Patent Publication Number: US-2022225667-A1

Title: Capsules including embedded heaters and heat-not-burn (hnb) aerosol-generating devices

Description:
BACKGROUND 
     Field 
     The present disclosure relates to capsules and heat-not-burn (HNB) aerosol-generating devices configured to generate an aerosol without involving a substantial pyrolysis of the aerosol-forming substrate. 
     Description of Related Art 
     Some electronic devices are configured to heat a plant material to a temperature that is sufficient to release constituents of the plant material while keeping the temperature below a combustion 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., heat-not-burn aerosol-generating devices), and the plant material heated may be tobacco. 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 to facilitate insertion and removal from an aerosol-generating device. 
     SUMMARY 
     At least one embodiment relates to a capsule for a heat-not-burn (HNB) aerosol-generating device. In an example embodiment, the capsule may include a housing defining inlet openings, outlet openings, and a chamber between the inlet openings and the outlet openings, the chamber having a longest dimension extending from at least one of the inlet openings to a corresponding one of the outlet openings; an aerosol-forming substrate within the chamber of the housing; and a heater extending into the housing from an exterior thereof, the heater including a first end section, an intermediate section, and a second end section, the intermediate section being disposed within the aerosol-forming substrate in the chamber. 
     At least one embodiment relates to a heat-not-burn (HNB) aerosol-generating device. In an example embodiment, the aerosol-generating device may include a capsule including a housing, an aerosol-forming substrate, and a heater, the housing defining inlet openings, outlet openings, and a chamber between the inlet openings and the outlet openings; a mouthpiece configured to engage with the capsule so as to be in fluidic communication with the chamber via the outlet openings; and a device body configured to receive and retain the capsule and the mouthpiece, the device body including a power source configured to supply an electric current to the heater to heat the aerosol-forming substrate. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The various features and advantages of the non-limiting 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, various dimensions of the drawings may have been exaggerated. 
         FIG. 1  is a front perspective view of an aerosol-generating device according to an example embodiment. 
         FIG. 2  is a rear perspective view of the aerosol-generating device of  FIG. 1 . 
         FIG. 3  is an upstream perspective view of the aerosol-generating device of  FIG. 1 . 
         FIG. 4  is the front perspective view of the aerosol-generating device of  FIG. 1 , wherein the door is open. 
         FIG. 5  is the front perspective view of the aerosol-generating device of  FIG. 4 , wherein the mouthpiece and the capsule are separated from the device body. 
         FIG. 6  is an enlarged view of the capsule in  FIG. 5 . 
         FIG. 7  is an upstream perspective view of the capsule of  FIG. 6 . 
         FIG. 8  is an exploded view of the capsule of  FIG. 6 . 
         FIG. 9  is a partially-disassembled view of the aerosol-generating device of  FIG. 1 . 
         FIG. 10  is a partially-disassembled view of the aerosol-generating device of  FIG. 2 . 
         FIG. 11  is a cross-sectional view of the aerosol-generating device of  FIG. 1 . 
         FIG. 12  is another cross-sectional view of the aerosol-generating device of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
     Some detailed example embodiments are disclosed herein. However, specific structural and functional details disclosed herein are merely representative for purposes of describing example embodiments. Example embodiments may, however, be embodied in many alternate forms and should not be construed as limited to only the example embodiments set forth herein. 
     Accordingly, while example embodiments are capable of various 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 thereof. Like numbers refer to like elements throughout the description of the figures. 
     It should be understood that when an element or layer is referred to as being “on,” “connected to,” “coupled to,” “attached to,” “adjacent to,” or “covering” another element or layer, it may be directly on, connected to, coupled to, attached to, adjacent to or covering the other element or layer or intervening elements or layers may be present. 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 or sub-combinations of one or more of the associated listed items. 
     It should be understood that, although the terms first, second, third, etc. may be used herein to describe various 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, region, layer, or section discussed below could be termed a second element, region, layer, or section without departing from the teachings of example embodiments. 
     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&#39;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. 
     The terminology used herein is for the purpose of describing various 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,” when used in this specification, 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. 
     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. 
     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. 
     The processing circuitry may be hardware including logic circuits; a hardware/software combination such as a processor executing software; or a combination thereof. For example, the processing circuitry more specifically may include, but is not limited to, a central processing unit (CPU), an arithmetic logic unit (ALU), a digital signal processor, a microcomputer, a field programmable gate array (FPGA), a System-on-Chip (SoC), a programmable logic unit, a microprocessor, application-specific integrated circuit (ASIC), etc. 
       FIG. 1  is a front perspective view of an aerosol-generating device according to an example embodiment.  FIG. 2  is a rear perspective view of the aerosol-generating device of  FIG. 1 .  FIG. 3  is an upstream perspective view of the aerosol-generating device of  FIG. 1 . Referring to  FIGS. 1-3 , an aerosol-generating device  1000  is configured to receive and heat an aerosol-forming substrate to produce an aerosol. The aerosol-generating device  1000  includes, inter alia, a front housing  1202 , a rear housing  1204 , and a bottom housing  1206  coupled to a frame  1208  (e.g., chassis). A door  1210  is also pivotally connected/attached to the front housing  1202 . For instance, the door  1210  is configured to move or swing about a hinge  1212  and configured to reversibly engage/disengage with the front housing  1202  via a latch  1214  in order to transition between an open position and a closed position. The aerosol-forming substrate, which may be contained within a capsule  100  (e.g.,  FIG. 5 ), may be loaded into the aerosol-generating device  1000  via the door  1210 . During an operation of the aerosol-generating device  1000 , the aerosol produced may be drawn from the aerosol-generating device  1000  via the aerosol outlet  1102  defined by the mouth-end segment  1104  of the mouthpiece  1100  (e.g.,  FIG. 5 ). 
     As illustrated in  FIG. 2 , the aerosol-generating device  1000  includes a first button  1218  and a second button  1220 . The first button  1218  may be a pre-heat button, and the second button  1220  may be a power button (or vice versa). Additionally, one or both of the first button  1218  and the second button  1220  may include a light-emitting diode (LED) configured to emit a visible light when the first button  1218  and/or the second button  1220  is pressed or when otherwise designated by the associated control circuitry. Where both of the first button  1218  and the second button  1220  includes an LED, the lights emitted may be of the same color or of different colors. The lights may also be of the same intensity or of different intensities. Furthermore, the lights may be configured as continuous lights or intermittent lights. For instance, the light in connection with the power button (e.g., second button  1220 ) may blink/flash to indicate that the power source (e.g., battery) is low and in need charging. While the aerosol-generating device  1000  is shown as having two buttons, it should be understood that more (e.g., three) or less buttons may be provided depending on the desired interface and functionalities. 
     The aerosol-generating device  1000  may have a cuboid-like shape which includes a front face, a rear face opposite the front face, a first side face between the front face and the rear face, a second side face opposite the first side face, a downstream end face, and an upstream end face opposite the downstream end face. As used herein, “upstream” (and, conversely, “downstream”) is in relation to a flow of the aerosol, and “proximal” (and, conversely, “distal”) is in relation to an adult operator of the aerosol-generating device  1000  during aerosol generation. Although the aerosol-generating device  1000  is illustrated as having a cuboid-like shape (e.g., rounded rectangular cuboid) with a polygonal cross-section, it should be understood that example embodiments are not limited thereto. For instance, in some embodiments, the aerosol-generating device  1000  may have a cylinder-like shape with a circular cross-section (e.g., for a circular cylinder) or an elliptical cross-section (e.g., for an elliptic cylinder). 
     As illustrated in  FIG. 3 , the aerosol-generating device  1000  includes an inlet insert  1222  configured to permit ambient air to enter the device body  1200  (e.g.,  FIG. 5 ). In an example embodiment, the inlet insert  1222  defines an orifice as an air inlet which is in fluidic communication with the aerosol outlet  1102 . As a result, when a draw or negative pressure is applied to the aerosol outlet  1102 , ambient air will be pulled into the device body  1200  via the orifice in the inlet insert  1222 . The size (e.g., diameter) of the orifice in the inlet insert  1222  made be adjusted, while also taking in account other variables (e.g., capsule  100 ) in the flow path, to provide the desired overall resistance-to-draw (RTD). In other embodiments, the inlet insert  1222  may be omitted altogether such that the air inlet is defined by the bottom housing  1206 . 
     The aerosol-generating device  1000  may additionally include a jack  1224  and a port  1226 . In an example embodiment, the jack  1224  permits the downloading of operational information for research and development (R&amp;D) purposes (e.g., via an RS232 cable). The port  1226  is configured to receive an electric current (e.g., via a USB/mini-USB cable) from an external power source so as to charge an internal power source within the aerosol-generating device  1000 . In addition, the port  1226  may also be configured to send data to and/or receive data (e.g., via a USB/mini-USB cable) from another aerosol-generating device or other electronic device (e.g., phone, tablet, computer). Furthermore, the aerosol-generating device  1000  may be configured for wireless communication (e.g., via Bluetooth) with another electronic device, such as a phone, via an application software (app) installed on that electronic device. In such an instance, an adult operator may control or otherwise interface with the aerosol-generating device  1000  (e.g., locate the aerosol-generating device, check usage information, change operating parameters) through the app. 
       FIG. 4  is the front perspective view of the aerosol-generating device of  FIG. 1 , wherein the door is open. Referring to  FIG. 4 , the mouthpiece  1100  includes a capsule-end segment  1106  that is visible when the door  1210  is opened and obscured/hidden from view when the door  1210  is closed. As illustrated, the capsule-end segment  1106  is larger (e.g., has a larger average diameter) than the mouth-end segment  1104 . The interior of the door  1210  has contoured ridges (e.g., with semicircular indentions) configured to correspond to the curvature of the mouth-end segment  1104  and the capsule-end segment  1106  of the mouthpiece  1100 . As a result, the mouthpiece  1100  may be in a relatively close fit arrangement between the front housing  1202  and the door  1210  when the door  1210  is closed. In an example embodiment, the contoured ridges on the interior of the door  1210  may be sized and positioned so as to be downstream from a larger adjacent or abutting segment of the mouthpiece  1100  when the door  1210  is closed. In this manner, the mouthpiece  1100  may be retained in a relatively secure manner so as to prevent the mouthpiece  1100  from being inadvertently detached from the device body  1200  when the door  1210  is closed. 
     The door  1210  is configured to swing open from a closed position (and, conversely, configured to swing closed/shut from an open position) about a hinge  1212 . The hinge  1212  may be configured such that the axis of rotation for the door  1210  is parallel to the longitudinal axis of the aerosol-generating device  1000 , although example embodiments are not limited thereto. The door  1210  has a latch  1214 , and the front housing  1202  defines a catch  1216 . The latch  1214  of the door  1210  is configured to engage with the catch  1216  of the front housing  1202  when the door  1210  is closed. The resulting engagement may be an interference fit. In another instance, the hinge  1212  may be configured (e.g., provided with the requisite friction) so as to require a continuous force to move the door  1210 . In such an instance, the door  1210  will maintain its position (e.g., closed position, partially open position, fully open position) and will not freely swing open/closed based on a normal movement of the aerosol-generating device  1000 . In another instance, the hinge  1212  may be spring-loaded such that the door  1210  is biased to default to a closed position. In yet another instance, the latch  1214  and the catch  1216  may be configured for a magnetic engagement. In such an instance, the latch  1214  may include a first magnet, while the catch  1216  may include a second magnet, wherein the first magnet and the second magnet are oriented to attract each other. Alternatively, one of the latch  1214  or the catch  1216  may include a magnet, while the other of the latch  1214  or the catch  1216  may include a material (e.g., ferromagnetic material) that is attracted to the magnet. 
       FIG. 5  is the front perspective view of the aerosol-generating device of  FIG. 4 , wherein the mouthpiece and the capsule are separated from the device body. Referring to  FIG. 5 , the aerosol-generating device  1000  includes a device body  1200  configured to receive a capsule  100  and a mouthpiece  1100 . In an example embodiment, the device body  1200  defines a receptacle  1228  configured to receive the capsule  100 . The receptacle  1228  may be in a form of a cylindrical socket with outwardly-extending, diametrically-opposed side slots to accommodate the electrical end sections/contacts of the capsule  100 . However, it should be understood that the receptacle  1228  may be in other forms based on the shape/configuration of the capsule  100 . 
     As noted supra, the device body  1200  includes a door  1210  configured to open to permit an insertion of the capsule  100  and the mouthpiece  1100  and configured to close to retain the capsule  100  and the mouthpiece  1100 . The mouthpiece  1100  includes a mouth end (e.g., of the mouth-end segment  1104 ) and an opposing capsule end (e.g., of the capsule-end segment  1106 ). In an example embodiment, the capsule end is larger than the mouth end and configured to prevent a disengagement of the mouthpiece  1100  from the capsule  100  when the door  1210  of the device body  1200  is closed. When received/secured within the device body  1200  and ready for aerosol generation, the capsule  100  may be hidden from view while the mouth-end segment  1104  defining the aerosol outlet  1102  of the mouthpiece  1100  is visible. As illustrated in the figures, the mouth-end segment  1104  of the mouthpiece  1100  may extend from/through the downstream end face of the device body  1200 . Additionally, the mouth-end segment  1104  of the mouthpiece  1100  may be closer to the front face of the device body  1200  than the rear face. 
     In some instances, the device body  1200  of the aerosol-generating device  1000  may optionally include a mouthpiece sensor and/or a door sensor. The mouthpiece sensor may be disposed on a rim of the receptacle  1228  (e.g., adjacent to the front face of the device body  1200 ). The door sensor may be disposed on a portion of the front housing  1202  adjacent to the hinge  1212  and within the swing path of the door  1210 . In an example embodiment, the mouthpiece sensor and the door sensor are spring-loaded (e.g., retractable) projections configured as safety switches. For instance, the mouthpiece sensor may be retracted/depressed (e.g., activated) when the mouthpiece  1100  is fully engaged with the capsule  100  loaded within the receptacle  1228 . Additionally, the door sensor may be retracted/depressed (e.g., activated) when the door  1210  is fully closed. In such instances, the control circuitry of the device body  1200  may permit an electric current to be supplied to the capsule  100  to heat the aerosol-forming substrate therein (e.g., pre-heat permitted when the first button  1218  is pressed). Conversely, the control circuitry of the device body  1200  may prevent or cease the supply of electric current when the mouthpiece sensor and/or the door sensor is not activated or deactivated (e.g., released). Thus, the heating of the aerosol-forming substrate will not be initiated if the mouthpiece  1100  is not fully inserted and/or if the door  1210  is not fully closed. Similarly, the supply of electric current to the capsule  100  will be disrupted/halted if the door  1210  is opened during the heating of the aerosol-forming substrate. 
     The capsule  100 , which will be discussed herein in more detail, generally includes a housing defining inlet openings, outlet openings, and a chamber between the inlet openings and the outlet openings. An aerosol-forming substrate is disposed within the chamber of the housing. Additionally, a heater may extend into the housing from an exterior thereof. The housing may include a body portion and an upstream portion (e.g., base portion). The body portion of the housing includes a proximal end and a distal end. The upstream portion of the housing may be configured to engage with the distal end of the body portion. 
       FIG. 6  is an enlarged view of the capsule in  FIG. 5 .  FIG. 7  is an upstream perspective view of the capsule of  FIG. 6 . Referring to  FIGS. 6-7 , the housing of the capsule  100  may include a first cover  110 , a second cover  120 , and a base portion  130 . Specifically, the body portion of the housing may be in the form of the first cover  110  (e.g., as a first body component) and the second cover  120  (e.g., as a second body component), while the upstream portion of the housing may be in the form of the base portion  130  (e.g., as a base component). In an example embodiment, the base portion  130  includes an engagement assembly  136 , and the first cover  110  and the second cover  120  are configured to engage with each other and the base portion  130  via the engagement assembly  136 . Additionally, the first cover  110  and the second cover  120  jointly define an upstream passageway  162  and a downstream passageway  166 . The upstream passageway  162  may be in the form of a plurality of serially-arranged inlet openings, while the downstream passageway  166  may be in the form of a plurality of serially-arranged outlet openings, although example embodiments are not limited thereto. The base portion  130  defines a base inlet  132  (e.g., as an air channel) through which incoming air initially enters the capsule  100  before passing through the upstream passageway  162  and into the chamber within the capsule  100  where the aerosol-forming substrate is disposed. Furthermore, as will be subsequently discussed herein in more detail, the capsule  100  includes a heater  140  (e.g.,  FIG. 8 ) with a first end section  142  and a second end section  146  as external sections that extend outward from the base portion  130 . 
     The capsule  100  may also include a first annular member  150   a  and a second annular member  150   b . In one instance, the first annular member  150   a  is configured to hold together the proximal (or downstream) ends of the first cover  110  and the second cover  120 . As a result, because the distal (or upstream) ends of the first cover  110  and the second cover  120  are coupled to (e.g., clamped onto) the engagement assembly  136  of the base portion  130 , the first annular member  150   a  can help keep the first cover  110  and the second cover  120  together and, thus, prevent their inadvertent disengagement from the base portion  130 . On the other hand, the second annular member  150   b  may be disposed on the base portion  130  so as to not physically contact the first cover  110  and the second cover  120 . In an example embodiment, the first annular member  150   a  and the second annular member  150   b  are configured to help provide the desired air sealing during the operation of the aerosol-generating device  1000 . Specifically, when the capsule  100  is engaged with the mouthpiece  1100 , the first annular member  150   a  and the second annular member  150   b  (e.g., as resilient O-rings) may interface with the inner surface of the capsule-end segment  1106  of the mouthpiece  1100  to provide an appropriate seal. Accordingly, when a draw or negative pressure is applied to the aerosol outlet  1102  of the mouthpiece  1100 , all or essentially all of the ambient air pulled into the device body  1200  may be drawn through the capsule  100  (with little or no bypass flow between outer surface of the capsule  100  and the inner surface of the mouthpiece  1100 ). 
     When the capsule  100  is loaded into the device body  1200 , the first end section  142  and the second end section  146  of the heater  140  along with a majority of the base portion  130  will be seated within the receptacle  1228  (e.g., below the plane of the rim round the receptacle  1228 ). In an example embodiment, the receptacle  1228  of the device body  1200  may have a depth such that both the first annular member  150   a  and the second annular member  150   b  are above the rim of the receptacle  1228  when the capsule  100  is fully seated within the receptacle  1228 . In such an instance, the mouthpiece  1100  will be able to interface with the first annular member  150   a , the second annular member  150   b , and optionally the rim around the receptacle  1228  when the mouthpiece  1100  is fully engaged with the capsule  100 . 
       FIG. 8  is an exploded view of the capsule of  FIG. 6 . Referring to  FIG. 8 , the aerosol-forming substrate contained within the capsule  100  may be in the form of a first aerosol-forming substrate  160   a  and a second aerosol-forming substrate  160   b . In an example embodiment, the first aerosol-forming substrate  160   a  and the second aerosol-forming substrate  160   b  are housed between the first cover  110  and the second cover  120 . During the operation of the aerosol-generating device  1000 , the first aerosol-forming substrate  160   a  and the second aerosol-forming substrate  160   b  may be heated by a heater  140  to generate an aerosol. As will be discussed herein in more detail, the heater  140  includes a first end section  142 , an intermediate section  144 , and a second end section  146 . Additionally, prior to the assembly of the capsule  100 , the heater  140  may be mounted in the base portion  130  during a manufacturing process. 
     As illustrated, the first cover  110  of the capsule  100  defines a first upstream groove  112 , a first recess  114 , and a first downstream groove  116 . The first upstream groove  112  and the first downstream groove  116  may each be in the form of a series of grooves. Similarly, the second cover  120  of the capsule  100  defines a second upstream groove, a second recess, and a second downstream groove  126 . In an example embodiment, the second upstream groove, the second recess, and the second downstream groove  126  of the second cover  120  are the same as the first upstream groove  112 , the first recess  114 , and the first downstream groove  116 , respectively, of the first cover  110 . Specifically, in some instances, the first cover  110  and the second cover  120  are identical and complementary structures. In such instances, orienting the first cover  110  and the second cover  120  to face each other for engagement with the base portion  130  will result in a complementary arrangement. As a result, one part may be used interchangeably as the first cover  110  or the second cover  120 , thus simplifying the method of manufacturing. 
     The first recess  114  of the first cover  110  and the second recess of the second cover  120  collectively form a chamber configured to accommodate the intermediate section  144  of the heater  140  when the first cover  110  and the second cover  120  are coupled with the base portion  130 . The first aerosol-forming substrate  160   a  and the second aerosol-forming substrate  160   b  may also be accommodated within the chamber so as to be in thermal contact with the intermediate section  144  of the heater  140  when the capsule  100  is assembled. The chamber may have a longest dimension extending from at least one of the inlet openings (e.g., of the upstream passageway  162 ) to a corresponding one of the outlet openings (e.g., of the downstream passageway  166 ). In an example embodiment, the housing of the capsule  100  has a longitudinal axis, and the longest dimension of the chamber extends along the longitudinal axis of the housing. 
     The first downstream groove  116  of the first cover  110  and the second downstream groove  126  of the second cover  120  collectively form the downstream passageway  166 . Similarly, the first upstream groove  112  of the first cover  110  and the second upstream groove of the second cover  120  collectively form the upstream passageway  162 . The downstream passageway  166  and the upstream passageway  162  are dimensioned to be small or narrow enough to retain the first aerosol-forming substrate  160   a  and the second aerosol-forming substrate  160   b  within the chamber but yet large or wide enough to permit a passage of air and/or an aerosol therethrough when the first aerosol-forming substrate  160   a  and the second aerosol-forming substrate  160   b  are heated by the heater  140 . 
     In one instance, each of the first aerosol-forming substrate  160   a  and the second aerosol-forming substrate  160   b  may be in a consolidated form (e.g., sheet, pallet, tablet) that is configured to maintain its shape so as to allow the first aerosol-forming substrate  160   a  and the second aerosol-forming substrate  160   b  to be placed in a unified manner within the first recess  114  of the first cover  110  and the second recess of the second cover  120 , respectively. In such an instance, the first aerosol-forming substrate  160   a  may be disposed on one side of the intermediate section  144  of the heater  140  (e.g., side facing the first cover  110 ), while the second aerosol-forming substrate  160   b  may be disposed on the other side of the intermediate section  144  of the heater  140  (e.g., side facing the second cover  120 ) so as to substantially fill the first recess  114  of the first cover  110  and the second recess of the second cover  120 , respectively, thereby sandwiching/embedding the intermediate section  144  of the heater  140  in between. Alternatively, one or both of the first aerosol-forming substrate  160   a  and the second aerosol-forming substrate  160   b  may be in a loose form (e.g., particles, fibers, grounds, fragments, shreds) that does not have a set shape but rather is configured to take on the shape of the first recess  114  of the first cover  110  and/or the second recess of the second cover  120  when introduced. 
     As noted supra, the housing of the capsule  100  may include the first cover  110 , the second cover  120 , and the base portion  130 . When the capsule  100  is assembled, the housing may have a height (or length) of about 30 mm-40 mm (e.g., 35 mm), although example embodiments are not limited thereto. Additionally, each of the first recess  114  of the first cover  110  and the second recess of the second cover  120  may have a depth of about 1 mm-4 mm (e.g., 2 mm). In such an instance, the chamber collectively formed by the first recess  114  of the first cover  110  and the second recess of the second cover  120  may have an overall thickness of about 2 mm-8 mm (e.g., 4 mm). Along these lines, the first aerosol-forming substrate  160   a  and the second aerosol-forming substrate  160   b , if in a consolidated form, may each have a thickness of about 1 mm-4 mm (e.g., 2 mm). As a result, the first aerosol-forming substrate  160   a  and the second aerosol-forming substrate  160   b  may be heated relatively quickly and uniformly by the intermediate section  144  of the heater  140 . 
     As discussed herein, an aerosol-forming substrate is a material or combination of materials that may yield an aerosol. An aerosol relates to the matter generated or output by the devices disclosed, claimed, and equivalents thereof. The material may include a compound (e.g., nicotine, cannabinoid), wherein an aerosol including the compound is produced when the material is heated. The heating may be below the combustion temperature so as to produce an aerosol without involving a substantial pyrolysis of the aerosol-forming substrate or the substantial generation of combustion byproducts (if any). Thus, in an example embodiment, pyrolysis does not occur during the heating and resulting production of aerosol. In other instances, there may be some pyrolysis and combustion byproducts, but the extent may be considered relatively minor and/or merely incidental. 
     The aerosol-forming substrate may be a fibrous material. For instance, the fibrous material may be a botanical material. The fibrous material is configured to release a compound when heated. The compound may be a naturally occurring constituent of the fibrous material. For instance, the fibrous material may be plant material such as tobacco, and the compound released may be nicotine. The term “tobacco” includes any tobacco plant material including tobacco leaf, tobacco plug, reconstituted tobacco, compressed tobacco, shaped tobacco, or powder tobacco, and combinations thereof from one or more species of tobacco plants, such as  Nicotiana rustica  and  Nicotiana tabacum.    
     In some example embodiments, the tobacco material may include material from any member of the genus  Nicotiana . In addition, the tobacco material may include a blend of two or more different tobacco varieties. Examples of suitable types of tobacco materials 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, and the like. The tobacco material may be provided in any suitable form, including, but not limited to, tobacco lamina, processed tobacco materials, such as volume expanded or puffed tobacco, processed tobacco stems, such as cut-rolled or cut-puffed stems, reconstituted tobacco materials, blends thereof, and the like. In some example embodiments, the tobacco material is in the form of a substantially dry tobacco mass. Furthermore, in some instances, the tobacco material may be mixed and/or combined with at least one of propylene glycol, glycerin, sub-combinations thereof, or combinations thereof. 
     The compound may also be a naturally occurring constituent of a medicinal plant that has a medically-accepted therapeutic effect. For instance, the medicinal plant may be a  Cannabis  plant, and the 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 a variety of medicinal purposes (e.g., treatment of pain, nausea, epilepsy, psychiatric disorders). The fibrous material may include the leaf and/or flower material from one or more species of  Cannabis  plants such as  Cannabis sativa, Cannabis indica , and  Cannabis ruderalis . In some instances, the fibrous material is a mixture of 60-80% (e.g., 70%)  Cannabis sativa  and 20-40% (e.g., 30%)  Cannabis  indica. 
     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), while cannabidiolic acid (CBDA) is precursor of cannabidiol (CBD). Tetrahydrocannabinolic acid (THCA) and cannabidiolic acid (CBDA) may be converted to tetrahydrocannabinol (THC) and cannabidiol (CBD), respectively, via heating. In an example embodiment, heat from a heater (e.g., heater  140  shown in  FIG. 8 ) may cause decarboxylation so as to convert the tetrahydrocannabinolic acid (THCA) in the capsule  100  to tetrahydrocannabinol (THC), and/or to convert the cannabidiolic acid (CBDA) in the capsule  100  to cannabidiol (CBD). 
     In instances where both tetrahydrocannabinolic acid (THCA) and tetrahydrocannabinol (THC) are present in the capsule  100 , the decarboxylation and resulting conversion will cause a decrease in tetrahydrocannabinolic acid (THCA) and an increase in tetrahydrocannabinol (THC). At least 50% (e.g., at least 87%) of the tetrahydrocannabinolic acid (THCA) may be converted to tetrahydrocannabinol (THC) during the heating of the capsule  100 . Similarly, in instances where both cannabidiolic acid (CBDA) and cannabidiol (CBD) are present in the capsule  100 , the decarboxylation and resulting conversion will cause a decrease in cannabidiolic acid (CBDA) and an increase in cannabidiol (CBD). At least 50% (e.g., at least 87%) of the cannabidiolic acid (CBDA) may be converted to cannabidiol (CBD) during the heating of the capsule  100 . 
     Furthermore, the compound may be or may additionally include a non-naturally occurring additive that is subsequently introduced into the fibrous material. In one instance, the fibrous material may include at least one of cotton, polyethylene, polyester, rayon, combinations thereof, or the like (e.g., in a form of a gauze). In another instance, the fibrous material may be a cellulose material (e.g., non-tobacco and/or non- Cannabis  material). In either instance, the compound introduced may include nicotine, cannabinoids, and/or flavorants. The flavorants may be from natural sources, such as plant extracts (e.g., tobacco extract,  Cannabis  extract), and/or artificial sources. In yet another instance, when the fibrous material includes tobacco and/or  Cannabis , the compound may be or may additionally include one or more flavorants (e.g., menthol, mint, vanilla). Thus, the compound within the aerosol-forming substrate may include naturally occurring constituents and/or non-naturally occurring additives. In this regard, it should be understood that existing levels of the naturally occurring constituents of the aerosol-forming substrate may be increased through supplementation. For example, the existing levels of nicotine in a quantity of tobacco may be increased through supplementation with an extract containing nicotine. Similarly, the existing levels of one or more cannabinoids in a quantity of  Cannabis  may be increased through supplementation with an extract containing such cannabinoids. 
     The first cover  110  and the second cover  120  also define a first furrow  118  and a second furrow  128 , respectively. The first furrow  118  and the second furrow  128  collectively form a downstream furrow configured to accommodate the first annular member  150   a . Similarly, the base portion  130  defines an upstream furrow  138  configured to accommodate the second annular member  150   b . As noted supra, the base portion  130  includes an engagement assembly  136  configured to facilitate a connection with the first cover  110  and the second cover  120 . The engagement assembly  136  may be an integrally formed part of the base portion  130 . In an example embodiment, the base portion  130  defines a base outlet  134  in fluidic communication with the base inlet  132 , and the engagement assembly  136  is in the form of a projecting rim/collar on each side of the base outlet  134 . Additionally, each of the first cover  110  and the second cover  120  may define a slot configured to receive a corresponding projecting rim/collar of the engagement assembly  136 . As a result, the first cover  110  and the second cover  120  (e.g., via their distal ends) may interlock with the engagement assembly  136  of the base portion  130  (while also interfacing with each other) to form the housing of the capsule  100 . 
     A sheet material may be cut or otherwise processed (e.g., stamping, electrochemical etching, die cutting, laser cutting) to produce the heater  140 . In such an instance, the heater  140  will have an integral, continuous form. The sheet material may be formed of one or more conductors configured to undergo Joule heating (which is also known as ohmic/resistive heating). Suitable conductors for the sheet material include an iron-based alloy (e.g., stainless steel, iron aluminides), a nickel-based alloy (e.g., nichrome), and/or a ceramic (e.g., ceramic coated with metal). For instance, the stainless steel may be a type known in the art as SS316L, although example embodiments are not limited thereto. The sheet material may have a thickness of about 0.10 mm-0.30 mm (e.g., 0.15 mm-0.25 mm). The heater  140  may have a resistance between 0.5 mm-2.5 Ohms (e.g., 1.0 mm-2.0 Ohms). 
     The heater  140  has a first end section  142 , an intermediate section  144 , and a second end section  146 . The first end section  142  and the second end section  146  are configured to receive an electric current from a power source during an activation of the heater  140 . When the heater  140  is activated (e.g., so as to undergo Joule heating), the temperature of the first aerosol-forming substrate  160   a  and the second aerosol-forming substrate  160   b  may increase, and an aerosol may be generated and drawn or otherwise released through the downstream passageway  166  of the capsule  100 . The first end section  142  and the second end section  146  may each include a fork terminal to facilitate an electrical connection with the power source (e.g., via a connection bolt), although example embodiments are not limited thereto. Additionally, because the heater  140  may be produced from a sheet material, the first end section  142 , the second end section  146 , and the intermediate section  144  may be coplanar. Furthermore, the intermediate section  144  of the heater  140  may have a planar and winding form resembling a compressed oscillation or zigzag with a plurality of parallel segments (e.g., eight to sixteen parallel segments). In one instance, each parallel segment may have a width of about 0.28 mm-0.32 mm (e.g., 0.30 mm) and a spacing between parallel segments of about 0.30 mm-0.34 mm (e.g., 0.32 mm). However, it should be understood that other forms for the intermediate section  144  of the heater  140  are also possible (e.g., spiral form, flower-like form). 
     In an example embodiment, the heater  140  extends through the base portion  130 . In such an instance, the terminus of each of the first end section  142  and the second end section  146  may be regarded as external segments of the heater  140  protruding from opposite sides of the base portion  130 . In particular, the intermediate section  144  of the heater  140  may be on the downstream side of the base portion  130  and aligned with the base outlet  134 . During manufacturing, the heater  140  may be embedded within the base portion  130  via injection molding (e.g., insert molding, overmolding). For instance, the heater  140  may be embedded such that the intermediate section  144  is evenly spaced between the pair of projecting rims/collars of the engagement assembly  136 . When the capsule  100  is assembled, the intermediate section  144  of the heater  140  may be aligned between the upstream passageway  162  and the downstream passageway  166 . 
     Although the first end section  142  and the second end section  146  of the heater  140  are shown in the drawings as projections (e.g., fins) extending from the sides of the base portion  130 , it should be understood that, in some example embodiments, the first end section  142  and the second end section  146  of the heater  140  may be configured so as to constitute parts of the side surface of the capsule  100 . For instance, the exposed portions of the first end section  142  and the second end section  146  of the heater  140  may be dimensioned and oriented so as to be situated/folded against the sides of the base portion  130  (e.g., while also following the underlying contour of the base portion  130 ). As a result, the first end section  142  and the second end section  146  may constitute a first electrical contact pad and a second electrical contact pad, respectively, as well as parts of the side surface of the capsule  100 . 
       FIG. 9  is a partially-disassembled view of the aerosol-generating device of  FIG. 1 .  FIG. 10  is a partially-disassembled view of the aerosol-generating device of  FIG. 2 . Referring to  FIGS. 9-10 , the frame  1208  (e.g., metal chassis) serves as a foundation for the internal components of the aerosol-generating device  1000 , which may be attached either directly or indirectly thereto. With regard to structures/components shown in the figures and already discussed above, it should be understood that such relevant teachings are also applicable to this section and may not have been repeated in the interest of brevity. In an example embodiment, the bottom housing  1206  is secured to the upstream end of the frame  1208 . Additionally, the receptacle  1228  (for receiving the capsule  100 ) may be mounted onto the front side of the frame  1208 . Between the receptacle  1228  and the bottom housing  1206  is an inlet channel  1230  configured to direct an incoming flow of ambient air to the capsule  100  in the receptacle  1228 . The inlet insert  1222  (e.g.,  FIG. 3 ), through which the incoming air may flow, may be disposed in the distal end of the inlet channel  1230 . Furthermore, the receptacle  1228  and/or the inlet channel  1230  may include a flow sensor (e.g., integrated flow sensor). 
     A covering  1232  and a power source  1234  therein (e.g.,  FIG. 11 ) may be mounted onto the rear side of the frame  1208 . To establish an electrical connection with the capsule  100  (e.g., which is in the receptacle  1228  and covered by the capsule-end segment  1106  of the mouthpiece  1100 ), a first power terminal block  1236   a  and a second power terminal block  1236   b  may be provided to facilitate the supply of an electric current. For instance, the first power terminal block  1236   a  and the second power terminal block  1236   b  may establish the requisite electrical connection between the power source  1234  and the capsule  100  via the first end section  142  and the second end section  146  of the heater  140 . The first power terminal block  1236   a  and/or the second power terminal block  1236   b  may be formed of brass. 
     The aerosol-generating device  1000  may also include a plurality of printed circuit boards (PCBs) configured to facilitate its operation. In an example embodiment, a first printed circuit board  1238  (e.g., bridge PCB for power and I2C) is mounted onto the downstream end of the covering  1232  for the power source  1234 . Additionally, a second printed circuit board  1240  (e.g., HMI PCB) is mounted onto the rear of the covering  1232 . In another instance, a third printed circuit board  1242  (e.g., serial port PCB) is secured to the front of the frame  1208  and situated behind the inlet channel  1230 . Furthermore, a fourth printed circuit board  1244  (e.g., USB-C PCB) is disposed between the rear of the frame  1208  and the covering  1232  for the power source  1234 . However, it should be understood that the example embodiments herein regarding the printed circuit boards should not be interpreted as limiting since the size, shapes, and locations thereof may vary depending on the desired features of the aerosol-generating device  1000 . 
       FIG. 11  is a cross-sectional view of the aerosol-generating device of  FIG. 1 .  FIG. 12  is another cross-sectional view of the aerosol-generating device of  FIG. 1 . With regard to structures/components shown in the figures and already discussed above, it should be understood that such relevant teachings are also applicable to this section and may not have been repeated in the interest of brevity. Referring to  FIGS. 11-12 , the mouth-end segment  1104  of the mouthpiece  1100  is illustrated as defining an aerosol outlet  1102  in the form of a single outlet. However, it should be understood that example embodiments are not limited thereto. For instance, the aerosol outlet  1102  may alternatively be in the form of a plurality of smaller outlets (e.g., two to six outlets). In one instance, the plurality of outlets may be in the form of four outlets. The outlets may be radially-arranged and/or outwardly-angled so as to release diverging streams of aerosol. 
     In an example embodiment, at least one of a filter or a flavor medium may be optionally disposed within the mouth-end segment  1104  of the mouthpiece  1100 . In such an instance, a filter and/or a flavor medium will be downstream from the chamber  164  such that the aerosol generated therein passes through at least one of the filter or the flavor medium before exiting through the at least one aerosol outlet  1102 . The filter may reduce or prevent particles from the aerosol-forming substrate (e.g., aerosol-forming substrate  160   a  and/or aerosol-forming substrate  160   b ) from being inadvertently drawn from the capsule  100 . The filter may also help reduce the temperature of the aerosol in order to provide the desired mouth feel. The flavor medium (e.g., flavor beads) may release a flavorant when the aerosol passes therethrough so as to impart the aerosol with a desired flavor. The flavorant may be the same as described above in connection with the aerosol-forming substrate. Furthermore, the filter and/or the flavor medium may have a consolidated form or a loose form as described supra in connection with the aerosol-forming substrate. 
     The aerosol-generating device  1000  may also include a third annular member  150   c  seated within the receptacle  1228 . The third annular member  150   c  (e.g., resilient O-ring) is configured to establish an air seal when the base portion  130  of the capsule  100  is fully inserted into the receptacle  1228 . As a result, most if not all of the air drawn into the receptacle  1228  will pass through the capsule  100 , and any bypass flow around the capsule  100  will be minuscule if any. In an example embodiment, the first annular member  150   a , the second annular member  150   b , and/or the third annular member  150   c  may be formed of clear silicone. 
     In addition to the printed circuit boards already discussed above, the aerosol-generating device  1000  may also include a fifth printed circuit board  1246  (e.g., main PCB) disposed between the frame  1208  and the power source  1234 . The power source  1234  may be a 900 mAh battery (e.g., lithium-ion rechargeable battery), although example embodiments are not limited thereto. Furthermore, a sensor  1248  may be disposed upstream from the capsule  100  to enhance an operation of the aerosol-generating device  1000 . For instance, the sensor  1248  may be an air flow sensor. In view of the sensor  1248  as well as the first button  1218  and the second button  1220 , the operation of the aerosol-generating device  1000  may be an automatic operation (e.g., puff-activated), a manual operation (e.g., button-activated), or a combination thereof. 
     Upon activating the aerosol-generating device  1000 , the capsule  100  within the device body  1200  may be heated to generate an aerosol. Specifically, in an example embodiment, pressing the second button  1220  will turn on the aerosol-generating device  1000 . Next, pressing the first button  1218  will initiate a heating of the capsule  100  by causing the control circuitry to instruct the power source  1234  to supply an electric current to the capsule  100  via the first end section  142  and the second end section  146  of the heater  140 . When the aerosol-forming substrate within the capsule  100  reaches the desired or predetermined temperature, the first button  1218  may emit a light (e.g., green light) to indicate that such a temperature (e.g., temperature for aerosol generation) has been attained. Afterwards, a draw or application of negative pressure on the aerosol outlet  1102  of the mouthpiece  1100  will pull ambient air into the device body  1200  via the inlet channel  1230 , wherein the air may initially pass through an inlet insert  1222  (e.g.,  FIG. 3 ). Once inside the device body  1200 , the air travels through the inlet channel  1230  to the receptacle  1228  where it is optionally detected by the sensor  1248  (e.g., for the generation of topography data). After the sensor  1248 , the air continues through the receptacle  1228  and enters the capsule  100  via the base portion  130 . Specifically, the air will flow through the base inlet  132  of the capsule  100  before passing through the upstream passageway  162  and into the chamber  164 . 
     As a result of the electric current to the capsule  100 , the temperature of the intermediate section  144  of the heater  140  will increase which, in turn, will cause the temperature of the aerosol-forming substrate (e.g., aerosol-forming substrate  160   a  and/or aerosol-forming substrate  160   b ) inside the chamber  164  to increase such that volatiles are released by the aerosol-forming substrate to produce an aerosol. The aerosol produced will be entrained by the air flowing through the chamber  164 . In particular, the aerosol produced in the chamber  164  will pass through the downstream passageway  166  of the capsule  100  before exiting the aerosol-generating device  1000  from the aerosol outlet  1102  of the mouthpiece  1100 . The control circuitry of the aerosol-generating device  1000  may include a control algorithm configured to manage the amount of energy/power (e.g., via an electric current) delivered to the heater  140  during and between draws/puffs by monitoring the temperature of the intermediate section  144  of the heater  140 . Accordingly, the aerosol may be generated at/with a relatively consistent temperature. 
     In another example embodiment, once the aerosol-generating device  1000  is turned on, pressing the first button  1218  will initiate a pre-heating of the capsule  100  to a sub-aerosol-generating temperature (e.g., 90%-95% of the aerosol-generating temperature for the aerosol-forming substrate). Next, the activation of the aerosol-generating device  1000  to increase the sub-aerosol-generating temperature to the aerosol-generating temperature may be triggered by the detection of an airflow by the sensor  1248 . During such a pre-heating stage/mode, the detection of the air flow by the sensor  1248  causes the control circuitry to instruct the power source  1234  to supply additional electric current to the capsule  100  via the first end section  142  and the second end section  146  of the heater  140  so as to attain the aerosol-generating temperature. The subsequently-generated aerosol may be drawn from the aerosol-generating device  1000  as described above. 
     In yet another example embodiment, the detection of an air flow by the sensor  1248  will turn on the aerosol-generating device  1000  and also initiate a heating of the capsule  100  by causing the control circuitry to instruct the power source  1234  to supply an electric current to the capsule  100  via the first end section  142  and the second end section  146  of the heater  140 . Thus, in such an instance, it is not necessary to press the first button  1218  and the second button  1220  to activate the aerosol-generating device  1000 . The subsequently-generated aerosol may be drawn from the aerosol-generating device  1000  as described above. 
     Additional details of the substrates, capsules, devices, and, methods (e.g., of heating/control) discussed herein may also be found in U.S. application Ser. No. ______, filed concurrently herewith, titled “HEAT-NOT-BURN (HNB) AEROSOL-GENERATING DEVICES INCLUDING ENERGY-BASED HEATER CONTROL, AND METHODS OF CONTROLLING A HEATER,” Atty. Dkt. No. 24000NV-000668-US; U.S. application Ser. No. ______, filed concurrently herewith, titled “HEAT-NOT-BURN (HNB) AEROSOL-GENERATING DEVICES INCLUDING INTRA-DRAW HEATER CONTROL, AND METHODS OF CONTROLLING A HEATER,” Atty. Dkt. No. 24000NV-000670-US; U.S. application Ser. No. ______, filed concurrently herewith, titled “HEAT-NOT-BURN (HNB) AEROSOL-GENERATING DEVICES AND CAPSULES,” Atty. Dkt. No. 24000NV-000717-US; and U.S. application Ser. No. ______, filed concurrently herewith, titled “HEAT-NOT-BURN (HNB) AEROSOL-GENERATING DEVICES AND CAPSULES,” Atty. Dkt. No. 24000NV-000718-US, the disclosures of each of which are incorporated herein in their entirety by reference. 
     While a number of example embodiments have been disclosed herein, it should be understood that other variations may be possible. Such variations are not to be regarded as a departure from the spirit and scope of the present disclosure, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.