Foldable capsule housing

Abstract

A consumable for an aerosol-generating device may include a body panel including a first edge and an opposing second edge, the body panel bent such that the first edge is adjacent to the second edge so as to define a chamber configured to contain an aerosol-forming substrate; and a lower panel extending from the body panel and folded to cover a first open end of the chamber, the lower panel and the body panel being a single contiguous piece of material, the lower panel defining at least one aperture in fluidic communication with the chamber.

Description

Atty. Dkt. No. 24000NV-001157-WO-POA FOLDABLE CAPSULE HOUSINGCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefits of U.S. Provisional Application No. 63 / 772,119, filed March 14, 2025, the entire disclosure of which is incorporated herein by reference in its entirety.BACKGROUND

[0002] The present disclosure relates to heated tobacco devices and consumables configured to generate an aerosol without involving a substantial pyrolysis of an aerosol-forming substrate.

[0003] Some electronics configured to heat a plant material to a temperature that is sufficient to release constituents of the plant material while keeping the temperature below an ignition point of the plant material so as to avoid any substantial pyrolysis of the plant material. Such devices may be referred to as aerosol-generating devices (e.g., heated tobacco aerosol-generating devices or heated tobacco products (HTP)), and the plant material heated may be tobacco and / or cannabis. In some instances, the plant material may be introduced directly into a heating chamber of an aerosol-generating device. In other instances, the plant material may be pre-packaged in individual containers or consumables to facilitate insertion and removal from an aerosol-generating device.SUMMARY

[0004] In some example embodiments, a consumable for an aerosol-generating device may include a body panel including a first edge and an opposing second edge, the body panel bent such that the first edge is adjacent to the second edge so as to define a chamber configured to contain an aerosol-forming substrate; and a lower panel extending from the body panel and folded to cover a first open end of the chamber, the lower panel and the body panel being a single contiguous pieceAtty. Dkt. No. 24000NV-001157-WO-PQA of material, the lower panel defining at least one aperture in fluidic communication with the chamber.

[0005] In some example embodiments, the first edge and the second edge of the body panel may extend in parallel, the first edge and the second edge of the body panel extending transversely to the lower panel.

[0006] In some example embodiments, the consumable may further include a conductive layer on an inner surface of the body panel.

[0007] In some example embodiments, the conductive layer may include a first edge and a second edge, each of the first edge and the second edge of the conductive layer including at least one of an insert portion and a receiving portion, the insert portion configured to interlock with the receiving portion.

[0008] In some example embodiments, the receiving portion may define a groove and the insert portion is configured to mate with the groove.

[0009] In some example embodiments, the receiving portion defines an orifice and the insert portion is configured to be seated within the orifice.

[0010] In some example embodiments, the receiving portion may define a first protrusion and the insert portion defines a second protrusion, and the first protrusion and the second protrusion are configured to interlock.

[0011] In some example embodiments, the conductive layer may include a first edge and a second edge, and the conductive layer is secured to the body panel in an offset manner such that the first edge and the second edge of the conductive layer are spaced apart from the first edge and the second edge of the body panel.Atty. Dkt. No. 24000NV-001157-WO-PQA

[0012] In some example embodiments, the conductive layer may have a thickness in a range of 0.10 mm to 0.35 mm.

[0013] In some example embodiments, the conductive layer may be bent so as to correspond to a periphery of the lower panel.

[0014] In some example embodiments, the consumable may further include an adhesive between the body panel and the conductive layer.

[0015] In some example embodiments, the adhesive may be positioned to adhere the first edge of the body panel to the conductive layer such that the first edge of the body panel is adjacent to the second edge of the body panel.

[0016] In some example embodiments, the body panel may include a cardstock sheet, and the conductive layer includes aluminum.

[0017] In some example embodiments, the conductive layer may be laminated to the body panel.

[0018] In some example embodiments, the consumable may further include a label on an outer surface of the body panel, the label overlapping the first edge and the second edge of the body panel.

[0019] In some example embodiments, the consumable may further include a heater within the chamber.

[0020] In some example embodiments, the consumable may further include an isolator component configured as a base structure on which the heater is supported.

[0021] In some example embodiments, the isolator component may be parallel to the lower panel.

[0022] In some example embodiments, the consumable may further include a conductive layer on an inner surface of the body panel, and the isolator component may abut the conductive layer.Atty. Dkt. No. 24000NV-001157-WO-PQA

[0023] In some example embodiments, the consumable may further include a conductive layer on an inner surface of the body panel, and the isolator component may be between the conductive layer and the lower panel.

[0024] In some example embodiments, the conductive layer may define a ledge, and the isolator component is on the ledge.

[0025] In some example embodiments, the isolator component may include a cardstock material.

[0026] In some example embodiments, the isolator component may define an airflow aperture.

[0027] In some example embodiments, the airflow aperture may be downstream from the at least one aperture of the lower panel.

[0028] In some example embodiments, the consumable may further include a porous plug.

[0029] In some example embodiments, the porous plug may be between the at least one aperture of the lower panel and the airflow aperture of the isolator component.

[0030] In some example embodiments, the isolator component may define at least one notch configured for engagement with a portion of the porous plug to facilitate an alignment of the porous Plug.

[0031] In some example embodiments, the porous plug may be between the isolator component and the lower panel.

[0032] In some example embodiments, the heater may include a heating region, a first terminal, and a second terminal.

[0033] In some example embodiments, the at least one aperture of the lower panel may include an inlet aperture, a first contact aperture, and a second contact aperture, and the isolator component defines an airflow aperture.Atty. Dkt. No. 24000NV-001157-WO-PQA

[0034] In some example embodiments, the inlet aperture of the lower panel may be upstream from the airflow aperture of the isolator component, the first contact aperture may expose the first terminal, and the second contact aperture may expose the second terminal.

[0035] In some example embodiments, the isolator component may define a pair of notches.

[0036] In some example embodiments, the first terminal and the second terminal of the heater may be engaged with the pair of notches of the isolator component.

[0037] In some example embodiments, the first terminal and the second terminal may be configured to form a friction fit with the isolator component.

[0038] In some example embodiments, the isolator component may be a thickness in a range of 0.40 mm to 0.80 mm.

[0039] In some example embodiments, the body panel and the lower panel may include a cardstock material.

[0040] In some example embodiments, the lower panel may be connected to the body panel by a folded corner.

[0041] In some example embodiments, the consumable may further include an end cap engaged with the body panel so as to cover a second open end of the chamber opposite the first open end covered by the lower panel.

[0042] In some example embodiments, the end cap may define at least one outlet aperture.

[0043] In some example embodiments, an upper panel may extend from the body panel opposite the lower panel, the upper panel configured to fold to cover a second open end of the chamber opposite the first open end covered by the lower panel.

[0044] In some example embodiments, the upper panel may be part of the single contiguous piece of material with the body panel and the lower panel.Atty. Dkt. No. 24000NV-001157-WO-PQA

[0045] In some example embodiments, the upper panel may be connected to the body panel by a folded corner.

[0046] In some example embodiments, the upper panel may define at least one outlet aperture.

[0047] In some example embodiments, a method of manufacturing a consumable for an aerosolgenerating device may include cutting a consumable blank from a sheet of cardstock, the consumable blank including a body panel and a lower panel; bending the body panel to define a chamber configured to contain an aerosol-forming substrate, the chamber having a first open end and an opposing second open end; inserting a heater into the first open end of the chamber; and bending the lower panel to cover the first open end of the chamber.

[0048] In some example embodiments, the method may further include inserting an end cap to cover the second open end of the chamber.

[0049] In some example embodiments, the end cap may define at least one aperture.

[0050] In some example embodiments, the cutting may include the consumable blank further including an upper panel, and bending the upper panel to cover the second open end of the chamber.

[0051] In some example embodiments, the upper panel may define at least one aperture.

[0052] In some example embodiments, the lower panel may define at least one aperture.

[0053] In some example embodiments, the lower panel may define a plurality of apertures including at least one air inlet.

[0054] In some example embodiments, the bending the body panel may include, attaching a first end of the body panel to a second end of the body panel that is opposite the first end of the body panel.Atty. Dkt. No. 24000NV-001157-WO-PQA

[0055] In some example embodiments, the attaching may include engaging an insert portion of the body panel with a receiving portion of the body panel such that the insert portion interlocks with the receiving portion.

[0056] In some example embodiments, the method may further include attaching a conductive layer to the consumable blank prior to the bending the body panel.

[0057] In some example embodiments, the conductive layer may be attached in an offset manner relative to the consumable blank.

[0058] In some example embodiments, the conductive layer may be within the chamber following the bending of the body panel.

[0059] In some example embodiments, the bending of the body panel may include attaching a first end and an opposing second end of the body panel to the conductive layer.

[0060] In some example embodiments, the method may further include, prior to the bending the lower panel, placing a porous plug for enclosure between the heater and the lower panel.BRIEF DESCRIPTION OF THE DRAWINGS

[0061] Some features and advantages of the non-limiting example embodiments herein may become more apparent upon review of the detailed description in conjunction with the accompanying drawings. The accompanying drawings are merely provided for illustrative purposes and should not be interpreted to limit the scope of the claims. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted. For purposes of clarity, some dimensions of the drawings may have been exaggerated.

[0062] FIG. 1 is a perspective view of a consumable housing blank, according to some example embodiments.Atty. Dkt. No. 24000NV-001157-WO-PQA

[0063] FIGS. 2A and 2B are lower perspective views of a foldable consumable housing, according to some example embodiments.

[0064] FIGS. 3A-3B are cross-sectional views along the A-A line of FIG. 2A depicting an interface of a first vertical edge and a second vertical edge of a body panel, according to some example embodiments.

[0065] FIGS. 3C-3D are perspective views in region B of FIG. 2A of an interface of a first vertical edge and a second vertical edge of a body panel, according to some example embodiments.

[0066] FIG. 4 is a perspective view of an isolator component, according to some example embodiments.

[0067] FIG. 5 is a perspective view of a heating element, according to some example embodiments.

[0068] FIG. 6 is a perspective view of a heating subassembly in combination with a foldable consumable housing, according to some example embodiments.

[0069] FIG. 7 is a perspective view of a plug material in combination with a heating subassembly inserted into a foldable consumable housing, according to some example embodiments.

[0070] FIG. 8 is a perspective view of a consumable top cap in combination with a heating subassembly inserted into a foldable consumable housing, according to some example embodiments.

[0071] FIG. 9 is a flow chart depicting a method of manufacturing a consumable according to some example embodiments.Atty. Dkt. No. 24000NV-001157-WO-PQA DETAILED DESCRIPTION

[0072] Accordingly, while example embodiments are capable of some modifications and alternative forms, example embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit example embodiments to the particular forms disclosed, but to the contrary, example embodiments are to cover all modifications, equivalents, and alternatives falling within the scope of example embodiments. Like numbers refer to like elements throughout the description of the figures.

[0073] Elements and / or properties thereof (e.g., structures, surfaces, directions, or the like) that are “substantially perpendicular”, “substantially parallel”, or “substantially coplanar” with regard to other elements and / or properties thereof will be understood to be “perpendicular”, “parallel”, or “coplanar”, respectively, with regard to the other elements and / or properties thereof within manufacturing tolerances and / or material tolerances and / or have a deviation in magnitude and / or angle from “perpendicular”, “parallel”, or “coplanar”, respectively, with regard to the other elements and / or properties thereof that is equal to or less than 10% (e.g., a. tolerance of ±10%).

[0074] It should be understood that when an element or layer is referred to as being "on," "connected to," "coupled to," or "covering" another element or layer, it may be directly on, connected to, coupled to, or covering the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly connected to." or "directly coupled to" another element or layer, there are no intervening elements or layers present. Like numbers refer to like elements throughout the specification. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.Atty. Dkt. No. 24000NV-001157-WO-PQA

[0075] It should be understood that, although the terms first, second, third, etc. may be used herein to describe some elements, regions, layers and / or sections, these elements, regions, layers, and / or sections should not be limited by these terms. These terms are only used to distinguish one element, region, layer, or section from another region, layer, or section. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, region, layer, or section without departing from the teachings of example embodiments.

[0076] Spatially relative terms (e.g., "beneath," "below," "lower," "above," "upper," and the like) may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It should be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the term "below" may encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0077] The terminology used herein is for the purpose of describing some example embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "includes," "including," "comprises," and / or "comprising," specify the presence of stated features, integers, steps, operations, and / or elements, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, and / or groups thereof.Atty. Dkt. No. 24000NV-001157-WO-POA

[0078] When the terms "about" or “substantially” are used in this specification in connection with a numerical value, it is intended that the associated numerical value includes a manufacturing or operational tolerance (e.g., ±10%) around the stated numerical value. Moreover, when the terms "generally" or "substantially" are used in connection with geometric shapes, it is intended that precision of the geometric shape is not required but that latitude for the shape is within the scope of the disclosure. Furthermore, regardless of whether numerical values or shapes are modified as "about," “generally,” or "substantially," it will be understood that these values and shapes should be construed as including a manufacturing or operational tolerance (e.g., ±10%) around the stated numerical values or shapes.

[0079] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, including those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0080] FIG. 1 is a perspective view of a consumable housing blank, according to some example embodiments.

[0081] As illustrated in FIG. 1, in some example embodiments, a blank 100 for a consumable for an aerosol-generating device may include a body panel 102 and a lower panel 104. In some example embodiments, the body panel 102 and the lower panel 104 may be a single continuous structure such that the body panel 102 and the lower panel 104 are formed of a single contiguous material. In some example embodiments, the body panel 102 and the lower panel 104 may include a thermally conductive material. In some example embodiments, the body panel 102 and the lowerAtty. Dkt. No. 24000NV-001157-WO-PQA panel 104 may include a metal. In some example embodiments, the body panel 102 and the lower panel 104 may include aluminum. In some example embodiments, the body panel 102 and the lower panel 104 may include cardstock (e.g., paperboard).

[0082] In some example embodiments in which the body panel 102 and the lower panel 104 includes cardstock, the cardstock may have a weight of about 240 gsm (“grams per square meter”) or more. For example, the cardstock may have a weigh of 220 gsm or more, 230 gsm or more, 240 gsm or more, 250 gsm or more, or 260 gsm or more.

[0083] With reference to FIG. 1, in some example embodiments in which the body panel 102 and the lower panel 104 include cardstock, the body panel 102 may additionally include a conductive layer 106 on a first surface of the body panel 102. In some example embodiments, the conductive layer 106 may be a metal. In some example embodiments, the conductive layer 106 may be aluminum. In some example embodiments, the conductive layer 106 may be a metal layer laminated on the body panel 102. In some example embodiments, the body panel 102 may include a conductive layer 106 and the lower panel 104 may not include a conductive layer 106. In some example embodiments, the conductive layer 106 may have a thickness in the range of 0.10 mm to 0.35 mm. For example, the conductive layer may have a thickness in the range of 0.10 mm to 0.40 mm, 0.10 mm to 0.30 mm, 0.10 mm to 0.25 mm, 0.10 mm to 0.20 mm, 0.15 mm to 0.35 mm, 0.2 mm to 0.35 mm, or 0.25 to 0.35 mm.

[0084] In some example embodiments, the conductive layer 106 may be adhered to the body panel 102. For example, the conductive layer 106 may be laminated to the body panel 102. In some example embodiments, the conductive layer 106 may be offset from the body panel 102. For example, there may be a portion of the conductive layer 106 that does not overlap the body panel 102. For example, there may be a portion of the body panel 102 that does not overlap theAtty. Dkt. No. 24000NV-001157-WO-PQA conductive layer 106. In some example embodiments, the conductive layer 106 may be spaced apart from the lower panel 104 such that a surface of the body panel 102 between the conductive layer 106 and the lower panel 104 may be exposed. However, the example embodiments are not so limited. For example, in some example embodiments, the body panel 102 may include a thermally conductive material and the conductive layer 106 may be omitted.

[0085] In some example embodiments, the lower panel 104 may define a first aperture 108. In some example embodiments, the lower panel 104 may define a first contact aperture and second contact aperture 110. In some example embodiments the first and second contact apertures 110 may be spaced apart by the first aperture 108.

[0086] In some example embodiments, the lower panel 104 may be configured to bend in a direction transverse to the horizontal dimensions of the body panel 102. For example, in a bent configuration, top and bottom surface of the lower panel 104 may face directions that are transverse to a direction that a top surface of the body panel 102 faces. For example, in some example embodiments, the lower panel 104 may be configured to bend with respect to the body panel 102 such that the lower panel 104 is connected to the body panel 102 by a folded corner as will be described in greater detail below.

[0087] In some example embodiments, the body panel 102 may define a first vertical edge 102a and a second vertical edge 102b spaced apart in a horizontal direction. In some example embodiments, the conductive layer 106 may define a first edge 106a and a second edge 106b that art spaced apart in a horizontal direction. In some example embodiments, the first edge 106a, the second edge 106b. the first vertical edge 102a, and the second vertical edge 102b may extend in a parallel direction. In some example embodiments, the first edge 106a may be offset from the first vertical edge 102a and the second edge 106b may be offset from the second vertical edge 102b inAtty. Dkt. No. 24000NV-001157-WO-PQA a horizontal direction. In some example embodiments, the first edge 106a, the second edge 106b, the first vertical edge 102a, and / or the second vertical edge 102b may extend in a direction transverse to the lower panel 104.

[0088] FIGS. 2A-2B are lower perspective views of some foldable consumable housings, according to some example embodiments.

[0089] As depicted in FIGS. 2A-2B, in some example embodiments, the body panel 102 may be folded such that a first vertical edge 102a and a second vertical edge 102b may contact each other. In some example embodiments, the conductive layer 106 may define a first edge 106a and a second edge 106b. In some example embodiments, the conductive layer 106 may be offset from the body panel 102 such that when the body panel 102 is folded such that the first vertical edge 102a contacts the second vertical edge 102b, the conductive layer 106 may overlap the interface between the first vertical edge 102a and the second vertical edge 102b. For example, in some example embodiments, the conductive layer 106 may have an outer surface in contact with the body panel 102 that is coated with an adhesive. In some example embodiments, the adhesive on the outer surface of the conductive layer 106 overlaps the interface between the first vertical edge 102a and the second vertical edge 102b. In some example embodiments, the adessive on the conductive layer 106 may hold the first vertical edge 102a and the second vertical edge 102b together. In some example embodiments, a label L adhered to an outer surface of the body panel 102 may overlap the interface between the first vertical edge 102a and the second vertical edge 102b. In some example embodiments, the label L may hold the first vertical edge 102a and the second vertical edge 102b together.

[0090] In some example embodiments, in the bent configuration, the body panel 102 may define a chamber 112 within the conductive layer 106 and the body panel 102. In some exampleAtty. Dkt. No. 24000NV-001157-WO-PQA embodiments, the chamber 112 may have a first open end and a second open end at opposite ends of the chamber 112. In some example embodiments, the lower panel 104 may be adjacent to the first open end. In some example embodiments, the second open end may be defined by an end of the body panel 102 opposite the first open end.

[0091] In some example embodiments, the first vertical edge 102a and the second vertical edge 102b may be configured to interlock. In some example embodiments, the first edge 106a and the second edge 106b may be configured to interlock.

[0092] FIGS. 3A-3B are cross-sectional views along the A-A line of FIG. 2A depicting an interface of a first vertical edge and a second vertical edge of a body panel, according to some example embodiments.

[0093] Referring to FIGS. 3A-3B, in some example embodiments, the first edge 106a may define a receiving portion and the second edge 106b may define an insert portion. For example, as depicted in FIG. 3 A, the first edge 106a of the conductive layer 106 may be folded over the second edge 106b of the conductive layer 106 such that the second edge 106b defines a groove and the first edge 106a defines an insert portion configured to insert into the groove.

[0094] In some example embodiments, the first vertical edge 102a may define a receiving portion and the second vertical edge 102b may define an insert portion. For example, as depicted in FIG.3B, the first vertical edge 102a of the body panel 102 may be folded over the second edge 106b of the conductive layer 106 such that the second edge 106b defines a groove and the first edge 106a defines an insert portion configured to insert into the groove.

[0095] FIGS. 3C-3D are perspective views in region B of FIG. 2A depicting an interface of a first edge and a second edge of a body panel, according to some example embodiments.Atty. Dkt. No. 24000NV-001157-WO-PQA

[0096] Referring to FIG. 3C, in some example embodiments, the first edge 106a may define an orifice 114 and the second edge 106b may define an insert portion 116 configured to be seated within the orifice 114. However, the example embodiments are not so limited thereto. In some example embodiments, for example where the body panel 102 includes aluminum, the first vertical edge 102a may define the orifice 114 and the second vertical edge 102b may define the insert portion 116.

[0097] Referring to FIG. 3D, in some example embodiments, the first edge 106a may define first protrusions 118 and second edge 106b may define second protrusions 120, and the first protrusion 118 and the second protrusion 120 are configured to interlock. However, the example embodiments are not so limited thereto. In some example embodiments, for example where the body panel 102 includes aluminum, the first vertical edge 102a may define the first protrusions 118 and the second vertical edge 102b may define the second protrusions 120.

[0098] Returning to FIG. 2, in some example embodiments, as the conductive layer 106 may be spaced apart from the lower panel 104, a bottom surface of the conductive layer 106 may serve as step or ledge in the chamber 112. In some example embodiments, such as those in which the conductive layer 106 is omitted, the panel body 102 may be stamped such that the panel body 102 forms a step or ledge in the chamber 112. In some example embodiments, the conductive layer 106 may be bent to correspond to a periphery of the lower panel 104. In some example embodiments, the body panel 102 may be bent to correspond to a periphery of the lower panel 104.

[0099] FIG. 4 is a perspective view of an isolator component, according to some example embodiments.

[0100] FIG. 5 is a perspective view of a heating element, according to some example embodiments.Atty. Dkt. No. 24000NV-001157-WO-PQA

[0101] FIG. 6 is a perspective view of a heating subassembly in combination with a foldable consumable housing, according to some example embodiments.

[0102] Referring to FIGS. 4-6, in some example embodiments, a heater assembly 122 may be inserted into the chamber 112 through the first open end. The heater assembly 122 may contact the bottom surface of the conductive layer 106 in the first open end.

[0103] In some example embodiments, the heater assembly may include a heating element 124 and an isolator component 126. In some example embodiments, the heating element 124 may include a heating region 124a, a first terminal 124b, and a second terminal 124c. In some example embodiments, the heating region may be between and connect the first terminal 124b and the second terminal 124c. In some example embodiments, the heating region 124a, a portion of the first terminal 124b and the second terminal 124c may define a planar portion of the heating element. In some example embodiments, the first terminal 124b and the second terminal 124c may each define a contact portion that extends in a direction transverse to the planar portion of the heating element 124.

[0104] In some example embodiments, the isolator component 126 may define an airflow aperture 128. In some example embodiments, the isolator component 126 may define a first pair of notches 130 that the contact portions of the first terminal 124b and the second terminal 124c may conform to or contact. For example, the first terminal 124b and the second terminal 124c may form a friction fit with the isolator component 126. For example, the first terminal 124b and the second terminal 124c may form a friction fit with the first pair of notches 130. In some example embodiments, the isolator component 126 may define a second pair of notches 132 that may accommodate a plug material 134 to be described in greater detail below. In some example embodiments, the first pair of notches 130 may be spaced apart by the airflow aperture 128 in aAtty. Dkt. No. 24000NV-001157-WO-PQA first direction. In some example embodiments, the second pair of notches 132 may be spaced apart by the airflow aperture 128 in a second direction different from the first direction. In some example embodiments, the isolator component 126 may include a cardstock material.

[0105] In some example embodiments, the isolator component 126 may have a thickness in the range of 0.40 mm to 0.80 mm. For example, the isolator component 126 may have a thickness in the range of 0.40 mm to 0.70 mm, 0.40 mm to 0.60 mm, 0.40 to 0.50 mm, 0.50 mm to 0.80 mm, 0.60 mm to 0.80 mm, or 0.70 mm to 0.80 mm.

[0106] In some example embodiments, when the heater assembly 122 is inserted into the first opening of the chamber 112, the isolator component 126 may rest on the bottom surface of the conductive layer 106. In some example embodiments, the isolator component 126 may be in contact with a bottom surface of the conductive layer 106 and inner surfaces of the body panel 102. In some example embodiments which omit the conductive layer 106 and the body panel 102 includes a metal, the heater assembly 122 may be in contact with the stamped step or ledge as described above. In some example embodiments, the heating element 124 may be spaced apart from contacting the conductive layer 106. In some example embodiments, for example when the body panel 102 includes a conductive material, the heating element 124 may be spaced apart from contacting the body panel 102.

[0107] FIG. 7 is a perspective view of a plug material in combination with a heating subassembly inserted into a foldable consumable housing, according to some example embodiments.

[0108] As depicted in some example embodiments, a plug material 134 may be inserted into the first opening of the body panel 102. In some example embodiments, the plug material 134 may overlap the airflow aperture 128. In some example embodiments, the plug material 134 may be aligned with the second pair of notches 132. In some example embodiments, the plug materialAtty. Dkt. No. 24000NV-001157-WO-PQA 134 may extend through the second pair of notches 132. In some example embodiments, the plug material 134 may be a material that is permeable to air but also impermeable to an aerosol-forming substrate. In some example embodiments, the plug material 134 may cover the airflow aperture 128. In some example embodiments, the plug material 134 may fill the second pair of notches 132. For example, in some example embodiments, the plug material 134 may block the airflow aperture 128 and the second pair of notches 132 such that aerosol-forming substrate is reduced in likelihood from exiting the consumable.

[0109] In some example embodiments, the plug material 134 may have a thickness such that when the lower panel 104 is bent to cover the first open end of the body panel 102, a surface of the lower panel facing the chamber 112 is in contact with the plug material 134 and spaced apart from the first terminal 124b and the second terminal 124c. In some example embodiments, the first terminal 124b and the second terminal 124c may be isolated from the conductive layer 106, the body panel 102, and the lower panel 16 by the isolator component 126 and / or the plug material 134.

[0110] In some example embodiments, after the plug material 134 is inserted into the first open end of the body panel 102, the lower panel 104 may be folded over the first opening in the body panel 102 covering the plug material 134 and the heater assembly 122. In some example embodiments, a top surface of the lower panel 104 (for example the surface facing upward in FIG.1) may be in contact with a bottom surface of the body panel 102 (for example a surface of the edge traverse to vertical edges 102a and 102b depicted in FIG. 1). Optionally, in some example embodiments, the top surface of the lower panel 104 may be in contact with a bottom surface of the plug material 134. Optionally, in some example embodiments, the top surface of the lower panel 104 may be in contact with bottom surfaces of the first terminal 124b and the second terminal 124c.Atty. Dkt. No. 24000NV-001157-WO-PQA

[0111] In some example embodiments, the lower panel 104 may be secured to the body panel 102 with an adhesive adhering the lower panel 104 to the body panel 102 and / or the isolator component 126. In some example embodiments, the lower panel 104 may be secured to the body panel 102 with a mechanical connection such as a staple. In some example embodiments, the lower panel 104 may be stapled to the body panel 102 and / or the isolator component 126. In some example embodiments, the lower panel 104 may be bent and held in place by an interference (e.g., friction) fit with the body panel 102 and may not include an adhesive or a mechanical method of connection. In some example embodiments, the top surface of the lower panel 104 may be parallel to top and / or bottom surfaces of the isolator component 126.

[0112] In at least one example embodiment, the airflow aperture 128 may be downstream from the first aperture 108. In some example embodiments, the airflow aperture 128 may vertically overlap the first aperture 108. In at least one example embodiment, the plug material 134 may be between the airflow aperture 128 and the first aperture 108. In at least one example embodiment, the first and second contact apertures 110 may expose contact portions of the first terminal 124b and the second terminal 124c. In some example embodiments, the airflow aperture 128 is in fluidic communication with the chamber 112.

[0113] FIG. 8 is a perspective view of a consumable top cap in combination with a heating subassembly inserted into a foldable consumable housing, according to some example embodiments.

[0114] Referring to FIG. 8, in some example embodiments, the heating region 124a may be housed within the chamber 112. In some example embodiments, the chamber 112 may be filled with an aerosol-forming substrate surrounding the heating region 124a. In some example embodiments, the aerosol-forming substrate may be a solid aerosol-forming substrate.Atty. Dkt. No. 24000NV-001157-WO-PQA

[0115] In some example embodiments a top cap 136 may be inserted into the second opening of the body panel 102 to form a consumable 150. In some example embodiments, the top cap 136 may form an interference (e.g., friction) fit with an inner surface of the body panel 102. In some example embodiments, the top cap 136 may rest on a top surface of the conductive layer 106. In some example embodiments, the top cap 136 may define at least one air outlet 138. However, the example embodiments are not so limited thereto.

[0116] In some example embodiments, the consumable 150 may not include a top cap 136. In some example embodiments, an upper panel substantially identical to the lower panel 104 described above may be attached to an end of body panel 102 opposite the lower panel 104. For example, the body panel 102, the lower panel 104, and the upper panel may be formed of a single contiguous material such that the body panel 102, the lower panel 104, and the upper panel may be a single continuous structure. In some example embodiments, the upper panel may be configured to bend such that the upper panel covers the second opening of the body panel 102. In some example embodiments, the upper panel may define at least one air outlet aperture. In some example embodiments, unlike the lower panel 104, the upper panel may not define first and second contact apertures 110.

[0117] FIG. 9 is a flow chart depicting a method of manufacturing a consumable according to some example embodiments.

[0118] Referring now to FIG. 9, some example embodiments of methods of manufacturing a consumable are provided.

[0119] In some example embodiments, the method 200 may include cutting a consumable blank including a body panel and a lower panel at the cutting 202. In some example embodiments, the consumable blank may be the same as the blank 100 described above with regard to FIG. 1. InAtty. Dkt. No. 24000NV-001157-WO-PQA some example embodiments, the cutting may include cutting a body panel 102 and lower panel 104 from a larger cardstock sheet or aluminum sheet. In some example embodiments, the cutting may include cutting an upper panel from a larger cardstock sheet or aluminum sheet with the body panel 102 and the lower panel 104. In some example embodiments, the cutting 202 may include cutting a conductive layer 106. In some example embodiments, the cutting 202 may include laminating the conductive layer 106 on the body panel 102. In some example embodiments, the cutting 202 may include cutting the blank 100 from a cardstock and aluminum laminate.

[0120] In some example embodiments, the method 200 may include bending the body panel to define a chamber at the bending 204. In some example embodiments, the bending 204 may include bending the body panel 102 such that a first vertical edge 102a may contact a second vertical edge 102b. For example, the body panel 102 may be bent into an obround shape. However, the example embodiments are not so limited thereto. In some example embodiments, the body panel 102 may be bent to define a chamber 112. In some example embodiments, the bending 204 may include securing the first vertical edge 102a to the second vertical edge 102b in any of the methods described above with regard to FIGS. 3A-3D.

[0121] In some example embodiments, the method 200 may include inserting a heater into an open end of the chamber at the inserting 206. In some example embodiments, the body panel 102 may define a first open end and a second open end of the chamber 112. In some example embodiments, the first open end of the chamber 112 may be adjacent to the lower panel 104. In some example embodiments, the heater may be the heater assembly 122 described above with regard to FIGS. 4-6. In some example embodiments, as described above, the inserting 206 may include resting the heater assembly 122 on a bottom surface of the conductive layer 106. In some example embodiments, the inserting 206 may include resting the heater assembly 122 on a step or ledgeAtty. Dkt. No. 24000NV-001157-WO-PQA defined by the body panel 102. In some example embodiments, the inserting 206 may include housing the heating region 124a in the chamber 112. In some example embodiments, the inserting 206 may include inserting a plug material 134 into the chamber 112.

[0122] In some example embodiments, the method 200 may include bending the lower panel to cover the open end of the chamber at the bending 208. In some example embodiments, the lower panel 104 may be bent in a direction transverse to the direction the body panel 102 was bent in 204. In some example embodiments, the lower panel 104 may be bent at an angle along a folded comer connecting the lower panel 104 and the body panel 102. In some example embodiments, the lower panel may be bent at a 90 degree angle. In some example embodiments, a top surface of the lower panel 104 may face the chamber 112. In some example embodiments, the lower panel 104 may cover the first open end of the chamber 112. In some example embodiments, the bending 208 may include securing the lower panel 104 to the body panel 102 as described above. For example, the securing may include applying adhesive, stapling, or a friction fit.

[0123] In some example embodiments, the method 200 may optionally include inserting an end cap into the second open end of the chamber 112. In some example embodiments, the end cap may be the same as the top cap 136 as described above. In some example embodiments, for example where the blank 100 includes an upper panel, the method 200 may additionally include bending the upper panel to cover the second open end of the chamber. In some example embodiments, the method 200 may additionally include securing the upper panel to the body panel 102. In some example embodiments, the securing may include applying adhesive, stapling, or a friction fit. In some example embodiments, the at least one panel may define at least one aperture.

[0124] Although described with reference to specific examples and drawings, modifications, additions and substitutions of example embodiments may be variously made according to theAtty. Dkt. No. 24000NV-001157-WO-POA description by those of ordinary skill in the art. For example, the described techniques may be performed in an order different with that of the methods described, and / or elements such as the described system, architecture, devices, circuit, and the like, may be connected or combined to be different from the above-described methods, or results may be appropriately achieved by other elements or equivalents.

Claims

Atty. Dkt. No. 24000NV-001157-WO-POA We claim:

1. A consumable for an aerosol-generating device, the consumable comprising:a body panel including a first edge and an opposing second edge, the body panel bent such that the first edge is adjacent to the second edge so as to define a chamber configured to contain an aerosol-forming substrate; anda lower panel extending from the body panel and folded to cover a first open end of the chamber, the lower panel and the body panel being a single contiguous piece of material, the lower panel defining at least one aperture in fluidic communication with the chamber.

2. The consumable of claim 1, wherein the first edge and the second edge of the body panel extend in parallel, the first edge and the second edge of the body panel extending transversely to the lower panel.

3. The consumable of claim 1, further comprising:a conductive layer on an inner surface of the body panel.

4. The consumable of claim 3, wherein the conductive layer includes a first edge and a second edge, each of the first edge and the second edge of the conductive layer including at least one of an insert portion and a receiving portion, the insert portion configured to interlock with the receiving portion.

5. The consumable of claim 4, wherein the receiving portion defines a groove and the insert portion is configured to mate with the groove.Atty. Dkt. No. 24000NV-001157-WO-PQA6. The consumable of claim 4, wherein the receiving portion defines an orifice and the insert portion is configured to be seated within the orifice.

7. The consumable of claim 4, whereinthe receiving portion defines a first protrusion and the insert portion defines a second protrusion, andthe first protrusion and the second protrusion are configured to interlock.

8. The consumable of claim 7, wherein the body panel includes a cardstock sheet, and the conductive layer includes aluminum.

9. The consumable of claim 7, wherein the conductive layer is laminated to the body panel.

10. The consumable of claim 3,wherein the conductive layer includes a first edge and a second edge,wherein the conductive layer is secured to the body panel in an offset manner such that the first edge and the second edge of the conductive layer are spaced apart from the first edge and the second edge of the body panel.

11. The consumable of claim 3, further comprising:an adhesive between the body panel and the conductive layer.Atty. Dkt. No. 24000NV-001157-WO-POA 12. The consumable of claim 1, further comprising:a heater within the chamber.

13. The consumable of claim 12, further comprising:an isolator component configured as a base structure on which the heater is supported.

14. The consumable of claim 13, wherein the isolator component includes a cardstock material.

15. The consumable of claim 13, wherein the isolator component defines an airflow aperture.

16. The consumable of claim 15, further comprising:a porous plug.

17. The consumable of claim 1, further comprising:an upper panel extending from the body panel opposite the lower panel, the upper panel configured to fold to cover a second open end of the chamber opposite the first open end covered by the lower panel.

18. The consumable of claim 17, wherein the upper panel is part of the single contiguous piece of material with the body panel and the lower panel.

19. The consumable of claim 18, wherein the upper panel defines at least one outlet aperture.Atty. Dkt. No. 24000NV-001157-WO-POA 20. A method of manufacturing a consumable for an aerosol-generating device, the method comprising:cutting a consumable blank from a sheet of cardstock, the consumable blank including a body panel and a lower panel;bending the body panel to define a chamber configured to contain an aerosol-forming substrate, the chamber having a first open end and an opposing second open end;inserting a heater into the first open end of the chamber; andbending the lower panel to cover the first open end of the chamber.

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