Patent Description:
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. <CIT> describes an electrically operated aerosol-generating system comprising an aerosol-generating device, and first and second removable aerosol-forming cartridges each comprising a resistive heater. The first removable aerosol-forming cartridge comprises a first aerosol-forming substrate requiring a first heating profile and the second removable aerosol-forming cartridge comprises a second aerosol-forming substrate requiring a second heating profile. The aerosol-generating device comprises a main body defining a cavity and at least one opening for removably receiving one of the first and second aerosol-forming cartridges in the cavity. The aerosol-generating device also comprises an electrical power supply and a control unit for controlling a supply of electrical current from the electrical power supply to the electric heater. The control unit is arranged to detect whether the first or second aerosol-forming cartridge has been received within the cavity based upon the resistive load of the respective resistive heater. The control unit is further arranged to control the supply of electrical current to the at least one electric heater according to either the first or the second heating profile in response to the detected aerosol-forming cartridge. <CIT> describes a heating assembly for an electronic cigarette vaporizer. In certain embodiments, the heating assembly includes: a pair of vaporizer shields, certain heating elements, an e-liquid medium, a pair of vapor guides, and a vaporizing chamber side cover. Vaporizer shields are disposed on a heating element base. An e-liquid medium opening is defined between the vaporizer shields. Each of the heating elements has a first terminal and a second terminal. The e-liquid medium is vertically positioned in the e-liquid medium opening. The e-liquid medium has certain heating element grooves for installing the heating elements. The vapor guides are placed between vaporizer shields and the e-liquid medium. The vaporizing chamber side cover is configured to surround the first vaporizer shield and the second vaporizer shield, the e-liquid medium. The vaporizing chamber side cover defines two e-liquid conduit openings, one on each side of the e-liquid medium. <CIT> describes vaporizer apparatuses, including cartridges and vaporizers having fluid-level windows through the body of the vaporizer allowing visualization into the cartridge and the vaporizer; the cartridge is magnetically coupled to the vaporizer.

The present invention as defined in claim <NUM> relates to a capsule for an aerosol-generating device. 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 base portion, a first cover, a second cover, an aerosol-forming substrate, and a heater. The base portion includes an engagement assembly. The first cover is
engaged with the base portion via the engagement assembly. The first cover includes a first interior surface and a first exterior surface. The first interior surface defines a first recess. The second cover is engaged with the base portion and the first cover via the engagement assembly. The second cover includes a second interior surface and a second exterior surface. The second interior surface defines a second recess. The first cover is aligned with the second cover such that the first recess and the second recess collectively form a chamber. The aerosol-forming substrate is within the chamber. The heater is configured to heat the aerosol-forming substrate to generate an aerosol. The heater includes a first end section, an intermediate section, and a second end section. The heater extends from the base portion such that the intermediate section is 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 and a device body. The capsule includes a housing containing an aerosol-forming substrate and a heater configured to heat the aerosol-forming substrate. The housing includes a base portion, a first cover, and a second cover. The first cover and the second cover jointly define therebetween a chamber, an aerosol channel, and an aerosol outlet. The aerosol-forming substrate is disposed in the chamber. The heater is supported by the base portion and extends into the chamber. The device body is configured to connect to the capsule. The device body includes a power source configured to supply an electric current to the heater.

At least one embodiment relates to a method of generating an aerosol. In an example embodiment, the method may include supplying an electric current to a capsule including a housing containing an aerosol-forming substrate and a heater such that the heater undergoes resistive heating. The housing includes a base portion, a first cover, and a second cover. The first cover and the second cover jointly define therebetween a chamber, an aerosol channel, and an aerosol outlet. The aerosol-forming substrate is disposed in the chamber. The heater is supported by the base portion and extends into the chamber. The method may optionally include drawing the aerosol generated by the resistive heating from the chamber and through the aerosol channel and the aerosol outlet.

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. 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'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. Thus, the term "below" may encompass both an orientation of above and below.

The terminology used herein is for the purpose of describing various example embodiments only and is not intended to be limiting of example embodiments. 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., ±<NUM>%) 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., ±<NUM>%) around the stated numerical values or shapes.

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> is a first perspective view of a capsule for an aerosol-generating device according to an example embodiment. <FIG> is a second perspective view of the capsule of <FIG>. Referring to <FIG>, a capsule <NUM> includes a housing configured to hold an aerosol-forming substrate and to accommodate a heater configured to heat the aerosol-forming substrate to generate an aerosol. The housing of the capsule <NUM> includes a base portion <NUM>, a first cover <NUM>, and a second cover <NUM>. The base portion <NUM> includes an engagement assembly <NUM> configured to facilitate a connection with the first cover <NUM> and the second cover <NUM>. Once connected to the base portion <NUM>, the first cover <NUM> and the second cover <NUM> are configured to be received by an end cap <NUM>. The end cap <NUM> defines at least one aerosol outlet <NUM>. As a result, the end cap <NUM> may be regarded as a mouthpiece that is integrated with the housing to produce a capsule <NUM> that is of a <NUM>-piece construction.

Additionally, when connected, the base portion <NUM> and the first cover <NUM> define a first air inlet <NUM> therebetween. Similarly, the base portion <NUM> and the second cover <NUM>, when connected, define a second air inlet <NUM> therebetween. The first air inlet <NUM> and the second air inlet <NUM> are in fluidic communication with the aerosol outlets <NUM>. As a result, air drawn into the first air inlet <NUM> and the second air inlet <NUM> will flow through the capsule <NUM> to the aerosol outlets <NUM>. A heater is configured to extend through the base portion <NUM> such that the first end section <NUM> and the second end section <NUM> are visible while the intermediate section of the heater is hidden from view when the capsule <NUM> is assembled. The heater will be discussed in further detail in connection with subsequent drawings.

<FIG> is a partially exploded view of the capsule of <FIG>. <FIG> is a partially exploded view of the capsule of <FIG>. Referring to <FIG>, the first cover <NUM> and the second cover <NUM> are configured to engage with each other and with the base portion <NUM> such that their adjacent surfaces are substantially flush. For instance, when engaged, the main external surface of the first cover <NUM> may be flush with the front surface of the base portion <NUM> (e.g., <FIG>). Similarly, in another instance, the main external surface of the second cover <NUM> may be flush with the rear surface of the base portion <NUM> (e.g., <FIG>). Additionally, in yet another instance, the opposing side surfaces of the base portion <NUM> may be flush with the adjoining side surfaces of the first cover <NUM> and the second cover <NUM>. Furthermore, in yet another instance, the downstream end surface of the first cover <NUM> may be flush with the downstream end surface of the second cover <NUM>.

When the first cover <NUM>, the second cover <NUM>, and the base portion <NUM> are coupled together, the resulting structure (e.g., housing) may have a form resembling a cuboid with a front face, an opposing rear face, a first side face, an opposing second side face, an upstream end face, and an opposing 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 device during aerosol generation. With a form resembling a cuboid, the resulting structure (from the coupling of the first cover <NUM>, the second cover <NUM>, and the base portion <NUM>) may have a rectangular cross-section. Alternatively, in other instances, the cuboid form of the resulting structure may have a square cross-section. However, it should be understood that example embodiments are not limited thereto. For instance, in lieu of a cuboid form, the resulting structure may have a form resembling a cylinder (e.g., elliptic cylinder, circular cylinder). For an elliptic cylinder, the resulting structure may have an elliptical cross-section. On the other hand, for a circular cylinder, the resulting structure may have a circular cross-section.

With regard to the cuboid form resulting from the coupling of the first cover <NUM>, the second cover <NUM>, and the base portion <NUM> as shown in the drawings, the main external surface of the first cover <NUM> and the front surface of the base portion <NUM> may be jointly regarded as the front face (e.g., which defines the first air inlet <NUM>). Similarly, the main external surface of the second cover <NUM> and the rear surface of the base portion <NUM> may be jointly regarded as the opposing rear face (e.g., which defines the second air inlet <NUM>). Additionally, the opposing side surfaces of the base portion <NUM> and the corresponding side surfaces of the first cover <NUM> and the second cover <NUM> may be jointly regarded as the first side face and the opposing second side face of the housing. Moreover, the underside or bottom of the base portion <NUM> may be regarded as the upstream end face (e.g., from which the first end section <NUM> and the second end section <NUM> of the heater extend). Furthermore, the downstream end surface of the first cover <NUM> and the corresponding downstream end surface of the second cover <NUM> may be jointly regarded as the downstream end face of the housing.

As shown in <FIG>, the downstream end face of the housing defines a passageway <NUM>. The passageway <NUM> is in fluidic communication with the first air inlet <NUM> and the second air inlet <NUM>. As a result, when the capsule <NUM> is fully assembled, the air drawn into the first air inlet <NUM> and the second air inlet <NUM> will flow through the passageway <NUM> en route to the aerosol outlets <NUM>. In an example embodiment, the first air inlet <NUM>, the second air inlet <NUM>, and the passageway <NUM> are dimensioned so as to be small enough to retain the aerosol-forming substrate within the housing while large enough to permit an adequate inflow of air via the first air inlet <NUM> and the second air inlet <NUM> and to permit an adequate outflow of aerosol via the passageway <NUM>.

Although the drawings illustrate the end cap <NUM> as defining four aerosol outlets <NUM>, it should be understood that example embodiments are not limited thereto. For instance, the end cap <NUM> may define less than four (e.g., <NUM>-<NUM>) aerosol outlets <NUM>. In another instance, the end cap <NUM> may define more than four (e.g., <NUM>-<NUM>) aerosol outlets <NUM>. The form of the end cap <NUM> may correspond to the form of the housing formed by the first cover <NUM>, the second cover <NUM>, and the base portion <NUM> (e.g., cuboid form for both the end cap <NUM> and the housing). Alternatively, the form of the end cap <NUM> may differ from the form of the housing formed by the first cover <NUM>, the second cover <NUM>, and the base portion <NUM> (e.g., cuboid form for the end cap <NUM> and cylindrical form for the housing or vice versa). Additionally, the aerosol outlets <NUM> may be arranged in a linear/sequential manner, in a radial manner, or in an array of rows and columns depending on the number of aerosol outlets <NUM> as well as the form and available space of the end cap <NUM>. Furthermore, the shape of each of the aerosol outlets <NUM> may be circular, elongated (e.g., elliptical), polygonal (e.g., rounded rectangular), or of another suitable shape.

As shown in <FIG>, the end cap <NUM> defines a cavity <NUM> configured to receive the first cover <NUM> and the second cover <NUM> of the housing during the assembly of the capsule <NUM>. In an example embodiment, when the capsule <NUM> is assembled, the main external surfaces of the first cover <NUM> and the second cover <NUM> will interface with the corresponding main internal surfaces of the end cap <NUM>. In lieu of (or in addition to) such an interfacial engagement, the external side surfaces of the first cover <NUM> and the second cover <NUM> may interface with the corresponding internal side surfaces of the end cap <NUM>. Such interfacial engagements may be via an interference fit (which may also be referred to as a press fit or friction fit). However, it should be understood that other attachment techniques may also be utilized. For instance, the attachment technique may include an adhesive (e.g., tape, glue) that has been deemed food-safe or otherwise acceptable by a regulatory authority. In another instance, the attachment technique may involve ultrasonic welding.

<FIG> is a further exploded view of the capsule of <FIG>. <FIG> is a further exploded view of the capsule of <FIG>. Referring to <FIG>, the first cover <NUM> defines a first notch <NUM>, a first recess <NUM>, and a first downstream rim <NUM>. Similarly, the second cover <NUM> defines a second notch <NUM>, a second recess <NUM>, and a second downstream rim <NUM>. In some instances, the first cover <NUM> and the second cover <NUM> may be identical parts. In such instances, orienting the first cover <NUM> and the second cover <NUM> to face each other for mating with the base portion <NUM> will result in a complementary arrangement. As a result, one part may be used interchangeably as the first cover <NUM> or the second cover <NUM>, thus simplifying the method of manufacturing.

In an example embodiment, the first notch <NUM> may be defined as a pair of notches at the upstream corners of the first cover <NUM>, wherein each notch may be adjacent to/exposed by the upstream end surface of the first cover <NUM> and also adjacent to/exposed by a side surface of the first cover <NUM> (e.g., <FIG>). Likewise, the second notch <NUM> may be defined as a pair of notches at the upstream corners of the second cover <NUM>, wherein each notch may be adjacent to/exposed by the upstream end surface of the second cover <NUM> and also adjacent to/exposed by a side surface of the second cover <NUM> (e.g., <FIG>). During assembly, the first notch <NUM> and the second notch <NUM> collectively form a T-shaped notch configured to mate with the engagement assembly <NUM> when the first cover <NUM> and the second cover <NUM> are coupled with the base portion <NUM>.

Additionally, the first recess <NUM> of the first cover <NUM> and the second recess <NUM> of the second cover <NUM> collectively form a chamber (e.g., chamber <NUM> in <FIG>) configured to accommodate the intermediate section <NUM> of the heater <NUM> when the first cover <NUM> and the second cover <NUM> are coupled with the base portion <NUM>. As illustrated in <FIG>, a first aerosol-forming substrate 160a and a second aerosol-forming substrate 160b may also be accommodated within the chamber so as to be in thermal contact with the intermediate section <NUM> of the heater <NUM> when the capsule <NUM> is assembled.

In one instance, each of the first aerosol-forming substrate 160a and the second aerosol-forming substrate 160b 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 160a and the second aerosol-forming substrate 160b to be placed in a unified manner within the first recess <NUM> of the first cover <NUM> and the second recess <NUM> of the second cover <NUM>, respectively. In such an instance, the first aerosol-forming substrate 160a may be disposed on one side of the intermediate section <NUM> of the heater <NUM> (e.g., side facing the first cover <NUM>), while the second aerosol-forming substrate 160b may be disposed on the other side of the intermediate section <NUM> of the heater <NUM> (e.g., side facing the second cover <NUM>) so as to substantially fill the first recess <NUM> of the first cover <NUM> and the second recess <NUM> of the second cover <NUM>, respectively, thereby sandwiching/embedding the intermediate section <NUM> of the heater <NUM> in between. Alternatively, one or both of the first aerosol-forming substrate 160a and the second aerosol-forming substrate 160b 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 <NUM> of the first cover <NUM> and/or the second recess <NUM> of the second cover <NUM> when introduced.

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 <NUM>-<NUM>% (e.g., <NUM>%) Cannabis sativa and <NUM>-<NUM>% (e.g., <NUM>%) 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 <NUM> shown in <FIG>) may cause decarboxylation so as to convert the tetrahydrocannabinolic acid (THCA) in the capsule <NUM> to tetrahydrocannabinol (THC), and/or to convert the cannabidiolic acid (CBDA) in the capsule <NUM> to cannabidiol (CBD).

In instances where both tetrahydrocannabinolic acid (THCA) and tetrahydrocannabinol (THC) are present in the capsule <NUM>, the decarboxylation and resulting conversion will cause a decrease in tetrahydrocannabinolic acid (THCA) and an increase in tetrahydrocannabinol (THC). At least <NUM>% (e.g., at least <NUM>%) of the tetrahydrocannabinolic acid (THCA) may be converted to tetrahydrocannabinol (THC) during the heating of the capsule <NUM>. Similarly, in instances where both cannabidiolic acid (CBDA) and cannabidiol (CBD) are present in the capsule <NUM>, the decarboxylation and resulting conversion will cause a decrease in cannabidiolic acid (CBDA) and an increase in cannabidiol (CBD). At least <NUM>% (e.g., at least <NUM>%) of the cannabidiolic acid (CBDA) may be converted to cannabidiol (CBD) during the heating of the capsule <NUM>.

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 a synthetic material. In another instance, the fibrous material may include a natural material such as 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 downstream rim <NUM> of the first cover <NUM> and the second downstream rim <NUM> of the second cover <NUM> jointly define the passageway <NUM> (e.g., <FIG>) when the first cover <NUM> and the second cover <NUM> are coupled with the base portion <NUM>. The first downstream rim <NUM> of the first cover <NUM> and the second downstream rim <NUM> of the second cover <NUM> are dimensioned to be small or narrow enough to retain the first aerosol-forming substrate 160a and the second aerosol-forming substrate 160b within the chamber but yet large or wide enough to permit a passage of an aerosol therethrough when the first aerosol-forming substrate 160a and the second aerosol-forming substrate 160b are heated by the heater <NUM>.

As noted supra, the base portion <NUM> includes an engagement assembly <NUM> configured to facilitate a connection with the first cover <NUM> and the second cover <NUM> via the first notch <NUM> and the second notch <NUM>, respectively. The engagement assembly <NUM> may be an integrally formed part of the base portion <NUM>. In an example embodiment, the engagement assembly <NUM> of the base portion <NUM> includes a pair of mating members. The pair of mating members of the engagement assembly <NUM> may be adjacent to opposite edges of the base portion <NUM>. Each of the pair of mating members of the engagement assembly <NUM> may have a head section and a body section, wherein the head section is wider than the body section. For instance, each of the pair of mating members of the engagement assembly <NUM> may have a T shape corresponding to the T-shaped notch collectively formed by the first notch <NUM> of the first cover <NUM> and the second notch <NUM> of the second cover <NUM>.

As illustrated in <FIG>, the base portion <NUM> defines a first indentation <NUM> and a second indentation <NUM>. As a result, when assembled, the surface of the base portion <NUM> defining the first indentation <NUM> and a corresponding surface of the first cover <NUM> jointly define the first air inlet <NUM> (e.g., <FIG>). Similarly, the surface of the base portion <NUM> defining the second indentation <NUM> and a corresponding surface of the second cover <NUM> jointly define the second air inlet <NUM> (e.g., <FIG>). The first air inlet <NUM> and the second air inlet <NUM> are in fluidic communication with the chamber (e.g., chamber <NUM> in <FIG>) where the first aerosol-forming substrate 160a and the second aerosol-forming substrate 160b are disposed along with the intermediate section <NUM> of the heater <NUM>.

A sheet material may be cut or otherwise processed (e.g., stamping, electrochemical etching, die cutting, laser cutting) to produce the heater <NUM>. 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 <NUM> - <NUM> (e.g., <NUM> - <NUM>).

The heater <NUM> has a first end section <NUM>, an intermediate section <NUM>, and a second end section <NUM>. The first end section <NUM> and the second end section <NUM> are configured to receive an electric current from a power source during an activation of the heater <NUM>. When the heater <NUM> is activated (e.g., so as to undergo Joule heating), the temperature of the first aerosol-forming substrate 160a and the second aerosol-forming substrate 160b may increase, and an aerosol may be generated and drawn or otherwise released through the aerosol outlets <NUM> of the capsule <NUM>. The first end section <NUM> and the second end section <NUM> may each define an aperture to facilitate an electrical connection with the power source, although example embodiments are not limited thereto. Additionally, because the heater <NUM> may be produced from a sheet material, the first end section <NUM>, the second end section <NUM>, and the intermediate section <NUM> may be coplanar. Furthermore, the intermediate section <NUM> of the heater <NUM> may have a planar and winding form resembling a compressed oscillation or zigzag with a plurality of parallel segments (e.g., eight to twelve parallel segments). However, it should be understood that other forms for the intermediate section <NUM> of the heater <NUM> are also possible (e.g., spiral form, flower-like form).

In an example embodiment, the heater <NUM> extends through the base portion <NUM>. In such an instance, the first end section <NUM> and the second end section <NUM> may be regarded as external segments of the heater <NUM> disposed on an opposite side of the base portion <NUM> from the engagement assembly <NUM>. In particular, the intermediate section <NUM> of the heater <NUM> may be on the downstream side of the base portion <NUM>, while the terminus of each of the first end section <NUM> and the second end section <NUM> may be on the upstream side of the base portion <NUM>. During manufacturing, the heater <NUM> may be embedded within the base portion <NUM> via injection molding (e.g., insert molding, over molding). For instance, the heater <NUM> may be embedded such that the intermediate section <NUM> is between the pair of mating members of the engagement assembly <NUM>.

Although the first end section <NUM> and the second end section <NUM> of the heater <NUM> are shown in the drawings as projections extending from the upstream side of the base portion <NUM>, it should be understood that, in some example embodiments, the first end section <NUM> and the second end section <NUM> of the heater <NUM> may be configured so as to constitute parts of the upstream end face of the capsule <NUM>. For instance, the exposed portions of the first end section <NUM> and the second end section <NUM> of the heater <NUM> may be dimensioned and oriented so as to be situated/folded against (e.g., substantially coplanar with) the underside or bottom of the base portion <NUM>. As a result, the first end section <NUM> and the second end section <NUM> may constitute a first electrical contact pad and a second electrical contact pad, respectively, as well as parts of the upstream end face of the capsule <NUM>.

<FIG> is a cross-sectional view of the capsule of <FIG>. Referring to <FIG>, when the capsule <NUM> is assembled, the upstream portions of the first cover <NUM> and the second cover <NUM> are coupled with the base portion <NUM>, while the downstream portions of the first cover <NUM> and the second cover <NUM> are received by the end cap <NUM>. In addition to defining the aerosol outlets <NUM> (e.g., <FIG>), the end cap <NUM> also defines a cavity <NUM>. The cavity <NUM> is downstream from and in fluidic communication with the chamber <NUM> via the passageway <NUM>. Specifically, the first air inlet <NUM>, the second air inlet <NUM>, the chamber <NUM>, the passageway <NUM>, the cavity <NUM>, and the aerosol outlets <NUM> (e.g., <FIG>) are all in fluidic communication with each other so as to permit a flow of air/aerosol therethrough.

As a result, when an electric current is supplied to the heater <NUM> and air is drawn into the capsule <NUM>, the air may enter the capsule <NUM> through the first air inlet <NUM> and the second air inlet <NUM> (e.g., through the front face and the rear face of the capsule <NUM>). After being drawn into the capsule <NUM>, the air may flow longitudinally along the intermediate section <NUM> of the heater <NUM> and through the aerosol-forming substrate within the chamber <NUM> (e.g., the first aerosol-forming substrate 160a and the second aerosol-forming substrate 160b in <FIG>). Inside the chamber <NUM>, volatiles are released by the aerosol-forming substrate heated by the intermediate section <NUM> of the heater <NUM> to produce an aerosol which is entrained by the air flowing through the chamber <NUM>, the passageway <NUM>, and the cavity <NUM> before exiting the capsule <NUM> through the aerosol outlets <NUM>.

In an example embodiment, at least one of a filter or a flavor medium may be optionally disposed in the cavity <NUM> of the end cap <NUM>. In such an instance, a filter and/or a flavor medium may be disposed in the cavity <NUM> within the end cap <NUM> so as to be downstream from the first cover <NUM> and the second cover <NUM> such that the aerosol generated within the chamber <NUM> passes through at least one of the filter or the flavor medium in the cavity <NUM> before exiting through the at least one aerosol outlet <NUM>. The filter may reduce or prevent particles from the aerosol-forming substrate from being inadvertently drawn from the capsule <NUM>, while the flavor medium 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.

<FIG> is a first perspective view of another capsule for an aerosol-generating device according to an example embodiment. <FIG> is a second perspective view of the capsule of <FIG>. Referring to <FIG>, a capsule <NUM> includes a housing configured to hold an aerosol-forming substrate and to accommodate a heater configured to heat the aerosol-forming substrate to generate an aerosol. The housing of the capsule <NUM> includes a base portion <NUM>, a first cover <NUM>, and a second cover <NUM>. The base portion <NUM> includes an engagement assembly (e.g., engagement assembly <NUM> in <FIG>) configured to facilitate a connection with the first cover <NUM> and the second cover <NUM>. Once connected to the base portion <NUM>, the first cover <NUM> and the second cover <NUM> jointly define an aerosol outlet <NUM> therebetween. As a result, the capsule <NUM> may be regarded as one that is of a <NUM>-piece construction.

Additionally, when connected, the base portion <NUM> and the first cover <NUM> define a first air inlet <NUM> therebetween. Similarly, the base portion <NUM> and the second cover <NUM>, when connected, define a second air inlet <NUM> therebetween. The first air inlet <NUM> and the second air inlet <NUM> are in fluidic communication with the aerosol outlet <NUM>. As a result, air drawn into the first air inlet <NUM> and the second air inlet <NUM> will flow through the capsule <NUM> to the aerosol outlet <NUM>. In an example embodiment, the downstream sector of the capsule <NUM> may taper to a mouth end (e.g., cylindrical end) defining the aerosol outlet <NUM>. A heater is configured to extend through the base portion <NUM> such that the first end section <NUM> and the second end section <NUM> are visible while the intermediate section of the heater is hidden from view when the capsule <NUM> is assembled. The heater will be discussed in further detail in connection with subsequent drawings.

Although the drawings illustrate the aerosol outlet <NUM> as a single outlet, it should be understood that example embodiments are not limited thereto. For instance, the aerosol outlet <NUM> may be defined as a plurality of outlets (e.g., <NUM>-<NUM> outlets). The aerosol outlet <NUM> may be defined by the first cover <NUM> and the second cover <NUM> or, alternatively, by a separate insert or end cap. Additionally, the aerosol outlet <NUM>, when provided as a plurality of outlets, may be arranged in a linear/sequential manner, in a radial manner, or in an array of rows and columns. Furthermore, the shape of the aerosol outlet <NUM> (or each of the outlets when a plurality are provided) may be circular, elongated (e.g., elliptical), polygonal (e.g., rounded rectangular), or of another suitable shape.

<FIG> is a partially exploded view of the capsule of <FIG>. <FIG> is a partially exploded view of the capsule of <FIG>. Referring to <FIG>, the first cover <NUM> and the second cover <NUM> are configured to engage with each other and with the base portion <NUM> during the assembly of the capsule <NUM>. In an example embodiment, to facilitate an engagement of the first cover <NUM> with the second cover <NUM>, the first cover <NUM> includes a first protrusion <NUM> and defines a first orifice <NUM>, while the second cover <NUM> includes a second protrusion <NUM> and defines a second orifice <NUM>. As a result, during assembly, the first protrusion <NUM> of the first cover <NUM> will mate with the second orifice <NUM> of the second cover <NUM>, while the second protrusion <NUM> of the second cover <NUM> will mate with the first orifice <NUM> of the first cover <NUM>. The resulting engagement between the first cover <NUM> and the second cover <NUM> may be via an interference fit.

As illustrated, the first cover <NUM> also defines one or more of a first notch <NUM>, a first recess <NUM>, a first groove <NUM>, and a first channel <NUM>. Similarly, the second cover <NUM> defines one or more of a second notch <NUM>, a second recess <NUM>, a second groove <NUM>, and a second channel <NUM>. In some instances, the first cover <NUM> and the second cover <NUM> may be identical parts. In such instances, orienting the first cover <NUM> and the second cover <NUM> to face each other for mating (as well as for coupling with the base portion <NUM>) will result in a complementary arrangement. As a result, one part may be used interchangeably as the first cover <NUM> or the second cover <NUM>, thus simplifying the method of manufacturing.

When the capsule <NUM> is assembled, the first recess <NUM> of the first cover <NUM> and the second recess <NUM> of the second cover <NUM> collectively form a chamber <NUM> (e.g., <FIG>) configured to accommodate both an aerosol-forming substrate and an intermediate section <NUM> of the heater <NUM>. Additionally, the first interior surface of the first cover <NUM> further defines a first channel <NUM> downstream from the first recess <NUM>, and the second interior surface of the second cover <NUM> further defines a second channel <NUM> downstream from the second recess <NUM>. The first channel <NUM> and the second channel <NUM> are configured to collectively form an aerosol channel <NUM> (e.g., <FIG>). Moreover, the first interior surface of the first cover <NUM> further defines first grooves <NUM> connecting the first recess <NUM> to the first channel <NUM>, and the second interior surface of the second cover <NUM> further defines second grooves <NUM> connecting the second recess <NUM> to the second channel <NUM>. The first grooves <NUM> and the second grooves <NUM> are aligned and dimensioned so as to collectively form passageways <NUM> (e.g., <FIG>) configured to retain the aerosol-forming substrate within the chamber <NUM> while allowing the aerosol generated to pass through to the aerosol channel <NUM>. The number of passageways <NUM> may range from four to eight (e.g., six), although example embodiments are not limited thereto.

The first notch <NUM> in the first cover <NUM> may be defined as a pair of notches at the upstream corners of the first cover <NUM>, wherein each notch may be adjacent to/exposed by the upstream end surface of the first cover <NUM> while bounded/obscured by a corresponding side surface of the first cover <NUM> (e.g., <FIG>). Likewise, the second notch <NUM> may be defined as a pair of notches at the upstream corners of the second cover <NUM>, wherein each notch may be adjacent to/exposed by the upstream end surface of the second cover <NUM> while bounded/obscured by a corresponding side surface of the second cover <NUM> (e.g., <FIG>). Alternatively, the first notch <NUM> and the second notch <NUM> may be provided as discussed in connection with the first notch <NUM> (e.g., <FIG>) and the second notch <NUM> (e.g., <FIG>), respectively, so as to also be exposed by a corresponding side surface of the first cover <NUM> and the second cover <NUM>, respectively. During assembly, the first notch <NUM> and the second notch <NUM> collectively form a T-shaped notch configured to mate with the engagement assembly <NUM> when the first cover <NUM> and the second cover <NUM> are coupled with the base portion <NUM>.

The engagement assembly <NUM> may be an integrally formed part of the base portion <NUM>. In an example embodiment, the engagement assembly <NUM> of the base portion <NUM> includes a pair of mating members. The pair of mating members of the engagement assembly <NUM> may be adjacent to and slightly spaced away from the corresponding opposite edges of the base portion <NUM>. As a result, the engagement assembly <NUM> may be hidden/obscured from view by the first cover <NUM> and the second cover <NUM> when the capsule <NUM> is assembled. Alternatively, the pair of mating members of the engagement assembly <NUM> may be positioned against (e.g., flush with) the corresponding opposite edges of the base portion <NUM>, such as that disclosed in connection with the engagement assembly <NUM> of capsule <NUM> (e.g., <FIG>). In such an instance, the engagement assembly <NUM> will still be partially visible when the capsule <NUM> is assembled. Each of the pair of mating members of the engagement assembly <NUM> may have a head section and a body section, wherein the head section is wider than the body section. For instance, each of the pair of mating members of the engagement assembly <NUM> may have a T shape corresponding to the T-shaped notch collectively formed by the first notch <NUM> of the first cover <NUM> and the second notch <NUM> of the second cover <NUM>.

As illustrated in <FIG>, the base portion <NUM> defines a first indentation <NUM> and a second indentation <NUM>. As a result, when the capsule <NUM> is assembled, the surface of the base portion <NUM> defining the first indentation <NUM> and a corresponding surface of the first cover <NUM> jointly define the first air inlet <NUM> (e.g., <FIG>). Similarly, the surface of the base portion <NUM> defining the second indentation <NUM> and a corresponding surface of the second cover <NUM> jointly define the second air inlet <NUM> (e.g., <FIG>). The first air inlet <NUM> and the second air inlet <NUM> are in fluidic communication with the chamber (e.g., chamber <NUM> in <FIG>) where the aerosol-forming substrate is disposed along with the intermediate section <NUM> of the heater <NUM>. The aerosol-forming substrate (not illustrated) for the capsule <NUM> may be as described in connection with any of the forms/formats for the first aerosol-forming substrate 160a and/or the second aerosol-forming substrate 160b of the capsule <NUM> (e.g., <FIG>). As a result, the relevant disclosures above with regard to aerosol-forming substrates should be understood to apply to this section and may not have been repeated in the interest of brevity.

The heater <NUM> has a first end section <NUM>, an intermediate section <NUM>, and a second end section <NUM>. The first end section <NUM> and the second end section <NUM> are configured to receive an electric current from a power source during an activation of the heater <NUM>. When the heater <NUM> is activated (e.g., so as to undergo Joule heating), the temperature of the aerosol-forming substrate may increase, and an aerosol may be generated and drawn or otherwise released through the aerosol outlet <NUM> of the capsule <NUM>. The first end section <NUM> and the second end section <NUM> may each define an aperture to facilitate an electrical connection with the power source, although example embodiments are not limited thereto. Additionally, because the heater <NUM> may be produced from a sheet material, the first end section <NUM>, the second end section <NUM>, and the intermediate section <NUM> may be coplanar. Furthermore, the intermediate section <NUM> of the heater <NUM> may have a planar and winding form resembling a compressed oscillation or zigzag with a plurality of parallel segments (e.g., eight to twelve parallel segments). However, it should be understood that other forms for the intermediate section <NUM> of the heater <NUM> are also possible (e.g., spiral form, flower-like form).

In an example embodiment, the heater <NUM> extends through the base portion <NUM>. In such an instance, the first end section <NUM> and the second end section <NUM> may be regarded as external segments of the heater <NUM> disposed on an opposite side of the base portion <NUM> from the engagement assembly <NUM>. In particular, the intermediate section <NUM> of the heater <NUM> may be on the downstream side of the base portion <NUM>, while the terminus of each of the first end section <NUM> and the second end section <NUM> may be on the upstream side of the base portion <NUM>. During manufacturing, the heater <NUM> may be seated within a slot extending through the base portion <NUM>. To enhance the seating (e.g., via an interference fit), the heater <NUM> may be provided with a base insert which covers segments of the heater <NUM> between the intermediate section <NUM> and the terminus of each of the first end section <NUM> and the second end section <NUM>. As a result, when the heater <NUM> is introduced through the slot in the base portion <NUM>, the base insert will be between the heater <NUM> and the base portion <NUM> so as to create a relatively close-fit arrangement, thus allowing the base portion <NUM> to grip the heater <NUM> in a relatively secure manner. Alternatively, the heater <NUM> may be embedded within the base portion <NUM> via injection molding (e.g., insert molding, over molding). For instance, the heater <NUM> may be embedded such that the intermediate section <NUM> is between the pair of mating members of the engagement assembly <NUM>.

In an example embodiment, the first cover <NUM> and the second cover <NUM> are configured to engage with each other and with the base portion <NUM> such that their adjacent surfaces are substantially flush. For instance, when engaged, the main external surface of the first cover <NUM> may be flush with the front surface of the base portion <NUM> (e.g., <FIG>). Similarly, in another instance, the main external surface of the second cover <NUM> may be flush with the rear surface of the base portion <NUM> (e.g., <FIG>). Additionally, in yet another instance, the opposing side surfaces of the base portion <NUM> may be flush with the adjoining side surfaces of the first cover <NUM> and the second cover <NUM>. Furthermore, in yet another instance, the downstream end surface of the first cover <NUM> may be flush with the downstream end surface of the second cover <NUM>.

When the first cover <NUM>, the second cover <NUM>, and the base portion <NUM> are coupled together, the resulting structure (e.g., housing) of the capsule <NUM> may have an upstream sector with a form resembling a cuboid with a front face, an opposing rear face, a first side face, an opposing second side face, and an upstream end face. With a cuboid form, the upstream sector of the capsule <NUM> may have a rectangular cross-section. Alternatively, in other instances, the cuboid form of the upstream sector of the capsule <NUM> may have a square cross-section. However, it should be understood that example embodiments are not limited thereto. For instance, in lieu of a cuboid form, the upstream sector of the capsule <NUM> may have a form resembling a cylinder (e.g., elliptic cylinder, circular cylinder). For an elliptic cylinder, the upstream sector of the capsule <NUM> may have an elliptical cross-section. On the other hand, for a circular cylinder, the upstream sector of the capsule <NUM> may have a circular cross-section.

With regard to the cuboid upstream sector resulting from the coupling of the first cover <NUM>, the second cover <NUM>, and the base portion <NUM> as shown in the drawings, the main external surface of the first cover <NUM> and the front surface of the base portion <NUM> may be jointly regarded as the front face (e.g., which defines the first air inlet <NUM>). Similarly, the main external surface of the second cover <NUM> and the rear surface of the base portion <NUM> may be jointly regarded as the opposing rear face (e.g., which defines the second air inlet <NUM>). Additionally, the opposing side surfaces of the base portion <NUM> and the corresponding side surfaces of the first cover <NUM> and the second cover <NUM> may be jointly regarded as the first side face and the opposing second side face of the housing. Moreover, the underside or bottom of the base portion <NUM> may be regarded as the upstream end face (e.g., from which the first end section <NUM> and the second end section <NUM> of the heater extend). As to the housing as a whole, the downstream end surface of the first cover <NUM> and the corresponding downstream end surface of the second cover <NUM> may be jointly regarded as the downstream end face.

As illustrated, the downstream sector of the capsule <NUM> may taper to a cylindrical end defining the aerosol outlet <NUM>. However, it should be understood that example embodiments are not limited thereto. For instance, in lieu of a cylindrical end with a circular or elliptical cross-section, the downstream sector of the capsule <NUM> may taper to a polygonal end, which may be a cuboidal end with a rectangular or square cross-section. In another instance, the downstream sector of the capsule <NUM> may taper to a flattened end resembling a wedge, chisel, duckbill shape.

<FIG> is a cross-sectional view of the capsule of <FIG>. Referring to <FIG>, when the capsule <NUM> is assembled, the upstream portions/ends of the first cover <NUM> and the second cover <NUM> are coupled/engaged with the base portion <NUM>, while the downstream portions/ends of the first cover <NUM> and the second cover <NUM> form a mouth end defining an aerosol channel <NUM> and an aerosol outlet <NUM> (e.g., <FIG>). The aerosol channel <NUM> is downstream from and in fluidic communication with the chamber <NUM> via the passageways <NUM>. Specifically, the first air inlet <NUM>, the second air inlet <NUM>, the chamber <NUM>, the passageways <NUM>, and the aerosol channel <NUM> are all in fluidic communication with each other so as to permit a flow of air/aerosol therethrough.

As a result, when an electric current is supplied to the heater <NUM> and air is drawn into the capsule <NUM>, the air may enter the capsule <NUM> through the first air inlet <NUM> and the second air inlet <NUM> (e.g., through the front face and the rear face of the capsule <NUM>). After being drawn into the capsule <NUM>, the air may flow longitudinally along the intermediate section <NUM> of the heater <NUM> and through the aerosol-forming substrate (not illustrated) within the chamber <NUM>. Inside the chamber <NUM>, volatiles are released by the aerosol-forming substrate heated by the intermediate section <NUM> of the heater <NUM> to produce an aerosol which is entrained by the air flowing through the chamber <NUM>, the passageways <NUM>, and the aerosol channel <NUM> before exiting the capsule <NUM> through the aerosol outlet <NUM>.

<FIG> is a first perspective view of another capsule for an aerosol-generating device according to an example embodiment. <FIG> is a second perspective view of the capsule of <FIG>. The capsule <NUM> in <FIG> may resemble the capsule <NUM> in <FIG> while differing with regard to the internal slots defined by the first cover <NUM> and the second cover <NUM> as well as the corresponding external protuberances, which will be discussed in more detail herein. As a result, the relevant disclosures above of the features in common should be understood to apply to this section and may not have been repeated in the interest of brevity.

The capsule <NUM> includes a housing configured to hold an aerosol-forming substrate as described herein and to accommodate a heater configured to heat the aerosol-forming substrate to generate an aerosol. The housing of the capsule <NUM> includes a base portion <NUM>, a first cover <NUM>, and a second cover <NUM>. The base portion <NUM> includes an engagement assembly (e.g., engagement assembly <NUM> in <FIG>) configured to facilitate a connection with the first cover <NUM> and the second cover <NUM>. Once connected to the base portion <NUM>, the first cover <NUM> and the second cover <NUM> jointly define an aerosol outlet <NUM> therebetween. As a result, the capsule <NUM> may be regarded as one that is of a <NUM>-piece construction.

Additionally, when connected, the base portion <NUM> and the first cover <NUM> define a first air inlet <NUM> therebetween. Similarly, the base portion <NUM> and the second cover <NUM>, when connected, define a second air inlet <NUM> therebetween. The first air inlet <NUM> and the second air inlet <NUM> are in fluidic communication with the aerosol outlet <NUM>. As a result, air drawn into the first air inlet <NUM> and the second air inlet <NUM> will flow through the capsule <NUM> to the aerosol outlet <NUM>. In an example embodiment, the downstream sector of the capsule <NUM> may taper to a mouth end (e.g., cylindrical end) defining the aerosol outlet <NUM>. A heater is configured to extend through the base portion <NUM> such that the first end section <NUM> and the second end section <NUM> are visible while the intermediate section <NUM> of the heater <NUM> (e.g., <FIG>) is hidden from view when the capsule <NUM> is assembled. The aerosol outlet <NUM>, the first air inlet <NUM>, the second air inlet <NUM>, the base portion <NUM>, the first end section <NUM>, and the second end section <NUM> in <FIG> may be the same as described in connection with the aerosol outlet <NUM>, the first air inlet <NUM>, the second air inlet <NUM>, the base portion <NUM>, the first end section <NUM>, and the second end section <NUM> in <FIG>. As a result, the relevant disclosures above of the features in common should be understood to apply to this section and may not have been repeated in the interest of brevity.

<FIG> is a partially exploded view of the capsule of <FIG>. <FIG> is a partially exploded view of the capsule of <FIG>. Referring to <FIG>, the first interior surface of the first cover <NUM> defines a first slot <NUM> oriented orthogonally to the first channel <NUM>, while the second interior surface of the second cover <NUM> defines a second slot <NUM> oriented orthogonally to the second channel <NUM>. Each of the first slot <NUM> and the second slot <NUM> may be a half-disk-shaped concavity, although example embodiments are not limited thereto. Additionally, the first cover <NUM> may have a first external protuberance corresponding to the first slot <NUM>. Similarly, the second cover <NUM> may have a second external protuberance corresponding to the second slot <NUM>. Alternatively, it should be understood that the thicknesses of the first cover <NUM> and the second cover <NUM> may be increased such that the depths of the first slot <NUM> and the second slot <NUM> do not result in corresponding external protuberances in the first cover <NUM> and the second cover <NUM>.

When the first cover <NUM> and the second cover <NUM> are engaged, the first slot <NUM> and the second slot <NUM> collectively form a compartment (e.g., compartment <NUM> in <FIG>). The compartment is configured to accommodate at least one of a filter or a flavor medium as described herein. The compartment may be a disk-shaped concavity. However, it should be understood that other shaped compartments (and, thus, other shaped slots) may be provided. For instance, the compartment may be a polygon-shaped (e.g., square-shaped, hexagon-shaped, octagon-shaped) concavity configured to accommodate a similarly shaped filter and/or flavor medium.

Unless otherwise described and/or illustrated with regard to differentiating features, it should be understood that the other aspects of the first cover <NUM> and the second cover <NUM> in <FIG> may be the same as described in connection with the first cover <NUM> and the second cover <NUM> in <FIG>. In particular, the first notch <NUM>, the first protrusion <NUM>, the first recess <NUM>, the first orifice <NUM>, the first groove <NUM>, and the first channel <NUM> in <FIG> may be the same as described in connection with the first notch <NUM>, the first protrusion <NUM>, the first recess <NUM>, the first orifice <NUM>, the first groove <NUM>, and the first channel <NUM> in <FIG>. Similarly, the second notch <NUM>, the second protrusion <NUM>, the second recess <NUM>, the second orifice <NUM>, the second groove <NUM>, and the second channel <NUM> in <FIG> may be the same as described in connection with the second notch <NUM>, the second protrusion <NUM>, the second recess <NUM>, the second orifice <NUM>, the second groove <NUM>, and the second channel <NUM> in <FIG>.

In some instances, the first cover <NUM> and the second cover <NUM> may be identical parts. In such instances, orienting the first cover <NUM> and the second cover <NUM> to face each other for mating (as well as for coupling with the base portion <NUM>) will result in a complementary arrangement. As a result, one part may be used interchangeably as the first cover <NUM> or the second cover <NUM>, thus simplifying the method of manufacturing.

Additionally, the base portion <NUM> and the heater <NUM> in <FIG> may be the same as described in connection with the base portion <NUM> and the heater <NUM> in <FIG>. In particular, the first indentation <NUM>, the second indentation <NUM>, and the engagement assembly <NUM> of the base portion <NUM> in <FIG> may be the same as described in connection with the first indentation <NUM>, the second indentation <NUM>, and the engagement assembly <NUM> of the base portion <NUM> in <FIG>. Likewise, the first end section <NUM>, the intermediate section <NUM>, and the second end section <NUM> of the heater <NUM> in <FIG> may be the same as described in connection with the first end section <NUM>, the intermediate section <NUM>, and the second end section <NUM> of the heater <NUM> in <FIG>. As a result, the relevant disclosures above of the features in common should be understood to apply to this section and may not have been repeated in the interest of brevity.

<FIG> is a cross-sectional view of the capsule of <FIG>. Referring to <FIG>, when the capsule <NUM> is assembled, the upstream portions/ends of the first cover <NUM> and the second cover <NUM> are coupled/engaged with the base portion <NUM>, while the downstream portions/ends of the first cover <NUM> and the second cover <NUM> form a mouth end defining an aerosol channel <NUM> and an aerosol outlet <NUM> (e.g., <FIG>). The aerosol channel <NUM> is downstream from and in fluidic communication with the compartment <NUM>. The compartment <NUM>, in turn, is in fluidic communication with the chamber <NUM> via the passageways <NUM>. Specifically, the first air inlet <NUM>, the second air inlet <NUM>, the chamber <NUM>, the passageways <NUM>, the compartment <NUM>, and the aerosol channel <NUM> are all in fluidic communication with each other so as to permit a flow of air/aerosol therethrough.

As a result, when an electric current is supplied to the heater <NUM> and air is drawn into the capsule <NUM>, the air may enter the capsule <NUM> through the first air inlet <NUM> and the second air inlet <NUM> (e.g., through the front face and the rear face of the capsule <NUM>). After being drawn into the capsule <NUM>, the air may flow longitudinally along the intermediate section <NUM> of the heater <NUM> and through the aerosol-forming substrate (not illustrated) within the chamber <NUM>. The aerosol-forming substrate for the capsule <NUM> may be as described in connection with any of the forms/formats for the first aerosol-forming substrate 160a and/or the second aerosol-forming substrate 160b of the capsule <NUM> (e.g., <FIG>). As a result, the relevant disclosures above with regard to aerosol-forming substrates should be understood to apply to this section and may not have been repeated in the interest of brevity.

Inside the chamber <NUM>, volatiles are released by the aerosol-forming substrate heated by the intermediate section <NUM> of the heater <NUM> to produce an aerosol which is entrained by the air flowing through the chamber <NUM>, the passageways <NUM>, the compartment <NUM>, and the aerosol channel <NUM> before exiting the capsule <NUM> through the aerosol outlet <NUM>. Optionally, at least one of a filter or a flavor medium as described herein may be provided within the compartment <NUM> such that the aerosol generated in the chamber <NUM> passes through at least one of the filter or the flavor medium before flowing through the aerosol channel <NUM>.

<FIG> is a front view of an aerosol-generating device according to an example embodiment. Referring to <FIG>, an aerosol-generating device <NUM> (e.g., heat-not-burn aerosol-generating device) may include a capsule <NUM> and a device body <NUM>. In a non-limiting manner, the capsule <NUM> may be the same as described in connection with the capsule <NUM>, the capsule <NUM>, and/or the capsule <NUM> so as to cover various combinations of the disclosed features. For instance, the capsule <NUM> may include a housing containing an aerosol-forming substrate and a heater that undergoes resistive heating when activated. The housing may include a base portion, a first cover, and a second cover. The first cover and the second cover may jointly define therebetween a chamber, an aerosol channel, and an aerosol outlet, wherein the aerosol-forming substrate is disposed in the chamber. The heater is supported by the base portion and extends into the chamber.

The device body <NUM> may define a socket or concavity configured to receive the capsule <NUM> such that the device body <NUM> is mechanically and electrically engaged with the capsule <NUM>. For instance, the socket or concavity of the device body <NUM> may be configured to grip at least two opposite external surfaces (e.g., opposing sidewalls) of the capsule <NUM>. Alternatively, the device body <NUM> and/or the capsule <NUM> may include a magnet configured to establish a magnetic arrangement such the device body <NUM> will attract and retain the capsule <NUM>. In addition, the device body <NUM> may include a first electrode and a second electrode within the socket or concavity that are configured to electrically contact a first end section and a second end section, respectively, of a heater of the capsule <NUM>.

A power source <NUM> and control circuitry <NUM> may be disposed within the device body <NUM> of the aerosol-generating device <NUM>. The power source <NUM> may include one or more batteries (e.g., rechargeable battery). When the capsule <NUM> is engaged with the device body <NUM>, the control circuitry <NUM> may instruct the power source <NUM> to supply an electric current to the capsule <NUM> via the first electrode and the second electrode of the device body <NUM>. The supply of current from the power source <NUM> may be in response to a manual operation (e.g., button-activation) or an automatic operation (e.g., puff-activation). As a result of the current, the aerosol-forming substrate within the capsule <NUM> may be heated to generate an aerosol. In addition, the change in resistance of the heater may be used by the control circuitry <NUM> to monitor and control the aerosolization temperature. The aerosol generated may be drawn from the aerosol-generating device <NUM> via the aerosol outlet at the mouth end of the capsule <NUM>.

Thus, during an operation of the aerosol-generating device <NUM>, a method of generating an aerosol may include supplying an electric current to the capsule <NUM> so as to heat (e.g., via resistive heating) an aerosol-forming substrate therein. The method may additionally include drawing the aerosol generated within the chamber of the capsule <NUM> such that the aerosol flows through the aerosol channel and exits the aerosol outlet of the capsule <NUM>.

Claim 1:
A capsule (<NUM>; <NUM>; <NUM>; <NUM>) for an aerosol-generating device, comprising:
a base portion (<NUM>; <NUM>; <NUM>) including an engagement assembly (<NUM>; <NUM>; <NUM>);
a first cover (<NUM>; <NUM>; <NUM>) engaged with the base portion (<NUM>; <NUM>; <NUM>) via the engagement assembly (<NUM>; <NUM>; <NUM>), the first cover (<NUM>; <NUM>; <NUM>) including a first interior surface and a first exterior surface, the first interior surface defining a first recess (<NUM>; <NUM>; <NUM>);
a second cover (<NUM>; <NUM>; <NUM>) engaged with the base portion (<NUM>; <NUM>; <NUM>) and the first cover (<NUM>; <NUM>; <NUM>) via the engagement assembly (<NUM>; <NUM>; <NUM>), the second cover (<NUM>; <NUM>; <NUM>) including a second interior surface and a second exterior surface, the second interior surface defining a second recess (<NUM>; <NUM>; <NUM>), the first cover (<NUM>; <NUM>; <NUM>) aligned with the second cover (<NUM>; <NUM>; <NUM>) such that the first recess (<NUM>; <NUM>; <NUM>) and the second recess (<NUM>; <NUM>; <NUM>) collectively form a chamber (<NUM>; <NUM>; <NUM>);
an aerosol-forming substrate (160a, 160b) within the chamber (<NUM>; <NUM>; <NUM>); and
a heater (<NUM>; <NUM>; <NUM>) configured to heat the aerosol-forming substrate (160a, 160b) to generate an aerosol, the heater (<NUM>; <NUM>; <NUM>) including a first end section (<NUM>; <NUM>; <NUM>), an intermediate section (<NUM>; <NUM>; <NUM>), and a second end section (<NUM>; <NUM>; <NUM>), the heater (<NUM>; <NUM>; <NUM>) extending from the base portion (<NUM>; <NUM>; <NUM>) such that the intermediate section (<NUM>; <NUM>; <NUM>) is in the chamber (<NUM>; <NUM>; <NUM>).