Classifications

• • A—HUMAN NECESSITIES
  • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
  • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
  • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
  • A24F40/20—Devices using solid inhalable precursors
• • A—HUMAN NECESSITIES
  • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
  • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
  • A24B15/00—Chemical features or treatment of tobacco; Tobacco substitutes, e.g. in liquid form
  • A24B15/10—Chemical features of tobacco products or tobacco substitutes
  • A24B15/16—Chemical features of tobacco products or tobacco substitutes of tobacco substitutes
  • A24B15/167—Chemical features of tobacco products or tobacco substitutes of tobacco substitutes in liquid or vaporisable form, e.g. liquid compositions for electronic cigarettes
• • A—HUMAN NECESSITIES
  • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
  • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
  • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
  • A24F40/40—Constructional details, e.g. connection of cartridges and battery parts
• • A—HUMAN NECESSITIES
  • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
  • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
  • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
  • A24F40/40—Constructional details, e.g. connection of cartridges and battery parts
  • A24F40/42—Cartridges or containers for inhalable precursors
• • A—HUMAN NECESSITIES
  • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
  • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
  • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
  • A24F40/50—Control or monitoring

Definitions

• the present disclosure relates to capsules, heat-not-burn (HNB) aerosol-generating devices, and methods of generating an aerosol without involving a substantial pyrolysis of the aerosol-forming substrate.
• HNB heat-not-burn
• 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.
• the plant material may be introduced directly into a heating chamber of an aerosol-generating device.
• the plant material may be pre-packaged in individual containers to facilitate insertion and removal from an aerosol-generating device.
• At least one example embodiment relates to a flavor carrier for an aerosol-generating device.
• a flavor carrier for an aerosol generating device includes an outer housing extending in a longitudinal direction, an inner housing extending in the longitudinal direction, and a flavor chamber between the outer housing and the inner housing.
• the outer housing includes at least one outer housing perforation defined in a wall of the outer housing.
• the inner housing is coaxial with the outer housing.
• the inner housing includes at least one inner housing perforation defined in a wall of the inner housing.
• the flavor chamber is configured to contain a flavoring material.
• an adapter is at an end of the flavor carrier.
• the adapter is configured to secure the flavor carrier within an aerosol-generating device.
• the adapter defines a channel therein. The channel is in fluid communication with an air passage defined in the inner housing.
• the adapter is formed of at least one of a polymer and a metal, the adapter being substantially impermeable to aerosol.
• the flavor carrier further comprises a gasket at a second end of the flavor carrier.
• the gasket is substantially impermeable to aerosol.
• the gasket is formed of at least one of a polymer and a metal.
• the outer housing has an outer diameter ranging from about 3.0 mm to about 10.0 mm or from about 3.0 mm to about 5.0 mm.
• the inner housing has an outer diameter ranging from about 1.0 mm to about 3.0 mm.
• the flavoring material includes at least one of a botanical material, a gel, a film, and a flavor bead.
• At least one of the wall of the outer housing and the wall of the inner housing has a thickness ranging from about 0.5 mm to about 1.5 mm. At least one of the wall of the outer housing and the wall of the inner housing is formed of at least one of paper, a fabric, a metal, and a polymer.
• At least one example embodiment relates to an aerosol generating device.
• an aerosol generating device includes plant material, a heating element configured to heat the plant material, and a flavor carrier.
• the flavor carrier includes an outer housing extending in a longitudinal direction, an inner housing extending in the longitudinal direction, and a flavor chamber between the outer housing and the inner housing.
• the outer housing includes at least one outer housing perforation defined in a wall of the outer housing.
• the inner housing is coaxial with the outer housing.
• the inner housing includes at least one inner housing perforation defined in a wall of the inner housing.
• the flavor chamber is configured to contain a flavoring material.
• FIG. 1 is a schematic view of an aerosol-generating device according to an example embodiment.
• FIG. 2 is a cross-sectional view of a flavor carrier and mouthpiece of the aerosol-generating device of FIG. 1 according to at least one example embodiment.
• FIG. 3 is a perspective view of a flavor carrier of an aerosol-generating device according to at least one example embodiment.
• FIG. 4 is a perspective view of a flavor carrier of an aerosol-generating device according to at least one example embodiment.
• FIG. 5 is a perspective view of a flavor carrier of an aerosol-generating device according to at least one example embodiment.
• FIG. 6 is a perspective view of a flavor carrier of an aerosol-generating device according to at least one example embodiment.
• FIG. 7 is a perspective view of a flavor carrier of an aerosol-generating device according to at least one example embodiment.
• FIG. 8 is a perspective view of a flavor carrier of an aerosol-generating device according to at least one example embodiment.
• FIG. 9 is a perspective view of a flavor carrier of an aerosol-generating device according to at least one example embodiment.
• FIG. 10 is a perspective view of a flavor carrier of an aerosol generating device according to at least one example embodiment.
• FIG. 12 is a cross-sectional view along line XI-XI of the flavor cartridge of FIG. 1 according at least one example embodiment.
• FIG. 12 is a cross-sectional view along line XI-XI of a flavor cartridge according to at least one example embodiment.
• FIG. 13 is a perspective view of a flavor cartridge according to at least one example embodiment.
• FIG. 14 is a schematic view showing airflow through an aerosol generating device including a flavor carrier according to at least one example embodiment.
• 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, component, region, layer, or section discussed below could be termed a second element, region, layer, or section without departing from the teachings of example embodiments.
• spatially relative terms e.g., "beneath,” “below,” “lower,” “above,” “upper,” and the like
• 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.
• FIG. 1 is a schematic view of an aerosol-generating device according to an example embodiment.
• an aerosol-generating device 1000 may include a mouthpiece 1015 and a device body 1025.
• a power source 1035 and control circuitry 1045 may be disposed within the device body 1025 of the aerosol-generating device 1000.
• the aerosol-generating device 1000 is configured to receive a capsule 1020, which may include plant material, such as tobacco as described in U.S. Patent Application No. 16/252,951, filed January 21 , 2019 titled“CAPSULES, HEAT- NOT-BURNG (HNB) AEROSOL-GENERATING DEVICES, AND METHODS OF GENERATING AN AEROSOL,” the entire content of which is incorporated herein by reference thereto.
• plant material such as tobacco as described in U.S. Patent Application No. 16/252,951, filed January 21 , 2019 titled“CAPSULES, HEAT- NOT-BURNG (HNB) AEROSOL-GENERATING DEVICES, AND METHODS OF GENERATING AN AEROSOL
• an aerosol-forming substrate is a material or combination of materials that may be transformed into 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).
• pyrolysis does not occur during the heating and resulting production of aerosol.
• 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.
• 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.
• the fibrous material may be plant material such as tobacco, and the compound released may be nicotine.
• 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 fabacum.
• the tobacco material may include material from any member of the genus Nicotiana.
• 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.
• the tobacco material is in the form of a substantially dry tobacco mass.
• 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.
• 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.
• 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.
• cannabinoids examples include tetrahydrocannabinolic acid (THCA), tetrahydrocannabinol (THC), cannabidiolic acid (CBDA), cannabidiol (CBD), cannabinol (CBN), cannabicyclol (CBL), cannabichromene (CBC), and cannabigerol (CBG).
• THCA tetrahydrocannabinolic acid
• THC cannabidiolic acid
• CBD cannabidiol
• CBD cannabidiol
• CBD cannabigerol
• CBD cannabidiolic acid
• CBD cannabidiol
• Tetrahydrocannabinolic acid (THCA) and cannabidiolic acid (CBDA) may be converted to tetrahydrocannabinol (THC) and cannabidiol (CBD), respectively, via heating.
• heat from the first heater 110 and/or the second heater 120 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).
• tetrahydrocannabinolic acid THCA
• tetrahydrocannabinol THC
• 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.
• CBD cannabidiolic acid
• CBD cannabidiol
• the compound may be a non-naturally occurring additive that is subsequently introduced into the fibrous material.
• 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).
• the fibrous material may be a cellulose material, and the compound introduced may be nicotine, cannabinoids, and/or flavorants by way of plant extracts (e.g., tobacco extract, cannabis extract) .
• the aerosol-generating device 1000 may also include a first electrode 1055a, a second electrode 1055b, a third electrode 1055c, and a fourth electrode 1055d configured to electrically contact the capsule 1020.
• the first electrode 1055a and the third electrode 1055c may electrically contact the first heater 1 10a
• the second electrode 1055b and the fourth electrode 1055d may electrically contact the second heater 1 10b.
• the first electrode 1055a and the third electrode 1055c (or the second electrode 1055b and the fourth electrode 1055d) may be omitted.
• the control circuitry 1045 may instruct the power source 1035 to supply an electric current to the first electrode 1055a, the second electrode 1055b, the third electrode 1055c, and/or the fourth electrode 1055d.
• the supply of current from the power source 1035 may be in response to a manual operation (e.g., button-activation) or an automatic operation (e.g., puff- activation) .
• a manual operation e.g., button-activation
• an automatic operation e.g., puff- activation
• aerosol generating device 1000 may also include a flavor carrier 760.
• the flavor carrier 760 may include an outer housing 765 extending in the longitudinal direction, an inner housing 780 extending in the longitudinal direction, and a flavor chamber 790 between the outer housing 765 and the inner housing 780.
• the outer housing 765 and/or the inner housing 780 may be generally cylindrical.
• a cross-section of the outer housing 765 and/or the inner housing 780 may be generally oval, rectangular, square, triangular, polygonal and/or may have any other cross- sectional shape.
• a cross section of the outer housing 765 may have generally the same shape as a cross section of the inner housing 780.
• a cross section of the outer housing 765 may have a different shape than a cross section of the inner housing 780.
• the outer housing 765 includes at least one outer housing perforation 770 defined in a wall 775 of the outer housing 765.
• the inner housing 780 may be coaxial with the outer housing 765. In other example embodiments, the inner housing 780 is not coaxial with the outer housing 765. In some example embodiments, the inner housing 780 is within the outer housing 765. In some example embodiments, at least a portion of the inner housing 780 is within at least a portion of the outer housing 765.
• an area of a cross-section of the inner housing 780 is smaller than an area of a cross- section of the outer housing 765.
• a cross section of the inner housing 780 is generally circular and a cross section of the outer housing 765 is generally circular, and a diameter of the cross section of the inner housing 780 is smaller than a diameter of the cross section of the outer housing 765.
• the inner housing 780 includes at least one inner housing perforation 785 defined in a wall 792 of the inner housing 780.
• the flavor chamber 790 is configured to contain a flavoring material 795.
• an adapter 797 is at an end of the flavor carrier 760.
• the adapter 797 is configured to secure the flavor carrier 760 within the device body 1025 of the aerosol-generating device 1000.
• the adapter 797 may be a ring-shaped body that fits snugly about an outer surface of the outer housing 765 of the flavor carrier 760.
• the adapter 797 is sized to friction fit between the outer housing 765 of the flavor carrier 760 and an inner surface 700 of the device body 1025 of the aerosol-generating device 1000.
• the adapter 797 is formed of one or more materials including a polymer, a metal, a sub-combination thereof, or a combination thereof.
• the adapter 797 is substantially impermeable to aerosol so that the aerosol is forced to flow through the flavor carrier 760, where the aromas and/or flavors from flavoring material 795 are eluted to the aerosol.
• the outer housing 765 of the flavor carrier 760 is a hollow cylinder having an outer diameter ranging from about 3.0 mm to about 10.0 mm (e.g., about 3.0 mm to about 5.0 mm, about 3.5 mm to about 4.5 mm or about 3.75 mm to about 4.25 mm, etc.). In other example embodiments, the outer housing 765 of the flavor carrier 760 is a hollow cylinder having an outer diameter that is less than about 3.0 mm, or greater than about 10.0 mm.
• the inner housing 780 is a hollow cylinder having an outer diameter ranging from about 1.0 mm to about 3.0 mm (e.g., about 1.5 mm to about 2.5 mm, about 1.75 mm to about 2.25 mm, etc.).
• the inner housing 780 of the flavor carrier 760 is a hollow cylinder having an outer diameter that is less than about 1.0 mm, or greater than about 3.0 mm.
• the diameter of the inner housing 780 and the outer housing 765 may be chosen to provide a desired volume of the flavor chamber 790 defined between the inner housing 780 and the outer housing 765.
• the wall 775 of the outer housing 765 and the wall 792 of the inner housing 780 or each have a thickness ranging from about 0.5 mm to about 1.5 mm (e.g., about 0.75 mm to about 1.25 mm). In some example embodiments, the wall 775 and/or the wall 792 have thicknesses that are smaller than about 0.5 mm, or greater than about 1.5 mm. In some example embodiments, the wall 775 of the outer housing 765 and the wall 792 of the inner housing 780, or both are formed of one or more materials that include paper, a fabric, a metal, a polymer and / or any other suitable materials.
• the flavoring material 795 includes a botanical material, a gel, a film, flavor bits, powders, discs of compressed powders, a flavor bead and/or any other flavoring materials.
• the botanical material may include tobacco plant material, cannabis plant material and/or other botanical material.
• the botanical material may include non-tobacco botanical material, such as teas, herbs, etc.
• the flavoring material 795 may include a gel.
• the gel may include a polymer, one or more flavorants and/or botanical material suspended in the gel.
• the flavoring material 795 may include a film.
• the film may be formed of at least one polymer and one or more flavorants.
• the film or films may be in flavor chamber 790, rolled around the inner housing 780 and/or provided in a tube form, such that the tube is inserted in flavor chamber 790 around the inner housing 780.
• the film may be water soluble and/or may disintegrate when exposed to heat, such that the film disintegrates as aerosol passes through the flavor chamber 790.
• the film may be porous. Other types of films may be used.
• the flavoring material 795 includes flavor beads include at least one polymer and at least one flavorant.
• the flavor beads may include an outer shell enclosing an inner core.
• the inner core and/or the outer shell may contain menthol or other volatile flavors.
• the inner core can contain mint flavors such as peppermint, spearmint or any other flavors.
• the flavor beads can each have a diameter ranging from about 0.5 mm to about 5 rnrn (e.g., about 1 rnrn to about 4 mm, about 2 mm to about 3 mm, etc.). In other example embodiments, the flavor beads can each have a diameter that is smaller than about 0.5 mm or greater than about 5mm.
• the flavor beads can he manufactured and/or include the features of the flavor beads and/or flavor capsules disclosed in U.S. Patent No. 7,878,962 to Karles et al., which issued February 1 , 201 1, and U.S. Patent No. 7,578,298 to Karles et al., which issued August 25, 2009, the entire content of each of which is incorporated herein by this reference thereto.
• the flavoring material 795 is in the form of a paper impregnated and/or coated with one or more flavorants.
• the film or paper may be chopped before being placed in the flavor chamber 790.
• the chopped film or paper may be mixed with at least one botanical material and / or with flavor beads.
• the flavoring material 795 may be coated with a second material including at least one polymer and/or a flavorant.
• a flavorant of the coating may be the same flavorant incorporated in the flavoring material 795 underlying the coating or the flavorant of the coating may be a different flavorant that the flavorant in the underlying flavoring material 795.
• the flavoring material 795 includes cellulose material with one or more flavorants.
• a flavorant is a volatile flavorant.
• the flavorant may be any flavorant commonly used in foods, confections, or other oral products.
• Example flavorants include, but are not limited to, berry flavors such as pomegranate, acai, raspberry, blueberry, strawberry, boysenberry, cranberry, etc..
• flavorants include, without limitation, any natural or synthetic flavor or aroma, such as menthol, peppermint, spearmint, wintergreen, bourbon, scotch, whiskey, cognac, hydrangea, lavender, chocolate, licorice, citrus and other fruit flavors, such as apple, peach, pear, cherry, plum, orange, lime, grape, and grapefruit, gamma octalactone, vanillin, ethyl vanillin, breath freshener flavors, butter, rum, coconut, almond, pecan, walnut, hazelnut, French vanilla, macadamia, sugar cane, maple, cassis, caramel, banana, malt, espresso, kahlua, white chocolate, spice flavors such as cinnamon, clove, cilantro, basil, oregano, garlic, mustard, nutmeg, rosemary, thyme, tarragon, dill, sage, anise, and fennel, methyl salicylate, linalool, jasmine, coffee, olive
• the flavoring material 795 includes a polymer and the polymer is a water soluble or water insoluble polymer.
• the polymer may be natural or synthetic.
• the polymers may be a hydrocolloid.
• Other example polymers include, without limitation, starch, dextrin, gum arabic, guar gum, chitosan, cellulose, polyvinyl alcohol, polylactide, gelatin, soy protein, whey protein, etc.
• FIG. 2 is a cross-sectional view of a flavor carrier and mouthpiece of an aerosol-generating device according to at least one example embodiment.
• the flavor carrier 760 and a mouthpiece 800 may joined together, such that the adapter 797 surrounds a portion of the flavor carrier 760 and the mouthpiece 800 fits with an end of the adapter 797.
• the mouthpiece 800 is formed of materials that include plastic, metal, wood and/or other suitable materials.
• the mouthpiece 800 is formed from at least one plastic material, such as polyethylene or polypropylene.
• the mouthpiece 800 may be rounded, and may not include any sharp edges.
• the cross-section of a mouthpiece 800 may be generally rectangular, oval, square, triangular, polygonal and/or may have any other cross-sectional shape.
• a mouthpiece 800 may include sharp edges.
• a surface of the mouthpiece 800 may be generally smooth.
• the adapter 797 is generally U-shaped and cylindrical, such that the flavor carrier 760 nests within the adapter 797.
• a bottom wall 910 of the adapter 797 defines a channel 900 that directs aerosol into the flavor carrier 760 when the flavor carrier 760 and the adapter 797 are engaged with the device body 1025 of the aerosol-generating device 1000.
• the adapter 797 also includes a flange portion 920 that engages with the device body 1025 of the aerosol-generating device 1000.
• the flavor carrier 765 of FIG. 2 may be retrofitted with the aerosol-generating device 1000 by removing an existing mouthpiece and inserting the adapter 797 within the housing of the aerosol generating device 1000.
• FIG. 3 is a perspective view of a flavor carrier of an aerosol-generating device according to at least one example embodiment.
• the flavor carrier 760 is generally the same as in FIGS. 1 and 2, except that the perforations 785 in the wall 792 of the inner housing 780 are aligned with the perforations 770 in the wall 775 of the outer housing 765.
• the perforations 785 and the perforations 770 may be arranged in columns.
• the perforations 785 in the wall 792 of the inner housing 780 are not aligned with the perforations 770 in the wall 775 of the outer housing 765.
• the wall 792 and/or the wall 775 may each include 1 to about 20 columns (e.g., about 2 to about 18, about 4 to about 16, about 6 to about 14, about 8 to about 12, or about 10 to about 12) of perforations 770, 785.
• the wall 792 and/or the wall 775 may each include more than 20 columns.
• each column of perforations 770, 785 in the wall 792 and/or the wall 775 may include 1 to about 20 perforations 770, 785 (e.g., about 2 to about 18, about 4 to about 16, about 6 to about 14, about 8 to about 12, or about 10 to about 12).
• each column of perforations 770, 785 in the wall 792 and/or the wall 775 may include more than 20 perforations.
• the perforations 770, 785 may be a same or different size.
• the perforations 770, 785 may be generally circular in shape in some example embodiments, or may be triangular, rectangular, oval, square, poloygonal or may have any other shape.
• the perforations 770 may be the same or different size and/or shape than perforations 785.
• the perforations 770, 785 may be larger at a first end of the flavor carrier 760 than at a second end of the flavor carrier 760.
• FIG. 4 is a perspective view of a flavor carrier of an aerosol-generating device according to at least one example embodiment.
• the flavor carrier 760 is generally the same as in FIGS. 1 and 2, except that the adapter 797 is in the form of a cover 1 100 that is placed over an end of the flavor carrier 760.
• the cover 1 100 also defines a channel 1 1 10 therein. Aerosol is directed into the inner housing 780, then through the perforations 785 in the wall 792 of the inner housing 780 and into the flavor chamber 790. The aerosol may then flow out of the flavor chamber 790 via the perforations 770 in the wall 775 of the outer housing 765.
• FIG. 5 is a perspective view of a flavor carrier of an aerosol-generating device according to at least one example embodiment.
• the flavor carrier 760 is generally the same as in FIGS. 1 and 2, except that the flavor carrier 760 further comprises a gasket 1200 at a second end of the flavor carrier 760.
• the gasket 1200 is substantially impermeable to aerosol, so as to force aerosol to pass through the perforations 770 in the wall 775 of the outer housing 765 of the flavor carrier 760.
• the gasket 1200 is formed of one or more materials including a polymer, a metal or a combination thereof, and/or other suitable materials.
• the gasket 1200 is formed of one or more materials that include a food-grade, GRAS (generally recognized as safe) material.
• FIG. 6 is a perspective view of a flavor carrier of an aerosol-generating device according to at least one example embodiment.
• the mouthpiece 800 fits around an end portion of the flavor carrier 760.
• FIG. 7 is a perspective view of an outer housing of a flavor carrier according to at least one example embodiment.
• perforations 770 of outer housing 765 are elongated and extend parallel to the longitudinal direction of the flavor carrier 760. As shown, the perforations 770 may be generally rectangular in shape. In at least one example embodiment, the perforations 785 of inner housing 780, not shown, may be the same or different than the perforations 770 shown in FIG. 7, for example, in shape, size and/or pattern, etc. The perforations 785 may align with the perforations 770 and may be about a same size. In other example embodiments, the perforations 785 may have a different size and/or may not align with the perforations 770.
• FIG. 8 is a perspective view of a flavor carrier of an aerosol-generating device according to at least one example embodiment.
• the perforations 770 of the outer housing 765 are elongated and extend perpendicular to the longitudinal direction of the flavor carrier 760.
• the perforations 785 of inner housing 780 may be the same or different than the perforations 770 shown in FIG. 8, for example, in shape, size and/or pattern, etc.
• the perforations 785 may align with the perforations 770 and may be about a same size. In other example embodiments, the perforations 785 may have a different size and/or may not align with the perforations 770.
• FIG. 9 is a perspective view of a flavor carrier of an aerosol-generating device according to at least one example embodiment.
• the perforations 770 of outer housing 765 are generally circular or oval in shape and are arranged in uniform rows and/or columns along outer housing 765.
• the perforations 785 of inner housing 780 may be the same or different than the perforations 770 shown in FIG. 9, for example, in shape, size and/or pattern, etc.
• the perforations 785 may align with the perforations 770 and may be about a same size. In other example embodiments, the perforations 785 may have a different size and/or may not align with the perforations 770.
• FIG. 10 is a perspective view of a flavor carrier of an aerosol generating device according to at least one example embodiment.
• the flavor carrier 760 is generally the same as in FIGS. 1-2, except that the perforations are generally circular in shape and are arranged in offset rows along the flavor carrier 760.
• the perforations 785 may be the same or different than the perforations 770.
• the perforations 785 may align with the perforations 770 and may be about a same size. In other example embodiments, the perforations 785 may have a different size and/or may not align with the perforations 770.
• FIG. 1 1 is a cross-sectional view along line XI-XI of the flavor cartridge of FIG. 1 according at least one example embodiment.
• the perforations 785 in the wall 792 of the inner housing 780 align with the perforations 770 in the wall 775 of the outer housing 765.
• FIG. 12 is a cross-sectional view of a flavor cartridge according to at least one example embodiment.
• the perforations 785 in the wall 792 of the inner housing 780 do not align with the perforations 770 in the wall 775 of the outer housing 765, such that a tortuous flow path is formed through the flavor chamber 790.
• FIG. 13 is a perspective view of a flavor cartridge according to at least one example embodiment.
• one or more features of a flavor carrier 760 are generally the same as one or more features that have been described herein, except that instead of including the outer housing 765 and the inner housing 780 with a flavor chamber 790 therebetween, the flavor carrier 760 is formed of a tube 2505 of paper impregnated with at least one flavorant.
• the tube 2505 has a thickness that is about the same as the gap between the outer housing 765 and the inner housing 780 as described herein.
• the tube 2505 includes a plurality of perforations 2500 therein.
• the perforations 2500 may be in any desired shape and/or configuration.
• FIG. 14 is a schematic view showing airflow through an aerosol generating device including a flavor carrier according to at least one example embodiment.
• aerosol shown by the arrows
• aromas, flavors and/or components from flavor material 795 may be eluted to the aerosol.
• some of the aerosol or portions of the aerosol may be filtered out as the aerosol flows through the flavor carrier 760.
• the flavor carrier may include one or more feature from one or more embodiments described herein.

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• Containers And Packaging Bodies Having A Special Means To Remove Contents (AREA)
• Cigarettes, Filters, And Manufacturing Of Filters (AREA)

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• 2019
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