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

Abstract

A capsule for a heat-not-burn (HNB) aerosol-generating device may include a housing and a heater within the housing. The housing has interior surfaces defining a chamber configured to hold an aerosol-forming substrate. In addition, the housing has exterior surfaces constituting a first face, an opposing second face, and a side face of the capsule. The first face and the second face of the capsule are permeable to an aerosol. The heater has a first end section, an intermediate section, and a second end section. The first end section and the second end section of the heater may be external segments constituting parts of the side face of the capsule. The intermediate section of the heater is an internal segment disposed within the chamber of the housing.

1 . A heater assembly for an aerosol-generating device, the heater assembly comprising:
 a housing having a first face, a second face, an inner side surface, and an exterior side surface, the inner side surface of the housing at least partially defining a cavity extending from the first face to the second face; and   a heater having a first end section, an intermediate section, and a second end section, the housing injection molded around the heater such that the intermediate section is within the cavity, and the first end section and the second end section extend through the inner side surface and the exterior side surface of the housing.   
     
     
         2 . The heater assembly of  claim 1 , wherein
 the first end section of the heater defines a first aperture, and   the second end section of the heater defines a second aperture.   
     
     
         3 . The heater assembly of  claim 2 , wherein the first aperture and the second aperture are external to the housing. 
     
     
         4 . The heater assembly of  claim 3 , wherein
 the first face and the second face are spaced apart in a first direction, and   the first aperture and the second aperture extend through the heater in a direction parallel to the first direction.   
     
     
         5 . The heater assembly of  claim 2 , wherein
 the first aperture and the second aperture are within the housing,   the housing defines a first housing aperture and a second housing aperture, and   the first housing aperture is aligned with the first aperture and the second housing aperture is aligned with the second housing aperture.   
     
     
         6 . The heater assembly of  claim 1 , wherein the heater is symmetrical about a longitudinal axis of the housing. 
     
     
         7 . The heater assembly of  claim 1 , wherein the first end section, the intermediate section, and the second end section of the heater are sections of a continuous structure. 
     
     
         8 . The heater assembly of  claim 1 , wherein the intermediate section of the heater has a planar and winding form. 
     
     
         9 . The heater assembly of  claim 1 , wherein the intermediate section of the heater has a resistance between 0.5-2.5 Ohms. 
     
     
         10 . A capsule for an aerosol-generating device, the capsule comprising:
 a first housing defining a first cavity;   a heater having a first end section, an intermediate section, and a second end section, the first housing injection molded around the heater such that the intermediate section is within the first cavity; and   a second housing configured to receive the first housing and the heater, the second housing defining a first opening, a second opening, and a second cavity, the first housing within the second cavity of the second housing such that the first cavity of the first housing is aligned with the first opening and the second opening of the second housing, the heater extending through the first housing such that the first end section and the second end section are exposed by the second housing.   
     
     
         11 . The capsule of  claim 10 , further comprising:
 a first permeable structure between the first housing and the second housing.   
     
     
         12 . The capsule of  claim 11 , wherein the first permeable structure is between the first cavity and the first opening. 
     
     
         13 . The capsule of  claim 12 , further comprising:
 a second permeable structure between the first housing and the second housing.   
     
     
         14 . The capsule of  claim 13 , wherein the second permeable structure is between the first cavity and the second opening. 
     
     
         15 . The capsule of  claim 10 , wherein the capsule has a thickness between 1-4 mm. 
     
     
         16 . The capsule of  claim 10 , wherein the capsule includes an aerosol-forming substrate including a plant material. 
     
     
         17 . The capsule of  claim 16 , wherein the plant material includes tobacco. 
     
     
         18 . The capsule of  claim 10 , wherein an outward facing surface of the first end section and an outward facing surface of the second end section are coplanar. 
     
     
         19 . The capsule of  claim 10 , wherein the first end section of the heater defines a first aperture and the second end section of the heater defines a second aperture. 
     
     
         20 . The capsule of  claim 19 , wherein the first aperture and the second aperture are external to the first housing.