AEROSOL-GENERATING SUBSTRATES AND ENCAPSULATED FLAVORANTS

Abstract

A capsule for an aerosol-generating device includes a housing and an aerosol-forming substrate. The housing defines an inlet opening, an outlet opening, and a chamber between the inlet opening and the outlet opening. The aerosol-forming substrate is in the housing. The aerosol-forming substrate includes tobacco, an encapsulated flavorant, and an aerosol-forming agent. The encapsulated flavorant includes a matrix and a flavorant in the matrix. The capsule has a resistance to draw ranging from 30 mmH2O to 130 mmH2O.

Description

BACKGROUND

Field

The present disclosure relates to aerosol-generating substrates and encapsulated flavorants, such as for use in heat-not-burn (HNB) aerosol generating devices and capsules configured to generate an aerosol without involving a substantial pyrolysis of an aerosol-forming substrate.

Description of Related Art

Some electronic devices are configured to heat an aerosol-forming substrate, such as 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 and/or Cannabis. In some instances, the plant material may be introduced directly into a heating chamber of an aerosol-generating device. In other instances, the plant material may be pre-packaged in individual containers to facilitate insertion and removal from an aerosol-generating device.

SUMMARY

At least one example embodiment relates to a capsule for an aerosol-generating device.

In at least one example embodiment, the capsule includes a housing and an aerosol-forming substrate. The housing defines an inlet opening, an outlet opening, and a chamber between the inlet opening and the outlet opening. The aerosol-forming substrate is in the housing. The aerosol-forming substrate includes tobacco, an encapsulated flavorant, and an aerosol-forming agent. The encapsulated flavorant includes a matrix and a flavorant in the matrix. The capsule has a resistance to draw ranging from 30 mmH₂O to 130 mmH₂O.

In at least one example embodiment, the tobacco is in a form of particles having a mean particle size ranging from 150 μm to 1250 μm.

In at least one example embodiment, the mean particle size ranges from 270 μm to 415 μm.

In at least one example embodiment, the aerosol-forming substrate has a bulk density ranging from 0.2 g/cm³ to 1.2 g/cm³.

In at least one example embodiment, the flavorant is present in the encapsulated flavorant in an amount ranging from 0.5 weight percent to 85 weight percent.

In at least one example embodiment, the aerosol-forming agent includes propylene glycol, glycerol, butylene glycol, or any combination thereof.

In at least one example embodiment, the matrix includes methyl cellulose, ethyl cellulose, hydroxypropyl methyl cellulose, starch, pectin, gelatin, sodium alginate, maltodextrin, pullulan, xanthan, gum acacia, sodium carboxy methyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose, polyethylene oxide, polyvinyl alcohol, polyvinyl pyrrolidone, low density polyethylene, polyethylene glycol, polyurethane, poly (methyl methacrylate), ethylene vinyl acetate, a polymer-thickened sugar alcohol, a wax, a fatty acid ester, a copolymer thereof, or any combination thereof.

In at least one example embodiment, the encapsulated flavorant further includes a plasticizer, a cross-linking agent, a foaming agent, or any combination thereof.

In at least one example embodiment, the flavorant includes menthol, peppermint, spearmint, wintergreen, cinnamon, chocolate, vanillin, licorice, clove, anise, sandalwood, geranium, rose, vanilla, lemon, Cassia, fennel, ginger, ethylacetate, isoamylacetate, propylisobutyrate, isobutyrate, ethylbutyrate, ethylvalerate, benzylformate, limonene, cymene, pinene, linalool, geraniol, citronellol, citral, orange, coriander, borneol, fruit extract, coffee, tea, cacao, mint, a terpene or any combination thereof.

In at least one example embodiment, the encapsulated flavorant further includes a carrier. The flavorant is absorbed in the carrier. The carrier is dispersed in the matrix.

In at least one example embodiment, the carrier includes cellulose, silica, pectin, or a combination thereof.

In at least one example embodiment, the carrier includes the cellulose. The cellulose includes microcrystalline cellulose.

In at least one example embodiment, the carrier includes the cellulose. The cellulose includes tobacco.

In at least one example embodiment, the encapsulated flavorant is in a form of a plurality of particles, granules, cuts, shreds, flakes, or any combination thereof.

In at least one example embodiment, the encapsulated flavorant is admixed with the tobacco and the aerosol-forming agent.

In at least one example embodiment, the encapsulated flavorant is on a surface of the housing.

In at least one example embodiment, the surface is an inner surface such that the encapsulated flavorant is in the chamber.

At least one example embodiment relates to an aerosol-forming device.

In at least one example embodiment, the aerosol-generating device includes a capsule, a heater, and a device body. The capsule includes a housing and an aerosol-forming substrate in the housing. The aerosol-forming substrate includes tobacco and an aerosol-forming agent. The heater is in thermal communication with the aerosol-forming substrate. The device body includes a lid, a mouthpiece, and an encapsulated flavorant. The lid is configured to open to permit an insertion of the capsule and configured to close to engage the capsule within the device body. The encapsulated flavorant is configured to be in fluid communication with an aerosol pathway of the aerosol-generating device, the encapsulated flavorant includes a matrix and a flavorant in the matrix. The capsule has a resistance to draw ranging from 30 mmH₂O to 130 mmH₂O.

In at least one example embodiment, the encapsulated flavorant is on a surface of the mouthpiece. In at least one example embodiment, the encapsulated flavorant is in an interior of the mouthpiece. The encapsulated flavorant is in a form of a plurality of particles, granules, cuts, shreds, flakes, or any combination thereof.

At least one example embodiment relates to a replaceable mouthpiece for an aerosol-generating device. The replaceable mouthpiece includes a wall and an encapsulated flavorant. The wall defines an inlet, an outlet, and a channel fluidly connecting the inlet and the outlet. The encapsulated flavorant is on a surface of the wall in fluid communication with the channel. The encapsulated flavorant includes a matrix and a flavorant in the matrix.

At least one example embodiment relates to a method of making a flavor sheet for an aerosol-generating device.

In at least one example embodiment, the method includes preparing a first film-forming solution by dissolving a first film-forming material in a first solvent. The method further includes combining a flavorant and the first film-forming solution. The method further includes preparing a film precursor by casting the first film-forming solution onto a surface. The method further includes preparing the flavor sheet by drying the film precursor. The flavor sheet includes the flavorant in an amount ranging from 0.5 weight percent to 90 weight percent.

In at least one example embodiment, the flavor sheet includes the flavorant in an amount ranging from 10 weight percent to 35 weight percent.

In at least one example embodiment, the combining includes preparing a flavorant solution by dissolving the flavorant in a second solvent. The combining further includes combining the first film-forming solution and the flavorant solution.

In at least one example embodiment, the combining includes dissolving the flavorant in the first solvent.

In at least one example embodiment, the preparing the first film-forming solution and the combining are performed concurrently.

In at least one example embodiment, the combining includes dispersing the flavorant in the first film-forming solution.

In at least one example embodiment, the combining includes reducing a temperature of the first film-forming solution and the flavorant.

In at least one example embodiment, the flavorant is in a form of a powder.

In at least one example embodiment, the combining includes preparing a flavorant solution by dissolving the flavorant and a second film-forming material in a second solvent. The flavorant is a water-insoluble flavorant. The combining further includes dispersing the flavorant solution in the first film-forming solution.

In at least one example embodiment, the method further includes, prior to the combining, absorbing the flavorant on a carrier.

In at least one example embodiment, the absorbing includes preparing a flavorant solution by dissolving the flavorant in a second solvent. The absorbing further includes absorbing the flavorant solution on the carrier. The absorbing further includes removing the second solvent from the carrier.

In at least one example embodiment, the method further includes forming a secondary film. The secondary film is in contact with the flavor sheet.

In at least one example embodiment, the method further includes forming a pair of secondary films including the secondary film. The flavor sheet is between the pair of secondary films.

In at least one example embodiment, the combining includes stirring the first film-forming solution for a desired duration.

In at least one example embodiment, the preparing the film precursor includes moving a blade across the first film-forming solution on the surface such that the flavor sheet has a desired thickness.

In at least one example embodiment, the preparing the flavor sheet includes drying the film precursor in a vacuum oven.

In at least one example embodiment, the method further includes subdividing the flavor sheet to form a plurality of particles, granules, cuts, shreds, flakes, or any combination thereof.

In at least one example embodiment, the first solvent includes ethanol, water, or both ethanol and water.

At least one example embodiment relates to a method of making a flavor sheet for an aerosol-generating device.

In at least one example embodiment, the method includes preparing a polymer melt by melting a polymer. The method further includes preparing an admixture including the polymer and a flavorant. The method further includes forming an encapsulated flavorant precursor including the polymer melt and the flavorant. The forming includes extruding, blow molding, or a combination of extruding and blow molding. The method further includes forming the encapsulated flavorant by cooling the encapsulated flavorant precursor.

In at least one example embodiment, the preparing the admixture is performed prior to the preparing the polymer melt.

In at least one example embodiment, the preparing the polymer melt is performed prior to the preparing the admixture.

In at least one example embodiment, the forming the flavor sheet precursor includes the extruding. The extruding is performed using a screw extruder and ribbon die.

In at least one example embodiment, the method further includes, prior to the preparing the admixture, absorbing the flavorant on a carrier.

In at least one example embodiment, the absorbing includes preparing a flavorant solution by dissolving the flavorant in a solvent. The absorbing further includes absorbing the flavorant solution on the carrier. The absorbing further includes removing the solvent from the carrier.

At least one example embodiment relates to a method of making an encapsulated flavorant for an aerosol-generating device.

In at least one example embodiment, the method includes preparing a polymer melt by melting a polymer. The method further includes preparing an admixture including the polymer and a flavorant. The method further includes forming an encapsulated flavorant precursor by extruding the admixture. The method further includes forming the encapsulated flavorant by cooling the encapsulated flavorant precursor.

In at least one example embodiment, the preparing the admixture is performed prior to the preparing the polymer melt.

In at least one example embodiment, the preparing the admixture includes admixing a plurality of solid polymer particles with a plurality of solid flavorant particles.

In at least one example embodiment, the forming the encapsulated flavorant precursor includes is performed using a screw extruder.

In at least one example embodiment, the method is performed in the absence of a solvent.

In at least one example embodiment, the method further comprises preparing a plurality of particles of the encapsulated flavorant.

In at least one example embodiment, the preparing the plurality of particles includes grinding, pelletizing, cutting, shredding, or any combination thereof.

In at least one example embodiment, the method further comprises admixing the plurality of particles with tobacco.

In at least one example embodiment, the preparing the admixture includes admixing solid ethyl cellulose particles and solid menthol particles.

In at least one example embodiment, the method further comprises, prior to the preparing the admixture, absorbing the flavorant on a carrier.

In at least one example embodiment, the absorbing includes preparing a flavorant solution by dissolving the flavorant in a solvent. The absorbing further includes absorbing the flavorant solution on the carrier. The absorbing further includes removing the solvent from the carrier.

BRIEF DESCRIPTION OF THE DRAWINGS

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

FIG. 1 is a perspective view of an example aerosol-forming substrate in consolidated form according to at least one example embodiment.

FIG. 2 is a perspective view of another example aerosol-forming substrate in consolidated form according to at least one example embodiment.

FIG. 3 is a perspective view of another example aerosol-forming substrate in loose form according to at least one example embodiment.

FIG. 4 is a perspective view of an aerosol-forming substrate in rod form according to at least one example embodiment.

FIG. 5 is a top right perspective view of a capsule according to at least one example embodiment.

FIG. 6 is a sectional view of the capsule of FIG. 5 along line XI-XI of FIG. 5 according to at least one example embodiment.

FIG. 7 is an exploded view of the capsule of FIG. 5 according to at least one example embodiment.

FIG. 8 is a perspective view of an aerosol-generating device having a lid in a closed position according to at least one example embodiment.

FIG. 9 is a partial perspective view of the aerosol-generating device of FIG. 8 with the lid in an open position and having the capsule of FIG. 5 therein according to at least one example embodiment.

FIG. 10 is a sectional view of a mouthpiece and capsule of the aerosol-generating device of FIG. 8, without a heater, according to at least one example embodiment.

FIG. 11 is a flowchart illustrating a method of manufacturing an encapsulated flavorant according to at least one example embodiment.

FIG. 12 is a flowchart illustrating another method of manufacturing an encapsulated flavorant according to at least one example embodiment.

FIG. 13A is a schematic illustration of a method of preparing an encapsulated flavorant by hot melt extrusion (HME) in accordance with at least one example embodiment.

FIG. 13B is a schematic illustration of a portion of an encapsulated flavorant formed by the method of FIG. 13A in accordance with at least one example embodiment.

FIG. 14 is a graph illustrating menthol distribution in aerosol by puff block for the first and second aerosol-forming substrates in accordance with at least one example embodiment.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

Some detailed example embodiments are disclosed herein. However, specific structural and functional details disclosed herein are merely representative for purposes of describing example embodiments. Example embodiments may, however, be embodied in many alternate forms and should not be construed as limited to only the example embodiments set forth herein.

Accordingly, while example embodiments are capable of various modifications and alternative forms, example embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit example embodiments to the particular forms disclosed, but to the contrary, example embodiments are to cover all modifications, equivalents, and alternatives falling within the scope of example embodiments. 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,” or “covering” another element or layer, it may be directly on, connected to, coupled to, or covering the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly connected to,” or “directly coupled to” another element or layer, there are no intervening elements or layers present. Like numbers refer to like elements throughout the specification. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

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

The terminology used herein is for the purpose of describing various example embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “includes,” “including,” “comprises,” and/or “comprising,” specify the presence of stated features, integers, steps, operations, and/or elements, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, and/or groups thereof.

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

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

At least one example embodiment relates to an aerosol-forming substrate for use in an aerosol-generating device.

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), where 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 at least one 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.

The aerosol-forming substrate may include a naturally occurring constituent of a medicinal plant that has a medically-accepted therapeutic effect. For instance, the medicinal plant may be a Cannabis plant, and the compound may be a cannabinoid. Cannabinoids interact with receptors in the body to produce a wide range of effects. As a result, cannabinoids have been used for a variety of medicinal purposes (e.g., treatment of pain, nausea, epilepsy, psychiatric disorders). The fibrous material may include the leaf and/or flower material from one or more species of Cannabis plants such as Cannabis sativa, Cannabis indica, and Cannabis ruderalis. In some instances, the fibrous material is a mixture of 60-80% (e.g., 70%) Cannabis sativa and 20-40% (e.g., 30%) Cannabis indica.

Examples of cannabinoids include tetrahydrocannabinolic acid (THCA), tetrahydrocannabinol (THC), cannabidiolic acid (CBDA), cannabidiol (CBD), cannabinol (CBN), cannabicyclol (CBL), cannabichromene (CBC), and cannabigerol (CBG). Tetrahydrocannabinolic acid (THCA) is a precursor of tetrahydrocannabinol (THC), while cannabidiolic acid (CBDA) is precursor of cannabidiol (CBD). Tetrahydrocannabinolic acid (THCA) and cannabidiolic acid (CBDA) may be converted to tetrahydrocannabinol (THC) and cannabidiol (CBD), respectively, via heating. In at least one example embodiment, heat from a heater may cause decarboxylation so as to convert the tetrahydrocannabinolic acid (THCA) in the capsule to tetrahydrocannabinol (THC), and/or to convert the cannabidiolic acid (CBDA) in the capsule to cannabidiol (CBD).

In instances where both tetrahydrocannabinolic acid (THCA) and tetrahydrocannabinol (THC) are present in the capsule, 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. Similarly, in instances where both cannabidiolic acid (CBDA) and cannabidiol (CBD) are present in the aerosol-forming substrate, the decarboxylation and resulting conversion will cause a decrease in cannabidiolic acid (CBDA) and an increase in cannabidiol (CBD). At least 50% (e.g., at least 87%) of the cannabidiolic acid (CBDA) may be converted to cannabidiol (CBD) during the heating of the aerosol-forming substrate.

Furthermore, the aerosol-forming substrate may additionally or alternatively include a non-naturally occurring additive that is subsequently introduced into the fibrous material. The non-naturally occurring additive may include, in at least one example embodiment, a non-nicotine alkaloid (e.g., caffeine), a vitamin, an amino acid (e.g., theanine), a soothing agent (e.g., melatonin), a focusing agent (e.g., Gingko biloba), a mineral, a dietary supplement, a nutraceutical, a chemesthetic agent, a botanical, or any combination thereof. In one instance, the fibrous material may include at least one of cotton, polyethylene, polyester, rayon, inulin, Psyllium, plant fibers, combinations thereof, or the like (e.g., in a form of a gauze). In another instance, the fibrous material may be a cellulose material (e.g., non-tobacco and/or non-Cannabis cellulosic material). In either instance, the aerosol-forming substrate introduced may include nicotine, cannabinoids, flavorants, and/or other additives (e.g., the non-naturally occurring additives). The aerosol-forming substrate may be free of tobacco, nicotine, Cannabis, and/or cannabinoids. The flavorant may be encapsulated, as will be described in greater detail below. 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.

In at least one example embodiment, the aerosol-forming substrate includes an aerosol-forming agent. The aerosol-forming agent may be admixed and/or combined with the plant material and/or fibrous material. The aerosol-forming agent may include propylene glycol, glycerol, butylene glycol, water or any combination thereof. The aerosol-forming agent may be present in an amount greater than or equal to about 10 weight percent of the aerosol-forming substrate (e.g., greater than or equal to about 15 weight percent, greater than or equal to about 20 weight percent, greater than or equal to about 25 weight percent, greater than or equal to about 30 weight percent, greater than or equal to about 35 weight percent, greater than or equal to about 40 weight percent, or greater than or equal to about 45 weight percent). The aerosol-forming agent may be present in an amount less than or equal to about 50 weight percent of the aerosol-forming substrate (e.g., less than or equal to about 45 weight percent, less than or equal to about 40 weight percent, less than or equal to about 35 weight percent, less than or equal to about 30 weight percent, less than or equal to about 25 weight percent, less than or equal to about 20 weight percent, or less than or equal to about 15 weight percent).

In at least one example embodiment, the aerosol-forming substrate further includes a humectant. The humectant may be admixed and/or combined with the plant material and/or fibrous material. The humectant may include propylene glycol, glycerol, butylene glycol, or any combination thereof. The humectant may be present in an amount greater than or equal to about 10 weight percent of the aerosol-forming substrate (e.g., greater than or equal to about 15 weight percent, greater than or equal to about 20 weight percent, greater than or equal to about 25 weight percent, greater than or equal to about 30 weight percent, greater than or equal to about 35 weight percent, greater than or equal to about 40 weight percent, or greater than or equal to about 45 weight percent). The humectant may be present in an amount less than or equal to about 50 weight percent of the aerosol-forming substrate (e.g., less than or equal to about 45 weight percent, less than or equal to about 40 weight percent, less than or equal to about 35 weight percent, less than or equal to about 30 weight percent, less than or equal to about 25 weight percent, less than or equal to about 20 weight percent, or less than or equal to about 15 weight percent).

In at least one example embodiment, the aerosol-forming substrate includes an encapsulated flavorant. The encapsulated flavorant may include a matrix or encapsulant and a flavorant. The flavorant may be partially or fully encapsulated in the matrix. The encapsulated flavorant may include one or more regions of flavorant. A flavorant region may be continuous throughout the matrix, or the encapsulated flavorant may include a plurality of discrete flavorant regions. In at least one example embodiment, the encapsulated flavorant further includes a flavorant carrier material, as will be described in greater detail below. In at least one example embodiments, the encapsulated flavorant further includes a plasticizer, a cross-linking agent, a foaming agent, filler, or any combination thereof, as will be described in greater detail below.

In at least one example embodiment, the encapsulated flavorant includes the matrix material in an amount greater than or equal to about 15 weight percent of the encapsulated flavorant (e.g., greater than or equal to about 20 weight percent, greater than or equal to about 25 weight percent, greater than or equal to about 30 weight percent, greater than or equal to about 35 weight percent, greater than or equal to about 40 weight percent, greater than or equal to about 45 weight percent, greater than or equal to about 50 weight percent, greater than or equal to about 55 weight percent, greater than or equal to about 60 weight percent, greater than or equal to about 65 weight percent, greater than or equal to about 70 weight percent, greater than or equal to about 75 weight percent, greater than or equal to about 80 weight percent, greater than or equal to about 85 weight percent, greater than or equal to about 90 weight percent, or greater than or equal to about 95 weight percent). The encapsulated flavorant may include the matrix material in an amount less than or equal to about 99.5 weight percent of the encapsulated flavorant (e.g., less than or equal to about 95 weight percent, less than or equal to about 90 weight percent, less than or equal to about 85 weight percent, less than or equal to about 80 weight percent, less than or equal to about 75 weight percent, less than or equal to about 70 weight percent, less than or equal to about 65 weight percent, less than or equal to about 60 weight percent, less than or equal to about 55 weight percent, less than or equal to about 50 weight percent, less than or equal to about 45 weight percent, less than or equal to about 40 weight percent, less than or equal to about 35 weight percent, less than or equal to about 30 weight percent, less than or equal to about 25 weight percent, or less than or equal to about 20 weight percent). In at least one example embodiment, the matrix includes a film-forming material and/or a polymer.

In at least one example embodiment, a matrix material is selected to have a desired melting temperature. The melting temperature may be compatible with the aerosol-forming device. For example, the desired melting temperature may be low enough to melt the matrix material, thereby releasing the flavorant, during use of the aerosol-forming device. The desired melting temperature may be high enough to facilitate extended release during a use period of the device, rather than an immediate release of substantially all of the flavorant at one time. In at least one example embodiment, the flavorant may be released over a time period of greater than or equal to about 1 minute (e.g., greater than or equal to about 2 minutes, greater than or equal to 3 minutes, greater than or equal to 4 minutes, greater than or equal to 5 minutes, greater than or equal to 6 minutes, greater than or equal to 7 minutes, greater than or equal to 8 minutes, greater than or equal to 9 minutes, greater than or equal to 10 minutes, or greater than or equal to 11 minutes). The flavorant may be released over a time period of less than or equal 12 minutes (e.g., less than or equal to about 11 minutes, less than or equal to about 10 minutes, less than or equal to about 9 minutes, less than or equal to about 8 minutes, less than or equal to about 7 minutes, less than or equal to about 6 minutes, less than or equal to about 5 minutes, less than or equal to about 4 minutes, less than or equal to about 3 minutes, or less than or equal to about 2 minutes).

In at least one example embodiment, the matrix includes a material including methyl cellulose, ethyl cellulose, hydroxypropyl methyl cellulose, starch, modified starch, pectin, gelatin, sodium alginate, maltodextrin, pullulan, xanthan, gum acacia, sodium carboxy methyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose, polyethylene oxide, polyvinyl alcohol, polyvinyl pyrrolidone, low density polyethylene, polyethylene glycol, polyurethane, poly (methyl methacrylate), ethylene vinyl acetate, polymer-thickened sugar alcohol, wax, fatty acid ester, a copolymer thereof, or any combination thereof. Commercially available modified starches include CAPSUL®, but it should be understood that there are many other modified starch products, such as CAPSUL TA®, HI-CAP 100®, and N-LOK®.

In at least one example embodiment, the encapsulated flavorant includes the flavorant in an amount greater than or equal to about 0.5 weight percent of the encapsulated flavorant (e.g., greater than or equal to about 1 weight percent, greater than or equal to about 2 weight percent, greater than or equal to about 3 weight percent, greater than or equal to about 5 weight percent, greater than or equal to about 7 weight percent, greater than or equal to about 10 weight percent, greater than or equal to about 15 weight percent, greater than or equal to about 20 weight percent, greater than or equal to about 25 weight percent, greater than or equal to about 30 weight percent, greater than or equal to about 35 weight percent, greater than or equal to about 40 weight percent, greater than or equal to about 45 weight percent, greater than or equal to about 50 weight percent, greater than or equal to about 55 weight percent, greater than or equal to about 60 weight percent, greater than or equal to about 65 weight percent, greater than or equal to about 70 weight percent, greater than or equal to about 75 weight percent, greater than or equal to about 80 weight percent, or greater than or equal to about 85 weight percent). The encapsulated flavorant may include the flavorant in an amount less than or equal to about 90 weight percent (e.g., less than or equal to about 85 weight percent, less than or equal to about 80 weight percent, less than or equal to about 75 weight percent, less than or equal to about 70 weight percent, less than or equal to about 65 weight percent, less than or equal to about 60 weight percent, less than or equal to about 55 weight percent, less than or equal to about 50 weight percent, less than or equal to about 45 weight percent, less than or equal to about 40 weight percent, less than or equal to about 35 weight percent, less than or equal to about 30 weight percent, less than or equal to about 25 weight percent, less than or equal to about 20 weight percent, less than or equal to about 15 weight percent, less than or equal to about 10 weight percent, less than or equal to about 7 weight percent, less than or equal to about 5 weight percent, less than or equal to about 3 weight percent, less than or equal to about 2 weight percent, or less than or equal to about 1 weight percent). In at least one example embodiment, the flavorant includes menthol, peppermint, spearmint, wintergreen, cinnamon, chocolate, vanillin, licorice, clove, anise, sandalwood, geranium, rose, vanilla, lemon, Cassia, fennel, ginger, ethylacetate, isoamylacetate, propylisobutyrate, isobutyrate, ethylbutyrate, ethylvalerate, benzylformate, limonene, cymene, pinene, linalool, geraniol, citronellol, citral, orange, coriander, borneol, fruit extract, coffee, tea, cacao, mint, terpene(s), or any combination thereof. The terpene may include 8-myrcene, 8-caryophyllene, d-limonene, linalool, pulegone, 1,8-cineole, α-pinene, α-terpineol, terpinen-4-ol, p-cymene, or any combination thereof.

In at least one example embodiment, the encapsulated flavorant includes nicotine and/or cannabinoid(s). In at least one other example embodiment, the encapsulated flavorant is substantially free of nicotine and cannabinoids.

In at least one example embodiment, the encapsulated flavorant includes the carrier material. The flavorant may be absorbed, adsorbed, and/or coated on the carrier material. The carrier material with flavorant therein and/or thereon may be embedded in and/or dispersed throughout the matrix. The encapsulated flavorant may include the carrier material in an amount greater than or equal to about 0.01 weight percent of the encapsulated flavorant (e.g., greater than or equal to about 0.1 weight percent, greater than or equal to about 1 weight percent, greater than or equal to about 5 weight percent, greater than or equal to about 10 weight percent, greater than or equal to about 15 weight percent, greater than or equal to about 20 weight percent, greater than or equal to about 25 weight percent, greater than or equal to about 30 weight percent, greater than or equal to about 35 weight percent, greater than or equal to about 40 weight percent, greater than or equal to about 45 weight percent, greater than or equal to about 50 weight percent, greater than or equal to about 55 weight percent, greater than or equal to about 60 weight percent, greater than or equal to about 65 weight percent, greater than or equal to about 70 weight percent, greater than or equal to about 75 weight percent, greater than or equal to about 80 weight percent, greater than or equal to about 85 weight percent, or greater than or equal to about 90 weight percent). The encapsulated flavorant may include the carrier material in an amount less than or equal to about 95 weight percent of the encapsulated flavorant (e.g., less than or equal to about 90 weight percent, less than or equal to about 85 weight percent, less than or equal to about 80 weight percent, less than or equal to about 75 weight percent, less than or equal to about 70 weight percent, less than or equal to about 65 weight percent, less than or equal to about 60 weight percent, less than or equal to about 55 weight percent, less than or equal to about 50 weight percent, less than or equal to about 45 weight percent, less than or equal to about 40 weight percent, less than or equal to about 35 weight percent, less than or equal to about 30 weight percent, less than or equal to about 25 weight percent, less than or equal to about 20 weight percent, less than or equal to about 15 weight percent, less than or equal to about 10 weight percent, less than or equal to about 5 weight percent, less than or equal to about 1 weight percent, or less than or equal to about 0.1 weight percent). The carrier may be in the form of a plurality of particles, granules, cuts, shreds, fibers, flakes, or any combination thereof. In at least one example embodiment, the carrier material includes cellulose, a cellulose derivative, silica, pectin, starch, modified starch, a starch derivative, or a combination thereof. In at least one example embodiment, the cellulose includes microcrystalline cellulose. In at least one example embodiment, the cellulose includes tobacco.

In at least one example embodiment, the encapsulated flavorant includes the plasticizer. The plasticizer may be combined with and/or dispersed throughout the matrix material such that the plasticizer is part of the matrix. The plasticizer may be present in the encapsulated flavorant in an amount greater than or equal to about 0.5 weight percent (e.g., greater than or equal to about 1 weight percent, greater than or equal to about 5 weight percent, greater than or equal to about 10 weight percent, greater than or equal to about 15 weight percent, greater than or equal to about 20 weight percent, greater than or equal to about 25 weight percent, or greater than or equal to about 30 weight percent). The plasticizer may be present in the encapsulated flavorant in an amount less than or equal to about 35 weight percent (e.g., less than or equal to about 30 weight percent, less than or equal to about 25 weight percent, less than or equal to about 20 weight percent, less than or equal to about 15 weight percent, less than or equal to about 10 weight percent, less than or equal to about 5 weight percent, or less than or equal to about 1 weight percent). The plasticizer may include water, propylene glycol, butanediol, glycerin, sugar alcohol(s), vegetable oil(s), triglyceride(s) (e.g., short, medium, and/or long chain triglycerides), phthalate(s), ester(s) of a polycarboxylic acid with a linear or branched aliphatic alcohol of moderate chain length, or any combination thereof. In at least one example embodiment, in addition to or as an alternative to the above plasticizers, other ingredients in the encapsulated flavorant can additionally function as a plasticizer, such as nicotine, cannabinoid(s) and/or flavorant(s). In at least one other example embodiment, the encapsulated flavorant is free of a plasticizer.

In at least one example embodiment, the encapsulated flavorant includes the cross-linking agent. The cross-linking agent may be combined with and/or dispersed throughout the matrix material such that the cross-linking agent is part of the matrix. The cross-linking agent may be present in the encapsulated flavorant in an amount greater than or equal to about 0.01 weight percent (e.g., greater than or equal to about 0.1 weight percent, greater than or equal to about 1 weight percent, greater than or equal to about 5 weight percent, greater than or equal to about 10 weight percent, greater than or equal to about 15 weight percent, greater than or equal to about 20 weight percent, or greater than or equal to about 25 weight percent). The cross-linking agent may be present in the encapsulated flavorant in an amount less than or equal to about 30 weight percent (e.g., less than or equal to about 25 weight percent, less than or equal to about 20 weight percent, less than or equal to about 15 weight percent, less than or equal to about 10 weight percent, less than or equal to about 5 weight percent, less than or equal to about 1 weight percent, or less than or equal to about 0.1 weight percent). The cross-linking agent may include Ca²⁺, Na⁺, polyol(s), polyacid(s), epichlorohydrin, or any combination thereof. In at least one other example embodiment, the encapsulated flavorant is free of a cross-linking agent.

In at least one example embodiment, the encapsulated flavorant includes the foaming agent. The foaming agent may be combined with and/or dispersed throughout the matrix material such that the foaming agent is part of the matrix. The foaming agent may be present in the encapsulated flavorant in an amount greater than or equal to about 0.5 weight percent (e.g., greater than or equal to about 1 weight percent, greater than or equal to about 5 weight percent, greater than or equal to about 10 weight percent, greater than or equal to about 15 weight percent, greater than or equal to about 20 weight percent, greater than or equal to about 25 weight percent, greater than or equal to about 30 weight percent, greater than or equal to about 35 weight percent, greater than or equal to about 40 weight percent, greater than or equal to about 45 weight percent, greater than or equal to about 50 weight percent, greater than or equal to about 55 weight percent, greater than or equal to about 60 weight percent, or greater than or equal to about 65 weight percent). The foaming agent may be present in the encapsulated flavorant in an amount less than or equal to about 70 weight percent (e.g., less than or equal to about 65 weight percent, less than or equal to about 60 weight percent, less than or equal to about 55 weight percent, less than or equal to about 50 weight percent, less than or equal to about 45 weight percent, less than or equal to about 40 weight percent, less than or equal to about 35 weight percent, less than or equal to about 30 weight percent, less than or equal to about 25 weight percent, less than or equal to about 20 weight percent, less than or equal to about 15 weight percent, less than or equal to about 10 weight percent, less than or equal to about 5 weight percent, or less than or equal to about 1 weight percent). The foaming agent may include bicarbonates, liquid CO₂, gelatin, alginic acid, sodium alginate, potassium alginate, ammonium alginate, calcium alginate, propane-1,2-diol alginate, xanthan gum, mono- and diglyceride(s) of fatty acids, acetic acid ester(s) of mono- and diglycerides of fatty acids, lactic acid esters of mono- and diglyceride(s) of fatty acids, sucrose ester(s) of fatty acids, polyglycerol esters of fatty acids, propan-1,2-diol esters of fatty acid, sodium steroyl-2-lactylate, calcium stearoyl-2-lactylate, quillaia extract, or any combination thereof. In at least one other example embodiment, the encapsulated flavorant is free of a foaming agent.

In at least one example embodiment, the encapsulated flavorant includes the filler. The filler may be combined with and/or dispersed throughout the matrix material such that the filler is part of the matrix. The filler material may be a solid, such as a powder, ground tobacco, microcrystalline cellulose, cellulose nanocrystals, cellulosic material(s), starch(es), modified starch(es), starch derivative(s), titanium dioxide, calcium carbonate, natural mineral(s), or any combination thereof. The filler may be present in the encapsulated flavorant in an amount greater than or equal to about 0.5 weight percent (e.g., greater than or equal to about 1 weight percent, greater than or equal to about 5 weight percent, greater than or equal to about 10 weight percent, greater than or equal to about 15 weight percent, greater than or equal to about 20 weight percent, greater than or equal to about 25 weight percent, greater than or equal to about 30 weight percent, greater than or equal to about 35 weight percent, greater than or equal to about 40 weight percent, greater than or equal to about 45 weight percent, greater than or equal to about 50 weight percent, greater than or equal to about 55 weight percent, greater than or equal to about 60 weight percent, greater than or equal to about 65 weight percent, or greater than or equal to about 70 weight percent). The filler material may be present in the encapsulated flavorant in an amount less than or equal to about 75 weight percent (e.g., less than or equal to about 70 weight percent, less than or equal to about 65 weight percent, less than or equal to about 60 weight percent, less than or equal to about 55 weight percent, less than or equal to about 50 weight percent, less than or equal to about 45 weight percent, less than or equal to about 40 weight percent, less than or equal to about 35 weight percent, less than or equal to about 30 weight percent, less than or equal to about 25 weight percent, less than or equal to about 20 weight percent, less than or equal to about 15 weight percent, less than or equal to about 10 weight percent, less than or equal to about 5 weight percent, or less than or equal to about 1 weight percent).

In at least one example embodiment, the encapsulated flavorant is in the form of a plurality of pellets, particles, granules, cuts, shreds, flakes, or any combination thereof. The encapsulated flavorant may have an average particle size of greater than or equal to about 5 μm (e.g., greater than or equal to about 10 μm, greater than or equal to about 15 μm, greater than or equal to about 20 μm, greater than or equal to about 25 μm, greater than or equal to about 50 μm, greater than or equal to about 100 μm, greater than or equal to about 150 μm, greater than or equal to about 200 μm, greater than or equal to about 250 μm, greater than or equal to about 300 μm, greater than or equal to about 350 μm, greater than or equal to about 400 μm, greater than or equal to about 450 μm, greater than or equal to about 0.5 mm, greater than or equal to about 0.75 mm, greater than or equal to about 1 mm, greater than or equal to about 1.25 mm, greater than or equal to about 1.5 mm, greater than or equal to about 1.75 mm, or greater than or equal to about 2 mm, or greater than or equal to about 2.25 mm). The encapsulated flavorant may have an average particle size of less than or equal to about 2.5 mm (e.g., less than or equal to about 2.25 mm, less than or equal to about 2 mm, less than or equal to about 1.75 mm, less than or equal to about 1.5 mm, less than or equal to about 1.25 mm, less than or equal to about 1 mm, less than or equal to about 0.75 mm, less than or equal to about 0.5 mm, less than or equal to about 450 μm, less than or equal to about 400 μm, less than or equal to about 350 μm, less than or equal to about 300 μm, less than or equal to about 250 μm, less than or equal to about 200 μm, less than or equal to about 150 μm, less than or equal to about 100 μm, less than or equal to about 50 μm, less than or equal to about 25 μm, less than or equal to about 20 μm, less than or equal to about 15 μm, or less than or equal to about 10 μm).

In at least one example embodiment, the aerosol-forming substrate may include the encapsulated flavorant. The encapsulated flavorant may be dispersed throughout the aerosol-forming substrate. For instance, the encapsulated flavorant may be admixed with the plant and/or fibrous material (e.g., tobacco). Distribution of the encapsulated flavorant throughout the aerosol-forming substrate may be heterogeneous or substantially homogeneous.

Additionally or alternatively, the encapsulated flavorant may be present as a coating on a surface of a capsule, as will be described in greater detail below in the discussion accompanying FIG. 10. Additionally or alternatively, the encapsulated flavorant may be present as a coating on a surface that is in fluid communication with an aerosol pathway. For instance, the encapsulated flavorant may be in the mouthpiece and in fluid communication with the aerosol-pathway, such as a coating on a surface of a mouthpiece of an aerosol-generating device, as will be described in greater detail below in the discussion accompanying FIG. 10 and/or in consolidated or loose form within a region of the mouthpiece. Additionally or alternatively, the encapsulated flavorant may be embedded within the mouthpiece itself.

In at least one example embodiment, a capsule has a resistance to draw (RTD) of greater than or equal to about 30 mmH₂O (e.g., greater than or equal to about 40 mmH₂O, greater than or equal to about 50 mmH₂O, greater than or equal to about 60 mmH₂O, greater than or equal to about 70 mmH₂O, greater than or equal to about 80 mmH₂O, greater than or equal to about 90 mmH₂O, greater than or equal to about 100 mmH₂O, greater than or equal to about 110 mmH₂O, or greater than or equal to about 120 mmH₂O). In at least one example embodiment, the RTD is less than or equal to about 130 mmH₂O (e.g., less than or equal to about 120 mmH₂O, less than or equal to about 110 mmH₂O, less than or equal to about 100 mmH₂O, less than or equal to about 90 mmH₂O, less than or equal to about 80 mmH₂O, less than or equal to about 70 mmH₂O, less than or equal to about 60 mmH₂O, less than or equal to about 50 mmH₂O, or less than or equal to about 40 mmH₂O). In at least one example embodiment, the RTD ranges from about 60 mmH₂O to about 80 mmH₂O (e.g., from about 65 mmH₂O to about 75 mmH₂O, from about 67 mmH₂O to about 73 mmH₂O, or from about 69 mmH₂O to about 71 mmH₂O). In at least one example embodiment, the RTD caused, at least in part, by the aerosol-forming substrate in the capsule.

In at least one example embodiment, the aerosol-forming substrate has a bulk density of greater than or equal to about 0.2 g/cm³ (e.g., greater than or equal to about 0.25 g/cm³, greater than or equal to about 0.3 g/cm³, greater than or equal to about 0.35 g/cm³, greater than or equal to about 0.4 g/cm³, greater than or equal to about 0.45 g/cm³, greater than or equal to about 0.5 g/cm³, greater than or equal to about 0.55 g/cm³, greater than or equal to about 0.6 g/cm³, greater than or equal to about 0.65 g/cm³, greater than or equal to about 0.7 g/cm³, greater than or equal to about 0.75 g/cm³, greater than or equal to about 0.8 g/cm³, greater than or equal to about 0.85 g/cm³, greater than or equal to about 0.9 g/cm³, greater than or equal to about 0.95 g/cm³, greater than or equal to about 1 g/cm³, greater than or equal to about 1.05 g/cm³, greater than or equal to about 1.1 g/cm³, or greater than or equal to about 1.15 g/cm³). In at least one example embodiment, the bulk density is less than or equal to about 1.2 g/cm³ (e.g., less than or equal to about 1.15 g/cm³, less than or equal to about 1.1 g/cm³, less than or equal to about 1.05 g/cm³, less than or equal to about 1 g/cm³, less than or equal to about 0.95 g/cm³, less than or equal to about 0.9 g/cm³, less than or equal to about 0.8 g/cm³, less than or equal to about 0.75 g/cm³, less than or equal to about 0.7 g/cm³, less than or equal to about 0.65 g/cm³, less than or equal to about 0.6 g/cm³, less than or equal to about 0.55 g/cm³, less than or equal to about 0.5 g/cm³, less than or equal to about 0.45 g/cm³, less than or equal to about 0.4 g/cm³, less than or equal to about 0.35 g/cm³, less than or equal to about 0.3 g/cm³, or less than or equal to about 0.25 g/cm³). In at least one example embodiment, the bulk density ranges from about 0.2 g/cm³ to about 1.2 g/cm³ (e.g., from about 0.3 g/cm³ to about 0.5 g/cm³, from about 0.35 g/cm³ to about 0.45 g/cm³, or from about 0.37 g/cm³ to about 0.43 g/cm³).

In at least one example embodiment, the plant and/or fibrous material (e.g., tobacco) of the aerosol-forming substrate has a particulate form with a mean particle size (e.g., diameter) of greater than or equal to about 150 μm (e.g., greater than or equal to about 175 μm, greater than or equal to about 200 μm, greater than or equal to about 225 μm, greater than or equal to about 250 μm, greater than or equal to about 270 μm, greater than or equal to about 280 μm, greater than or equal to about 290 μm, greater than or equal to about 300 μm, greater than or equal to about 310 μm, greater than or equal to about 320 μm, greater than or equal to about 330 μm, greater than or equal to about 340 μm, greater than or equal to about 350 μm, greater than or equal to about 360 μm, greater than or equal to about 370 μm, greater than or equal to about 380 μm, greater than or equal to about 390 μm, greater than or equal to about 400 μm, greater than or equal to about 410 μm, greater than or equal to about 425 μm, greater than or equal to about 450 μm, greater than or equal to about 475 μm, greater than or equal to about 500 μm, greater than or equal to about 600 μm, greater than or equal to about 650 μm, greater than or equal to about 700 μm, greater than or equal to about 800 μm, greater than or equal to about 900 μm, greater than or equal to about 1000 μm, greater than or equal to about 1100 μm, or greater than or equal to about 1200 μm). In at least one example embodiment, the mean particle size is less than or equal to about 1250 μm (e.g., less than or equal to about 1200 μm, less than or equal to about 1100 μm, less than or equal to about 1000 μm, less than or equal to about 900 μm, less than or equal to about 800 μm, less than or equal to about 700 μm, less than or equal to about 600 μm, less than or equal to about 500 μm, less than or equal to about 550 μm, less than or equal to about 500 μm, less than or equal to about 450 μm, less than or equal to about 425 μm, less than or equal to about 415 μm, less than or equal to about 400 μm, less than or equal to about 390 μm, less than or equal to about 380 μm, less than or equal to about 370 μm, less than or equal to about 360 μm, less than or equal to about 350 μm, less than or equal to about 340 μm, less than or equal to about 330 μm, less than or equal to about 320 μm, less than or equal to about 310 μm, less than or equal to about 300 μm, less than or equal to about 290 μm, less than or equal to about 280 μm, less than or equal to about 270 μm, less than or equal to about 250 μm, less than or equal to about 225 μm, less than or equal to about 200 μm, or less than or equal to about 175 μm).

In at least one example embodiment, the aerosol-forming substrate has a 10th percentile diameter ranging from about 160 μm to about 225 μm. In at least one example embodiment, the aerosol-forming substrate has a 50th percentile (or median) diameter ranging from about 260 μm to about 385 μm. In at least one example embodiment, the aerosol-forming substrate has a 90th percentile diameter ranging from about 390 μm to about 635 μm.

FIG. 1 is a perspective view of an aerosol-forming substrate in consolidated form according to at least one example embodiment.

In at least one example embodiment, as shown in FIG. 1, an aerosol-forming substrate 100 may include a first aerosol-forming substrate 102a and a second aerosol-forming substrate 102b to facilitate substrate loading during an assembly of a capsule. Each of the first aerosol-forming substrate 120a and the second aerosol-forming substrate 120b may be in a consolidated form that is configured to maintain its shape so as to allow placement in a unified manner within a chamber of the capsule. For instance, the first aerosol-forming substrate 120a and the second aerosol-forming substrate 120b may be in the form of rectangular sheets/slabs dimensioned for insertion into the capsule.

FIG. 2 is a perspective view of another aerosol-forming substrate in consolidated form according to at least one example embodiment.

In at least one example embodiment, as shown in FIG. 2, an aerosol-forming substrate 200 may differ from the aerosol-forming substrate 100 (shown in FIG. 1) with regard to its shape and dimensions. Otherwise, the aerosol-forming substrate 200 may be the same as described in connection with the aerosol-forming substrate 100. The aerosol-forming substrate 200 may include a first aerosol-forming substrate 202a and a second aerosol-forming substrate 202b, wherein each may be in a consolidated form. For instance, the first aerosol-forming substrate 202a and the second aerosol-forming substrate 202b may be in the form slabs/pallets with a semi-obround cross-section dimensioned for insertion into a capsule (e.g., capsule 500 of FIGS. 5-7).

FIG. 3 is a perspective view of an aerosol-forming substrate in loose form according to at least one example embodiment.

In at least one example embodiment, as shown in FIG. 3, an aerosol-forming substrate 300 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 an available space within a chamber when introduced into a capsule. Specifically, during assembly/loading, the loose form of the aerosol-forming substrate 300 may partially or fully occupy the available space within a chamber of a capsule so as to be on respective sides of an intermediate section of a heater. For instance, the loose form of the aerosol-forming substrate 300 may be used to fill in a remainder of a chamber (e.g., top off a chamber) that is already loaded with an aerosol-forming substrate in consolidated form. In another instance, the loose form of the aerosol-forming substrate 300 may be used to fill an entirety of a chamber of a capsule. Furthermore, the aerosol-forming substrate 300 may be loaded into capsule via a vacuum-assisted process.

FIG. 4 is a perspective view of an aerosol-forming substrate in rod form according to at least one example embodiment.

In at least one example embodiment, as shown in FIG. 4, an aerosol-forming substrate 400 may be consolidated in the form of a rod 402. A circumference of the aerosol-forming substrate 400 may be surrounded by a wrap 404. For instance, the wrap 404 may be a tipping paper. In at least one example embodiment, the rod 402 may be used in an aerosol-generating device without being in a capsule.

In at least one example embodiment, an aerosol-forming substrate may be used in an aerosol-generating device, optionally within a capsule. The aerosol-forming substrate may include or be similar to the aerosol-forming substrate 100 (shown in FIG. 1), the aerosol-forming substrate 200 (shown in FIG. 2), and/or the aerosol-forming substrate 300 (shown in FIG. 3). The capsule may include an encapsulated flavorant, as described above. The encapsulated flavorant may be present in the aerosol-forming substrate, on a surface of the capsule, in a mouthpiece, and/or elsewhere in the device (e.g., along an aerosol pathway).

FIG. 5 is a top right perspective view of a capsule according to at least one example embodiment.

In at least one example embodiment, as shown in FIG. 5, a capsule 500 has a housing 502 configured to contain an aerosol-forming substrate (e.g., aerosol-forming substrate 200 in FIG. 2 and/or aerosol-forming substrate 300 in FIG. 3). A downstream portion of the housing 502 may be in the form of a first end cap 506 (e.g., downstream cap). An upstream portion of the housing 502 may be in the form of a second end cap 508 (e.g., upstream cap, connector cap). The body portion of the housing may be in the form of a cover 510 (e.g., shell, box sleeve). The first end cap 506 may define a first opening 512. In at least the example embodiment shown, the first opening 512 is in the form of a series of outlet openings (e.g., nine outlet openings).

FIG. 6 is a sectional view of the capsule of FIG. 5 along line XI-XI according to at least one example embodiment.

In at least one example embodiment, as shown in FIG. 6, the housing 502 at least partially encloses and/or contains a heater 600. The heater 600 is a conductive component including a first end section 602, an intermediate section 604, and a second end section 606. The intermediate section 604 is an internal segment configured to heat an aerosol-forming substrate within the capsule 500. The first end section 602 and the second end section 606 are external segments configured to establish an electrical connection with a power source.

In at least one example embodiment, the intermediate section 604 of the heater 600 has a planar and winding form resembling a compressed oscillation or zigzag with a plurality of parallel segments (e.g., eight to sixteen parallel segments). However, it should be understood that other forms for the intermediate section 604 of the heater 600 are also possible (e.g., spiral form, flower-like form). The terminus of each of the first end section 602 and the second end section 606 may be oriented orthogonally to the plane of the intermediate section 604. Each of the first end section 602 and the second end section 606 may also include segments having a sideways J-shape. As a result, the first end section 602 and the second end section 606 may be embedded relatively securely within the second end cap 508 while providing a pair of electrical contact surfaces.

The second end cap 508 may define a second opening 610. In at least the example embodiment shown, the second opening 610 is in the form of a series of inlet openings (e.g., eight inlet openings). In at least one example embodiment, the second end cap 508 may expose the first end section 602 and the second end section 606 of the heater 600. As illustrated, the second opening 610 may be between the exposed portions of the first end section 602 and the second end section 606. The first end cap 506 and/or the second end cap 508 may be transparent so as to serve as windows configured to permit a viewing of the contents/components (e.g., aerosol-forming substrate and/or heater) within the capsule 500.

In addition to the second opening 610, the second end cap 508 also defines an alignment recess 612 and an inlet recess 614. The alignment recess 612 and the inlet recess 614 may be viewed as being in a multi-level arrangement, wherein the base/inner end surface of the alignment recess 612 (which exposes the first end section 602 and the second end section 606) may be regarded as being on one level, while the base/inner end surface of the inlet recess 614 (or the grille-like surface of the second opening 610) may be regarded as being on another level. The alignment recess 612 is configured to facilitate a positioning of the capsule 500 during its insertion into a device body of an aerosol-generating device (e.g., aerosol-generating device 800 of FIGS. 8-9). In an example embodiment, the alignment recess 612 has angled sidewalls that taper inward toward the inlet recess 614. With the angled sidewalls, the alignment recess 612 may be quickly coupled with a corresponding engagement member of the device body with greater ease.

FIG. 7 is an exploded view of the capsule of FIG. 5 according to at least one example embodiment.

Referring to FIG. 7, the first end cap 506 includes a first sealing ridge 700 and the second end cap 508 includes a second sealing ridge 702. In an example embodiment, the first sealing ridge 700 is in the form of a series of ribs (e.g., four ribs), and the second sealing ridge 702 is in the form of a series of ribs (e.g., four ribs). In some instances, the ribs in each of the series may be of different heights to ensure a desired contact with the cover 510. When the capsule 500 is assembled, the first sealing ridge 700 of the first end cap 506 and the second sealing ridge 702 of the second end cap 508 are configured to interface with the inner surface of the cover 510 (e.g., via an interference fit) to provide an air seal. As a result, when air is directed to the capsule 500 during an operation of the aerosol-generating device (e.g., aerosol-generating device 800 of FIGS. 8-9), the air will enter the capsule 500 via the inlet recess 614 and the second opening 610 in the second end cap 508 (as opposed to entering the capsule 500 via a gap between the second end cap 508 and the cover 510, wherein such air may essentially just flow along the inner surface of the cover 510 so as to primarily bypass the aerosol-forming substrate and/or the intermediate section 604 of the heater 600). Similarly, with an appropriate seal, the aerosol generated within the chamber of the capsule 500 will be drawn out through the first opening 512 in the first end cap 506 (as opposed to leaking out through a gap between the first end cap 506 and the cover 510).

FIG. 8 is a perspective view of an aerosol-generating device having a lid in a closed position according to at least one example embodiment.

In at least one example embodiment, an aerosol-generating device 800 (e.g., heat not-burn (HNB) aerosol-generating device) has a general oblong or pebble shape and a replaceable mouthpiece 802 that extends from the main body of the aerosol generating device 800. For example, the aerosol-generating device 800 may include a housing 804 that receives a capsule, such as the capsule 500 (shown in FIGS. 5-7). The aerosol-generating device 800 may further include a lid 806 that is configured to open and close relative to the housing 804. The lid 806 may be configured to be coupled to the replaceable mouthpiece 802.

In at least one example embodiment, an exterior of the housing 804 and/or lid 806 may be formed from a metal (such as aluminum, stainless steel, and the like); an aesthetic, food contact rated plastic (such as, a polycarbonate (PC), acrylonitrile butadiene styrene (ABS) material, liquid crystalline polymer (LCP), a copolyester plastic, or any other suitable polymer and/or plastic); or any combination thereof. The replaceable mouthpiece 802 may be similarly formed from a metal (such as aluminum, stainless steel, and the like); an aesthetic, food contact rated plastic (such as, a polycarbonate (PC), acrylonitrile butadiene styrene (ABS) material, liquid crystalline polymer (LCP), a copolyester plastic, or any other suitable polymer and/or plastic); and/or plant-based materials (such as wood, bamboo, and the like). One or more interior surfaces or the housing 804 and/or lid 806 may be formed from or coated with a high temperature plastic (such as, polyetheretherketone (PEEK), liquid crystal polymer (LCP), or the like). The lid 806 and the housing 804 may be collectively regarded as the main body of the aerosol-generating device 800.

In at least one example embodiment, the housing 804 encases or houses a latch release mechanism for the lid 806, a power source, and a processing or control circuitry. The control circuitry may be hardware including logic circuits; a hardware/software combination such as a processor executing software; or a combination thereof. For example, the control circuitry 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. The supply of current from the power source may be in response to a manual operation (e.g., button activation) or an automatic operation (e.g., puff-activation). The power source may include one or more batteries (e.g., rechargeable dual battery arrangement, lithium-ion battery, and/or fuel cells). In at least some example embodiments, the control circuitry may further include a haptic motor that may be disposed on a side of the power source.

FIG. 9 is a partial perspective view of the aerosol-generating device of FIG. 8 with the lid in an open position and including the cartridge of FIG. 5 according to at least one example embodiment.

In at least one example embodiment, as shown in FIG. 9, the housing 804 encloses a capsule connector 900. Additionally, in some instances, the capsule connector 900 may be mounted or otherwise secured to a printed circuit board (PCB) within the housing 804. In at least one example embodiment, the capsule connector 900 defines the capsule-receiving cavity 902.

In at least some example embodiments, the method of control/heating and associated circuitry and electrical contacts (e.g., capsule connector 900 having electrical contacts) may be as described in U.S. application Ser. No. 17/151,375, titled “Heat-Not-Burn (HNB) Aerosol-Generating Devices Including Energy Based Heater Control, And Methods Of Controlling A Heater,” filed Jan. 18, 2021; and U.S. application Ser. No. 17/151,409, titled “Heat-Not-Burn (HNB) Aerosol-Generating Devices Including Intra-Draw Heater Control, and Methods of Controlling a Heater,” filed Jan. 18, 2021, the entire contents of each of which are incorporated herein by reference.

The capsule 500 is loaded into the aerosol-generating device 800 by initially inserting the capsule 500 into the capsule-receiving cavity 902 defined by the capsule connector 900. In at least one example embodiment, the capsule 500 makes contact (e.g., full contact) with electrical contacts within capsule-receiving cavity 902 only upon the application of force (e.g., downward/inward force) to the capsule 500. In at least one example embodiment, a force is applied to the capsule 500 by the closure and/or latching of the lid 806. In other example embodiments, a force is applied to the capsule 500 by an adult consumer. In still other example embodiments, a force is applied by a combination of pressure applied by the adult consumer and the closure and/or latching of the lid 806. For example, in each instance, a forced is applied until a resistance is felt and/or a clicking sound is heard, which signals a complete engagement of the capsule 500 in the capsule-receiving cavity 902.

Additional details and/or alternatives for the aerosol-generating device, the capsule, and/or the aerosol-forming substrate may be found in U.S. application Ser. No. 17/151,277, titled “Capsules Including Embedded Heaters And Heat-Not-Burn (HNB) Aerosol-Generating Devices,” filed Jan. 18, 2021; U.S. application Ser. No. 17/151,327, titled “Heat-Not-Burn (HNB) Aerosol Generating Devices And Capsules,” filed Jan. 18, 2021; U.S. application Ser. No. 17/151,336, titled “Heat-Not-Burn (HNB) Aerosol-Generating Devices And Capsules”, filed Jan. 18, 2021; U.S. application Ser. No. 17/151,340, titled “Heat-Not-Burn (HNB) Aerosol Generating Devices And Capsules,” filed Jan. 18, 2021; U.S. application Ser. No. 17/947,436, titled “Heat-Not-Burn (HNB) Aerosol-Generating Devices And Capsules,” filed Sep. 19, 2022; U.S. application Ser. No. 17/981,973, titled “Capsules Having Electrical Contact Pads With Surface Discontinuities And Heat-Not-Burn (HNB) Aerosol-Generating Devices Including The Same,” filed Nov. 7, 2022; U.S. application Ser. No. 29/859,073, titled “Aerosol-Generating Capsules,” filed Nov. 7, 2023; U.S. application Ser. No. 29/859,076, titled “Electrical Contact Pads,” filed Nov. 7, 2022; U.S. application Ser. No. 29/853,736, titled “Heat-Not-Burn Aerosol Generating Device With A Flip-Top Lid,” filed Sep. 19, 2022, 2022; U.S. application Ser. No. 17/982,138, titled “Heat-Not-Burn (Hnb) Aerosol-Generating Devices And Capsules Having Electrical Contact Pads With Surface Discontinuities,” filed Nov. 7, 2022, the entire contents of each of which are incorporated herein by reference.

FIG. 10 is a sectional view of a mouthpiece and capsule of the aerosol-generating device of FIG. 8, without a heater, according to at least one example embodiment.

In at least one example embodiment, as shown in FIG. 10, The mouthpiece 802 extends between a first or downstream end 1000 and a second or upstream end 1002. The first end 1000 defines a mouthpiece outlet 1004. In at least the example embodiment shown, the mouthpiece outlet 1004 includes a plurality of openings (e.g., five openings). The second end 1002 defines an opening or depression 1006 and a mouthpiece inlet 1008. The mouthpiece outlet 1004 and inlet 1008 are fluidly connected by a mouthpiece channel 1010. The mouthpiece channel 1010 may be defined by an interior mouthpiece wall 1012.

In at least one example embodiment, a mouthpiece seal 1020 may be on and/or near the second end 1002 of the mouthpiece 802. At least a portion of the mouthpiece seal 1020 is in the opening 1006 at the second end 1002 of the mouthpiece 802. The mouthpiece seal 1020 may include a top ridge 1022 that extends around the mouthpiece seal 1020. The top ridge 1022 fits at least partially within the opening 1006 to securely hold the mouthpiece seal 1020 in position with respect to the mouthpiece 802. In at least one example embodiment, as illustrated, the mouthpiece seal 1020 defines a seal channel 1024 that at least partially aligns with the mouthpiece channel 1010. The seal channel 1024 and the mouthpiece channel 1010 are in fluid communication with and/or lead to the outlet 1004 of the mouthpiece 802.

The capsule 500 is in fluid communication with the seal channel 1024 and the mouthpiece channel 1010. In at least one example embodiment, the first end cap 506 of the capsule 500 engages the mouthpiece seal 1020. During use of the aerosol-generating device 800 (shown in FIGS. 8-9), air may enter the capsule 500 through the inlet recess 614 and the second opening 514. Air and aerosol (e.g., formed by heating an aerosol-forming substrate within the capsule 500 with the heater 600) may exit the capsule 500 through the first opening 512. The air and aerosol may flow through the seal channel 1024 and mouthpiece channel 1010 and exit the mouthpiece 802 at the mouthpiece outlet 1004.

In at least one example embodiment, an encapsulated flavorant may be included in the capsule 500 and/or the aerosol-generating device 800 (shown in FIGS. 8-9), such as in the mouthpiece 802. Additionally or alternatively, the encapsulated flavorant may be included in the aerosol-forming substrate, as described above. The encapsulated flavorant may be positioned such that it is in fluid communication with the airflow path and configured to be heated by the heater 600 (shown in FIG. 6). The encapsulated flavorant may be in the form of a substantially uniform film, a coating (e.g., of particles, granules, cuts, shreds, and/or flakes of encapsulated flavorant), and/or loose pellets, particles, granules, cuts, shreds, and/or flakes.

In at least one example embodiment, a first coating or film 1030 of the encapsulated flavorant is on an interior cover surface 1032 of the cover 510 of the capsule 500. The first coating 1030 may cover a portion of the interior cover surface 1032, as shown, or the entirety of the interior cover surface 1032. Additionally or alternatively, a second coating or film 1034 may be on a first interior end cap surface 1036. The second coating 1034 may cover a portion of the first interior cap surface 1036, as shown, or the entirety of the interior cap surface 1036. Additionally or alternatively, a coating or film may be on a second interior end cap surface 1038 and/or surface(s) 1040 that define the first opening 512. In at least one example embodiment, a third coating or film 1042 is on an interior mouthpiece surface 1044. The third coating 1042 may cover a portion of the interior mouthpiece surface 1044, as shown, or an entirety of the interior mouthpiece surface 1044. Additionally or alternatively, a coating may be present on an interior seal surface 1046 and/or surface(s) 1048 that define the mouthpiece outlet 1004. Accordingly, the encapsulated flavorant may be present as a coating on the interior cover surface 1032, the first interior cap surface 1036, the second interior cap surface 1038, the surface(s) 1040 defining the first opening 512, the interior mouthpiece surface 1044, the interior seal surface 1046, and/or the surface(s) 1048 defining the mouthpiece outlet 1004.

In at least one example embodiment, a coating (e.g., the first, second, and/or third coatings 1030, 1034, 1042) including the encapsulated flavorant has a thickness of greater than or equal to about 1 μm (e.g., greater than or equal to about 5 μm, greater than or equal to about 10 μm, greater than or equal to about 15 μm, greater than or equal to about 20 μm, greater than or equal to about 25 μm, greater than or equal to about 50 μm, greater than or equal to about 100 μm, greater than or equal to about 150 μm, greater than or equal to about 200 μm, greater than or equal to about 250 μm, greater than or equal to about 300 μm, greater than or equal to about 350 μm, greater than or equal to about 400 μm, greater than or equal to about 450 μm, greater than or equal to about 0.5 mm, greater than or equal to about 0.75 mm, greater than or equal to about 1 mm, or greater than or equal to about 1.25 mm). The thickness may be less than or equal to about 1.5 mm (e.g., less than or equal to about 1.25 mm, less than or equal to about 1 mm, less than or equal to about 0.75 mm, less than or equal to about 0.5 mm, less than or equal to about less than or equal to about 400 μm, less than or equal to about 350 μm, less than or equal to about 300 μm, less than or equal to about 250 μm, less than or equal to about 200 μm, less than or equal to about 150 μm, less than or equal to about 100 μm, less than or equal to about 50 μm, less than or equal to about 25 μm, less than or equal to about 20 μm, less than or equal to about 15 μm, less than or equal to about 10 μm, or less than or equal to about 5 μm).

In at least one example embodiment, in addition to or being admixed with the aerosol-forming substrate and/or being in a coating, the encapsulated flavorant may be embedded within the mouthpiece (e.g., adjacent to an inlet of mouthpiece, adjacent to an outlet of the mouthpiece, and/or in a middle portion of the mouthpiece). Additionally or alternatively, the encapsulated flavorant may be present within one of the walls (e.g., the interior mouthpiece wall 1012) defining the mouthpiece. For example, the flavorant may be embedded within a polymer forming the walls.

FIG. 11 is a flowchart illustrating a method of manufacturing an encapsulated flavorant according to at least one example embodiment.

In at least one example embodiment, as shown in FIG. 11, a method of manufacturing an encapsulated flavorant includes preparing a first film-forming solution at S1100. The method further includes combining a flavorant and the first film-forming solution at S1104. The method further includes preparing a film precursor at S1108. The method further includes preparing a flavor film at S1112 (i.e., the encapsulated flavorant). The method may optionally further include forming a multilayer flavor film at S1116. The method may optionally include preparing a plurality of particles, granules, cuts, shreds, and/or flakes from the flavor film at S1120. Each of these steps is described in greater detail below.

At S1100, the method may include preparing a first film-forming solution. In at least one example embodiment, preparing the first film-forming solution includes dissolving a first film-forming material in a first solvent. The first film-forming material may include methyl cellulose, ethyl cellulose, hydroxypropyl ethyl cellulose, starch, modified starch, polyvinylpyrrolidone, carrageenan, carboxymethylcellulose, gum Arabic, pectin, pullulan, sodium alginate, xanthan gum, casein, whey protein, soy protein, corn zein, gelatin, or any combination thereof. The solvent may be a polar solvent (e.g., water and/or ethanol) or a non-polar solvent. Preparing the first film-forming solution may further include stirring or agitating the first film-forming solution for a desired (or alternatively, predetermined) duration at a desired (or alternatively, predetermined) temperature.

In one instance, the preparing includes dispersing the first film-forming material in the first solvent at a first temperature. The method may further include hydrating the first film-forming material by reducing a temperature of the first solvent to a second temperature lower than the first temperature. The reducing may include adding additional or different solvent(s) to the first solvent, the additional or different solvent(s) being at a temperature lower than the first temperature. The method may further include dissolving the first film-forming material in the first solvent at the second temperature.

At S1104, the method includes combining a flavorant and the first film-forming solution. The combining may include stirring or agitating the first film-forming solution and flavorant for a desired (or alternatively, predetermined) duration at a desired temperature (e.g., room temperature). In at least one example embodiment, the combining includes co-solvating the flavorant with the film-forming material by dissolving the flavorant in the first solvent. The flavorant may be added after, concurrently with, or before S1100. In another instance, the flavorant may be dissolved in a second solvent to form a flavor solution and the flavor solution may be admixed and/or combined with the first film-forming solution. The second solvent may be the same as the first solvent or different from the first solvent.

In at least one other example embodiment, the combining includes dispersing the flavorant in the first solvent. In one instance, the dispersing includes dispersing a flavorant powder in the first solvent.

In another instance, the flavorant is in a second film-forming solution that is dispersed in the first film-forming solution. The method may include preparing the second film-forming solution by dissolving the flavorant and a second film-forming material in a second solvent. The second solvent may have a different polarity than the first solvent. For example, the second film-forming solution may be an oil phase that is dispersed in the first film-forming solution, which is a water phase. The dispersing may be performed in the absence or presence of a surfactant.

In another instance, the flavorant is in the form of flavorant-carrier particles. The method may include preparing the flavorant-carrier particles. Preparing the flavorant-carrier particles may include absorbing, adsorbing, and/or coating the flavorant into/onto a carrier material. For example, a flavorant solution may be prepared by dissolving the flavorant in a solvent, and then forming a dispersion by combining and/or admixing the solution with the carrier material. The dispersion may be dried to reduce or remove the solvent, such as by casting the dispersion onto a surface and evaporating the solvent, with or without added heat.

At S1108, the method includes preparing a film precursor. Preparing the film precursor may include casting the film-forming solution having the flavorant therein onto a surface. The surface may be on a glass panel. The method may further include moving a blade across a surface the cast solution to achieve a desired (or alternatively, predetermined) thickness and/or uniformity of the film precursor.

At S1112, the method includes preparing a flavor film (i.e., the encapsulated flavorant). Preparing the flavor film may include drying the film precursor. Drying may be performed for a desired (or alternatively, predetermined) duration. The drying may be performed at room temperature or with added heat. Accordingly, the drying may include heating the film precursor to a desired (or alternatively, predetermined) temperature. In one instance, the drying is performed in a vacuum oven.

At S1116, the method optionally includes forming a multilayer film. Forming a multilayer film includes forming one or more secondary films on the flavor film. The secondary film may be the same as the flavor film or different from the flavor film. The secondary film may be different in terms of type of flavorant, presence of flavorant (e.g., it may be free of flavorant), amount of flavorant, thickness, and/or film forming material. The secondary film may be formed by repeating S1100, optionally S1104 (i.e., when the secondary film includes a flavorant), S1108, and S1112. In S1108, the surface may be a surface of the flavor film. In one instance, the flavor film is sandwiched between two plain or flavorant-free films.

At S1120, the method optionally includes preparing a plurality of particles, granules, cuts, shreds, and/or flakes from the flavor film. In at least one example embodiment, S1120 includes grinding, milling, shredding, and/or cross-cutting the film to form the plurality of particles, granules, cuts, shreds, and/or flakes.

FIG. 12 is a flowchart illustrating another method of manufacturing an encapsulated flavorant according to at least one example embodiment.

In at least one example embodiment, as shown in FIG. 12, a method of preparing an encapsulated flavorant includes preparing a polymer melt at S1200. The method further includes preparing an admixture including a polymer and a flavorant at S1204. The method optionally includes combining a filler with the polymer at S1208. The method further includes forming an encapsulated flavorant precursor at S1212. The method further includes forming an encapsulated flavorant at S1216. The method optionally further includes preparing a plurality of particles, granules, cuts, shreds, and/or flakes from the encapsulated flavorant at S1220. Each of these steps is described in greater detail below.

At S1200, the method includes preparing a polymer melt. Preparing the polymer melt may include heating the polymer to a desired (or alternatively, predetermined) temperature. The method may include stirring and/or agitating the polymer during the heating. In at least one example embodiment, the polymer is substantially free of a solvent. In at least one example embodiment, the polymer melt includes the polymer and a plasticizer. In at least one example embodiment, such as in a hot melt extrusion (HME) process, the polymer may be heated to a plurality of desired temperatures in a plurality of respective zones.

At S1204, the method further includes preparing an admixture including the polymer and a flavorant. The polymer may include the matrix materials described above. The polymer may include a thermoplastic polymer. In one instance, the polymer includes low density polyethylene, polyethylene glycol, polyurethane, poly (methyl methacrylate), ethylene vinyl acetate, ethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methyl cellulose, or any combination thereof. The flavorant may be in the form of a liquid, a solution, and/or a solid (e.g., a powder, flavorant-carrier particles). The flavorant may include a plurality of flavorants, with each flavorant independently being in the form of a liquid, solution, or solid.

Preparing the admixture S1204 may be performed after S1200, concurrently with S1200, or prior to preparing the polymer melt at S1200. In at least one example embodiment, preparing the admixture S1204 is performed after preparing the polymer melt S1200 by adding flavorants to a polymer melt (e.g., via one or more funnels in an extruder). In at least one example embodiment, preparing the admixture S1204 is performed concurrently with preparing the polymer melt S1200 by adding polymer solids (e.g., resin, powder) to an extruder concurrently with adding flavorant to the extruder (e.g., via another funnel). In at least one example embodiment, preparing the admixture S1204 is performed concurrently with preparing the polymer melt S1200 by adding flavorant to the extruder after adding polymer solids to the extruder, but before the polymer solids are fully melted. In at least one example embodiment, preparing the admixture S1204 is performed before preparing the polymer melt S1200 by admixing polymer solids with flavorant before adding the resulting admixture to the extruder. In at least one example embodiment, such as in the HME process, multiple flavorants are added at different points in a process, such as in different zones of an extruder. In another example embodiment, multiple flavorants are concurrently combined with a polymer.

In at least one example embodiment, the flavorant is in the form of flavorant-carrier particles. The method may include preparing the flavorant-carrier particles. Preparing the flavorant-carrier particles may include absorbing, adsorbing, and/or coating the flavorant into/onto a carrier material. For example, a flavorant solution may be prepared by dissolving the flavorant in a solvent, and then forming a dispersion by combining and/or admixing the solution with the carrier material. The dispersion may be dried to reduce or remove the solvent, such as by casting the dispersion onto a surface and evaporating the solvent, with or without added heat.

At S1208, the method optionally includes combining a filler with the polymer. The filler may be in the form of a powder or other solid. In at least one example embodiment, the filler includes ground tobacco, microcrystalline cellulose, starch, modified starch, or any combination thereof. S1208 may be performed concurrently with S1200 and/or S1204, or sequentially. In at least one example embodiment, such as in the HME process, the filler may be added in a zone of the extruder.

At S1212, the method further includes forming an encapsulated flavorant precursor. Forming the encapsulated flavorant precursor may include extruding or blow molding the polymer and flavorant melt. Extrusion may be performed using a single screw extruder, co-rotating twin-screw extruders, or counter-rotating twin-screw extruders. The method may include extruding the polymer and flavorant melt through a die, such as a ribbon die, a rod die, or a die having another desired cross-sectional shape, such as oval, square, star, or another shape. The die may include one or more openings having the desired shape. In at least one example embodiment, the extrudate is in the form of one or more thin rods or filaments, such as rods having a diameter of greater than or equal to about 0.1 mm (e.g., greater than or equal to about 0.5 mm, greater than or equal to about 1 mm, greater than or equal to about 5 mm, greater than or equal to about 10 mm, greater than or equal to about 15 mm, or greater than or equal to about 20 mm). The rods may have a diameter of less than or equal to about 25 mm (e.g., less than or equal to about 20 mm, less than or equal to about 15 mm, less than or equal to about 15 mm, less than or equal to about 10 mm, less than or equal to about 5 mm, less than or equal to about 1 mm, or less than or equal to about 0.5 mm).

At S1216, the method further includes forming the encapsulated flavorant. Forming the encapsulated flavorant may include cooling the encapsulated flavorant precursor. In at least one example embodiment, the encapsulated flavorant precursor may be cooled at room temperature. The cooling may include conveying the encapsulated flavorant precursor past one or more fans and/or through a water bath. In at least one example embodiment, the cooling may be performed for a duration of greater than or equal to about 5 seconds (e.g., greater than or equal to about 10 seconds, greater than or equal to about 15 seconds, greater than or equal to about 30 seconds, greater than or equal to about 45 seconds, greater than or equal to about 1 minute, greater than or equal to about 2 minutes, greater than or equal to about 3 minutes, greater than or equal to about 4 minutes, greater than or equal to about 5 minutes, greater than or equal to about 7.5 minutes, or greater than or equal to about 10 minutes). The duration may me less than or equal to about 15 minutes (e.g., less than or equal to about 10 minutes, less than or equal to about 7.5 minutes, less than or equal to about 5 minutes, less than or equal to about 4 minutes, less than or equal to about 3 minutes, less than or equal to about 2 minutes, less than or equal to about 1 minute, less than or equal to about 45 seconds, less than or equal to about 30 seconds, less than or equal to about 15 seconds, or less than or equal to about 10 seconds).

At S1220, the method optionally further includes preparing a plurality of pellets, particles, granules, cuts, shreds, and/or flakes from the encapsulated flavorant. S1220 may be performed sequentially after S1216, prior to S1216, or concurrently with S1216. In at least one example embodiment, a grinding process is performed after completion of S1212. In at least one other example embodiment, a hot-face cutter is used to cut an extrudate as it is discharged from a die. The hot extrudates are then transferred (e.g., vacuumed) into a receiver/cooling chamber to cool, and then transferred (e.g., dropped) into a catch bin after a desired (or alternatively, predetermined) cooling or holding time.

In at least one example embodiment, the plurality of pellets, particles, granules, cuts, shreds, and/or flakes are admixed or combined with a reminder of an aerosol-forming substrate (e.g., tobacco, cellulose, etc.). In at least one example embodiment, the admixing is performed in a tumbler mixer. The admixing may be performed for a duration of greater than or equal to about 1 minute (e.g., greater than or equal to about 2 minutes, greater than or equal to about 5 minutes, greater than or equal to about 10 minutes, greater than or equal to about 15 minutes, greater than or equal to about 20 minutes, greater than or equal to about 30 minutes, greater than or equal to about 40 minutes, greater than or equal to about 50 minutes, greater than or equal to about 60 minutes, greater than or equal to about 70 minutes, greater than or equal to about 80 minutes, greater than or equal to about 90 minutes, greater than or equal to about 100 minutes, or greater than or equal to about 110 minutes). The duration may be less than or equal to about 120 minutes (e.g., less than or equal to about 110 minutes, less than or equal to about 100 minutes, less than or equal to about 90 minutes, less than or equal to about 80 minutes, less than or equal to about 70 minutes, less than or equal to about 60 minutes, less than or equal to about 50 minutes, less than or equal to about 40 minutes, less than or equal to about 30 minutes, less than or equal to about 20 minutes, less than or equal to about 10 minutes, less than or equal to about 5 minutes, or less than or equal to about 2 minutes).

FIG. 13A is a schematic illustration of a method of preparing an encapsulated flavorant by HME in accordance with at least one example embodiment.

In at least one example embodiment, S1200, S1204, S1208, 1212, S1216, and S1220 (shown in FIG. 12) are performed in a continuous process and/or using a single machine, such as in the HME process. As shown in FIG. 13A, in at least one example embodiment, the HME process may generally include feeding pellets and/or granules of a polymer 1300 into a feeder 1302 of an extruder 1304. The polymer pellets and/or granules 1300 may optionally be admixed with one or more first flavorants 1306 during or prior to being fed into the extruder 1304. The HME process further includes melting and/or softening the polymer using heat and/or pressure. The method may further include passing the polymer (and optional first flavorant) through a plurality of zones, with each zone having a desired (or alternatively, predetermined) temperature. A quantity of zones may be greater than or equal to 2 (e.g., greater than or equal to 3, greater than or equal to 4, greater than or equal to 5, greater than or equal to 6, greater than or equal to 7, greater than or equal to 8, greater than or equal to 9, or greater than or equal to 10). The quantity of zones may be less than or equal to about 15 (e.g., less than or equal to about 10, less than or equal to about 9, less than or equal to about 8, less than or equal to about 7, less than or equal to about 6, less than or equal to about 5, less than or equal to about 4, or less than or equal to about 3).

In at least one other example embodiment, the HME process may further include adding one or more flavorants to the polymer at one or more desired zones of the extruder, such as via a side stuffer and/or injector. The second and third flavorants may be added into the same or different barrels of the extruder. The second and third flavorants may have different formats, such as a powdered second flavorant and an oil third flavorant. The HME process may optionally include adding a filler to the extruder at a desired zone, such as via a side stuffer.

Returning to FIG. 13A, the HME process includes forming the encapsulated flavorant precursor (or extrudate) 1308 by extruding an admixture of the polymer, the flavorant(s), and the optional filler, through a die 1310, such as a ribbon die, a rod die, or a die having another desired cross-sectional shape, such as oval, triangle, square, star, or another shape. Upon discharge from the die 1310, the extrudate 1308 may be conveyed, by a conveyor 1312. While on the conveyor 1312, the extrudate 1308 may be cooled, such as by a plurality of fans 1314. The extrudate 1308 may be conveyed into a grinder, cutter, or pelletizer 1316 to form a plurality of granules 1318. The granules 1318 may be discharged into a catch bin 1320.

In at least one other example embodiment, upon discharge from the extruder 1302, a plurality of pellets may be formed using a hot-face cutter. The pellets may be transferred into a receiving/cooling chamber to cool. After a desired duration, the cooled pellets of encapsulated flavorant are dropped into a catch bin.

FIG. 13B is a schematic illustration of a portion of an encapsulated flavorant formed by the method of FIG. 13A in accordance with at least one example embodiment.

As shown in FIG. 13B, in at least one example embodiment, an encapsulated flavorant 1350 includes a polymer 1352 and a flavorant 1354. The flavorant 1354 is present in a plurality of zones 1356. During use, the polymer 1352 is configured to melt to gradually release the flavorant 1354.

The methods of FIG. 11 and/or FIG. 12 may further include incorporating the encapsulated flavorant into an aerosol-generating device and/or capsule. In at least one example embodiment, the incorporating includes incorporating the encapsulated flavorant into the aerosol-forming substrate. For instance, the encapsulated flavorant may be admixed with other ingredients of the aerosol-forming substrate (e.g., tobacco, aerosol-forming agent, etc.). The admixture may be disposed in the capsule (e.g., in consolidated form, such as shown in FIGS. 1-2, and/or loose form, such as shown in FIG. 3) and/or formed into a rod (e.g., as shown in FIG. 4). In at least one example embodiment, the incorporating includes coating the encapsulated flavorant onto a surface of the cartridge, mouthpiece, and/or any other surface in fluid communication with the aerosol pathway. In one instance, the coating includes spraying the encapsulated flavorant onto the surface with an atomizer. In another instance, the coating includes heat-gluing the encapsulated flavorant onto the surface. In at least one example embodiment, the incorporating includes disposing the encapsulated flavorant in a region of the mouthpiece (e.g., in consolidated and/or loose form). In at least one example embodiment, the incorporating includes manufacturing the mouthpiece, cartridge, and/or other portion of the device such that the encapsulated flavorant is embedded in the body of the respective mouthpiece, cartridge, and/or other portion of the device.

Example 1

2 g of Aqualon® EC-N100 ethyl cellulose is dissolved into 40 g of ethanol with vigorous stirring to form a hazy solution. 1 g of menthol is added into the solution and becomes dissolved by stirring. The mixture is stirred vigorously for an extended period before being cast onto a glass panel. A transparent menthol film is formed by moving a BYK-Gardner film casting knife over the viscous mixture at the set thickness, followed by a drying step.

Example 2

Klucel® hydroxypropyl cellulose (HPC) is used as film-forming material. In detail, 10 g of HPC is first dissolved in 87.5 g of ethanol under stirring to form a clear and smooth solution. 2.5 g of menthol is then added into the viscous solution and vigorously stirred until it is completely dissolved. The mixture is then cast into film.

Example 3

4 g of Benecel® E5 methyl cellulose is dispersed into 16 g of 80° C. water. When the temperature of the dispersion is lowered to room temperature, methyl cellulose gets hydrated and finally dissolved into clear viscous solution under mild stirring. 1.0 g of ground menthol powder is dispersed into the solution. The dispersion is cast onto a glass panel and dried in a vacuum oven overnight at room temperature to form a flexible rubbery clear film with fine menthol crystals dispersed inside.

Example 4

10 g of HPC is first hydrated in 60 g of 55° C. hot water to form a slurry. After soaking for 10 minutes with agitation, 27.5 g of cold water is added into the slurry. When the temperature of the system drops to room temperature, the slurry gradually turns into clear HPC solution with medium-shear agitation. Menthol powders are dispersed into the solution at this point with high shear agitation. The dispersion is then cast onto a glass panel to form film.

Example 5

8 g of Aqualon® EC-N100 ethyl cellulose is dissolved in 21 g of ethanol to form a hazy solution, and then 2 g of menthol crystal is dissolved into this viscous solution under high-shear agitation. This solution is used as the oil phase. 7 g of CAPSUL® modified starch granules are hydrated in 13 g of cold water and then dissolved at 85° C., and this solution is used as the water phase. The oil phase is then dispersed into the water phase using high shear agitation to form an emulsion. The emulsion is then cast into film. The dry film is rigid and crispy, and it can be easily broken into flakes. The film can seal the menthol odor very well during storage.

Example 6

30 g of 50 wt % menthol ethanol solution is first mixed with 25 g of ARBOCEL® A300 powdered cellulose and then dried to remove ethanol. Afterwards, the dry mixture is dispersed into 100 g of 25 wt % methyl cellulose. The dispersion is then cast on a glass panel to a rubbery film after water evaporation. The menthol-impregnated cellulose powder can also be dispersed into ethyl cellulose ethanol solution, isomalt, mannitol, erythritol aqueous solution, and then cast onto a glass panel to form film.

Example 7

8 g of Aqualon® EC-N100 ethyl cellulose and 2 g of menthol are dissolved in 21 g of ethanol to yield the flavored solution. The plain solution is created by first hydrating 14 g of CAPSUL TAR modified starch granules in 26 g of water and then raising the temperature to 65° C. with vigorous agitation. The plain solution is cast onto a glass panel to form the first plain film. After a while, the flavor solution is cast onto the gel-like plain film to form the middle flavor layer. Finally, another plain layer is formed on top of the first two layers. The tri-layer film is dried completely. The slightly yellowish film is neither as brittle as the CAPSUL TA® film nor as strong as the ethyl cellulose film. It can be peeled off the glass panel.

Example 8

120 g of LDPE and 40 g of ground menthol are pre-mixed and then feed into a single screw extruder equipped with a 0.8 mm×50 mm ribbon die. The mixture is heated to 140° C. and extruded at 110° C. The extruded ribbon via the die into an air-cooled conveyer and then winded in a film winder or blown into flavor film. Tween 80 and PEG 300 may be used to increase product stability.

Example 9

1333.34 g of 50 wt % menthol ethanol solution is absorbed into 1000 g of ARBOCEL® A300 powdered cellulose. After the evaporation of ethanol, the menthol impregnated cellulose powder and one or more film-forming polymer are mixed and extruded into film in a process described in Example 8.

Example 10

Four parts of Low-Density Polyethylene (LDPE) pellets or granules and one part of ground menthol are mixed at room temperature before being fed into a three-zone Brabender single screw extruder equipped with a ribbon die. When all three zones and the die zone are heated to 140° C., LDPE and menthol melt in the extruder and are extruded into 0.8 mm ribbons at 100 psi melt pressure. When solidified, ribbons are shredded into the desired size and mixed with tobacco-containing ingredients to make fillable materials for the consumables. Menthol is released in a controllable manner when such a consumable is used in a heated tobacco product (HTP) device.

Example 11

Ethyl cellulose (EC) and menthol are fed into a 7-zone Leistritz 18HP extruder with the temperatures set to 60° C., 95° C., 125° C., 130° C., 130° C., 125° C., 115° C. from Zone 1 (first zone next to the feed zone) to Zone 7 (exit zone). The mixture is melted in the extruder, extruded through a rod die, and cooled down into hard rod on a conveyor mounted with cooling fans. The rods are then ground into 0.3-2 mm flakes which are subsequently included in consumables and/or capsules from 5% to 25% by weight. The delivery of menthol lasts throughout a 7-minute session, and the consistency of menthol delivery over puffs is improved to a satisfactory extent.

Example 12

Ethyl cellulose is fed into the extruder. Peppermint oil is injected into the extruder at Zone 6 and mixed with the hot ethyl cellulose melt in the rest zones. The extrudates are processed in a similar way into consumables as described Example 11. The release of the encapsulated peppermint oil over puffs is more consistent than its control sample, in which the peppermint oil is applied directly without encapsulation.

Hydroxypropyl cellulose (HPC), hydroxyethyl cellulose (HEC), and methyl cellulose (MC) can also be used in HME to encapsulate flavorants without the use of solvent. For example, HPC is dried in an oven to remove the moisture, then 4 parts HPC and 1 part menthol are fed into a 7-zone extruder with temperatures set to 95° C., 130° C., 155° C., 155° C., 145° C., 140° C., 135° C. from Zone 1 to 7. The extrudates are frozen to −20° to increase brittleness and then ground into the desired shape and size before being included into for consumables.

Example 13

EC is fed into a 7-zone extruder with the temperatures from Zones 1 to 7 set to 60° C., 95° C., 125° C., 130° C., 130° C., 125° C., and 115° C., respectively. Infusible flavor-containing powders are fed into the extruder at Zone 3 by a side stuffer. The resulting extrudates go through a similar process as described in the previous example before being included into the consumables and/or capsules. In the sensory evaluation, the encapsulated flavorant is released in a more consistent manner over puffs in comparison with the unencapsulated counterpart.

Example 14

A first aerosol-forming substrate including tobacco and a menthol flavorant is prepared. A flavorant solution is prepared by combining (e.g., dissolving and/or dispersing) the flavorant with a solvent. The flavorant solution is sprayed and/or dripped onto the tobacco while blending.

A second aerosol-forming substrate including tobacco and encapsulated flavorant is prepared. The encapsulated flavorant includes ethyl cellulose as a matrix and menthol as a flavorant. The encapsulated flavorant is prepared by one of the methods in the above examples, such as forming a film with the flavorant and a polymer or extruding and then cutting into micro-pellets. The encapsulated flavorant is then blended with the aerosol-forming substrate. The blending process may include or be similar to powder mixing.

FIG. 14 is a graph illustrating menthol distribution by puff block for the first and second aerosol-forming substrates in accordance with at least one example embodiment.

The first and second aerosol-forming substrates are heated in respective aerosol-forming devices. In at least one example embodiment, as shown in FIG. 14, the encapsulated flavorant is configured to release menthol more evenly across 12 puffs than the sprayed flavorant. That is, amount of menthol in each of the three puff blocks is relatively consistent for the encapsulated flavorant, with the last puff block being only about 10% lower than the first puff block. In contrast, the sprayed flavorant has a large initial release and then decreases with each puff block, with the last puff block being about 25% less than the first puff block. Accordingly, encapsulating the flavorant controlled, gradual, and/or consistent flavorant release during use. Additionally, the encapsulated flavorant releases more menthol to the aerosol such that it is available to an adult consumer. As shown in FIG. 14, the encapsulated flavorant releases about 3.2 mg menthol to the aerosol, while the sprayed flavorant releases about 1.0 mg menthol to the aerosol.

While some example embodiments have been disclosed herein, it should be understood that other variations may be possible. Such variations are not to be regarded as a departure from the spirit and scope of the present disclosure, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.

Although described with reference to specific examples and drawings, modifications, additions and substitutions of example embodiments may be variously made according to the description by those of ordinary skill in the art. For example, the described techniques may be performed in an order different with that of the methods described, and/or elements such as the described system, architecture, devices, circuit, and the like, may be connected or combined to be different from the above-described methods, or results may be appropriately achieved by other elements or equivalents.

Claims

1. A capsule for an aerosol-generating device, the capsule comprising: a housing defining an inlet opening, an outlet opening, and a chamber between the inlet opening and the outlet opening;an aerosol-forming substrate in the housing, the aerosol-forming substrate including, tobacco;an encapsulated flavorant including, a matrix, anda flavorant in the matrix; andan aerosol-forming agent,the capsule having a resistance to draw ranging from 30 mmH2O to 130 mmH2O.

2. The capsule of claim 1, wherein the tobacco is in a form of particles having a mean particle size ranging from 150 μm to 1250 μm.

3. The capsule of claim 2, wherein the mean particle size ranges from 270 μm to 415 μm.

4. The capsule of claim 1, wherein the aerosol-forming substrate has a bulk density ranging from 0.2 g/cm3 to 1.2 g/cm3.

5. The capsule of claim 1, wherein the flavorant is present in the encapsulated flavorant in an amount ranging from 0.5 weight percent to 85 weight percent.

6. The capsule of claim 1, wherein the aerosol-forming agent includes propylene glycol, glycerol, butylene glycol, or any combination thereof.

7. The capsule of claim 1, wherein the matrix includes methyl cellulose, ethyl cellulose, hydroxypropyl methyl cellulose, starch, pectin, gelatin, sodium alginate, maltodextrin, pullulan, xanthan, gum acacia, sodium carboxy methyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose, polyethylene oxide, polyvinyl alcohol, polyvinyl pyrrolidone, low density polyethylene, polyethylene glycol, polyurethane, poly (methyl methacrylate), ethylene vinyl acetate, a polymer-thickened sugar alcohol, a wax, a fatty acid ester, a copolymer thereof, or any combination thereof.

8. The capsule of claim 1, wherein the encapsulated flavorant further includes a plasticizer, a cross-linking agent, a foaming agent, or any combination thereof.

9. The capsule of claim 1, wherein the flavorant includes menthol, peppermint, spearmint, wintergreen, cinnamon, chocolate, vanillin, licorice, clove, anise, sandalwood, geranium, rose, vanilla, lemon, Cassia, fennel, ginger, ethyl acetate, isoamyl acetate, propylisobutyrate, isobutyrate, ethyl butyrate, ethyl valerate, benzylformate, limonene, cymene, pinene, linalool, geraniol, citronellol, citral, orange, coriander, borneol, fruit extract, coffee, tea, cacao, mint, a terpene or any combination thereof.

10. The capsule of claim 1, wherein the encapsulated flavorant further includes a carrier, the flavorant absorbed in the carrier, the carrier dispersed in the matrix.

11. The capsule of claim 10, wherein the carrier includes cellulose, silica, pectin, or a combination thereof.

12. The capsule of claim 11, wherein the carrier includes the cellulose, the cellulose including microcrystalline cellulose.

13. The capsule of claim 11, wherein the carrier includes the cellulose, the cellulose including tobacco.

14. The capsule of claim 1, wherein the encapsulated flavorant is in a form of a plurality of particles, granules, cuts, shreds, flakes, or any combination thereof.

15. The capsule of claim 14, wherein the encapsulated flavorant is admixed with the tobacco and the aerosol-forming agent.

16. The capsule of claim 1, wherein the encapsulated flavorant is on a surface of the housing.

17. The capsule of claim 16, wherein the surface is an inner surface such that the encapsulated flavorant is in the chamber.

18. An aerosol-generating device, comprising: a capsule including, a housing, andan aerosol-forming substrate in the housing, the aerosol-forming substrate including, tobacco, andan aerosol-forming agent;a heater in thermal communication with the aerosol-forming substrate; anda device body including, a lid configured to open to permit an insertion of the capsule and configured to close to engage the capsule within the device body,a mouthpiece, andan encapsulated flavorant configured to be in fluid communication with an aerosol pathway of the aerosol-generating device, the encapsulated flavorant including, a matrix, anda flavorant in the matrix,the capsule having a resistance to draw ranging from 30 mmH2O to 130 mmH2O.

19. A replaceable mouthpiece for an aerosol-generating device, the replaceable mouthpiece comprising: a wall defining an inlet, an outlet, and a channel fluidly connecting the inlet and the outlet; andan encapsulated flavorant on a surface of the wall in fluid communication with the channel, the encapsulated flavorant including, a matrix, anda flavorant in the matrix.

20. A method of making an encapsulated flavorant for an aerosol-generating device, the method comprising: preparing a polymer melt by melting a polymer;preparing an admixture including the polymer and a flavorant;forming an encapsulated flavorant precursor by extruding the admixture; andforming the encapsulated flavorant by cooling the encapsulated flavorant precursor.