planar in shape. The proximal end of the capsule (200) may have a curved proximal edge, and the distal end opposite thereto may have a straight distal edge. A pair of straight lateral edges may be parallel to each other. Additionally, the connection between the straight lateral edges and the straight circular edge may be in the form of a curved edge.

[0051] Although the capsule (200) is illustrated in the drawing as being similar to a rectangular shape with semicircular ends (e.g., cage-shaped semicircular, semi-obround), it should be understood that other configurations may be employed. For example, the shape of the capsule (200) may be circular so that it has a disc-like appearance. In other examples, the shape of the capsule (200) may be elliptical or racetrack-shaped. In other cases, the capsule (200) may have a polygonal shape (regular or irregular) including a triangle, a rectangle (e.g., square), a pentagon, a hexagon, a heptagon, or an octagon. The layered structure and generally flat shape of the capsule (200) facilitate stacking, allowing multiple capsules to be stored in an aerosol generating device or other receiving device to dispense new capsules or receive used capsules.

[0052] The capsule (200) may include a housing and a heater (270) (e.g., FIG. 11) within the housing. The housing of the capsule (200) has interior surfaces that define a chamber configured to hold an aerosol-forming substrate. Additionally, the housing of the capsule (200) has exterior surfaces that constitute a first surface, an opposing second surface, and a side surface of the capsule (200). The first surface and the second surface of the capsule (200) are permeable to the aerosol. The side surface of the capsule (200) is located between the first surface and the second surface. The side surface of the capsule (200) may be referred to as the periphery of the capsule (200).

[0053] The housing of the capsule (200) includes a first frame (230) and a second frame (240). The first frame (230) and the second frame (240) may have the same shape and size (when viewed in a planar view) and may be aligned so that their outer walls are substantially on the same plane, but are not limited thereto. The first frame (230) and the second frame (240) may be formed from a suitable polymer material such as polyether ether ketone (PEEK), liquid crystal polymer (LCP), and / or ultra high molecular weight polyethylene (UHMWPE). The first frame (230) and the second frame (240) may be connected by a welded arrangement.

[0054] The first permeable structure (210) is fixed and exposed by the first frame (230). Similarly, the second permeable structure (220) is fixed and exposed by the second frame (240). As discussed in more detail herein, a third frame (250) is positioned between the first permeable structure (210) and the second permeable structure (220) (also between the first frame (230) and the second frame (240)). The capsule (200) is configured to hold an aerosol-forming substrate that may be within the third frame (250) and between the first permeable structure (210) and the second permeable structure (220). The first concavity (233) (e.g., the first dimple portion) of the first frame (230) and the second concavity (243) (e.g., the second dimple portion) of the second frame (240) may be formed from an injection molding process. In this case, the size, location, and / or shape of the first concavity (233) and the second concavity (243) may vary depending on the manufacturing technology (or these concavities may not be formed).

[0055] The first permeable structure (210) and the second permeable structure (220) may be in the form of a mesh sheet, a perforated sheet, or a combination thereof. For example, both the first permeable structure (210) and the second permeable structure (220) may be in the form of a mesh sheet. In another example, both the first permeable structure (210) and the second permeable structure (220) may be in the form of a perforated sheet (e.g., 80, 100, or 250 mesh equivalent). The perforated sheet may be mechanically or chemically perforated (e.g., through photochemical processing / etching). As another example, either of the first permeable structure (210) and the second permeable structure (220) may be in the form of a mesh sheet, and the other of the first permeable structure (210) and the second permeable structure (220) may be in the form of a perforated sheet. The first permeable structure (210) and the second permeable structure (220) (also the first frame (230) and the second frame (240)) may be substantially the same size when viewed in a planar view (e.g., ±10% of a given dimension).

[0056] As illustrated in FIG. 7, the exposed surface of the first permeable structure (210) and the surface of the adjacent first frame (230) (e.g., substantially coplanar / parallel surfaces) can be considered together as the first surface of the capsule (200). Similarly, as illustrated in FIG. 8, the exposed surface of the second permeable structure (220) and the surface of the adjacent second frame (240) (e.g., substantially coplanar / parallel surfaces) can be considered together as the second surface of the capsule (200). In one example, the first surface, the second surface, or both may comprise a perforated sheet. In another example, the first surface, the second surface, or both may comprise a mesh sheet. In yet another example, one of the first surface and the second surface may comprise a perforated sheet, and the other of the first surface and the second surface may comprise a mesh sheet.

[0057] As described above and as discussed in more detail in this specification, a heater (270) (e.g., FIG. 11) may be placed within the capsule (200) to heat the aerosol-forming substrate. The heater (270) includes a first end section (272) and a second end section (276) configured to receive current from a power source, particularly during the activation (operation) of the heater (270). When the heater (270) is activated, the temperature of the aerosol-forming substrate may rise, and an aerosol may be generated and released through the first permeable structure (210) and / or the second permeable structure (220) of the capsule (200).

[0058] As illustrated in FIGS. 7 and 8, the exposed surface of the third frame (250) and the adjacent side walls of the first frame (230) and second frame (240) can be viewed together as the side of the capsule (200). The first end section (272) and the second end section (276) may protrude out of the housing (e.g., the side) of the capsule (200) (e.g., for easy electrical connection with a power source) and may be the outer segments of the heater (270). The first end section (272) and the second end section (276) of the heater (270) may be on the same plane, but exemplary embodiments are not limited thereto. The first end section (272) and the second end section (276) of the heater (270) also define a hole (278a) and a hole (278b), respectively. In another example, the first end section (272) and the second end section (276) of the heater (270) may be configured similarly to the first end section (172) and the second end section (176) as shown in FIG. 2 to form part of the side of the capsule (200). In such a case, the first end section (172) and the second end section (176) of FIG. 2 form part of the side at the distal end of the capsule (100), whereas the first end section (272) and the second end section (276) of FIG. 7 may form part of the side at the proximal end of the capsule (200).

[0059] FIG. 9 is an exploded view of the capsule of FIG. 7. FIG. 10 is an exploded view of the capsule of FIG. 8. Referring to FIG. 9 and FIG. 10, the first frame (230) has a first inner surface and a first outer surface. Additionally, the first frame (230) defines a first opening (231). In an exemplary embodiment, the side walls of the first opening (231) may have opposing straight sections and optionally opposing curved sections, one of the curved sections may be adjacent to the proximal end of the first frame (230) and the other of the curved sections may be adjacent to the distal end opposite the proximal end of the first frame (230). A first permeable structure (210) is fixed to the first inner surface of the first frame (230) so as to be exposed by the first opening (231). In another perspective, the first permeable structure (210) may also be considered to cover the first opening (231). Additionally, the first permeable structure (210) may define a first aperture (212). The position and size of the first aperture (212) may be determined to accommodate the first convex portion (235) when the first permeable structure (210) is fixed to the first frame (230).

[0060] The second frame (240) has a second inner surface and a second outer surface. Additionally, the second frame (240) defines a second opening (241). In an exemplary embodiment, the side walls of the second opening (241) have opposing straight sections and, optionally, opposing curved sections, one of the curved sections may be adjacent to the proximal end of the second frame (240) and the other of the curved sections may be adjacent to the distal end opposite the proximal end of the second frame (240). The second permeable structure (220) may be fixed to the second inner surface of the second frame (240) so as to be exposed by the second opening (241). In another aspect, the second permeable structure (220) may be considered to cover the second opening (241). The size and shape of the second opening (241) may correspond to the size and shape of the first opening (231) (e.g., mirror symmetry). Additionally, the second permeable structure (220) may define a second hole (222). The position and size of the second hole (222) may be determined to accommodate a second convex portion (245) when the second permeable structure (220) is fixed to the second frame (240).

[0061] The third frame (250) defines a cavity (251) configured to accommodate an aerosol-forming substrate. As will be described in more detail, the third frame (250) may be formed of a part (250a) and a part (250b). The side walls of the cavity (251) and the inner surfaces of the first permeable structure (210) and the second permeable structure (220) (covering the cavity (251)) may be considered together to define a chamber. In an exemplary embodiment, the side walls of the cavity (251) have opposing straight sections and opposing curved sections, one of the curved sections is adjacent to the proximal end of the third frame (250), and the other of the curved sections is adjacent to the distal end opposite the proximal end of the third frame (250). The third frame (250), when viewed in a plan view, may be substantially the same size as the first transparent structure (210) and the second transparent structure (220) (e.g., ±10% of the given dimensions). In addition to the constituent materials for the first frame (230) and the second frame (240), the third frame (250) may also be formed of other suitable materials such as ceramic, sintered glass and / or reinforcing fibers (e.g., cardboard).

[0062] The heater (270) is configured to extend into the cavity (251) through the third frame (250). Additionally, the heater (270) may be considered to be supported by the third frame (250). The heater (270) comprises a first end section (272), an intermediate section (274), and a second end section (276). The first end section (272) and the second end section (276) of the heater (270) are outer segments disposed outside the capsule (200). The first end section (272) and the second end section (276) of the heater (270) also have a hole (278a) and a hole (278b), respectively, but exemplary embodiments are not limited thereto. The intermediate section (274) of the heater (270) is an inner segment disposed within the capsule (200) (e.g., within the chamber of the housing containing the aerosol-forming substrate). The first end section (272), the middle section (274), and the second end section (276) of the heater (270) are sections of a continuous structure. In an exemplary embodiment, the middle section (274) of the heater (270) is planar and has a winding shape.

[0063] The first permeable structure (210) and the second permeable structure (220) may be fixed to the first frame (230) and the second frame (240), respectively, through various attachment techniques. For example, the attachment technique may include injection molding (e.g., insert molding, overmolding). In other examples, the attachment technique may include ultrasonic welding. In other cases, the attachment technique may include an adhesive (e.g., tape, glue) that is considered food-safe or permitted by regulatory authorities. Alternatively, instead of separate attachment techniques, the first permeable structure (210) and the second permeable structure (220) may be clamped (or otherwise restrained) to the third frame (250) by the first frame (230) and the second frame (240), respectively.

[0064] The first frame (230) includes at least one first connection protruding from its first inner surface. At least one first connection of the first frame (230) may be in the form of a first connection (238). In an exemplary embodiment, the first connection (238) may extend along the edge of the first inner surface of the first frame (230) in the form of a ridge (e.g., a first ridge). The ridge may define a trench extending along the entire length to resemble an elevated trench or a concave / furrowed ridge. Additionally or alternatively, the ridge may have a tapering ridgeline and may be referred to as a tapered ridgeline. It should be understood that although the first connecting portion (238) is depicted as being separated into a plurality of individual structures (e.g., four individual structures), exemplary embodiments are not limited thereto. For example, alternatively, the first connecting portion (238) may be a single continuous structure extending along the edge to completely surround the first inner surface of the first frame (230).

[0065] Similarly, the second frame (240) includes at least one second connecting portion protruding from its second inner surface. At least one second connecting portion of the second frame (240) may be in the form of a second connecting portion (248). The second connecting portion (248) of the second frame (240) and the first connecting portion (238) of the first frame (230) are complementary structures configured to fit together. In an exemplary embodiment, the second connecting portion (248) may extend in the form of a ridge (e.g., a second ridge) along the edge of the second inner surface of the second frame (240). The ridge may define a trench extending along the entire length to resemble a raised trench or a concave / furrowed ridge. Additionally or alternatively, the ridge may have a tapering ridge line and, as a result, may be referred to as a tapered ridge. It should be understood that although the second connecting portion (248) is depicted as being separated into a plurality of individual structures (e.g., four individual structures), exemplary embodiments are not limited thereto. For example, alternatively, the second connecting portion (248) may be a single continuous structure extending along the periphery to completely surround the second inner surface of the second frame (240).

[0066] In the non-limiting embodiment illustrated in FIGS. 9 and 10, where the first connecting portion (238) of the first frame (230) is separated into four individual structures, two of the four separated structures may be raised trenches, while the other two may be tapered ridges. Conversely, the second connecting portion (248) of the second frame (240) may be separated into four individual structures, where two of the four separated structures are tapered ridges and the other two are raised trenches. A mixed set of raised trenches and tapered ridges of the first frame (230) is configured to be combined, respectively, with a mixed set of tapered ridges and raised trenches of the second frame (240) during the assembly of the capsule (200). It should be understood that various combinations of raised trenches and tapered ridges are possible for the first frame (230) and the second frame (240). Additionally, each of the first permeable structure (210) and the second permeable structure (220) may have tab-like extensions (e.g., four tab-like extensions), and these tab-like extensions are placed between the separated structures of the first connection (238) and between the separated structures of the second connection (248), respectively, when the capsule (200) is assembled.

[0067] The tapered ridge of the first connection (238) and / or the second connection (248) may have a shoulder portion and an inclined portion rising from the shoulder to form a tapered ridge. The tapered ridge may function as an energy detector during assembly (e.g. to facilitate welding). The raised trench of the first connection (238) and / or the second connection (248) corresponding to the tapered ridge may have a rim portion and a trench bottom. As illustrated in FIGS. 9 and 10, the trench bottom of the raised trench may be a flat bottom. Alternatively, the trench bottom of the raised trench may be a V-shaped bottom. In an exemplary embodiment of the connection between the first frame (230) and the second frame (240), the inclined portion of the tapered ridge is configured to contact the bottom of the corresponding raised trench, while the shoulder portion of the tapered ridge interfaces with the edge portion of the raised trench. Accordingly, the fastening (interlocking) surfaces of the first connecting portion (238) and the second connecting portion (248) may be configured in reverse or complementarily to facilitate alignment.

[0068] When a mixed set of raised trenches and tapered ridges of each frame is grouped such that the raised trenches are on one straight side edge and the tapered ridges are on the other straight side edge, the first frame (230) and the second frame (240) may be the same part, as illustrated in FIGS. 9 and 10. In such a case, if the first frame (230) and the second frame (240) are oriented to face each other for alignment, it will lead to a mutually complementary arrangement. As a result, either part can be used interchangeably as the first frame (230) or the second frame (240), thereby simplifying the manufacturing method.

[0069] To assemble the capsule (200), after the aerosol-forming material is placed within the cavity (251) of the third frame (250) (e.g., placed on both sides of the middle section (274) of the heater (270)), the first frame (230) can be connected to the second frame (240). In this case, the third frame (250) will be sandwiched between the first permeable structure (210) and the second permeable structure (220) when the first frame (230) is connected to the second frame (240). During assembly, at least one first connection of the first frame (230) will be joined to at least one connection of the second frame (240) to form at least one connection (e.g., four connections). For example, the raised trench (and / or tapered ridge) of the first connecting portion (238) is configured to align with the corresponding tapered ridge (and / or raised trench) of the second connecting portion (248). Additionally, the connection between the first connecting portion (238) of the first frame (230) and the second connecting portion (248) of the second frame (240) can be achieved by welding (e.g., ultrasonic welding). Furthermore, the outer wall of the first frame (230) may be substantially flat with the outer wall of the second frame (240) when the capsule (200) is assembled, but is not limited thereto. Once assembled, the capsule (200) is difficult or impossible to open without damaging the connecting portion, the frame, and / or other components of the capsule (200). Thus, the capsule (200) is protected from tampering by unauthorized third-party actions.

[0070] The above capsule (200) has been described as including a first frame (230) which is a separate component from the second frame (240). Alternatively, in some examples, the first frame (230) and the second frame (240) may be manufactured as a single structure configured to be folded during assembly so that the first connecting part (238) is joined to the second connecting part (248). For example, the first frame (230) and the second frame (240) may resemble a clamshell structure, such as a door that opens to both sides, and the straight distal edge of the first frame (230) may be connected to the straight distal edge of the second frame (240) by an integral section of reduced thickness that functions as a folding line. In other examples, the straight side edge of the first frame (230) may be connected to the straight side edge of the second frame (240) by an integral section of reduced thickness that functions as a folding line. It should be understood that, in a clamshell structure, one or more connections (e.g., along the folded lines) may be omitted from the capsule (200).

[0071] FIG. 11 is an exploded view of the heater and the third frame of FIG. 9. FIG. 12 is an exploded view of the heater and the third frame of FIG. 10. As shown in FIG. 11 and FIG. 12, the heater (270) includes a first end section (272), a first arm section (273), an intermediate section (274), a second arm section (275), and a second end section (276). As previously described, the first arm section (273) and the second arm section (275) of the heater (270) define holes (278a) and (278b), respectively. Additionally, the first arm section (273) and the second arm section (275) define holes (278c) and (278d), respectively, but exemplary embodiments are not limited thereto. As an example, the heater (270) may be in a planar shape. As a result, the first end section (272), the first arm section (273), the middle section (274), the second arm section (275), and the second end section (276) may be on the same plane. Alternatively, the heater (270) may have the first end section (272) and the second end section (276) in a shape resembling the first end section (172) and the second end section (176) of the heater (170) (e.g., a folded configuration as shown in FIG. 5-6). Furthermore, the heater (270) may be symmetric with respect to its longitudinal axis. The longitudinal axis of the heater (270) lies within the plane corresponding to the heater (270), bisects the middle section (274), and may extend (e.g., equidistantly) between the first end section (272) and the second end section (276).

[0072] In an exemplary embodiment, the heater (270) is configured to undergo Joule heating (also known as ohmic / resistance heating) when current is applied. Specifically, the heater (270) may be formed of one or more conductors and configured to generate heat when current flows. Current may be supplied to the first end section (272) and the second end section (276) of the heater (270) from a power source (e.g., a battery) within the aerosol generating device. Conductors suitable for the heater (270) include iron-based alloys (e.g., stainless steel, iron aluminide), nickel-based alloys (e.g., nichrome), and / or ceramics (e.g., metal-coated ceramics). The middle section (274) of the heater (270) may have a thickness of about 0.1 to 0.3 mm (e.g., 0.15 to 0.25 mm) and a resistance of about 0.5 to 2.5 ohms (e.g., 1 to 2 ohms).

[0073] Current from the power source within the aerosol generating device may be transmitted through electrodes configured to make electrical contact with the first end section (272) and the second end section (276) of the heater (270) when the capsule (200) is inserted into the aerosol generating device. In a non-limiting embodiment, the electrodes may be mounted by springs to improve the connection with the heater (270) of the capsule (200). For example, the spring-mounted first electrode within the aerosol generating device may have a rounded or beveled connection configured to make electrical contact with the first end section (272) of the heater (270), and this connection is seated within the hole (278a) of the first end section (272). Similarly, the spring-mounted second electrode in the aerosol generating device may have a rounded or beveled fastening portion configured to make electrical contact with the second end section (276) of the heater (270), and this fastening portion is seated within the hole (278b) of the second end section (276). In such a case, when the first and second electrodes of the aerosol generating device are fastened to the first end section (272) and the second end section (276) of the heater (270), the fastening can be confirmed by a clicking sound (confirmatory click). The spring-mounted load of the electrodes may be perpendicular to the plane of the heater (270). In addition to or instead of spring-mounting, movement of the electrodes (e.g., fastening, unfastening) may be achieved by mechanical operation. Additionally, the supply of current from the aerosol generating device to the capsule (200) may be manual (e.g., button operation) or automatic (e.g., puff operation).

[0074] The third frame (250) may be composed of or structured with parts (250a) and parts (250b) configured to fasten and clamp a heater (270) between them. For example, the parts (250a, 250b) may each form corresponding openings (251a, 251b) that form a cavity (251) of the third frame (250). In this example, when assembled, the middle section (274) of the heater (270) is within the cavity (251) of the third frame (250), the first arm (273) and the second arm (275) of the heater (270) are within at least the proximal and lateral portions of the third frame (250), and the first end section (272) and the second end section (276) of the heater (270) are outside the cavity (251) and extend beyond the proximal end of the third frame (250).

[0075] In an exemplary embodiment, the part (250b) may include a ridge portion (257), and the part (250a) may define a groove portion (254) corresponding to the ridge portion configured to accommodate the ridge portion (257) when the parts (250a, 250b) are engaged (or vice versa). In this embodiment, the ridge portion (257) may be located between the first end section (272) and the second end section (276) of the heater (270) and insulate them from each other when the heater (270) is clamped by the parts (250a, 250b) of the third frame (250). Additionally, the part (250b) may include protrusions (255a, 255b), and the part (250a) may define holes (252a, 252b) corresponding to the protrusions configured to receive the protrusions (255a, 255b) respectively when the parts (250a, 250b) are engaged (or vice versa). Also, the protrusions (255a, 255b) of the part (250b) may extend through the first arm (273) and the second arm (275) of the heater (270) through the holes (278c, 278d), respectively.

[0076] Part (250a) is received by part (250b) to form a third frame (250). In an exemplary embodiment, part (250a) is dimensioned so as to be seated within a corresponding recess of part (250b). In such an embodiment, the outer sidewall of part (250a) may be engaged (interlocked) with the inner sidewall of part (250b). This engagement may be achieved through an interference fit (also referred to as a press fit or friction fit). Additionally, the thickness of part (250a) and / or the depth of the corresponding recess of part (250b) may be dimensioned so that when the heater (270) is clamped between part (250a) and part (250b), the outer surface of part (250a) is substantially the same height as the edge of part (250b). Although the third frame (250) is disclosed as being composed of parts (250a) and (250b), it should be understood that in other cases, the third frame (250) may be a monolithic structure. In such cases, the heater (270) may be embedded within the third frame (250) through injection molding.

[0077] The intermediate section (274) of the heater (270) may be in the form of a pattern extending across most of the open area of ​​the cavity (251). For example, such a pattern may be a pattern in which the intermediate section (274) of the heater (270) meanders or flows around the center of the cavity (251) of the third frame (250). In such a case, the intermediate section (274) of the heater (270) may alternate between extending toward the center of the cavity (251) and extending away from the center of the cavity (251). As illustrated in FIGS. 11 and 12, the wavy shape of the middle section (274) of the heater (270) may be in the form of five protrusions (e.g., lobe, wing, finger) that do not come into contact with the side wall of the cavity (251) of the third frame (250), but the example embodiments are not limited thereto.

[0078] FIG. 13 is a top view of a patterned sheet related to the manufacture of a heater according to an exemplary embodiment. As shown in FIG. 13, the sheet material may be cut or processed in other ways (e.g., stamping, electrochemical etching, die cutting, laser cutting) to produce a patterned sheet (370'). The sheet material is formed into one or more conductors configured to enable Joule heating (also called ohmic / resistance heating). Conductors suitable for the sheet material include iron-based alloys (e.g., stainless steel, iron aluminide), nickel-based alloys (e.g., nichrome), and / or ceramics (e.g., metal-coated ceramics). For example, stainless steel may be of the type known in the art as SS316L, but is not limited thereto. The sheet material may have a thickness of about 0.1 to 0.3 mm (e.g., 0.15 to 0.25 mm).

[0079] The patterned sheet (370') includes a heater having a first end section (372), an intermediate section (374), and a second end section (376). The first end section (372) and the second end section (376) may each define holes (378a and 378b). The sheet portion (309) is connected to the first end section (372), the intermediate section (374), and the second end section (376) through a cutting portion (311). During the manufacturing process, the cutting portion (311) is cut to separate the first end section (372), the intermediate section (374), and the second end section (376) of the heater (370) from the sheet portion (309). Although six cutting portions (311) are shown, it should be understood that exemplary embodiments are not limited thereto.

[0080] FIG. 14 is a perspective view of a partially assembled capsule comprising a heater obtained from the patterned sheet of FIG. 13. The partially assembled capsule of FIG. 14 is similar to the corresponding features of the capsule (200) of FIG. 7 through 12. For example, the second permeable structure (320), the second frame (340), and the second connecting part (348) of FIG. 14 may be as described, respectively, in relation to the second permeable structure (220), the second frame (240), and the second connecting part (248) of FIG. 9. Consequently, the above related disclosures regarding common features should be understood as applicable to this section and may not be repeated for the sake of brevity.

[0081] In an exemplary embodiment, the proximal portion of the third frame (350) defines a recess or channel configured to accommodate a heater (370). Each segment of the heater (370) seated in the channel of the third frame (350) may be wider than the segment of the heater (370) within the cavity of the third frame (350) (e.g., the intermediate section (374)). Each of these wider segments of the heater (370) will have lower resistance than the narrower segment of the heater (370) and thus can function as a heat relief segment.

[0082] The intermediate section (374) of the heater (370) may be in the form of a pattern extending across most of the open area of ​​the cavity of the third frame (350). For example, such a pattern may be a pattern in which the intermediate section (374) of the heater (370) meanders or flows around the center of the cavity of the third frame (350). In such a case, the intermediate section (374) of the heater (370) may alternately extend toward the center of the cavity and extend away from the center of the cavity. As illustrated in FIG. 14, the meandering shape of the intermediate section (374) of the heater (370) may be in the form of six protrusions (e.g., lobes, wings, fingers) that do not come into contact with the sidewalls of the cavity of the third frame (350), but the embodiments are not limited thereto.

[0083] Although not illustrated in FIG. 14, a first frame and a first permeable structure (as described herein) together with an inner frame (complementing the third frame (350)) may be provided to surround an aerosol-forming substrate to complete the assembly of the capsule. The complementary inner frame may mimic the third frame (350) while omitting the channel for the heater (370). In such an example, the complementary inner frame may have completely flat inner and outer surfaces. Alternatively, the complementary inner frame may include a ridge configured to be seated between the wider segments of the heater (370) in the channel of the third frame (350) when the capsule is assembled.

[0084] FIG. 15 is a plan view of another patterned sheet related to the manufacture of a heater according to an exemplary embodiment. As illustrated in FIG. 15, the sheet material may be cut or otherwise processed (e.g., stamping, electrochemical etching, die cutting, laser cutting) to produce a patterned sheet (470'). The patterned sheet (470') may be as described in relation to the patterned sheet (370') of FIG. 13, except that it has arm sections. Consequently, the above related disclosures regarding common features should be understood as applicable to this section and may not be repeated for brevity. As illustrated, the patterned sheet (470') comprises a heater having a first end section (472), a first arm section (473), an intermediate section (474), a second arm section (475), and a second end section (476). The first end section (472) and the second end section (476) may each define a hole (478a) and a hole (478b). The first arm (473) and the second arm (475) may function as a support structure as well as a heat relief segment. The sheet section (409) is connected to the first end section (472), the first arm (473), the second arm (475), and the second end section (476) through the cutting section (411). During the manufacturing process, the cutting section (411) is cut so that the first end section (472), the first arm (473), the second arm (475), and the second end section (476) of the heater are separated from the sheet section (409). Although six cutting sections (411) are shown, it is understood that exemplary embodiments are not limited thereto. Additionally, the first arm portion (473) and the second arm portion (475) may include alignment tabs (e.g., six alignment tabs) adjacent to the cutting portion (411) to facilitate the placement of the heater during the assembly of the capsule.

[0085] FIG. 16 is a plan view of another patterned sheet related to the manufacture of a heater according to an exemplary embodiment. As illustrated in FIG. 16, the sheet material is cut or otherwise processed (e.g., stamping, electrochemical etching, die cutting, laser cutting) to produce a patterned sheet (570'). The patterned sheet (570') may be the same as described in relation to the patterned sheet (470') of FIG. 15, except for the shape of the intermediate section of the heater. Consequently, the above related disclosures regarding common features should be understood as applicable to this section and may not be repeated for brevity. As illustrated, the patterned sheet (570') comprises a heater having a first end section (572), a first arm section (573), an intermediate section (574), a second arm section (575), and a second end section (576). The first end section (572) and the second end section (576) may each define a hole (578a) and a hole (578b). The first arm section (573) and the second arm section (575) may function as a support structure as well as a heat relief segment. The intermediate section (574) may include a loop, whorl, and / or arch and may have a winding shape similar to a maze or fingerprint. The sheet section (509) is connected to the first end section (572), the first arm section (573), the second arm section (575), and the second end section (576) through the cutting section (511). During the manufacturing process, the cutting section (511) is cut so that the first end section (572), the first arm section (573), the second arm section (575), and the second end section (576) of the heater can be separated from the sheet section (509). Although six cutting sections (511) are shown, it is understood that exemplary embodiments are not limited thereto. Additionally, the first arm section (573) and the second arm section (575) may include alignment tabs (e.g., six alignment tabs) adjacent to the cutting section (511) to facilitate the placement of the heater during the assembly of the capsule.

[0086] FIG. 17 is a plan view of another patterned sheet related to the manufacture of a heater according to an exemplary embodiment. As illustrated in FIG. 17, the sheet material may be cut or otherwise processed (e.g., stamping, electrochemical etching, die cutting, laser cutting) to produce the patterned sheet (670'). The patterned sheet (670') may be as described in relation to the patterned sheet (470') of FIG. 15, except for the shape of the intermediate section of the heater. Consequently, the above related disclosures regarding common features should be understood as applicable to this section and may not be repeated for brevity. As illustrated, the patterned sheet (670') comprises a heater having a first end section (672), a first arm section (673), an intermediate section (674), a second arm section (675), and a second end section (676). The first end section (672) and the second end section (676) may each define a hole (678a) and a hole (678b). The first arm section (673) and the second arm section (675) may function as a support structure as well as a heat relief segment. The intermediate section (674) may have a compressed oscillation or zigzag-like winding shape having a plurality of parallel segments (e.g., 8 to 12 parallel segments). The sheet section (609) is connected to the first end section (672), the first arm section (673), the second arm section (675), and the second end section (676) through the cutting section (611). During the manufacturing process, the cutting section (611) is cut so that the first end section (672), the first arm section (673), the second arm section (675), and the second end section (676) of the heater can be separated from the sheet section (609). It is understood that exemplary embodiments are not limited thereto. Additionally, the first arm section (673) and the second arm section (675) may include alignment tabs (e.g., six alignment tabs) adjacent to the cutting section (611) to facilitate the placement of the heater during the assembly of the capsule.

[0087] FIGS. 18 through 20 are perspective views of a method for manufacturing a capsule for an aerosol generating device according to an exemplary embodiment. Referring to FIG. 18, a partially assembled capsule may be similar to the corresponding features of the capsule (200) of FIGS. 7 through 12. For example, the second permeable structure (620), the second frame (640), and the second connecting part (648) of FIG. 18 may be as described, respectively, in relation to the second permeable structure (220), the second frame (240), and the second connecting part (248) of FIG. 9. Consequently, the above related disclosures regarding common features should be understood as applicable to this section and may not be repeated for the sake of brevity.

[0088] After the second permeable structure (620), the third frame (650), and the aerosol-forming substrate (not shown) are placed on the second frame (640), a patterned sheet (670') may be placed such that the intermediate section (674) is aligned within the opening defined by the third frame (650) to hold the aerosol-forming substrate. In an exemplary embodiment, the internal contours of the first arm (673) and the second arm (675) correspond to the shape and size of the opening defined by the third frame (650). The intermediate section (674) of the heater may be in the form of a pattern that spans most of the open area of ​​the opening of the third frame (650). For example, such a pattern may be a pattern in which the intermediate section (674) of the heater reciprocates over the opening of the third frame (650). In such a case, the intermediate section (674) of the heater may alternately extend the proximal end of the second frame (640) and extend toward the distal end of the second frame (640).

[0089] As illustrated in FIG. 18, when the second connecting portion (648) of the second frame (640) is separated into four individual structures (e.g., two raised trenches and two tapered ridges), four spaces are defined between the individual structures. In an exemplary embodiment, the four spaces include a proximal end space, a distal end space, and two opposing side spaces. During assembly, a patterned sheet (670') is positioned on the second frame (640) such that the outer segment of the heater, comprising a first end section (672) and a second end section (676), extends through the proximal end space of the second frame (640). Additionally, the patterned sheet (670') is positioned so that three pairs of alignment tabs of the first arm portion (673) and the second arm portion (675) are seated in the distal end space and the two opposing side spaces. Additionally, the outer contours of the first arm portion (673) and the second arm portion (675) substantially match the shape and size of the third frame (650) and the inner surface of the second frame (640) in order to achieve a relatively tight connection.

[0090] Referring to FIG. 19, the first insert (602) is seated in the proximal portion of the third frame (650) between the first arm portion (673) and the second arm portion (675). Additionally, the second insert (604) is seated in the distal portion of the third frame (650) between the first arm portion (673) and the second arm portion (675). In an exemplary embodiment, the first insert (602) and the second insert (604) are each in the form of a strip (e.g., silicone) having a thickness substantially corresponding to the thickness of the patterned sheet (670') and a width substantially corresponding to the gap between the first arm portion (673) and the second arm portion (675). The first insert (602) and the second insert (604) may also be aligned with the longitudinal axis of the patterned sheet (670'), and this longitudinal axis bisects the middle section (674) and extends (e.g., equidistantly) between the first arm portion (673) and the second arm portion (675). The first insert (602) and the second insert (604) may function as plugs to improve airflow (e.g., orthogonal airflow) through the first permeable structure (610) (Fig. 20) and the second permeable structure (620). Additionally, the first insert (602) and the second insert (604) may serve as insulating spacers to prevent or reduce the occurrence of electrical short circuits.

[0091] Referring to FIG. 20, an inner frame defining an opening (e.g., identical to the third frame (650)) is placed on a patterned sheet (670') together with additional aerosol-forming material within the opening of the inner frame, and subsequently, a first permeable structure (610) and a first frame (630) are placed to surround the aerosol-forming material in particular. The first permeable structure (610) and the first frame (630) may be as described in FIG. 7 in relation to the first permeable structure (210) and the first frame (230), respectively. Additionally, the first recess (633) may be as described in FIG. 7 in relation to the first recess (233). Consequently, the above related disclosures should be understood as applicable to this section and may not be repeated for brevity. The first frame (630) and the second frame (640) may be connected by welding. After connecting the first frame (630) and the second frame (640), the cutting portion (611) is cut (e.g., die cutting, laser cutting) to separate the sheet portion (609) from the capsule.

[0092] FIG. 21 is a schematic cross-sectional view of an aerosol generating device according to an exemplary embodiment. Referring to FIG. 21, an aerosol generating device (1000) (e.g., a non-combustion heating aerosol generating device) comprises a mouthpiece (1015) and a device body (1025). A power source (1035) and a control circuit (1045) may be disposed within the device body (1025) of the aerosol generating device (1000). The power source (1035) may include one or more batteries (e.g., a rechargeable dual battery). The aerosol generating device (1000) is configured to accommodate a capsule (700), which may be as described in relation to any embodiment herein. The aerosol generating device (1000) also includes a fastening assembly (1055) configured to make electrical contact with the capsule (700). In an exemplary embodiment, the fastening assembly (1055) includes a first electrode and a second electrode, and these electrodes are electrically in contact with the first end section and the second end section of the heater of the capsule (700), respectively.

[0093] When the capsule (700) is inserted into the aerosol generating device (1000), the control circuit (1045) may instruct the power supply (1035) to supply current to the first electrode and the second electrode of the fastening assembly (1055). The supply of current from the power supply (1035) may be in response to manual operation (e.g., button operation) or automatic operation (e.g., puff operation). As a result of the current supply, the capsule (700) may be heated to generate an aerosol. Additionally, the aerosolization temperature may be monitored and controlled using a change in the resistance of the heater. The generated aerosol may also be drawn from the aerosol generating device (1000) through the mouthpiece (1015).

[0094] FIG. 22 is another perspective view of a capsule for an aerosol generating device according to an exemplary embodiment. FIG. 23 is an internal view of the capsule of FIG. 23. FIG. 24 is a cross-sectional plan view of the capsule of FIG. 22. FIG. 25 is a side cross-sectional view of the capsule of FIG. 22. With reference to FIG. 22 through FIG. 25, the capsule (800) may be configured to be accommodated within an aerosol generating device (e.g., a non-combustion heating aerosol generating device). The proximal end of the capsule (800) (e.g., the upper end of FIG. 22) may have a curved proximal edge, and the distal end opposite thereto (e.g., the lower end of FIG. 22) may have a straight distal edge. Additionally, a pair of straight side edges may connect the curved proximal edge and the straight distal edge. The pair of straight side edges may be parallel to each other. In addition, the joint between the straight side edge and the straight distal edge may be in the form of a rounded corner.

[0095] Although the capsule (800) is depicted in the drawing as resembling a rectangle with a curved handle, it should be understood that other configurations may be used. For example, the shape may be circular so that the capsule (800) has a disc-like appearance. In other examples, the shape of the capsule (800) may be elliptical or racetrack-shaped. In other cases, the capsule (800) may have a polygonal shape (regular or irregular) including a triangle, a rectangle (e.g., a square), a pentagon, a hexagon, a heptagon, or an octagon. Generally, a flat capsule (800) can facilitate stacking so that multiple capsules can be stored in an aerosol generating device or other container for dispensing new capsules or accommodating depleted capsules.

[0096] The capsule (800) includes a housing and a heater within the housing. The housing of the capsule (800) has inner surfaces that define a chamber configured to hold an aerosol-forming substrate. Additionally, the housing of the capsule (800) has outer surfaces that constitute a first surface of the capsule (800), a second surface opposite the first surface, and a side surface. The first surface and the second surface of the capsule (800) are permeable to the aerosol. The side surface of the capsule (800) is located between the first surface and the second surface. The side surface can be considered as the periphery of the capsule (800).

[0097] The housing of the capsule (800) comprises a first frame (830) and a second frame (840). The outer surface of the first frame (830) may be considered as the first surface of the capsule (800). Similarly, the outer surface of the second frame (840) may be considered as the second surface of the capsule (800). The first frame (830) and the second frame (840) may have the same shape and size (e.g., based on the plan view) and may be aligned so that their outer sidewalls are substantially coplanar with each other. However, exemplary embodiments are not limited thereto. The first frame (830) and the second frame (840) may be formed from a suitable polymer material such as PEEK (Polyether Ether Ketone), LCP (Liquid Crystal Polymer), and / or UHMWPE (Ultra-High Molecular Weight Polyethylene). The first frame (830) and the second frame (840) may be connected by welding (e.g., ultrasonic welding) or by an adhesive (e.g., tape, glue) that is considered safe for food or otherwise permitted by regulatory authorities.

[0098] The second frame (840) may be in the form of a vessel defining a cavity or containment space. In an exemplary embodiment, the side walls of the cavity defined by the second frame (840) have opposing straight sections and, optionally, opposing curved sections, one of the curved sections may be adjacent to the proximal end of the second frame (840) and the other of the curved sections may be adjacent to the distal end of the second frame (840). The first frame (830) may be in the form of a cover configured to be coupled to the second frame (840) to close the cavity. The combination of the cavity of the second frame (840) and the corresponding inner surface of the first frame (830) (covering the cavity) may be considered to define a chamber.

[0099] As illustrated in FIG. 22, the first frame (830) defines a first perforation (832) that corresponds to the cavity of the second frame (840), and the periphery of the first frame (830) that corresponds to the edge of the second frame (840) is not perforated. Similarly, as illustrated in FIG. 23 and FIG. 24, the second frame (840) defines a second perforation (842) in the cavity. The pattern and size of the first perforation (832) may mimic the pattern and size of the second perforation (842) (e.g., staggered, 80, 100, or 250 mesh equivalents), but exemplary embodiments are not limited thereto. The first perforation (832) and the second perforation (842) may be achieved mechanically or chemically (e.g., through photochemical processing / etching).

[0100] A heater is placed within the capsule (800) to heat the aerosol-forming substrate. In an exemplary embodiment, the heater extends into the cavity through a second frame (840). For example, the heater may be embedded within the second frame (840) via injection molding. The heater may be in the form of a ribbon-shaped strip having length, width, and thickness, such that in such a heater, the width is a dimension greater than the thickness, and the direction of the width is orthogonal to the first and second surfaces of the capsule (800). The heater comprises a first end section (872), an intermediate section (874), and a second end section (876). The first end section (872), the intermediate section (874), and the second end section (876) of the heater are sections of a continuous structure. At least the intermediate section (874) of the heater has a coiled (e.g., wavy) shape. The winding shape of the intermediate section (874) may include a plurality of parallel and uniformly spaced segments (e.g., 8 segments).

[0101] The intermediate section (874) of the heater may be in the form of a pattern extending across most of the open area in the cavity of the second frame (840). For example, this pattern may be a pattern in which the intermediate section (874) of the heater moves in a zigzag pattern within the cavity of the second frame (840). In this case, the intermediate section (874) of the heater may alternately extend toward the proximal end of the second frame (840) and extend toward the distal end of the second frame (840). As illustrated in FIGS. 23-24, the serpentine pattern of the intermediate section (874) of the heater may be in the form of three or four protrusions (e.g., fingers) that do not come into contact with the sidewalls of the cavity of the second frame (840), but exemplary embodiments are not limited.

[0102] The first end section (872) and the second end section (876) of the heater are outer segments configured to receive current from a power source during the activation of the heater. The middle section (874) of the heater is an inner segment disposed within the capsule (800) (e.g., within the chamber of the housing holding the aerosol-forming substrate). When the heater is activated, the temperature of the aerosol-forming substrate may rise (by the aerosol-forming substrate coming into thermal contact with the middle section (874)), and an aerosol may be generated and released through the first perforation (832) and / or the second perforation (842) of the capsule (800).

[0103] The side walls of the first frame (830) and the second frame (840) can be considered together as the side of the capsule (800). Additionally, the first end section (872) and the second end section (876) may also be outer segments of a heater that constitute part of the side of the capsule (800). For example, as shown in FIGS. 23 and 24, the first end section (872) and the second end section (876) of the heater may extend through the distal end of the second frame (840) and surround the proximal end while conforming to the contour of the periphery of the second frame (840), but exemplary embodiments are not limited thereto.

[0104] To assemble the capsule (800), the first frame (830) may be connected to the second frame (840) after the aerosol-forming material is placed within the cavity of the second frame (840). The aerosol-forming material may not have a fixed shape but may be a loose form (e.g., particles, fibers, grounds, fragments, pieces) configured to fill the space between the coil shapes of the intermediate section (874) of the heater and take the shape of the cavity of the second frame (840). Based on the ribbon shape of the heater, the intermediate section (874) may be considered to form a channel or partition within the cavity of the second frame (840) to accommodate the aerosol-forming material. Additionally, as previously described, the connection between the first frame (830) and the second frame (840) may be achieved by welding or by an adhesive that is considered safe for food or otherwise permitted by regulatory authorities. Additionally, the outer wall of the first frame (830) may be substantially flat with the outer wall of the second frame (840) when the capsule (800) is assembled, but is not limited thereto. Once assembled, the capsule (800) is difficult or impossible to open without damaging the first frame (830), the second frame (840), and / or other parts of the capsule (800). Thus, the capsule (800) is protected from tampering by unauthorized acts of a third party.

[0105] In an exemplary embodiment, the heater is configured to perform Joule heating (also known as ohmic / resistance heating) upon the application of current. More specifically, the heater may be formed of one or more conductors and configured to generate heat when current flows through it. Current may be supplied to the first end section (872) and the second end section (876) of the heater from a power source (e.g., a battery) within the aerosol generating device. Conductors suitable for the heater include iron-based alloys (e.g., stainless steel, iron aluminide), nickel-based alloys (e.g., nichrome), and / or ceramics (e.g., metal-coated ceramics). The middle section (874) of the heater may have a resistance of about 0.5 to 2.5 ohms (e.g., 1 to 2 ohms).

[0106] Current from the power source within the aerosol generating device may be transmitted through electrodes configured to make electrical contact with the first end section (872) and the second end section (876) of the heater when the capsule (800) is inserted into the aerosol generating device. In a non-limiting embodiment, the electrodes may be spring-loaded to improve the engagement of the capsule (800) with the heater. Additionally, the first end section (872) and the second end section (876) of the heater may provide a relatively wide contact surface for the electrodes to facilitate a proper and consistent electrical connection. The spring load of the electrodes may be in a direction orthogonal to the side of the capsule (800). In addition to or instead of spring-loading, movement of the electrodes (e.g., engaging, disengaging) may be achieved by mechanical operation. Additionally, the supply of current from the aerosol generating device to the capsule (800) may be manual (e.g., button operation) or automatic (e.g., puff operation).

[0107] FIG. 26 is an unlocked perspective view of a fastening assembly for a capsule according to an exemplary embodiment. As illustrated in FIG. 26, an aerosol generating device may include a device body having a fastening assembly configured to be fastened to a capsule (900) containing an aerosol-forming substrate. The capsule (900) includes a first permeable surface, an opposing second permeable surface, and a side. The fastening assembly of the device body may include at least one heating pad configured to heat the aerosol-forming substrate within the capsule (900) via conduction to generate an aerosol. For example, the device body may be configured to receive the capsule (900) such that the heating pad(s) engage with and cover the first permeable surface and / or the second permeable surface of the capsule (900). In other cases, the fastening assembly of the device body may further include a sealing pad that operates in combination with the heating pad. In this case, the device body may be configured to accommodate the capsule (900) so that the capsule (900) is sandwiched between the heating pad and the sealing pad.

[0108] The capsule (900) may be similar to the corresponding features of the capsule (100) and / or capsule (200) discussed herein. For example, the first frame (930), second frame (940), second permeable structure (920), and second recess (943) of FIG. 26 may be as described for the first frame (230), second frame (240), second permeable structure (220), and second recess (243) of FIG. 8, respectively. Additionally, the third frame (950) of FIG. 26 may be as described in relation to the third frame (150) of FIG. 2 and / or the third frame (250) of FIG. 8. Accordingly, the above related disclosures regarding common features should be understood as applicable to this section and may not be repeated for the sake of brevity.

[0109] The fastening assembly of the device body may include a first pad (1110), a second pad (1120), and / or a holder (1150). The first pad (1110) may include a plateau portion (1114) defining a plurality of first perforations (1112) (e.g., a 5 x 6 array). The dimensions of the plateau portion (1114) of the first pad (1110) may correspond to a first opening of the first frame (930) (exposing the first permeable structure). Although not shown in FIG. 26, the first opening and the first permeable structure may be as described in relation to the first opening (231) and the first permeable structure (210) of FIG. 10. The first pad (1110) may also include a raised portion (e.g., a sealing ridgeline) surrounding the ground portion (1114). The height of this raised portion may be lower than the height of the ground portion (1114). As illustrated, this raised portion substantially follows the shape of the ground portion (1114) and extends along at least the distal and lateral edges of the first pad (1110), but exemplary embodiments are not limited thereto.

[0110] Additionally, although obscured from view in FIG. 26 (but illustrated in FIG. 28), the second pad (1120) may include a ground portion defining a plurality of second perforations (1122) (e.g., a 5 x 5 array). The dimensions of the ground portion of the second pad (1120) may correspond to the second opening of the second frame (940) (exposing the second permeable structure (920)). Although not shown in FIG. 26, the second opening may be as described in relation to the second opening (241) of FIG. 10. The second pad (1120) may also include a raised portion (e.g., a sealing ridge) surrounding the ground portion (as described in relation to the first pad (1110)).

[0111] The first pad (1110) and / or the second pad (1120) may be formed of silicone or other heat-resistant polymer. In an exemplary embodiment, the first pad (1110) may be a heating pad configured to heat an aerosol-forming substrate within the capsule (900) via conduction to generate an aerosol, while the second pad (1120) may be a sealing pad. In another example, both the first pad (1110) and the second pad (1120) may be heating pads. When configured as heating pads, the first pad (1110) and / or the second pad (1120) may include an integral heating element as is known. Furthermore, in some cases, when a heating pad is used to heat an aerosol-forming substrate, the capsule (900) may not include a heater. Accordingly, the first pad (1110) and / or the second pad (1120) as heating pads can serve as a primary method for heating the aerosol-forming substrate within the capsule (900). Alternatively, the first pad (1110) and / or the second pad (1120) as heating pads can serve as a supplementary method for heating the aerosol-forming substrate within the capsule (900), wherein the primary method is through a heater (e.g., heater (170)) as described in this specification.

[0112] The holder (1150) is configured to receive and support the capsule (900). As illustrated, the holder (1150) includes a rim (1152) and a shelf (1154). The shelf (1154) may extend along the perimeter of the lower (e.g., bottom half) part of the inner wall of the holder (1150), but is not limited thereto. The shelf (1154) is configured to support the capsule (900) when the capsule (900) is received within the holder (1150). The holder (1150) may be a fixed or movable part of the fastening assembly of the device body. When configured as a movable part, the holder (1150) may be configured to slide outward (e.g., outward) from the device body so that the capsule (900) is seated within the holder (1150).

[0113] FIG. 27 is a partially assembled perspective view of the fastening assembly of FIG. 26. Referring to FIG. 27, the capsule (900) is partially fastened to the fastening assembly. In particular, as illustrated, the capsule (900) is received to be seated within the holder (1150). In an exemplary embodiment, the opening defined by the holder (1150) substantially corresponds to the shape and size of the capsule (900) (e.g., based on the plan view). Consequently, when the capsule (900) is within the opening defined by the holder (1150) and placed on the shelf (1154), the degrees of freedom for movement (e.g., rotation and / or lateral movement within the plane of the capsule) are relatively small. Additionally, the depth of the opening defined by the holder (1150) for the capsule (900) may substantially correspond to the thickness of the first frame (930). The depth of the opening defined by the holder (1150) may be the distance from the rim (1152) along the inner wall to the shelf (1154).

[0114] FIG. 28 is a cross-sectional view of the fastening assembly of FIG. 26 in a fastened state. Referring to FIG. 26, the capsule (900) is fully fastened to the fastening assembly. In particular, as illustrated, the capsule (900) is supported by the shelf (1154) of the holder (1150) and sandwiched between the first pad (1110) and the second pad (1120). The first pad (1110) and the second pad (1120) are configured to move axially (e.g., along the longitudinal axis of the device body) to clamp the capsule (900). In an exemplary embodiment, the ground portion (1114) of the first pad (1110) interfaces with the first permeable structure of the capsule (900), while the adjacent portion (e.g., including a sealing ridge) interfaces with the first frame (930) for sealing. Similarly, the ground portion of the second pad (1120) interfaces with the second permeable structure (920) of the capsule (900), while the adjacent portion (e.g., including a sealing ridge) interfaces with the second frame (940) for sealing.

[0115] A plurality of first holes (1112) of the first pad (1110) may be offset from or otherwise misaligned with a plurality of second holes (1122) of the second pad (1120) when the first pad (1110) and the second pad (1120) are coupled to the capsule (900). In this case, the air flowing through the plurality of first holes (1112) and entering the capsule (900) will have a longer residence time or retention time within the aerosol-forming substrate of the capsule (900) (e.g., compared to the case where the first holes (1112) are aligned with the second holes (1122). A longer residence time or retention time in the aerosol-forming substrate may increase the amount of volatile substances carried (entrained) by the air flowing through the aerosol-forming substrate. As a result, the amount and / or quality of the aerosol leaving the capsule (900) (through the second permeable structure (920)) and exiting through the plurality of second perforations (1122) of the second pad (1120) can be improved.

[0116] Using the capsule and apparatus disclosed herein, an aerosol can be generated by heating an aerosol-forming substrate. In an exemplary embodiment, the method of generating an aerosol may include securing a capsule (900) between a first pad (1110) and a second pad (1120) of an aerosol-generating device. As previously described, the capsule (900) contains an aerosol-forming substrate and includes a first permeable surface, an opposing second permeable surface, and a side. The method of generating an aerosol may further include heating the aerosol-forming substrate to at least one of the first pad (1110) or the second pad (1120) so that the generated aerosol exits the permeable surface of the capsule (900) and passes through at least one of the first pad (1110) or the second pad (1120). The generated aerosol may also be drawn from the aerosol-generating device through a mouthpiece (e.g., the mouthpiece (1015) of FIG. 21). Alternatively, instead of or in addition to external heating by the first pad (1110) and / or the second pad (1120), the aerosol-forming substrate within the capsule (900) may be internally heated by one or more internal heaters disclosed herein.

[0117] In addition to the non-limiting embodiments described herein, further details of the descriptions, capsules, apparatus, and methods discussed herein are in U.S. Application No. 16 / 451,662, Agent Management No. 24000NV-000522-US, filed June 25, 2019, titled "CAPSULES, HEAT-NOT-BURN (HNB) AEROSOL-GENERATING DEVICES, AND METHODS OF GENERATING AN AEROSOL"; U.S. Application No. 16 / 252,951, Agent Management No. 24000NV-000521-US, filed January 21, 2019, titled "CAPSULES, HEAT-NOT-BURN (HNB) AEROSOL-GENERATING DEVICES, AND METHODS OF GENERATING AN AEROSOL"; This can also be confirmed in U.S. application number 15 / 845,501, agent management number 24000DM-000012-US, for the title "VAPORIZING DEVICES AND METHODS FOR DELIVERING A COMPOUND USING THE SAME" filed on December 18, 2017; and U.S. application number 15 / 559,308, agent management number 24000DM-000003-US-NP, for the title "VAPORIZER FOR VAPORIZING AN ACTIVE INGREDIENT" filed on September 18, 2017; and the disclosures of each of these applications are incorporated herein by reference as disclosures in their entirety.

[0118] Although many exemplary embodiments have been disclosed herein, it should be understood that other variations may be possible. Such variations should not be construed as departing from the spirit and scope of the invention, and all such variations that are obvious to a person skilled in the art are intended to be included within the scope of the following claims.

Claims

Claim 1 A capsule for an aerosol generating device, wherein the capsule comprises a housing and a heater, the housing having inner surfaces defining a chamber configured to hold an aerosol forming substrate, the housing having a first surface defining a first opening, a second surface facing the first surface defining a second opening, and outer surfaces forming a side, the heater having a first end section, an intermediate section, and a second end section, wherein the first end section and the second end section are outer segments forming part of the side of the capsule, and the intermediate section is an inner segment disposed within the chamber of the housing. Claim 2 In claim 1, the capsule comprises a perforated sheet, wherein the first surface, the second surface, or both the first surface and the second surface. Claim 3 In paragraph 2, the perforated sheet is a capsule fixed to the inner surface of the housing. Claim 4 In claim 1, the capsule, wherein the first surface, the second surface, or both the first surface and the second surface comprise a mesh sheet. Claim 5 In claim 1, the above side is a capsule located between the first surface and the second surface. Claim 6 In paragraph 1, the above side is a capsule, which is a peripheral part of the capsule. Claim 7 In claim 1, the housing comprises a capsule including a first frame and a second frame. Claim 8 In claim 7, the capsule is structured such that the first frame includes a first connecting portion extending from its inner surface, the second frame includes a second connecting portion extending from its inner surface, and the first connecting portion and the second connecting portion are aligned with each other. Claim 9 In claim 7, the capsule, wherein the first opening comprises a plurality of first holes in the first frame and the second opening comprises a plurality of second holes in the second frame. Claim 10 In claim 7, the first end section and the second end section of the heater are capsules that conform to the peripheral contour of the second frame. Claim 11 In claim 1, the first end section, the intermediate section, and the second end section of the heater are sections of a continuous structure, a capsule. Claim 12 In paragraph 1, the intermediate section of the heater is a capsule having a flat and coiled shape. Claim 13 In claim 1, the intermediate section of the heater is a capsule having a resistance of 0.5 to 2.5 ohms. Claim 14 In claim 1, the heater is in the form of a ribbon-shaped strip having length, width, and thickness, wherein the length is greater than the dimension of the thickness, and the direction of the width is orthogonal to the first surface and the second surface of the capsule. Claim 15 In claim 1, the capsule has a thickness of 1 to 4 mm. Claim 16 In claim 1, the aerosol-forming substrate is a capsule comprising a plant material. Claim 17 In paragraph 16, the above plant material is a capsule containing tobacco. Claim 18 A capsule according to claim 1, wherein the outward surface of the first end section and the outward surface of the second end section are coplanar. Claim 19 In claim 1, the heater is symmetrical with respect to the longitudinal axis of the capsule. Claim 20 In claim 1, the first end section of the heater defines a first hole, and the second end section of the heater defines a second hole, a capsule. Claim 21 A capsule for an aerosol generating device, wherein the capsule comprises a housing and a heater, wherein the housing has inner surfaces defining a chamber, and the housing has outer surfaces including a first surface defining a first opening, a second surface facing the first surface defining a second opening, and a side of the capsule between the first surface and the second surface, and the heater has a first end section, an intermediate section, and a second end section, wherein the heater extends through the side of the capsule, the first end section and the second end section are located outside the housing, and the intermediate section is an inner segment contained within the chamber of the housing. Claim 22 In claim 21, the capsule, wherein the first end section and the second end section are oriented orthogonally to the intermediate section. Claim 23 In claim 21, the above intermediate section is a capsule having a thickness of about 0.1 mm to 0.3 mm. Claim 24 In claim 21, the heater comprises a first arm between the first end section and the intermediate section, and a second arm between the second end section and the intermediate section, in a capsule. Claim 25 In paragraph 24, the first arm defines a first hole, the second arm defines a second hole, and the first arm and the second arm are a capsule located within the distal portion of the housing.

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