AEROSOL-GENERATING DEVICES WITH FILLED HINGES

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63/685,049 filed in the United States Patent and Trademark Office on Aug. 20, 2024, the entire contents of which are incorporated herein by reference.

BACKGROUND

Field

The present inventive concepts relate generally to aerosol-generating devices configured to generate an aerosol and more particularly to aerosol-generating devices having a filled hinge fixedly coupling a lid of the aerosol-generating devices to an aerosol generator thereof independently of a housing that encloses a lower portion of the aerosol generator.

Description of Related Art

Some 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. Some devices are configured to heat an aerosol-forming substrate to a temperature that is sufficient to release constituents of the aerosol-forming substrate while keeping the temperature below a combustion point of the aerosol-forming substrate so as to avoid any substantial pyrolysis of the aerosol-forming substrate. Some devices are configured to heat an aerosol-forming substrate to a temperature that is at or above a combustion point of the aerosol-forming substrate. Such devices may be referred to as aerosol-generating devices, and the aerosol-forming substrate heated may be a plant material, for example tobacco and/or cannabis. In some instances, the aerosol-forming substrate, for example a plant material, may be introduced directly into a heating chamber of an aerosol-generating device. In other instances, the aerosol-forming substrate, for example a plant material, may be pre-packaged in individual containers to facilitate insertion and removal from an aerosol-generating device. Devices that are configured to heat an aerosol-forming substrate to a temperature that is sufficient to release constituents of the aerosol-forming substrate while keeping the temperature below a combustion point of the aerosol-forming substrate so as to avoid any substantial pyrolysis of the aerosol-forming substrate may be referred to as heated tobacco aerosol-generating devices.

SUMMARY

At least some example embodiments relate to an aerosol-generating device. The aerosol-generating device may be a heated tobacco aerosol-generating device, but example embodiments are not limited thereto.

According to some example embodiments, an aerosol-generating device may include an aerosol generator configured to generate an aerosol based on heating of an aerosol-forming substrate, a housing enclosing a lower portion of the aerosol generator and exposing an upper portion of the aerosol generator, a lid, and a filled hinge fixedly coupling the lid to the aerosol generator independently of the housing. The filled hinge may define an axis of rotation between the aerosol generator and the lid. The axis of rotation may cross a central longitudinal axis of the aerosol generator. The filled hinge may include a hinge knuckle, a hinge dowel pin, and a torsion spring. The hinge knuckle may include two knuckle structures spaced apart from each other along the axis of rotation to at least partially define opposite axial ends of a central cavity between the two knuckle structures along the axis of rotation. The hinge dowel pin may be coupled between the two knuckle structures. The hinge dowel pin may extend along the axis of rotation through the central cavity between the two knuckle structures. The torsion spring may be configured to at least contact the lid. The torsion spring may include a spring coil. The spring coil may surround at least a portion of the hinge dowel pin between the two knuckle structures within the central cavity.

The aerosol-generating device may be a heated tobacco aerosol-generating device, wherein the aerosol generator is configured to generate the aerosol based on non-combustion heating of the aerosol-forming substrate.

The hinge knuckle may further include a first cover at least partially defining a first vertical end of the central cavity that extends at least partially between the opposite axial ends of the central cavity. The first cover may overlap a first coil section of the spring coil in a vertical direction. The vertical direction may extend perpendicular to the axis of rotation and paraxial to the central longitudinal axis of the aerosol generator.

The first cover may at least partially define a groove extending in a direction extending toward the central longitudinal axis and crossing the central longitudinal axis, such that the groove exposes a portion of the central cavity in the vertical direction.

The hinge knuckle may further include a second cover at least partially defining a second vertical end of the central cavity that extends at least partially between the opposite axial ends of the central cavity. The second vertical end may be opposite to the first vertical end in the vertical direction. The second cover may at least partially overlap the spring coil in the vertical direction.

The first cover may be an upper cover and the second cover may be a lower cover, such that the lower cover is configured to be between the upper cover and a lowermost end of the aerosol-generating device in the vertical direction.

The hinge knuckle may include one or more inner surfaces at least partially defining a slot extending from the central cavity to a latch structure. The torsion spring may include a first leg extending from one end of the spring coil to at least contact the lid and a second leg extending from an opposite end of the spring coil and further extending through at least a portion of the slot to engage the latch structure.

The hinge knuckle may define the latch structure.

The two knuckle structures may be defined by separate, respective portions of a single unitary piece of material, the single unitary piece of material further defining at least a portion of the aerosol generator.

The two knuckle structures may define separate, respective pin holes that are each coaxial with the axis of rotation. The hinge dowel pin may extend through both the central cavity and at least a portion of each of the separate, respective pin holes of the two knuckle structures.

The hinge dowel pin may extend entirely through each of the separate, respective pin holes, such that the two knuckle structures are between opposite ends of the hinge dowel pin along the axis of rotation. The lid may be fixedly coupled to the hinge dowel pin at each of the opposite ends of the hinge dowel pin.

According to some example embodiments, an aerosol-generating device may include an aerosol generator configured to generate an aerosol based on heating of an aerosol-forming substrate, a housing enclosing a lower portion of the aerosol generator and exposing an upper portion of the aerosol generator, a lid, and a filled hinge fixedly coupling the lid to the aerosol generator independently of the housing. The filled hinge may be configured to enable the lid to pivot around an axis of rotation between a closed position and an open position. The closed position may be a position wherein the lid at least partially covers both the upper portion of the aerosol generator and the filled hinge in at least a vertical direction extending parallel to a central longitudinal axis of the aerosol generator. The open position may be a position wherein the lid exposes the upper portion of the aerosol generator to an external environment in at least the vertical direction. The filled hinge may include a hinge dowel pin, a hinge knuckle, and a torsion spring. The hinge dowel pin may extend along the axis of rotation. The hinge knuckle may include two knuckle structures supporting the hinge dowel pin at each of opposite end portions of the hinge dowel pin. The two knuckle structures may further at least partially define opposite axial ends of a central cavity between the two knuckle structures along the axis of rotation. The torsion spring may be configured to at least contact the lid. The torsion spring may include a spring coil. The spring coil may surround at least a portion of the hinge dowel pin between the two knuckle structures within the central cavity.

The aerosol-generating device may be a heated tobacco aerosol-generating device, wherein the aerosol generator is configured to generate the aerosol based on non-combustion heating of the aerosol-forming substrate.

The vertical direction may include at least a first vertical direction, the first vertical direction extending toward the axis of rotation. The hinge knuckle may further include a first cover configured to at least partially shield the spring coil within the central cavity in at least the first vertical direction.

The filled hinge may be configured to enable the lid to pivot around the axis of rotation such that at least a portion of the torsion spring moves azimuthally in relation to the axis of rotation from an open-lid position to a closed-lid position, the open-lid position azimuthally offset from the first cover, the closed-lid position at least partially overlapping the first cover in an axial direction that is paraxial to the axis of rotation.

The vertical direction may include a second vertical direction, the second vertical direction extending toward the axis of rotation, the second vertical direction extending opposite to the first vertical direction. The hinge knuckle may further include a second cover configured to at least partially shield the spring coil within the central cavity in at least the second vertical direction.

The first cover may be an upper cover and the second cover may be a lower cover, such that the upper cover is configured to be between the lower cover and a lowermost end of the aerosol-generating device.

The hinge knuckle may include one or more inner surfaces at least partially defining a slot extending from the central cavity to a latch structure. The torsion spring may include a first leg extending from one end of the spring coil to at least contact the lid, and a second leg extending from an opposite end of the spring coil and further extending through the slot to engage the latch structure.

The hinge knuckle may define the latch structure.

The two knuckle structures may be defined by separate portions of a single, unitary piece of material, the single, unitary piece of material further defining at least a portion of the aerosol generator.

The two knuckle structures may define separate, respective pin holes that are each coaxial with the axis of rotation. The hinge dowel pin may extend through both the central cavity and at least a portion of each of the separate, respective pin holes of the two knuckle structures.

The hinge dowel pin may extend entirely through each of the separate, respective pin holes, such that the two knuckle structures are between opposite ends of the hinge dowel pin along the axis of rotation. The lid may be fixedly coupled to the hinge dowel pin at each of the opposite ends of the hinge dowel pin.

BRIEF DESCRIPTION OF THE DRAWINGS

The various features and advantages of the non-limiting example 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.

FIGS. 1A and 1B are top left, front perspective views of an aerosol-generating device in a closed-lid configuration and an open-lid configuration, respectively, according to some example embodiments.

FIGS. 2A and 2B are bottom right, front perspective views of an aerosol-generating device in a closed-lid configuration and an open-lid configuration, respectively, according to some example embodiments.

FIGS. 3A and 3B are top left, rear perspective views of an aerosol-generating device in a closed-lid configuration and an open-lid configuration, respectively, according to some example embodiments.

FIGS. 4A and 4B are left elevation views of an aerosol-generating device in a closed-lid configuration and an open-lid configuration, respectively, according to some example embodiments.

FIGS. 5A and 5B are rear elevation views of an aerosol-generating device in a closed-lid configuration and an open-lid configuration, respectively, according to some example embodiments.

FIG. 6A is a left elevation cross-sectional view of an aerosol-generating device along view line VIA-VIA′ in FIG. 1A, according to some example embodiments.

FIG. 6B is a top plan cross-sectional view along view line VIB-VIB′ in FIG. 6A, according to some example embodiments.

FIG. 6C is a top plan cross-sectional view along view line VIC-VIC′ in FIG. 6A, according to some example embodiments.

FIGS. 7A and 7B are top left, rear perspective views of an aerosol-generating device with a lid having a transparent lid housing in a closed-lid configuration and an open-lid configuration, respectively, according to some example embodiments.

FIGS. 8A and 8B are cross-sectional elevation views of an aerosol-generating device in a closed-lid configuration, where FIG. 8A is a view of region A in FIG. 6A, according to some example embodiments.

FIG. 8C is a cross-sectional elevation view of an aerosol-generating device in an open-lid configuration, according to some example embodiments.

FIGS. 9A and 9B are top left, rear perspective views of a portion of an aerosol-generating device including a filled hinge in a closed-lid configuration and an open-lid configuration, respectively, according to some example embodiments.

FIG. 9C is a top left, rear cross-sectional perspective view of a portion of an aerosol-generating device including a filled hinge in an open-lid configuration along view line IXC-IXC′ of FIG. 9B, according to some example embodiments.

FIG. 9D is a plan cross-sectional view along view line IXD-IXD′ in FIG. 8C, according to some example embodiments.

FIG. 9E is a right elevation view of a filled hinge in an open-lid configuration, according to some example embodiments.

FIGS. 10A and 10B are top plan views of a portion of an aerosol-generating device including a filled hinge in a closed-lid configuration and an open-lid configuration, respectively, according to some example embodiments.

FIGS. 11A and 11B are rear plan views of a portion of an aerosol-generating device including a filled hinge in a closed-lid configuration and an open-lid configuration, respectively, according to some example embodiments.

FIGS. 12A and 12B are rear plan cross-sectional views of a portion of an aerosol-generating device including a filled hinge in a closed-lid configuration and an open-lid configuration, respectively, according to some example embodiments.

FIG. 13A is a top left, rear perspective view of a portion of an aerosol-generating device having transparent representations of elements thereof excepting a structure including the knuckle structure of a filled hinge, according to some example embodiments.

FIG. 13B is a top left, rear perspective view of a structure including the knuckle structure of a filled hinge and at least a portion of an aerosol generator of an aerosol-generating device, according to some example embodiments.

FIG. 14A is a top left, rear perspective view of a knuckle structure of a filled hinge, according to some example embodiments.

FIG. 14B is a top left, rear perspective cross-sectional view along view line XIVB-XIVB′ in FIG. 14A, according to some example embodiments.

FIG. 14C is a left elevation cross-sectional view along view line XIVB-XIVB′ in FIG. 14A, according to some example embodiments.

FIG. 14D is a rear elevation view of the knuckle structure of FIG. 14A, according to some example embodiments.

FIG. 14E is a rear elevation view along view line XIVE-XIVE′ in FIG. 14A, according to some example embodiments.

FIG. 15 is a top left, rear perspective cross-sectional view along view line XV-XV′ of FIG. 14C, according to some example embodiments.

FIG. 16 is a block diagram of an example aerosol-generating device in accordance with some example embodiments.

DETAILED DESCRIPTION

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

Accordingly, while some example embodiments are capable of various modifications and alternative forms, some example embodiments 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.

As used herein, “coupled” includes both removably coupled and permanently coupled. For example, when an elastic layer and a support layer are removably coupled to one another, the elastic layer and the support layer can be separated upon the application of sufficient force.

FIGS. 1A to 15 are illustrations of an aerosol-generating device 100 in accordance with some example embodiments. FIGS. 1A and 1B are top left, front perspective views of an aerosol-generating device 100 in a closed-lid configuration and an open-lid configuration, respectively, according to some example embodiments. FIGS. 2A and 2B are bottom right, front perspective views of an aerosol-generating device 100 in a closed-lid configuration and an open-lid configuration, respectively, according to some example embodiments. FIGS. 3A and 3B are top left, rear perspective views of an aerosol-generating device 100 in a closed-lid configuration and an open-lid configuration, respectively, according to some example embodiments. FIGS. 4A and 4B are left elevation views of an aerosol-generating device 100 in a closed-lid configuration and an open-lid configuration, respectively, according to some example embodiments. FIGS. 5A and 5B are rear elevation views of an aerosol-generating device 100 in a closed-lid configuration and an open-lid configuration, respectively, according to some example embodiments. FIG. 6A is a left elevation cross-sectional view of an aerosol-generating device 100 along view line VIA-VIA′ in FIG. 1A, according to some example embodiments. FIG. 6B is a top plan cross-sectional view of an aerosol-generating device 100 along view line VIB-VIB′ in FIG. 6A, according to some example embodiments. FIG. 6C is a top plan cross-sectional view of an aerosol-generating device 100 along view line VIC-VIC′ in FIG. 6A, according to some example embodiments. FIGS. 7A and 7B are top left, rear perspective views of an aerosol-generating device 100 with a lid having a transparent lid housing in a closed-lid configuration and an open-lid configuration, respectively, according to some example embodiments. FIGS. 8A and 8B are cross-sectional elevation views of an aerosol-generating device 100 in a closed-lid configuration, where FIG. 8A is a view of region A in FIG. 6A, according to some example embodiments. FIG. 8C is a cross-sectional elevation view of an aerosol-generating device in an open-lid configuration, according to some example embodiments. FIGS. 9A and 9B are top left, rear perspective views of a portion of an aerosol-generating device 100 including a filled hinge in a closed-lid configuration and an open-lid configuration, respectively, according to some example embodiments. FIG. 9C is a top left, rear cross-sectional perspective view of a portion of an aerosol-generating device 100 including a filled hinge in an open-lid configuration along view line IXC-IXC′ of FIG. 9B, according to some example embodiments. FIG. 9D is a plan cross-sectional view along view line IXD-IXD′ in FIG. 8C, according to some example embodiments. FIG. 9E is a right elevation view of a filled hinge in an open-lid configuration, according to some example embodiments. FIGS. 10A and 10B are top plan views of a portion of an aerosol-generating device including a filled hinge in a closed-lid configuration and an open-lid configuration, respectively, according to some example embodiments. FIGS. 11A and 11B are rear plan views of a portion of an aerosol-generating device including a filled hinge in a closed-lid configuration and an open-lid configuration, respectively, according to some example embodiments. FIGS. 12A and 12B are rear plan cross-sectional views of a portion of an aerosol-generating device including a filled hinge in a closed-lid configuration and an open-lid configuration, respectively, according to some example embodiments. FIG. 13A is a top left, rear perspective view of a portion of an aerosol-generating device having transparent representations of elements thereof excepting a structure including the knuckle structure of a filled hinge, according to some example embodiments. FIG. 13B is a top left, rear perspective view of a structure including the knuckle structure of a filled hinge and at least a portion of an aerosol generator of an aerosol-generating device, according to some example embodiments. FIG. 14A is a top left, rear perspective view of a knuckle structure of a filled hinge, according to some example embodiments. FIG. 14B is a top left, rear perspective cross-sectional view along view line XIVB-XIVB′ in FIG. 14A, according to some example embodiments. FIG. 14C is a left elevation cross-sectional view along view line XIVB-XIVB′ in FIG. 14A, according to some example embodiments. FIG. 14D is a rear elevation view of the knuckle structure of FIG. 14A, according to some example embodiments. FIG. 14E is a rear elevation view along view line XIVE-XIVE′ in FIG. 14A, according to some example embodiments. FIG. 15 is a top left, rear perspective cross-sectional view along view line XV-XV′ of FIG. 14C, according to some example embodiments.

As shown, FIGS. 1A, 2A, 3A, 4A, 5A, 6A-6C, 7A, 8A-8B, 9A, 10A, 11A, and 12A, illustrate the aerosol-generating device 100 or portions thereof in a closed-lid configuration, and FIGS. 1B, 2B, 3B, 4B, 5B, 7B, 8C, 9B-9E, 10B, 11B, 12B, and 13A illustrate the aerosol-generating device 100 or portions thereof in an open-lid configuration. In some example embodiments, FIGS. 1A to 15 may be different views of the same aerosol-generating device 100, but example embodiments are not limited thereto.

As illustrated in FIGS. 1A to 15, and as shown for example in FIGS. 1A-1B, 2A-2B, and 6A-6C, in some example embodiments, the aerosol-generating device 100 may include an aerosol generator 200 configured to generate an aerosol based on heating of an aerosol-forming substrate, a housing 120, and a lid 110. As further described herein, the aerosol-generating device 100 may include a filled hinge 400 fixedly coupling the lid 110 to the aerosol generator 200 independently of the housing 120.

In some example embodiments, the aerosol-generating device 100 may be a heated tobacco aerosol-generating device that is configured to heat an aerosol-forming substrate (which may be a plant material but example embodiments are not limited thereto) to a temperature that is sufficient to release constituents of the aerosol-forming substrate in an aerosol while keeping the temperature below a combustion point of the aerosol-forming substrate so as to avoid any substantial pyrolysis and/or combustion of the aerosol-forming substrate. Such heating may be referred to herein as non-combustion heating. For example, in example embodiments where the aerosol-generating device 100 is a heated tobacco aerosol-generating device, the aerosol generator 200 may be configured to generate an aerosol based on non-combustion heating of the aerosol-forming substrate, which may include heating of the aerosol-forming substrate such that combustion and/or pyrolysis of the aerosol forming substrate is less than 10% by mass or volume of the aerosol-forming substrate.

In some example embodiments, the aerosol-generating device 100 may be configured to heat an aerosol-forming substrate (which may be a plant material but example embodiments are not limited thereto) to a temperature that is equal to or greater than a combustion point of the aerosol-forming substrate, which may cause at least partial pyrolysis and/or combustion of the aerosol-forming substrate. Such heating may be referred to herein as combustion heating or pyrolysis heating. For example, in some example embodiments, the aerosol generator 200 may be configured to generate an aerosol based on at least partial combustion of the aerosol-forming substrate (e.g., based on heating of the aerosol-forming substrate to a temperature at or above a combustion point of the aerosol-forming substrate such that combustion and/or pyrolysis of a portion of the aerosol-forming substrate that is equal to or greater than 10% by mass or volume of the aerosol forming substrate occurs).

The housing 120 may include an outer housing 120a (also referred to herein as a lower housing) and an inner housing 120b (also referred to herein as an upper housing). The outer and inner housings 120a and 120b may collectively enclose at least a lower portion 200a of the aerosol generator 200 and may expose at least an upper portion 200b of the aerosol generator 200. For example, as shown, the outer and inner housings 120a and 120b may enclose at least a control circuitry 220 and power source 230 and lateral structures and surfaces of a capsule connector 210 of the aerosol generator 200 and may at least partially expose at least an upper portion 200b of the aerosol generator 200 which may include a capsule-receiving cavity 212 (which may be at least partially defined by one or more inner surfaces 210s of the capsule connector 210), at least one surface to which the filled hinge 400 may be coupled (e.g., outer surface 210w of the capsule connector 210), or any combination thereof. The upper portion 200b of the aerosol generator 200 may include at least a portion of a structure (e.g., some or all of the capsule connector 210, for example a portion of the capsule connector 210 including one or more surfaces 210s at least partially defining the capsule-receiving cavity 212 and/or the outer surface 210w) that at least partially defines the capsule-receiving cavity 212 and which may be coupled to the filled hinge 400. The lower portion 200a of the aerosol generator 200 may at least the power source 230, the control circuitry 220, and at least some portions of the capsule connector 210 (e.g., external side surfaces, excluding the inner surfaces 210s at least partially defining the capsule-receiving cavity 212. The lid 110 may be fixedly coupled (e.g., by a filled hinge 400 as described herein) to the aerosol generator 200 independently of the housing 120.

As illustrated in FIGS. 1A to 15, in some example embodiments, the aerosol-generating device 100 may include a general oval or oblong or pebble shape and a mouthpiece 190 (which may be a replaceable mouthpiece or an irreplaceable mouthpiece) that extends from the main body of the aerosol-generating device 100. For example, at least a portion of the housing 120 (e.g., a portion of the inner housing 120b) may at least partially define an opening 1200 into the capsule-receiving cavity 212 (as shown for example in FIG. 1B), and at least a portion of the aerosol generator 200 (e.g., one or more inner surfaces 210s of the capsule connector 210) may at least partially define the capsule-receiving cavity 212.

A lid 110 that is configured to open/close relative to the housing 120 may be coupled to the mouthpiece 190. For example, the lid 110 may be fixedly coupled to a structure of the aerosol generator 200 (e.g., the capsule connector 210) at a first point 122 (which may be at least partially defined by the filled hinge 400) and releasably coupled to the aerosol generator 200 and/or the housing 120 at a second point 124. The first point 122 may be on a first side 102 of the aerosol-generating device 100, while the second point 124 of the housing 120 may be on a second side 104 of the aerosol-generating device 100. In some example embodiments, the lid 110 may also be referred to as a door.

An exterior of the housing 120 and/or lid 110 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 mouthpiece 190 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 of the housing 120 and/or lid 110 may be formed from or coated with a high temperature plastic (such as, polyetheretherketone (PEEK), liquid crystal polymer (LCP), or the like). The lid 110 and at least a portion of the housing 120 (e.g., the lid 110 and the outer housing 120a) may be collectively regarded as the main body of the aerosol-generating device 100.

The lid 110 may be fixedly coupled to the aerosol generator 200, independently of the housing 120, at the first point 122 by a filled hinge 400 that enables the lid 110 to move (e.g., swing and rotate, or pivot 404) around an axis of rotation 402 between a closed position (such as illustrated in FIGS. 1A, 2A, 3A, 4A, 5A, 6A-6C, 7A, 8A-8B, 9A, 10A, 11A, and 12A) and an open position (such as illustrated in FIGS. 1B, 2B, 3B, 4B, 5B, 7B, 8C, 9B-9E, 10B, 11B, 12B, and 13A). The housing 120 (e.g., the inner housing 120b) includes (e.g., includes one or more surfaces that define) a recess 126 at the first point 122. The recess 126 may be configured to receive a portion of the lid 110 so as to allow for an easy and smooth movement of the lid 110 from the open position to the closed position (and vice versa). The recess 126 may have a structure that corresponds with a relative portion of the lid 110. For example, as illustrated, the recess 126 may include a substantially curved portion 127 that has a general concave shape that corresponds with the curvature of the lid 110, which has a general convex shape.

The lid 110 may be releasably coupleable to the aerosol generator 200 and/or to the housing 120 at the second point 124 by a latch 114, or other similar connector, that allows the lid 110 to be fixed or secured in the closed position and easily releasable so as to allow the lid 110 to move from the secured closed position to the open position. In some example embodiments, the latch 114 may be coupled to a latch release mechanism 115. The latch release mechanism 115 may be configured to move the latch 114 from a first or closed position to a second or open position. For example, such as best illustrated in FIG. 6A, the latch 114 may extend downwards in the housing 120 and the latch release mechanism 115 may be configured to move a distal end thereof perpendicular to the downwards length of the latch 114. As such, the latch release mechanism 115 is configured to apply pressure to the latch 114. For example, the latch release mechanism 115 may be movable between a first position and a second position. In the first position, the latch release mechanism 115 may be neutral relative to the latch 114. In the second position, the latch release mechanism 115 may apply pressure to the downwards length of the latch 114 so as to move the latch 114 from the secured or latched close position to the open position.

In some example embodiments, such as best illustrated in FIG. 6A, the latch release mechanism 115 is in communication with or includes a latch release button 116 that is configured to activate the latch release mechanism 115—i.e., to move the latch 114 from the first or closed or secured position to the second or pressure-applying position and to move/return the latch 114 from the open position to the secured or closed position. In some example embodiments, the latch release button 116 is an adult consumer interaction button disposed on the second side 104 of the aerosol-generating device 100. For example, when the latch release button 116 is pressed by the adult consumer, the latch release mechanism 115 may move from the first or closed or secured position to the second or pressure-applying position so as to move the latch 114 from the secured or closed position to the open position. The latch release button 116 may have a substantially circular shape with a center depression or dimple configured to direct the pressure applied by the adult consumer, although example embodiments are not limited thereto. One or more sensors (not shown) configured to detect the lid 110 opening and closure may be embedded or otherwise disposed within the housing 120 and/or one or more of the elements therein (e.g., latch 114, latch release mechanism 115, latch release button 116).

Referring to FIG. 6A, the aerosol generator 200 may include a capsule connector 210, a processing or control circuitry 220, and a power source 230. In some example embodiments, the latch 114, latch release mechanism 115, latch release button 116, consumer interface panel 140, power button 142, and/or connector 170 may be included in the aerosol generator 200, but example embodiments are not limited thereto. In some example embodiments, the aerosol generator 200 may exclude one or more of the latch 114, latch release mechanism 115, latch release button 116, consumer interface panel 140, power button 142, and/or connector 170.

In some example embodiments, including the example embodiments shown in at least FIG. 6A, the capsule connector 210 may be configured to receive and connect with a capsule 300 that includes a heater 340 and an aerosol-forming substrate 342. The capsule connector 210 may be configured to electrically connect the capsule 300 with the power source 230 (e.g., electrically connect the heater 340 with the power source 230), and the control circuitry 220 may be configured to control a supply of electrical power from the power source 230 to the capsule connector 210 to be further supplied to the connected capsule 300 to cause the aerosol-forming substrate 342 within the capsule 300 to be heated to generate an aerosol.

In some example embodiments, such as best illustrated in FIGS. 6A-6C, the housing 120 encases or houses (e.g., encloses) at least a lower portion 200a of the aerosol generator 200, including for example the processing or control circuitry 220, the power source 230 and a portion of the capsule connector 210 (e.g., portions of the capsule connector 210 excluding the surfaces 210s defining the capsule-receiving cavity 212 and one or more outer surfaces 210w to which the filled hinge 400 is coupled).

The control circuitry 220 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 220 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. In some example embodiments, the control circuitry 220 may further include a haptic motor that may be disposed on a side of the power source 230.

The power source 230 may include one or more batteries (e.g., rechargeable dual battery arrangement, lithium-ion battery, and/or fuel cells). It should be understood that the shape of the battery (or batteries) for the power supply may vary. For example, the battery may be cylindrical, prismatic, disc-shaped, a pouch battery, or any other variation of battery shape known in the art. Additionally, it should be understood that the battery may be any of a variety of types. For example, in some example embodiments, the battery may be a rechargeable battery (e.g., lithium-ion). In some example embodiments, the battery may be a non-rechargeable battery (e.g., alkaline). In some example embodiments, the battery may include silver oxide, carbon zinc, cadmium, nickel, or any another material known in the art. Furthermore, the battery may include a primary cell and/or a secondary cell. It will be understood by those of ordinary skill in the art that various changes in form and details of the battery may be made without departing from the spirit and the scope of the inventive concepts.

In some example embodiments, the supply of current from the power source 230 may be executed (e.g., based on operation of the control circuitry 220) in response to a manual operation (e.g., button-activation) or an automatic operation (e.g., puff-activation).

In some example embodiments, such as best illustrated in FIGS. 1A-1B, 2A-2B, and 4A-4B, the housing 120 includes a consumer interface panel 140 disposed on the second side 104 of the aerosol-generating device 100. For example, the consumer interface panel 140 may be an oval-shaped panel that runs along the second side 104 of the aerosol-generating device 100. The consumer interface panel 140 may include the latch release button 116, such as discussed above, as well as at least a power button 142. As illustrated, the latch release button 116 may be disposed towards a top of the aerosol-generating device 100, and the power button 142 may be disposed towards bottom of the aerosol-generating device 100. Like the latch release button 116, the power button 142 may also be an adult consumer interaction button. The power button 142 may have a substantially circular shape with a center depression or dimple configured to direct the pressure applied by the adult consumer, although example embodiments are not limited thereto. The power button 142 may turn on and off the aerosol-generating device 100. Though only the two buttons are illustrated, it should be understood more or less buttons may be provided depending on the available features and desired adult consumer interface.

In some example embodiments, the housing 120 defines a charging connector 170 (also referred to herein interchangeably as a charging port). For example, as best illustrated in FIGS. 2A, 2B, and 6A the charging connector 170 may be defined/disposed in a bottom or second end of the housing 120 distal from the capsule-receiving cavity 212. As shown, the charging connector 170 may be at and/or may define a lowermost end of the aerosol-generating device 100 in a vertical direction extending parallel to a central longitudinal axis 202 that may be the central longitudinal axis of the aerosol-generating device 100 and/or of the aerosol generator 200. The charging connector 170 may be configured to receive an electric current (e.g., via a USB/mini-USB cable) from an external power source so as to charge the power source 230 internal to the aerosol-generating device 100. For example, the charging connector 170 may be configured to send data to and/or receive data (e.g., via a USB/mini-USB cable) from another aerosol-generating device (e.g., heated tobacco aerosol-generating device) and/or other electronic device (e.g., phone, tablet, computer, and the like). In some example embodiments, the aerosol-generating device 100 may instead or additionally be configured for wireless communication (e.g., via Bluetooth) with such other aerosol-generating devices and/or electronic devices.

In some example embodiments, such as best illustrated in FIGS. 2A, 2B, and 6A, a protective grille 172 is disposed around the charging connector 170. The protective grille 172 may be configured to help reduce, minimize, or prevent debris ingress and/or the inadvertent blockage of the incoming airflow. For example, the protective grille 172 may define a plurality of pores 173 along its length or course. As illustrated, the protective grille 172 may have an annular form that surrounds the charging connector 170. In this regard, the pores 173 may also be arranged (e.g., in a serial arrangement) around the charging connector 170. Each of the pores 173 may have an oval or circular shape, although not limited thereto. In some example embodiments, the protective grille 172 may include an approved food contact material. For example, the protective grille 172 may include plastic, metal (e.g., stainless steel, aluminum), or any combination thereof. In some example embodiments, a surface of the protective grille 172 may be coated, for example with a thin layer of plastic, and/or anodized.

The pores 173 in the protective grille 172 may function as inlets for air drawn into the aerosol-generating device 100. During the operation of the aerosol-generating device 100, ambient air entering through the pores 173 in the protective grille 172 around the charging connector 170 will converge to form a combined flow that then travels to the capsule-receiving cavity 212 and thus to any capsule 300 located in the capsule-receiving cavity 212. For example, the pores 173 may be in fluidic communication with the capsule-receiving cavity 212. In some example embodiments, air may be drawn from the pores 173 and through the capsule-receiving cavity 212. For example, air may be drawn through a capsule 300 received by the capsule-receiving cavity 232 and out of the mouthpiece 190.

In some example embodiments, the capsule-receiving cavity 212 may be in fluid communication with the one or more air inlets or pores 173 via one or more internal conduits, channels or the like (e.g., air passage 182, manifold 184, and air inlet connection 216) through an interior of the housing 120 and/or of the aerosol generator 200, such that the aerosol-generating device 100 may be configured to direct the incoming airflow (that is drawn in through the pores 173) to the capsule-receiving cavity 212 through such one or more internal conduits, channels or the like. In some example embodiments, one or more flow sensors 185 may be disposed within the interior of the aerosol generator 200. In some example embodiments, the one or more flow sensors 185 includes a microelectromechanical system (MEMS) flow or pressure sensor or another type of sensor configured to measure air flow, such as a hot-wire anemometer. In some example embodiments, the one or more flow sensors 185 may include pressure sensors, such as a capacitive pressure sensor, that are configured to measure a negative pressure during a draw event. In some example embodiments, the aerosol generator 200 may omit the one or more flow sensors 185.

In some example embodiments, one or more portions of the aerosol-generating device 100 include one or more surfaces defining one or more air passages through an interior of the aerosol-generating device 100 from the pores 173 to the capsule-receiving cavity 212 to thereby establish fluid communication between the pores 173 and a capsule 300 connected to the aerosol generator 200 in the capsule-receiving cavity 212, such that the aerosol-generating device 100 may be configured to cause air to be drawn from the pores 173 to the capsule 300 held in the capsule-receiving cavity 212 via one or more air passages (e.g., air passage 182, manifold 184, and air inlet connection 216), for example, based on a vacuum or partial vacuum being established at a “downstream” end of the capsule 300 (e.g., based on interaction between an adult consumer and the mouthpiece 190).

For example, as shown in at least FIG. 6A, the outer housing 120a may include one or more housing structures 120c and 120d having one or more inner surfaces 120s that at least partially define an air passage 182 that extends along the length of the outer housing 120a of housing 120 and within the interior defined by the outer housing 120a. For example, at a top or first end of the outer housing 120a, the air passage 182 may be in fluid communication with (e.g., connected or coupled to) a manifold 184 (also referred to herein interchangeably as an air channel) that in turn is in communication with (e.g., connected or coupled to) the capsule-receiving cavity 212 via air inlet connection 216 (which may be at least partially defined by one or more surfaces of the capsule connector 210). Because the air passage 182 may be defined by one or more inner surfaces 120s of one or more housing structures (e.g., 120c and 120d) of the housing 120, the aerosol-generating device 100 may be configured to omit internal tubing. For example, because the air passage 182 is integrated into the housing 120, the aerosol-generating device 100 may require less tubing and additional structures, easing manufacture processes and reducing costs.

The capsule 300 (for example, as illustrated in FIG. 6A) may have various forms and configurations. In some example embodiments, the capsule 300 may have a housing configured to contain an aerosol-forming substrate 342 and a heater 340 configured to heat the aerosol-forming substrate 342, where the downstream end 310 of the housing may define one or more first openings 312 (e.g., one or more outlet openings) and the upstream end 320 of the housing may define one or more second openings 322 (e.g., one or more inlet openings). The body portion of the housing may be in the form of a cover (e.g., shell, box sleeve). The heater 340 may include external segments configured to establish an electrical connection with a power source (e.g., electrical connection with the power source 230 via the electrical contacts 152a and 152b). The heater 340 may include an intermediate section between two end sections, where the intermediate section of the heater 340 may have a planar and winding form resembling a compressed oscillation or zigzag with a plurality of parallel segments (e.g., eight to sixteen parallel segments). However, it should be understood that other forms for the intermediate section of the heater 340 are also possible (e.g., spiral form, flower-like form). The terminus of each of the two end sections may be oriented orthogonally to the plane of the intermediate section. Each of the two end sections may also include segments having a sideways J-shape. As a result, the two end sections may be embedded relatively securely within the upstream end 320 of the capsule 300 while providing a pair of electrical contact surfaces.

The above discussion should be understood to be a non-limiting introduction to the capsule 300.

In some example embodiments, the capsule connector 210 may be mounted or otherwise secured to a printed circuit board (PCB) (e.g., the control circuitry 220) within the housing 120. In some example embodiments, the capsule connector 210 at least partially defines the capsule-receiving cavity 212. In some example embodiments, such as best illustrated in FIG. 6A, the body of the capsule connector 210 includes an air inlet connection 216 which may be in fluid communication with pores 173 via one or more channels, conduits, or the like (e.g., at least air passage 182 and manifold 184) through the interior of the aerosol-generating device 100.

In some example embodiments, the capsule connector 210 includes one or more electrical contacts 152a, 152b (also referred to herein interchangeably as electrical connectors). For example, as illustrated, the capsule connector 210 may include a first electrical contact 152a and a second electrical contact 152b. As illustrated, the first electrical contact 152a may be in the form of three contact members. Similarly, the second electrical contact 152b may also be in the form of three contact members. The electrical contacts 152a, 152b are configured to apply current or other electrical signals to the capsule 300 received by the capsule-receiving cavity 212. In some example embodiments, the electrical contacts 152a, 152b may be in electrical communication with the power source 230 and/or control circuitry 220 disposed within the housing 120. The electrical contacts 152a, 152b can be formed of copper or of a copper alloy (e.g., copper-titanium), and in some example embodiments, the electrical contacts 152a, 152b may have a gold plating. Although the electrical contacts 152a, 152b are shown as including three contact members each, it should be understood that example embodiments are not limited thereto. In some example embodiments, the electrical contacts 152a, 152b may include more (e.g., four contact members each) or less (e.g., one or two contact members each) than the three contact members each shown in the drawings.

In some example embodiments, the method of control/heating and associated circuitry and electrical contacts (e.g., capsule connector 210 including the one or more electrical connectors or contacts 152a, 152b) may be as described in U.S. application Ser. No. 17/151,375, filed Jan. 18, 2021 and published as U.S. Pub. No. 2022/0225685-A1 on Jul. 21, 2022; and U.S. application Ser. No. 17/151,409, filed Jan. 18, 2021 and published as U.S. Pub. No. 2022/0229453-A1 on Jul. 21, 2022, the entire contents of each of which are incorporated herein by reference.

The capsule 300 is loaded into the aerosol generator 200 of the aerosol-generating device 100 by initially inserting the capsule 300 into the capsule-receiving cavity 212 defined by the capsule connector 210. In some example embodiments, the capsule 300 makes contact (e.g., full contact) with the electrical contacts 152a, 152b within capsule-receiving cavity 212 only upon the application of force (e.g., downward/inward force) to the capsule 300. In some example embodiments, a force is applied to the capsule 300 by the closure and/or latching of the lid 110. In some example embodiments, a force is applied to the capsule 300 by an adult consumer. In some 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 110. For example, in each instance, a force is applied until a resistance is felt and/or a clicking sound is heard, which signals a complete engagement of the capsule 300 in the capsule-receiving cavity 212.

The underside of the lid 110 may include an impingement/engagement member or surface 113 configured to engage the capsule 300 when the lid 110 is pivoted to transition to a closed position. The impingement/engagement member or surface 113 of the lid 110 may include a recess (e.g., that corresponds to the size and shape of the capsule 300) and/or a resilient material to enhance an interface with the capsule 300 so as to provide the desired seal. When the capsule 300 is inserted into the capsule-receiving cavity 212, the weight of the capsule 300 itself may not be sufficient to compress the electrical contacts 152a, 152b (e.g., at least not to any significant degree). As a result, the capsule 300 may simply rest on the exposed pins of the electrical contacts 152a, 152b without any compression (or without any significant compression) of the electrical contacts 152a, 152b. Additionally, the weight of the lid 110 itself, when pivoted to transition to a closed position, may not compress the electrical contacts 152a, 152b to any significant degree and, instead, may simply rest on the capsule 300 in an intermediate, partially open/closed position. In such an instance, a deliberate action (e.g., downward force) to close the lid 110 will cause the impingement/engagement member or surface 113 of the lid 110 to press down onto the capsule 300 to provide the desired seal and also cause the capsule 300 to compress and, thus, fully engage electrical contacts 152a, 152b. Additionally, a full closure of the lid 110 will result in an engagement with the latch 114, which will maintain the closed position and the desired mechanical/electrical engagements involving the capsule 300 until released (e.g., via the latch release button 116). The force requirement for closing the lid 110 may help to ensure and/or improve air/aerosol sealing and to provide a more robust electrical connection, as well as improved device and thermal efficiency and battery life by reducing or eliminating early power draws and/or parasitic heating of the capsule 300.

In some example embodiments, such as best illustrated in FIG. 6A, the capsule-receiving cavity 212 includes a first end 218a (also referred to as a top end) and a second end 218b (also referred to as a bottom end) distal from the first end 218a. For example, the electrical contacts 152a, 152b may extend through the second end 218b of the capsule-receiving cavity 212. When the lid 110 is in a closed position, the first end 218a may be in communication with the lid 110 and/or mouthpiece 190. In some example embodiments, the first end 218a has a first width and the second end 218b has a second width. The first width may be greater than the second width. For example, in some example embodiments, a first cross-sectional dimension of the capsule-receiving cavity 212 at the first end 218a may be about 7.2 mm×13.6 mm, and the second cross-sectional dimension of the capsule-receiving cavity 212 at the second end 218b may be about 6.2 mm×12.6 mm, when the capsule 300 has a cross-sectional dimension of about 6.0 mm×12.4 mm. In this manner, in some example embodiments, the capsule-receiving cavity 212 may be tapered between the first end 218a and the second end 218b (e.g., about 5% to 15% decrease in a width/lateral dimension), such that the capsule-receiving cavity 212 is configured to steer the capsule 300 into position. The tapered configuration may also improve moldability, as well as providing for a thin air layer around the capsule 300 (e.g., for thermal insulation) during use of the aerosol-generating device 100.

In some example embodiments, as best illustrated in FIG. 6A, the second end 218b of the capsule-receiving cavity 212 includes a capsule seal 168. When the capsule 300 is seated within the capsule-receiving cavity 212, the capsule seal 168 is configured to mate with the inlet of the capsule 300 (e.g., one or more first openings 312). The capsule seal 168 may be configured to help ensure and/or improve air/aerosol sealing between the capsule 300 and the capsule connector 210 such that all (or substantially all) of the air received via the air inlet connection 216 is directed into the capsule 300. In some example embodiments, the capsule seal 168 may be a silicone seal.

In some example embodiments, the mouthpiece 190 includes a first end 192 and a second end 194 distal from the first end 192. In some example embodiments, the mouthpiece 190 may be tapered between the first end 192 and the second end 194. For example, the diameter or average length/width dimensions of the first end 192 may be smaller than the diameter or average length/width dimensions of the second end 194. Towards the first end 192, the taper may have a slight inward curvature 191 that is configured to receive the lips of an adult consumer and improve the comfort and experience. The first end 192 may have an oblong or elliptical shape and may include one or more outlets 196. The second end 194 may be coupleable to the lid 110. In some example embodiments, the mouthpiece 190 may be inserted through an opening 111 of the lid 110 that is configured to receive and secure the second end 194 of the mouthpiece 190 (e.g., via a snap-fit arrangement).

The aerosol-generating device in accordance with at least some example embodiments (such as the aerosol-generating device 100, which may be a heated tobacco aerosol-generating device although example embodiments are not limited thereto) are configured to receive a capsule (e.g., capsule 300) that includes an aerosol-forming substrate (e.g., aerosol-forming substrate 342). 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, filed Jan. 18, 2021 and published as U.S. Pub. No. 2022/0225667-A1 on Jul. 21, 2022; and U.S. application Ser. No. 17/151,336, filed Jan. 18, 2021 and published as U.S. Pub. No. 2022/0225669-A1 on Jul. 21, 2022, the entire contents of each of which are incorporated herein by reference.

As discussed herein, an aerosol-forming substrate is a material or combination of materials that may yield an aerosol. An aerosol relates to the matter generated or output by the devices disclosed, claimed, and equivalents thereof. The material may include a compound (e.g., nicotine, cannabinoid), where an aerosol including the compound is produced when the material is heated. In some example embodiments, for example in example embodiments where the aerosol-generating device 100 is a heated tobacco aerosol-generating device, the heating may include a heating of the aerosol-forming substrate to a temperature that is below the combustion temperature of the aerosol-forming substrate 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). Such heating may be referred to herein as non-combustion heating. Thus, in some example embodiments, pyrolysis does not occur during the heating of the aerosol-forming substrate 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. In some example embodiments, the heating may include a heating of the aerosol-forming substrate to a temperature that is at or above the combustion temperature of the aerosol-forming substrate so as to produce an aerosol based on at least a partial (e.g., substantial, non-incidental) pyrolysis and/or combustion of the aerosol-forming substrate. Such heating may be referred to herein as combustion heating or pyrolysis heating. Thus, in some example embodiments, substantial and/or non-incidental pyrolysis and/or combustion of the aerosol-forming substrate may occur during the heating (e.g., combustion heating or pyrolysis heating) of the aerosol-forming substrate and resulting production of aerosol. Substantial and/or non-incidental pyrolysis and/or combustion of the aerosol-forming substrate may include pyrolysis and/or combustion of a portion of the aerosol-forming substrate that is equal to or greater than 10% by mass or volume of the aerosol forming substrate.

The aerosol-forming substrate may be a fibrous material. For instance, the fibrous material may be a botanical material (e.g., plant 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. Example embodiments of the aerosol-forming substrate are not limited to fibrous material, botanical material, plant material, or the like. In some example embodiments, the aerosol-forming substrate may include a liquid material, a liquid formulation, a gel formulation, a gel material, a solid material, or the like.

In some example embodiments, the tobacco material may include material from any member of the genus Nicotiana. In addition, the tobacco material may include a blend of two or more different tobacco varieties. Examples of suitable types of tobacco materials that may be used include, but are not limited to, flue-cured tobacco, Burley tobacco, Dark tobacco, Maryland tobacco, Oriental tobacco, rare tobacco, specialty tobacco, blends thereof, and the like. The tobacco material may be provided in any suitable form, including, but not limited to, tobacco lamina, processed tobacco materials, such as volume expanded or puffed tobacco, processed tobacco stems, such as cut-rolled or cut-puffed stems, reconstituted tobacco materials, blends thereof, and the like. In some example embodiments, the tobacco material is in the form of a substantially dry tobacco mass. Furthermore, in some instances, the tobacco material may be mixed and/or combined with at least one of propylene glycol, glycerin, sub-combinations thereof, or combinations thereof.

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

Examples of cannabinoids include tetrahydrocannabinolic acid (THCA), tetrahydrocannabinol (THC), cannabidiolic acid (CBDA), cannabidiol (CBD), cannabinol (CBN), cannabicyclol (CBL), cannabichromene (CBC), and cannabigerol (CBG). Tetrahydrocannabinolic acid (THCA) is a precursor of tetrahydrocannabinol (THC), while cannabidiolic acid (CBDA) is precursor of cannabidiol (CBD). Tetrahydrocannabinolic acid (THCA) and cannabidiolic acid (CBDA) may be converted to tetrahydrocannabinol (THC) and cannabidiol (CBD), respectively, via heating. In some example embodiments, 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 capsule, the decarboxylation and resulting conversion will cause a decrease in cannabidiolic acid (CBDA) and an increase in cannabidiol (CBD). At least 50% (e.g., at least 87%) of the cannabidiolic acid (CBDA) may be converted to cannabidiol (CBD) during the heating of the capsule.

Furthermore, the compound may be or may additionally include a non-naturally occurring additive that is subsequently introduced into the fibrous material. In one instance, the fibrous material may include at least one of cotton, polyethylene, polyester, rayon, combinations thereof, or the like (e.g., in a form of a gauze). In another instance, the fibrous material may be a cellulose material (e.g., non-tobacco and/or non-cannabis material). In either instance, the compound introduced may include nicotine, cannabinoids, and/or flavorants. The flavorants may be from natural sources, such as plant extracts (e.g., tobacco extract, cannabis extract), and/or artificial sources. In yet another instance, when the fibrous material includes tobacco and/or cannabis, the compound may be or may additionally include one or more flavorants (e.g., menthol, mint, vanilla). Thus, the compound within the aerosol-forming substrate may include naturally occurring constituents and/or non-naturally occurring additives. In this regard, it should be understood that existing levels of the naturally occurring constituents of the aerosol-forming substrate may be increased through supplementation. For example, the existing levels of nicotine in a quantity of tobacco may be increased through supplementation with an extract containing nicotine. Similarly, the existing levels of one or more cannabinoids in a quantity of cannabis may be increased through supplementation with an extract containing such cannabinoids.

In some example embodiments, the aerosol-forming substrate 342 has a resistance-to-draw (RTD), e.g., as contained within a capsule 300, 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 some example embodiments, 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 some example embodiments, 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 some example embodiments, the aerosol-forming substrate 342 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). In some example embodiments, the bulk density is less than or equal to about 0.8 g/cm3 (e.g., 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 some example embodiments, the bulk density ranges from about 0.3 g/cm³ to about 0.5 g/cm³ (e.g., 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 some example embodiments, the aerosol-forming substrate 342 has a particulate form with a mean particle size (e.g., diameter) of greater than or equal to about 270 μm (e.g., 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, or greater than or equal to about 410 μm). In some example embodiments, the mean particle size is less than or equal to about 415 μm (e.g., less than or equal to about 410 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, or less than or equal to about 280 μm).

In some example embodiments, the aerosol-forming substrate 342 has a 10th percentile diameter ranging from about 260 μm to about 225 μm. In some example embodiments, the aerosol-forming substrate has a 50th percentile (or median) diameter ranging from about 260 μm to about 385 μm. In some example embodiments, the aerosol-forming substrate 342 has a 90th percentile diameter ranging from about 390 μm to about 635 μm.

The aerosol-generating device 100 in accordance with at least some example embodiments (such as a heated tobacco aerosol-generating device) is configured to heat a capsule (e.g., capsule 300) to generate an aerosol. In some example embodiments, a method of generating an aerosol may include initially loading a capsule 300 into the aerosol-generating device 100. To load the capsule 300, the lid 110 is pivoted to the open position, and the capsule 300 is inserted into the capsule-receiving cavity 212 defined by the capsule connector 210. Next, pivoting the lid 110 to the closed position such that the lid 110 engages the latch 114 and will maintain the closed position while pressing the capsule 300 further into the capsule-receiving cavity 212 to fully seat the capsule 300.

When the capsule 300 is fully seated within the capsule-receiving cavity 212, the end sections of the capsule 300 may be pressed against the electrical contacts 152a, 152b. As a result, a relatively secure electrical connection and desirable seal may be established with the capsule 300.

The aerosol-generating device 100 may be activated using the consumer interface panel 140 (e.g., by pressing the power button 142) and/or upon the detection of a draw event (e.g., via the flow sensor 185). Upon activation, the control circuitry 220 is configured to instruct the power source 230 to supply an electrical current to the capsule 300 via the electrical contacts 152a, 152b in the capsule-receiving cavity 212. Specifically, the capsule 300 includes a heater 340 that is configured to undergo resistive heating in response to the electrical current from the power source 230 that is introduced via its end sections. As a result of the resistive heating, the temperature of the aerosol-forming substrate within the capsule 300 will increase such that volatiles are released so as to generate an aerosol.

In some example embodiments, for example in example embodiments where the aerosol-generating device 100 is a heated tobacco aerosol-generating device, the aerosol generator 200 may be configured to heat the aerosol-forming substrate 342 within the capsule 300 to a temperature that may be below a combustion temperature of the aerosol-forming substrate 342 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). Such heating may be referred to herein as non-combustion heating. Thus, in some example embodiments, 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 (e.g., combustion and/or pyrolysis of less than 10% by mass or volume of the aerosol-forming substrate 342, combustion and/or pyrolysis of less than 5% by mass or volume of the aerosol-forming substrate 342, combustion and/or pyrolysis of less than 1% by mass or volume of the aerosol-forming substrate 342, or the like). The method of heating/control may be as described in U.S. application Ser. No. 17/151,375, filed Jan. 18, 2021 and published as U.S. Pub. No. 2022/0225685-A1 on Jul. 21, 2022; and U.S. application Ser. No. 17/151,409, filed Jan. 18, 2021 and published as U.S. Pub. No. 2022/0229453-A1 on Jul. 21, 2022, the entire contents of each of which are incorporated herein by reference. In some example embodiments, the aerosol generator 200 may be configured to heat the aerosol-forming substrate 342 within the capsule 300 to a temperature that may be at or above the combustion temperature of the aerosol-forming substrate 342 so as to produce an aerosol based on at least a partial (e.g., substantial, non-incidental) pyrolysis of the aerosol-forming substrate 342 and/or at least partial (e.g., substantial, non-incidental) combustion of the aerosol-forming substrate 342. Such heating may be referred to herein as combustion heating or pyrolysis heating. Substantial and/or non-incidental combustion of the aerosol-forming substrate 342 may include combustion of a portion of the aerosol-forming substrate 342 that is equal to or greater than 10% by mass or volume of the aerosol-forming substrate 342. Substantial and/or non-incidental pyrolysis of the aerosol-forming substrate 342 may include pyrolysis of a portion of the aerosol-forming substrate 342 that is equal to or greater than 10% by mass or volume of the aerosol-forming substrate 342.

Upon a draw or application of negative pressure to the aerosol-generating device 100 (e.g., via one or more outlets 196 of the mouthpiece 190), ambient air is drawn into the aerosol-generating device 100 through the pores 173 in the protective grille 172. Once inside, the air streams from the pores 173 converge and may pass through one or more internal channels, conduits, or the like (e.g., air passage 182 and manifold 184) through the aerosol-generating device 100 to the air inlet connection 216 of the capsule connector 210. The converged airflow may be optionally detected/monitored with a flow sensor 185 within the one or more internal channels, conduits, or the like through the aerosol-generating device 100 to the air inlet connection 216 of the capsule connector 210. The airflow then travels through the capsule seal 168 and enters the one or more second openings 322 in the capsule 300. Inside the capsule 300, the air may flow (e.g., longitudinally) through the aerosol-forming substrate 342 and along the plane of the heater 340 so as to entrain the volatiles released by the aerosol-forming substrate 342, which results in an aerosol. Finally, the resulting aerosol passes through the first opening(s) 312 in the capsule 300 before exiting the aerosol-generating device 100 (e.g., via one or more outlets 196 in the mouthpiece 190).

In some example embodiments, the method of use regarding the aerosol-generating device 100 may include securing the replaceable mouthpiece (e.g., mouthpiece 190) to the lid (e.g., 110). For example, the method may include inserting the replaceable mouthpiece into the opening (e.g., opening 111) of the lid when the lid is in an opened position until resistance is felt and/or a click is heard. In some example embodiments, the method of use may include replacing the replaceable mouthpiece (e.g., mouthpiece 190). Replacing the replaceable mouthpiece may including opening the lid (e.g., 110); removing a first replaceable mouthpiece from the opening (e.g., opening 111); and inserting a second replaceable mouthpiece into the opening until resistance is felt and/or a click is heard.

Although a capsule 300 has been illustrated as one example in connection with the aerosol-generating device 100, it should be understood other suitable examples are also available. It will also be understood that, in some example embodiments, the capsule 300 may be omitted as a separate component, such that the heater 340, the aerosol-forming substrate 342, or any combination thereof may be integrated as one or more components of the aerosol generator 200 and may not be reversibly and/or removably separable from the aerosol generator 200. For example, in some example embodiments the heater 340 may be irremovably fixed (e.g., welded, soldered, bolted, adhered, etc.) to a structure of the aerosol generator 200 (e.g., the connector 210, the power source 230, one or more wires, conductive pathways, circuits or the like, etc.), and at least two ends of the heater 340 may be fixed to and/or integral with the electrical contacts 152a, 152b as part of the connector 210 (or the electrical contacts 152a, 152b may be at least partially omitted such that the heater 340 may be electrically coupled to the power source 230 in a common electrical circuit via one or more wires, conductive pathways, circuits or the like without any interposing separate electrical contacts 152a, 152b). In such an example the cavity 212 defined by one or more inner surfaces 210s of the connector 210 may be configured to receive an aerosol-forming substrate 342 thereinto to be in thermal contact with the heater 340 and thus to be heated by the heater 340 (based on power received at the heater 340 from the power source 230) to form an aerosol.

In some example embodiments, as shown in at least FIGS. 1A, 2A, 3A, 4A, 5A, 6A-6C, 7A, 8A-8B, 9A, 10A, 11A, and 12A, the aerosol-generating device 100 may include a lid 110 that may be in a closed position with respect to the housing 120. The lid 110 may be fixedly coupled to the housing 120 at a first point 122 by a filled hinge 400 that enables the lid 110 to move (e.g., swing, rotate, and/or pivot 404 around the axis of rotation 402) between the closed position (such as illustrated in at least FIGS. 1B, 2B, 3B, 4B, 5B, 7B, 8C, 9B-9E, 10B, 11B, 12B, and 13A) and an open position (such as illustrated and described with respect to at least FIGS. 1B, 2B, 3B, 4B, 5B, 7B, 8C, 9B-9E, 10B, 11B, 12B, and 13A). The lid 110 may be releasably couplable to the housing 120 at a second point 124 by a latch 114 that allows the lid 110 to be fixed or secured in the closed position and easily releasable so as to allow the lid 110 to move from the secured, closed position to the open position.

In some example embodiments, the consumer interface panel 140 may include one or more light emitting diodes (LEDs). The latch release button 116 and the power button 142 may include raised or lowered portions that indicate function of the button. The raised or lowered portion may be identified visually or by feel. The LEDs may illuminate the entire consumer interface panel 140 or only a portion thereof. For example, the raised or lowered portions of the latch release button 116 and the power button 142 may be transparent such that light only shows through the raised or lowered portions thereof.

In some example embodiments, as shown in at least FIGS. 1A, 2A, 3A, 4A, and 5A, the aerosol-generating device 100 includes the lid 110 and the housing 120 having rounded edges and smooth surfaces so as to be comfortable in an adult consumer's hand. The lid 110 is releasably coupled to the housing 120 at the first side 102 of the housing 120.

In some example embodiments, as shown in at least FIGS. 6A, 7A-7B, and 8A-8C, an aerosol-generating device 100 may include a lid 110 and may further include a filled hinge 400 fixedly coupling the lid 110 to the aerosol generator 200 independently of the housing 120, where the filled hinge 400 configures the lid 110 to pivot 404 around an axis of rotation 402 of the filled hinge 400 to cause the lid 110 to move between the closed position (e.g., shown in FIGS. 6A, 7A, and 8A-8B) and an open position (e.g., shown in FIGS. 7B and 8C).

In some example embodiments, as shown in at least FIG. 1B, the inner housing 120b defines an opening 1200 that extends through the inner housing 120b to expose at least the capsule-receiving cavity 232 to an exterior of the inner housing 120b and thus to expose at least the capsule-receiving cavity 212 to an exterior environment that is external to the aerosol-generating device 100 based on the lid 110 being in the open position (e.g., as shown in at least FIG. 1B). As shown in at least FIG. 1B, the inner housing 120b may have a mesa shape. Further, as shown in at least FIG. 1B, in some example embodiments the aerosol-generating device 100 may be configured to expose the inner housing 120b and capsule-receiving cavity 212 (e.g., through opening 1200) to an external environment that is external to the aerosol-generating device 100 based on the lid 110 being in the open position with respect to a remainder portion 130 of the aerosol-generating device 100, where the remainder portion 130 includes at least the housing 120 and the aerosol generator 200. In some example embodiments, and as shown in at least FIG. 1B, the aerosol-generating device may be configured to expose the latch 114 (also referred to herein as a latching arm) based on the lid 110 is in the open position.

In some example embodiments, the inner housing 120b may be configured to surround at least a portion of the capsule connector 210 and the capsule-receiving cavity 212. In some example embodiments, the inner housing 120b includes an opening 1200 that extends through the thickness of the inner housing 120b to expose at least the capsule-receiving cavity 212 of the capsule connector 210 and may further include an opening that exposes at least the outer surface 210w of the capsule connector 210 and thereby exposing an upper portion 200b of the aerosol generator 200. As shown, the inner housing 120b may include a finger-sized and/or shaped indent on one or both sides of the capsule-receiving cavity 212 that allows an adult consumer to more easily grasp a capsule 300 held within the capsule-receiving cavity 212 for removal.

Referring to FIGS. 1A to 15, and as shown for example in at least FIGS. 6A, 6C, 7A-7B, 8A-8C, 9A-9E, 10A-10B, 11A-11B, 12A-12B, 13A-13B, 14A-14E, and 15, the aerosol-generating device 100 may include a filled hinge 400. The filled hinge 400 may be configured to fixedly couple the lid 110 to the aerosol generator 200 independently of the housing 120. Based on the filled hinge 400 fixedly coupling the lid 110 to the aerosol generator 200 independently of the housing 120, the lid 110 may be isolated from coupling to the housing 120 (e.g., any of the inner housing 120b or the outer housing 120a) independently of the filled hinge 400.

In some example embodiments, and as shown for example in at least FIGS. 6A, 6C, 7A-7B, 8A-8C, 9A-9E, 10A-10B, 11A-11B, 12A-12B, 13A-13B, 14A-14E, and 15, the filled hinge 400 may be coupled between the lid 110 and the capsule connector 210 (e.g., a portion of the capsule connector 210 including outer surface 210w and at least partially defining the capsule-receiving cavity 212) and may not directly connect with either the outer housing 120a or the inner housing 120b. As a result, and as shown in at least FIGS. 7A-7B, the housing 120 and the lid 110 may cooperate to enclose the filled hinge 400 within an internal enclosure defined by at least the lid 110 (e.g., the outer lid 110a and the inner lid 110b) and the housing 120 (e.g., the outer housing 120a). Such enclosure of the filled hinge 400 when the lid 110 is in the closed position may provide improved shielding of the filled hinge 400 or any portion thereof.

As described herein, shielding of the filled hinge 400 or any portion thereof (e.g., the central cavity 420, the spring coil 442 within the central cavity 420, the hinge dowel pin 430, etc.) may include shielding the filled hinge 400 or any portion thereof from external impacts, thereby reducing likelihood of damage to the filled hinge 400 and thereby improving functionality of the aerosol-generating device 100 (specifically, the functionality of enabling the lid 110 to move between open and closed positions). However, as described herein, example embodiments are not limited thereto. For example, as described herein, shielding of the filled hinge 400 or any portion thereof may include shielding the filled hinge 400 or any portion thereof from external impacts, shielding the filled hinge 400 or any portion thereof from ingress of foreign matter into any portion of the filled hinge 400 that may otherwise jam the filled hinge 400 and reduce or prevent the ability of the filled hinge 400 to enable the lid 110 to move between open and closed positions in relation to the housing 120, shielding the filled hinge 400 or any portion thereof from external observation by an adult consumer, mitigating or preventing manual access to and interaction with any portion of the filled hinge 400, any combination thereof, or the like.

In some example embodiments, the filled hinge 400 may be coupled to and/or integrated with one or more structures of the aerosol generator 200. For example, as shown in at least FIGS. 6A, 6C, 7A-7B, 8A-8C, 9A-9E, 10A-10B, 11A-11B, 12A-12B, 13A-13B, 14A-14E, and 15, the filled hinge 400 may be coupled to and/or may be integrated with an outer surface 210w of the capsule connector 210 that is exposed from the housing 120. As shown in at least FIGS. 6C, 7A-7B, 8A-8C, and 12A-12B, the filled hinge 400 may be configured to define an axis of rotation 402 between the lid 110 and a remainder portion 130 of the aerosol-generating device 100 (said remainder portion 130 including at least one of the aerosol generator 200 or the housing 120), such that the filled hinge 400 is configured to enable the lid 110 to pivot 404 around the axis of rotation 402 to move between the open and closed positions in relation to the remainder portion 130 of the aerosol-generating device 100. As shown, the axis of rotation 402 may cross a central longitudinal axis 202 which may be a central longitudinal axis of the aerosol generator 200 and/or of the aerosol-generating device 100. The axis of rotation 402 may be perpendicular to the central longitudinal axis 202 as shown, but example embodiments are not limited thereto. In some example embodiments, the axis of rotation 402 may cross the central longitudinal axis 202 at an angle that is equal to, greater than, or less than 90 degrees. As shown, the filled hinge 400 is horizontally offset from the central longitudinal axis 202 in a horizontal direction that is perpendicular to the central longitudinal axis 202 (e.g., axes 202 and 402 may extend through separate, parallel planes). As a result, in some example embodiments the axis of rotation 402, in addition to crossing the central longitudinal axis 202, is horizontally offset from the central longitudinal axis 202.

In some example embodiments, including the example embodiments shown in at least FIGS. 7A-7B and 8A-8C, the filled hinge 400 may be configured to enable the lid 110 to pivot 404 around the axis of rotation 402 and in relation to at least a portion of the remainder portion 130 of the aerosol-generating device 100 between a closed position and an open position. As shown in at least FIG. 7A, the lid 110, when at the closed position, at least partially covers both an upper portion of the aerosol generator 200 (e.g., the capsule-receiving cavity 212 of the capsule connector 210) and the filled hinge 400 in at least a vertical direction extending parallel to the central longitudinal axis 202 (which may be a central longitudinal axis of the aerosol generator 200 and/or of the aerosol-generating device 100). As shown in at least FIG. 7B, the aerosol-generating device 100 may be configured to cause the lid 110, based on being at the open position, to expose at least the upper portion of the aerosol generator 200 (e.g., at least the capsule-receiving cavity 212 of the capsule connector 210, exposed via the opening 1200 in the inner housing 120b) to the external environment (e.g., ambient environment 198) in at least the vertical direction.

In some example embodiments, including the example embodiments shown in at least FIGS. 6C and 8A-8C, the filled hinge 400 may couple with the lid 110 at a first point 122 that is between opposite side ends 119a and 119b of the lid 110 in a horizontal direction extending perpendicular to the central longitudinal axis 202 (and crossing and/or perpendicular to the axis of rotation 402) such that the filled hinge 400 is configured to enable the lid 110 to pivot 404 at least one or both of the side ends 119a and 119b around the axis of rotation 402 to cause a first side end 119a of the lid 110 to pivot 404 underneath the filled hinge 400 (e.g., between the filled hinge 400 and at least a portion of the aerosol generator 200, the housing 120, or the like in the vertical direction), while the opposite side end 119b of the lid 110 pivots above the filled hinge 400 (e.g., such that the axis of rotation 402 is between the first and second side ends 119a and 119b in a vertical direction paraxial to the central longitudinal axis 202) based on the lid 110 pivoting 404 to the open position (e.g., as shown in FIG. 8C). As shown, based on the lid 110 being in the open position, the lid 110 may cover the filled hinge 400 in horizontal directions that are not covered by the aerosol generator 200 (e.g., the capsule connector 210) or the housing (e.g., inner housing 120b), thereby improving shielding of the filled hinge 400 or any portion thereof when the lid 110 is in either the open or closed positions, and thereby improving protection and functionality of the aerosol-generating device 100. As described herein, paraxial may be referred to interchangeably as parallel.

As described herein, shielding of the filled hinge 400 or any portion thereof (e.g., shielding of the central cavity 420, shielding of the spring coil 442 within the central cavity 420, shielding of the hinge dowel pin 430, etc.) may include shielding the filled hinge 400 or any portion thereof from external impacts. Shielding the filled hinge 400 or any portion thereof from external impacts may reduce a likelihood of damage to the filled hinge 400 or any portion thereof and thereby may improve a functionality of the aerosol-generating device 100 (specifically, the functionality of enabling the lid 110 to move between open and closed positions).

As described herein, shielding of the filled hinge 400 or any portion thereof (e.g., shielding of the central cavity 420, shielding of the spring coil 442 within the central cavity 420, shielding of the hinge dowel pin 430, etc.) may include shielding the filled hinge 400 or any portion thereof from ingress of foreign matter into any portion of the filled hinge 400 that may otherwise jam the filled hinge 400 and reduce or prevent the ability of the filled hinge 400 to enable the lid 110 to move between open and closed positions in relation to the housing 120. For example, such shielding may include shielding the filled hinge 400 or any portion thereof from an ingress of foreign matter into the central cavity 420. Shielding the filled hinge 400 or any portion thereof from ingress of foreign matter into any portion of the filled hinge 400 (e.g., into the central cavity 420) may reduce a likelihood of damage to the filled hinge 400 (e.g., damage to the spring coil 442 within the central cavity 420, damage to the hinge dowel pin 430, etc.) and thereby may improve a functionality of the aerosol-generating device 100 (specifically, the functionality of enabling the lid 110 to move between open and closed positions in relation to the housing 120).

As described herein, shielding of the filled hinge 400 or any portion thereof (e.g., shielding of the central cavity 420, shielding of the spring coil 442 within the central cavity 420, shielding of the hinge dowel pin 430, etc.) may include shielding (e.g., obscuring) the filled hinge 400 or any portion thereof from external observation by an adult consumer, mitigating or preventing manual access to and interaction with any portion of the filled hinge 400, including for example the central cavity 420 and or any element within the central cavity 420, the torsion spring 440 or any portion thereof including for example the spring coil 442 within the central cavity 420, the hinge dowel pin 430 or any portion thereof, or the like. Such shielding of the filled hinge 400 from external observation may deter an adult consumer from interacting with (and/or being compelled to interact with) the filled hinge 400 or any portions thereof, including the central cavity 420, the torsion spring 440 or any portion thereof including for example the spring coil 442 within the central cavity 420, the hinge dowel pin 430 or any portion thereof, or the like, for example based on the adult consumer being unable to observe some or all of the central cavity 420, the torsion spring 440 or any portion thereof including for example the spring coil 442 within the central cavity 420, the hinge dowel pin 430 or any portion thereof, or the like even when the lid 110 is in the open position. Such deterrence may thereby reduce the likelihood of thereby reducing likelihood of damage to the filled hinge 400 due to manual interaction with the filled hinge 400 or any portion thereof by an adult consumer. Manual interactions with the filled hinge 400 or any portion thereof may include touching or attempting to manually manipulate any portion of the filled hinge 400, including for example the central cavity 420 or any element within the central cavity 420, the torsion spring 440 or any portion thereof including for example the spring coil 442 within the central cavity 420, the hinge dowel pin 430 or any portion thereof, or the like using an adult consumer's fingers or any separate object or tool held by the adult consumer.

In some example embodiments, including the example embodiments shown in at least FIG. 9A-9C, the filled hinge 400 may include a hinge knuckle 410, also referred to herein as a knuckle structure. The hinge knuckle 410 may include at least two knuckle structures 412, including at least a first knuckle structure 412a and a second knuckle structure 412b. The first and second knuckle structures 412a and 412b may be referred to herein interchangeably as the two knuckle structures 412. In some example embodiments, including the example embodiments shown in FIGS. 9D, 12A, and 12B, the two knuckle structures 412 may be spaced apart from each other (e.g., isolated from direct contact with each other) along the axis of rotation 402 to at least partially define respective opposite axial ends 422a and 422b of a central cavity 420 between the two knuckle structures 412 along the axis of rotation 402.

In some example embodiments, including the example embodiments shown in FIGS. 6A-15, the hinge knuckle 410 may be or may include a single, unitary piece of material that defines the knuckle structures 412, such that the at least two knuckle structures 412 may be defined by separate, respective portions of a single, unitary piece of material. However, it will be understood that example embodiments are not limited thereto. For example, in some example embodiments, the two knuckle structures 412 (e.g., the first and second knuckle structures 412a and 412b) may comprise separate pieces of material that may be coupled together via any known means (e.g., adhesive, bolts, fasteners, etc.) to at least partially define the hinge knuckle 410 as comprising a plurality of coupled pieces of material. In some example embodiments, the hinge knuckle 410 may comprise a plurality of coupled pieces of material, coupled via any known means (e.g., adhesive, bolts, fasteners, etc.), where one of the pieces of material at least partially defines multiple knuckle structures or each knuckle structure of the two knuckle structures 412.

In some example embodiments, including the example embodiments shown in at least FIGS. 6A, 6C, 7A-7B, 8A-8C, 9A-9D, 11A-11B, 12A-12B, 13A-13B, 14A-14E, and 15, the filled hinge 400 may be coupled to the aerosol generator 200 based on the hinge knuckle 410 being coupled to a surface of the aerosol generator 200 that is exposed from the housing 120, for example based on the hinge knuckle 410 being coupled to an outer surface 210w of the capsule connector 210 that is exposed from the housing 120 as shown. In some example embodiments, including the example embodiments shown in at least FIGS. 6A, 6C, 7A-7B, 8A-8C, 9A-9D, 11A-11B, 12A-12B, 13A-13B, 14A-14E, and 15, the aerosol-generating device 100 may include a support structure 240 which may engage the hinge knuckle 410 to provide structural support to the hinge knuckle 410 to reduce, minimize, or prevent bending of the hinge knuckle 410 around the interface between the hinge knuckle 410 and the surface at which the hinge knuckle 410 is coupled to the aerosol generator 200 (e.g., the outer surface 210w). In some example embodiments, and as shown, the hinge knuckle 410 may be integrated into the structure of the aerosol generator 200 that is exposed through the housing 120 such that the hinge knuckle 410 and the structure (e.g., at least a portion of the capsule connector 210) are defined by separate portions of a single unitary piece of material. For example, as shown, the hinge knuckle 410 may be integrated with at least a portion of the capsule connector 210 (e.g., a structure of the capsule connector 210 defining at least the outer surface 210w), such that the hinge knuckle 410 and at least a portion the capsule connector 210 are at least partially defined by separate, respective portions of a single unitary piece of material. However, it will be understood that example embodiments are not limited thereto, and in some example embodiments the hinge knuckle 410 and the portion of the aerosol generator 200 to which the hinge knuckle is coupled may be separate piece of material that are coupled together via any known means (e.g., adhesive, fastening via one or more fasteners, etc.). As shown, the support structure 240 may extend between a portion of the aerosol generator 200 (e.g., a surface of the capsule connector 210 to an opposing surface of the hinge knuckle 410 to provide structural support to the hinge knuckle 410 against bending in relation to the capsule connector 210. In some example embodiments, the support structure 240 may be a shielding structure that is configured to provide protection (e.g., shielding) to the capsule connector 210 from being directly engaged (e.g., contacted) by the lid 110 when the lid 110 is in an open position. The support structure 240 may comprise any material, including for example steel, any plastic material (e.g., a high temperature plastic, including for example polyetheretherketone (PEEK), liquid crystal polymer (LCP), etc.), or the like.

While the filled hinge 400 is shown to couple the lid 110 to the aerosol generator 200 independently of a housing 120 that includes the inner and outer housings 120b and 120a, example embodiments are not limited thereto. For example, in some example embodiments, the filled hinge 400 (e.g., the hinge knuckle 410) may be coupled with the inner housing 120b independently of the outer housing 120a (e.g., directly connected to the inner housing 120b, integrated as a part of a same unitary piece of material as the inner housing 120b, etc.), where the lid 110 may be configured to enclose some or all of the inner housing 120b (e.g., at least a portion of the inner housing 120b to which the filled hinge 400 is coupled) based on the lid 110 being in the closed position. As a result, in some example embodiments, the lid 110 and the outer housing 120a may collectively at least partially enclose at least the inner housing 120b and the filled hinge 400 based on the lid 110 being in the closed position, and the filled hinge 400 may couple the lid 110 to the inner housing 120b independently of the outer housing 120b. In some example embodiments, the inner housing 120b may be considered to be part of the aerosol generator 200 instead of being part of the housing 120 with the outer housing 120a, such that a filled hinge 400 may be understood to couple the lid 110 to the aerosol generator 200 independently of the housing 120 (e.g., the outer housing 120a) based on the filled hinge 400 (e.g., the hinge knuckle 410) being coupled to the inner housing 120b (e.g., directly connected to the inner housing 120b, integrated as a part of a same unitary piece of material as the inner housing 120b, etc.).

As shown, in some example embodiments the two knuckle structures 412 may have respective inner surfaces 414as and 414bs that define separate, respective pin holes 414a and 414b that are each coaxial with the axis of rotation 402 (e.g., the respective central axes of the pin holes 414a and 414b are each coaxial with the axis of rotation 402). In some example embodiments, including the example embodiments shown in FIGS. 1A-15, each pin hole 414a and 414b may extend through an entirety of a respective knuckle structure 412a or 412b, but example embodiments are not limited thereto. For example, in some example embodiments, one or both of the pin holes 414a and 414b may extend along the axis of rotation 402 through a limited portion of a respective knuckle structure 412a or 412b, such that the respective one or both pin holes 414a and/or 414b may be open at one end to the central cavity 420 and may be closed at an opposite end by a portion of the respective knuckle structure 412a or 412b defining the pin hole.

As further shown, the filled hinge 400 may include a hinge dowel pin 430 coupled between at least the first and second knuckle structures 412a and 412b. The hinge dowel pin 430 may extend along the axis of rotation 402 through the central cavity 420 between at least the first and second knuckle structures 412a and 412b.

As shown, the two knuckle structures 412 may structurally support each of opposite end portions 432a and 432b of the hinge dowel pin 430 along a longitudinal axis of the hinge dowel pin 430, where the longitudinal axis may be coaxial with the axis of rotation 402. For example, in some example embodiments, the first and second knuckle structures 412a and 412b may each have one or more inner surfaces 414as and 414bs defining separate, respective pin holes 414a and 414b, and the opposite end portions 432a and 432b of the hinge dowel pin 430 may extend through some or all of the separate, respective pin holes 414a and 414b, such that the opposite end portions 432a and 432b may contact and be structurally supported by the separate, respective knuckle structures 412a and 412b via the respective inner surfaces 414as and 414bs of the separate, respective pin holes 414a and 414b and a central portion 432c of the hinge dowel pin 430 may extend between the two knuckle structures 412 through the central cavity 420 along the axis of rotation 402. Thus, a structural load (e.g., weight) of the hinge dowel pin 430 may be transferred to the hinge knuckle 410 from both of the opposite end portions 432a and 432b via the knuckle structures 412a and 412b, and such structural load of at least the hinge dowel pin 430 may be equally or substantially equally distributed between and/or supported by the two knuckle structures 412.

In some example embodiments, the hinge dowel pin 430 may extend through both the central cavity 420 and at least a portion of each of the separate, respective pin holes 414a and 414b of the two knuckle structures 412, although example embodiments are not limited thereto. As shown, the hinge dowel pin 430 may extend through an entirety of each of the separate, respective pin holes 414a and 414b, such that the two knuckle structures 412 are between opposite end portions 432a and 432b of the hinge dowel pin 430 along the axis of rotation 402. However, example embodiments are not limited thereto. In some example embodiments, the hinge dowel pin 430 may extend partially through one or both of the two knuckle structures 412 such that one or both ends 434a and 434b of the hinge dowel pin 430 vertically overlap one or both of the two knuckle structures 412.

In some example embodiments, the lid 110 may be coupled to the filled hinge 400 based on the lid 110 being fixedly coupled to the hinge dowel pin 430 at each of the opposite end portions 432a and 432a of the hinge dowel pin 430. For example, as shown, the hinge dowel pin 430 may be coupled (e.g., directly connected) to the lid 110 based on opposite end portions 432a and 432b of the hinge dowel pin 430 connecting with opposing side portions 112a and 112b of the lid 110 (which may include separate, respective holes 113a and 113b configured to receive and engage at least a portion of the opposite end portions 432a and 432b of the hinge dowel pin 430). As shown, the opposing side portions 112a and 112b of the lid 110 may include opposing holes 113a and 113b extending through at least the opposing side portions 112a and 112b of the inner lid 110b and which may further extend through at least apportion of opposing side portions of the outer lid 110a, although example embodiments are not limited thereto.

In some example embodiments, the two knuckle structures 412 may each comprise a same or substantially same volume and/or amount of material, and the hinge dowel pin 430 may be positioned to be longitudinally centered along the axis of rotation 402 between the two knuckle structures 412, such that the center of mass 436 of the hinge dowel pin 430 along the axis of rotation 402 is equidistant or substantially equidistant from the two knuckle structures 412a and 412 along the axis of rotation 402. Furthermore, the knuckle structures 412a and 412b may evenly (e.g., equally or substantially equally) support and/or distribute the load of the hinge dowel pin 430 at the opposite end portions 432a and 432b of the hinge dowel pin. Restated, the structural support of the load of the hinge dowel pin 430 may be more closely balanced along the axis of rotation 402 based on the hinge knuckle 410 supporting the hinge dowel pin 430 at opposite end portions 432a and 432b at opposite sides of the center of mass 436 along the axis of rotation 402 (e.g., instead of supporting the hinge dowel pin 430 at a single side of the center of mass 436).

As a result, based on the two knuckle structures 412 supporting the hinge dowel pin 430 at opposite end portions 432a and 432b of the hinge dowel pin 430 (e.g., at opposite sides of the center of mass 436) and/or structurally supporting the hinge dowel pin 430 at opposite end portions 432a and 432b that are equidistant or substantially equidistant from the center of mass 436 along the axis of rotation 402, the hinge knuckle 410 may be configured to structurally support (e.g., support the load of) the hinge dowel pin 430 across a greater distance along the axis of rotation 402 and with improved balance of said support. In addition, based on the hinge dowel pin 430 being coupled between the two knuckle structures 412, the contact area (e.g., cumulative area) of contact surfaces between the hinge dowel pin 430 and the hinge knuckle 410 (e.g., the cumulative area of one or more surfaces of the hinge knuckle 410 contacting the hinge dowel pin 430, for example a cumulative area of inner surfaces 414as and 414bs defining the first and second pin holes 414a and 414b, respectively) may be increased, relative to example embodiments where the hinge dowel pin is supported at one side of the center of mass 436 along the axis of rotation 402. As a result, the filled hinge 400 may be configured to reduce, minimize, or prevent a tendency of the hinge dowel pin 430 to wobble or have “play” in relation to the axis of rotation 402 and thereby reduce, minimize, or prevent wobble or play of the lid 110 that is coupled to the hinge dowel pin 430 in relation to the remainder portion 130 of the aerosol-generating device 100, thereby improving the reliability, durability, and/or functionality of the aerosol-generating device 100.

As a result, the filled hinge 400 may be configured to reduce, minimize, or prevent play in the hinge dowel pin 430 in directions crossing the axis of rotation 402 and thus may be configured to reduce, minimize, or prevent play in the lid 110 in relation to the remainder portion 130 of the aerosol-generating device 100 (e.g., the housing 120 and/or the aerosol generator 200). Accordingly, the filled hinge 400 may be configured to reduce, minimize, or prevent structural damage to the aerosol-generating device 100 resulting from play in the lid 110 in relation to the remainder portion 130 of the aerosol-generating device 100. The filled hinge 400 may thus improve the functionality of the aerosol-generating device 100, based on the filled hinge 400 that fixedly couples the lid 110 to the aerosol generator 200 including two knuckle structures 412 and a hinge dowel pin 430 coupled therebetween, for example such that the two knuckle structures 412 support the hinge dowel pin 430 at each of opposite end portions 432a and 432b of the hinge dowel pin 430.

In addition, based on the hinge knuckle 410 being coupled to and/or integrated with at least a portion of the aerosol generator 200 (e.g., outer surface 210w of the capsule connector 210 as shown), the filled hinge 400 may be configured to enable the lid 110 and the housing 120 to collectively partially or entirely enclose at least the hinge dowel pin 430 when the lid 110 is in one or both of the closed position and the open position while simultaneously reducing play in the lid 110 relative to the remainder portion 130 of the aerosol-generating device 100, based on the hinge dowel pin 430 being coupled between and/or structurally supported at opposite end portions 432a and 432b by the two knuckle structures 412. As a result, the filled hinge 400 may improve the functionality of the aerosol-generating device 100 based on reducing, minimizing, or preventing the likelihood of damage to the aerosol-generating device 100 due to excessive wobble or play in the hinge dowel pin 430 and/or the lid 110 in relation to the remainder portion 130 of the aerosol-generating device 100 (e.g., the aerosol generator 200 and/or the housing 120).

Still referring to FIGS. 1A to 15, the filled hinge 400 may include a torsion spring 440. The torsion spring 440 may be configured to be in contact with one or both of the lid 110 and/or the hinge knuckle 410. The torsion spring 440 may be configured to exert a spring force (e.g., an opening force) on the lid 110 in relation to the remainder portion 130 of the aerosol-generating device 100 (e.g., aerosol generator 200 and/or housing 120) to return the lid 110 to a rest position in which may correspond to the open position or the closed position. For example, in some example embodiments, the torsion spring 440 is configured to have a rest state (also referred to herein interchangeably as a rest position, rest configuration, or the like) that corresponds to the open position of the lid 110, such that, when the lid 110 is in the closed position and secured to the remainder portion 130 of the aerosol-generating device 100 via engaging the latch 114, the torsion spring 440 may exert a spring force on the lid 110 that is countered by the retaining force exerted on the lid 110 by the engaged latch 114 to hold the lid 110 in the closed position. In response to the latch 114 being disengaged from the lid 110 (e.g., based on an adult consumer pressing the latch release button 116), the torsion spring 440 may exert the spring force on the lid 110 to cause the lid 110 to pivot 404 around the axis of rotation 402 to move from the closed position to the open position, to thereby cause the torsion spring 440 to move towards and/or to approach the rest state of the torsion spring 440. An adult consumer may move the lid 110 from the open position to the closed position based on exerting a force on the lid 110 and/or the remainder of the aerosol-generating device 100 that overcomes the spring force exerted by the torsion spring 440 and causes the lid 110 to pivot 404 around the axis of rotation 402 to cause the second side end 119b of the lid 110 to move towards and to engage the latch 114.

In some example embodiments, including the example embodiments shown in at least FIGS. 6A-13A, the torsion spring 440 may include a helical torsion spring, for example a torsion spring 440 including a spring coil 442, also referred to interchangeably as a spring coil having a plurality of coil rotations or turns around a central longitudinal axis (which in some example embodiments may be coaxial and/or paraxial (e.g., parallel) with the axis of rotation 402). For example, the torsion spring 440 may include a spring coil 442 having a total of 5 coil rotations around a central longitudinal axis that is coaxial with the axis of rotation 402 as shown, but example embodiments are not limited thereto, and the torsion spring 440 may include a spring coil 442 having any quantity of coil rotations around a central longitudinal axis. The torsion spring 440 may be configured to exert a spring force based on twisting of the spring coil 442 (e.g., helical twisting) around the axis of rotation 402 based on forces (e.g., one or more bending forces) applied to opposite axial ends of the spring coil 442 along the axis of rotation 402 (e.g., forces applied to the opposite axial ends via one or both of the first and/or second legs 444 and/or 446 described herein), but example embodiments are not limited thereto. It will be understood that the torsion spring 440 is not limited to a helical torsion spring and may include any type of torsion spring. The torsion spring 440 may comprise any material, including for example any metal material, for example stainless steel, spring steel, or the like. In some example embodiments, the spring coil 442 may be located at least partially within the central cavity 420 at least partially defined between the two knuckle structures 412. The spring coil 442 may surround at least a portion of the hinge dowel pin 430 between the two knuckle structures 412 within the central cavity 420. For example, the spring coil 442 may surround at least a central portion 432c of the hinge dowel pin 430 that is defined as a portion of the hinge dowel pin 430 extending between the axial ends 422a and 422b of the central cavity 420 along the axis of rotation 402.

In some example embodiments, and as shown in at least FIGS. 6A-13A, the torsion spring 440 may include a first leg 444 extending from one end (e.g., one axial end) of the spring coil 442. The first leg 444 may extend from the spring coil 442 at a proximate end thereof to an end structure 444a at a distal end thereof. As shown, the end structure 444a is configured to engage (e.g., at least contact) an inner lid surface 110s of the lid 110. The torsion spring 440 may be configured to exert a spring force (e.g., opening force) on the lid 110 based on transmitting the spring force through the first leg 444 to the lid 110 via contact between the end structure 444a and any surface and/or structure of the lid 110 (e.g., the inner lid surface 110s). As shown, the end structure 444a may include a hooked structure having increased contact area with one or more surfaces and/or structures of the lid 110, but example embodiments are not limited thereto. The end structure 444a may be any structure configured to contact, couple, and/or engage with any surface and/or structure of the lid 110.

In some example embodiments, and as shown, the torsion spring 440 may include a second leg 446 extending from an opposite end (e.g., opposite axial end) of the spring coil 442 in relation to the one axial end from which the first leg 444 extends. The second leg 446 may extend from the spring coil 442 at a proximate end thereof to an end structure 446a at a distal end thereof. As shown, the end structure 446a is configured to engage (e.g., at least contact) a structure and/or surface of the hinge knuckle 410, but example embodiments are not limited thereto. The end structure 446a of the second leg 446 may engage (e.g., contact) any surface and/or structure of the aerosol-generating device 100 excluding the lid 110. The torsion spring 440 may be configured to exert a spring force on the remainder portion 130 of the aerosol-generating device 100 based on transmitting the spring force through the second leg 446 to the remainder portion 130 via contact between the end structure 446a and any surface and/or structure of the hinge knuckle 410 (e.g., latch structure 482 as described herein) which may be coupled to and/or integrated into a structure of the aerosol generator 200, any part of the remainder portion 130, or the like. As shown, the end structure 446a may include a hooked structure having increased contact area with one or more surfaces and/or structures of the hinge knuckle 410 (e.g., latch structure 482 as described herein) and/or any part of the remainder portion 130, but example embodiments are not limited thereto. For example, the end structure 446a may be any structure configured to contact, couple, and/or engage with any surface and/or structure of the hinge knuckle 410 (e.g., latch structure 482 as described herein) and/or any part of the remainder portion 130.

In some example embodiments, including the example embodiments shown in at least FIGS. 6A-15, the hinge knuckle 410 may include one or more covers (also referred to herein interchangeably as cover structures, shield structures, shields, shield covers, or the like) that may at least partially define one or more vertical ends of the central cavity 420 that extends at least partially between the opposite axial ends 422a and 422b of the central cavity 420 so as to at least partially overlap the spring coil 442 and/or the central portion 432c of the hinge dowel pin 430 that are in the central cavity 420 in a vertical direction that crosses the axis of rotation 402 and is paraxial (e.g., parallel) to the central longitudinal axis 202 of the aerosol generator 200 and/or the aerosol-generating device 100. The one or more covers may each be configured to at least partially shield the spring coil 442 within the central cavity 420 in one or more vertical directions. As described herein, such shielding may include shielding the spring coil 442 from impacts from a source external to the filled hinge 400 in one or more vertical directions (e.g., an upwards vertical direction and/or a downwards vertical direction that is opposite to the upwards vertical direction), thereby improving durability and functionality of the aerosol-generating device 100. However, example embodiments are not limited thereto. For example, as described herein, shielding of the spring coil 442 may include shielding the spring coil 442 from external impacts in one or more vertical directions, shielding the spring coil 442 from ingress of foreign matter into the central cavity 420 in one or more vertical directions, shielding the spring coil 442 from external observation, manual access, and/or manual manipulation by an adult consumer in one or more vertical directions, any combination thereof, or the like.

For example, as shown in at least FIGS. 6A-14E, the hinge knuckle 410 may include a first cover 450, also referred to herein as an “upper cover,” “upper shield,” or the like. As shown, in some example embodiments, the first cover 450 may at least partially define a first vertical end 424a of the central cavity 420 that extends at least partially between the opposite axial ends 422a and 422b of the central cavity 420. In some example embodiments, including the example embodiments shown in FIGS. 12A-12B, the first cover 450 may overlap at least a portion of a first coil section 442a of the spring coil 442 overlapping the axis of rotation 402 in a vertical direction 426 that crosses the axis of rotation 402 and is paraxial (e.g., parallel) to the central longitudinal axis 202. The vertical direction 426 may include a vertical direction that may be referred to as a first vertical direction 426a, which may be a direction extending paraxial (e.g., parallel) to the central longitudinal axis 202 from the first cover 450 towards the axis of rotation 402. In example embodiments where the first cover 450 is an “upper cover” that at least partially defines a first vertical end 424a that is an upper end of the central cavity 420, the first vertical direction 426a may be a “downwards” vertical direction. However, example embodiments are not limited thereto.

In some example embodiments, the first cover 450 may be configured to at least partially shield the spring coil 442 within the central cavity 420 in at least the first vertical direction 426a. As described herein, such shielding may include shielding the spring coil 442 from impacts in at least the first vertical direction 426a (e.g., impacts from an external source directed towards the central cavity in the first vertical direction 426a). However, example embodiments are not limited thereto. For example, as described herein, shielding of the spring coil 442 may include shielding the spring coil 442 from external impacts in at least the first vertical direction 426a, shielding the spring coil 442 from ingress of foreign matter into the central cavity 420 in at least the first vertical direction 426a, shielding the spring coil 442 from external observation, manual access, and/or manual manipulation by an adult consumer in at least the first vertical direction 426a, any combination thereof, or the like.

For example, based on the first cover overlapping at least the first coil section 442a of the spring coil 442 in a vertical direction 426a, the first cover 450 may at least partially isolate the spring coil 442 and/or the central portion 432c of the hinge dowel pin 430 in the central cavity 420 from an exterior environment that is external to the filled hinge 400. The first cover 450 may thus be configured to at least partially shield the spring coil 442 and/or the central portion 432c of the hinge dowel pin 430 in the central cavity 420 in the first vertical direction 426a (e.g., shielding the spring coil 442 and/or the hinge dowel pin 430 from being impacted by structures and/or forces directed towards the axis of rotation 402 in the first vertical direction 426a from outside the filled hinge 400, from ingress of foreign matter in the first vertical direction 426a, from external observation, manual access, and/or manual manipulation by an adult consumer in the first vertical direction 426a, any combination thereof, or the like). As a result, the first cover 450 may improve protection of the hinge dowel pin 430 and/or the spring coil 442 and may improve the functionality of the aerosol-generating device 100 based on reducing, minimizing, or preventing damage to the filled hinge 400. Accordingly, the first cover 450 may configure the filled hinge 400, and thus the aerosol-generating device 100, to improve the ability of the lid 110 to pivot between the open and closed positions with reduced, minimize, or prevented damage to the filled hinge 400, based on at least partially shielding the spring coil 442 and/or the central portion 432c of the hinge dowel pin 430 in the central cavity 420 in the first vertical direction 426a (e.g., shielding the spring coil 442 and/or the hinge dowel pin 430 from being impacted by structures and/or forces directed towards the axis of rotation 402 in the first vertical direction 426a from outside the filled hinge 400, from ingress of foreign matter in the first vertical direction 426a, from external observation, manual access, and/or manual manipulation by an adult consumer in the first vertical direction 426a, any combination thereof, or the like).

As shown, the first coil section 442a may be a limited portion of the spring coil 442, including a limited portion of the coil rotations (e.g., 4 of the 5 coil rotations as shown in at least FIGS. 12A and 12B), such that at least a portion of the spring coil 442 may be exposed from the first cover 450 in the vertical direction (e.g., the first vertical direction 426a). However, example embodiments are not limited thereto. In some example embodiments the first cover 450 may overlap an entirety (e.g., all) of the spring coil 442 in the first vertical direction 426a.

In some example embodiments, the hinge knuckle 410 (e.g., the first cover 450, one or more of the two knuckle structures 412a and/or 412b, etc.) may include and/or may include one or more surfaces 460s that at least partially define a groove 460 extending horizontally in relation to the axis of rotation 402 and/or the central longitudinal axis 202 and exposing a portion of the central cavity 420 in a vertical direction 426 (e.g., the first vertical direction 426a and/or the second vertical direction 426b). For example, as shown, one or more inner surfaces of the second knuckle structure 412b and the first cover 450, including opposing surfaces thereof, may at least partially define the groove 460 to extend in at least a horizontal direction crossing the axis of rotation 402 and/or horizontally towards the central longitudinal axis 202 (e.g., perpendicular and towards the central longitudinal axis 202). The groove 460 may thus expose at least a portion of the central cavity 420 in a vertical direction (e.g., the first vertical direction 426a). As shown, the groove 460 may thus expose at least a portion of the torsion spring 440 in the vertical direction, including for example exposing at least a portion of the spring coil 442 in the vertical direction.

As shown, the groove 460 may be configured to enable the first leg 444 to move circumferentially and/or azimuthally around the axis of rotation 402 based on the lid 110 moving between the closed position and the open position in relation to the remainder of the aerosol-generating device 100 (e.g., based on twisting of the opposite axial ends of the spring coil 442 around the axis of rotation 402). As shown in at least FIGS. 7B, 9B-9E, 10B, 11B, and 13A, based on the lid 110 being in the open position, the first leg 444 may be at an open-lid position that is outside of the groove 460 (e.g., azimuthally offset from the first cover 450) but may be aligned with the groove in the vertical direction. Based on the lid 110 moving (e.g., pivoting 404 around the axis of rotation 402) from the open position to the closed position (e.g., as shown in at least FIGS. 7A, 8B, 9A, 10A, and 11A, the first leg 444 may move around the axis of rotation 402 towards the groove 460 and may further move into the groove 460 via an open end thereof to a closed-lid position wherein a portion of the first leg 444 is within the groove 460 and at least partially overlaps the first cover 450 in an axial direction that is paraxial (e.g., parallel) to the axis of rotation 402. Accordingly, the filed hinge 400 may be configured to enable the lid 110 to pivot 404 around the axis of rotation 402 such that at least a portion of the torsion spring 440 (e.g., the first leg 444) moves azimuthally in relation to the axis of rotation 402 from an open-lid position to a closed-lid position, wherein the open-lid position of the portion of the torsion spring 440 (e.g., the first leg 444) is azimuthally offset from the first cover 450 and the closed-lid position of the portion of the torsion spring 440 (e.g., the first leg 444) is at least partially overlapping the first cover 450 in an axial direction that is paraxial (e.g., parallel) to the axis of rotation 402.

As shown, the groove 460 may be open at one end that is distal from the central longitudinal axis 202 and may be closed at an opposite end (e.g., a closed end 462) that is proximate to the central longitudinal axis 202. The closed end 462 of the groove 460 may be defined by one or more surfaces of the hinge knuckle 410. In some example embodiments where the filed hinge 400 is configured to enable a portion of the torsion spring 440 (e.g., the first leg 444) to move to a closed-lid position that is within the groove 460 and at least partially overlapping the first cover 450 in an axial direction that is paraxial (e.g., parallel) to the axis of rotation 402, the filled hinge 400 may be configured (e.g., based on the relative positioning of the contact point between the end structure 444a of the first leg 444 and the lid 110, the contact points between the lid 110 and the filled hinge 400, the size and horizontal extent of the groove 460, etc.) to isolate the portion of the torsions spring 440 from directly contacting the closed end 462 of the groove 460. Accordingly, the filled hinge 400 may be configured to reduce, minimize, or prevent damage thereto that might otherwise occur due to contact between the portions of the torsion spring 440 (e.g., the first leg 444) and the closed end 462 of the groove 460 as a result of the lid 110 pivoting 404 to the closed position.

In some example embodiments, the filled hinge 400 is configured to enable the lid 110 to pivot 404 around the axis of rotation 402 such that at least a portion of the torsion spring 440 (e.g., the first leg 444) moves azimuthally in relation to the axis of rotation 402 from an open-lid position to a closed-lid position, the open-lid position azimuthally offset from the first cover 450, the closed-lid position at least partially overlapping the first cover 450 in an axial direction that is paraxial (e.g., parallel) to the axis of rotation 402.

As shown in at least FIG. 8A, the first cover 450 may extend beyond vertically overlapping the axis of rotation 402 and may further extend horizontally away from the central longitudinal axis 202 and the axis of rotation 402, for example such that the first cover 450 may entirely overlap the first coil section 442a in the vertical direction and may further at least partially overlap the spring coil 442 and/or the hinge dowel pin 430 in an angled direction 464 that is perpendicular to the axis of rotation 402 and is at an angle 464a to the vertical direction (e.g., direction 426a and/or 426b) and is directed away from the central longitudinal axis 202. As a result, in addition to at least partially shielding the spring coil 442 and/or the hinge dowel pin 430 in the first vertical direction 426a (e.g., shielding the spring coil 442 and/or the hinge dowel pin 430 from externally-originating impacts in the first vertical direction 426a, from ingress of foreign matter in the first vertical direction 426a, from external observation, manual access, and/or manual manipulation by an adult consumer in the first vertical direction 426a, any combination thereof, or the like), the first cover 450 may be further configured to at least partially shield the spring coil 442 and/or the hinge dowel pin 430 in a direction that is at least partially in a horizontal direction crossing the first vertical direction 426a (e.g. shielding the spring coil 442 and/or the hinge dowel pin 430 from externally-originating impacts in said direction, from ingress of foreign matter in said direction, from external observation, manual access, and/or manual manipulation by an adult consumer in said direction, any combination thereof, or the like). As a result, the first cover 450 may provide improved protection (e.g., improved protection from non-vertically-directed impacts, ingresses of foreign matter, ingresses of limbs and/or manually manipulated tools, etc.).

In some example embodiments, the hinge knuckle 410 may include a second cover 470, also referred to herein as a “lower cover,” “lower shield,” or the like. As shown, in some example embodiments, the second cover 470 may at least partially define a second vertical end 424b of the central cavity 420 that extends at least partially between the opposite axial ends 422a and 422b of the central cavity 420. As shown (e.g., in at least FIGS. 11A-11B and 12A-12B), the second cover 470 may extend entirely between the opposite axial ends 422a and 422b of the central cavity 420 and thus may entirely overlap at least a portion of the spring coil 442 overlapping the axis of rotation 402 in a vertical direction that crosses the axis of rotation 402 and is paraxial (e.g., parallel) to the central longitudinal axis 202. The vertical direction may be referred to as a second vertical direction 426b, which may be a direction extending paraxial (e.g., parallel) to the central longitudinal axis 202 from the second cover 470 towards the axis of rotation 402. In example embodiments where the second cover 470 is a “lower cover” that at least partially defines a second vertical end 424b that is a lower end of the central cavity 420 and is opposite to (e.g., is an opposing end to) the first vertical end 424a, the second vertical direction 426b may be an “upwards” vertical direction. However, example embodiments are not limited thereto. As shown, the second vertical direction 426b may extend opposite to the first vertical direction 426a, but example embodiments are not limited thereto. For example, the second vertical direction 426b may be at an angle that is different from 180 degrees in relation to the first vertical direction 426a.

In some example embodiments, the second cover 470 may be configured to at least partially shield the spring coil 442 within the central cavity 420 in the second vertical direction 426b (e.g., shielding the spring coil 442 and/or the hinge dowel pin 430 from impacts in at least the second vertical direction 426b. Impacts from an external source directed towards the central cavity in the second vertical direction 426b, from ingress of foreign matter in the second vertical direction 426b, from external observation, manual access, and/or manual manipulation by an adult consumer in the second vertical direction 426b, any combination thereof, or the like). For example, based on the second cover 470 overlapping at least the axis of rotation 402 within the central cavity 420 in the second vertical direction 426b and thus vertically overlapping at least a portion of the spring coil 442 vertically overlapping the axis of rotation 402 in a vertical direction 426a, the second cover 470 may at least partially isolate the spring coil 442 and/or the central portion 432c of the hinge dowel pin 430 in the central cavity 420 from the exterior environment that is external to the filled hinge 400. The second cover 470 may thus be configured to at least partially shield the spring coil 442 and/or the central portion 432c of the hinge dowel pin 430 in the central cavity 420 (e.g., shielding the spring coil 442 and/or the hinge dowel pin 430 from being impacted by structures and/or forces directed towards the axis of rotation 402 in the second vertical direction 426b from outside the filled hinge 400, from ingress of foreign matter from outside the filled hinge 400, from external observation, manual access, and/or manual manipulation by an adult consumer from outside the filled hinge 400, any combination thereof, or the like). As a result, the second cover 470 may improve protection of the hinge dowel pin 430 and/or the spring coil 442 and may improve the functionality of the aerosol-generating device 100 based on reducing, minimizing, or preventing damage to the filled hinge 400. The second cover 470 may thus configure the filled hinge 400, and thus the aerosol-generating device 100, to improve the ability of the lid 110 to pivot between the open and closed positions, based on at least partially shielding the spring coil 442 and/or the central portion 432c of the hinge dowel pin 430 in the central cavity 420 in the second vertical direction 426b (e.g., shielding the spring coil 442 and/or the hinge dowel pin 430 from being impacted by structures and/or forces directed towards the axis of rotation 402 in the second vertical direction 426b from outside the filled hinge 400 from ingress of foreign matter in the second vertical direction 426b, from external observation, manual access, and/or manual manipulation by an adult consumer in the second vertical direction 426b, any combination thereof, or the like).

As shown in at least FIG. 8A, the second cover 470 may extend beyond vertically overlapping the axis of rotation 402 and may further extend horizontally away from the central longitudinal axis 202 and the axis of rotation 402, for example such that the second cover 470 may at least partially overlap the spring coil 442 and/or the hinge dowel pin 430 in an angled direction 466 that is perpendicular to the axis of rotation 402 and is at an angle 466a to the vertical direction (e.g., direction 426a and/or 426b) and is directed away from the central longitudinal axis 202. As a result, in addition to at least partially shielding the spring coil 442 and/or the hinge dowel pin 430 in the second vertical direction 426b (e.g., shielding the spring coil 442 and/or the hinge dowel pin 430 from externally-originating impacts in the second vertical direction 426b, from ingress of foreign matter in the second vertical direction 426b, from external observation, manual access, and/or manual manipulation by an adult consumer in the second vertical direction 426b, any combination thereof, or the like), the second cover 470 may be further configured to at least partially shield the spring coil 442 and/or the hinge dowel pin 430 in a direction that is at least partially in a horizontal direction crossing the second vertical direction 426b (e.g. shielding the spring coil 442 and/or the hinge dowel pin 430 from externally-originating impacts in said direction, from ingress of foreign matter in said direction, from external observation, manual access, and/or manual manipulation by an adult consumer in said direction, any combination thereof, or the like). As a result, the second cover 470 may provide improved protection to the spring coil 442 and/or the hinge dowel pin 430 (e.g., improved protection from non-vertically directed impacts, ingresses of foreign matter, ingresses of limbs and/or manually manipulated tools, etc.).

As shown, the hinge knuckle 410 may include both the first cover 450 and the second cover 470, but example embodiments are not limited thereto. In some example embodiments, one of both of the first cover 450 and/or the second cover 470 may be omitted from the filled hinge 400. As shown, the first cover 450 extends over a limited portion of the central cavity 420 and partially defines a groove 460 while the second cover 470 extends under the entire central cavity 420, but example embodiments are not limited thereto. In some example embodiments, one or both of the first cover 450 and/or the second cover 470 may partially or entirely define one or more grooves 460. In some example embodiments, the groove 460 may be omitted from the filled hinge. In some example embodiments, the first cover 450 and/or the second cover 470 may extend along an entirety of a respective first and/or second vertical end 424a and/or 424b of the central cavity between the two knuckle structures 412.

As shown in at least FIGS. 6A-14E, the first cover 450 may be an upper cover (e.g., upper shield) and the second cover 470 may be a lower cover (e.g., lower shield), such that such that the first cover 450 is configured to be between the second cover 470 and an uppermost end of the lid 110 (e.g., outlet 196) based on the lid 110 being in the closed position, and/or the second cover 470 is configured to be between the first cover 450 and a lowermost end of the aerosol-generating device 100 (e.g., connector 170). But example embodiments are not limited thereto. For example, in some example embodiments the positions of the first cover 450 and the second cover 470 as illustrated may be swapped with each other.

In some example embodiments, the hinge knuckle 410 includes one or more inner surfaces 480s that at least partially define a conduit, referred to herein as a slot 480, extending from the central cavity 420 and at least partially through the hinge knuckle 410 interior. As shown, the slot 480 may extend to at least a latch structure 482 which may be defined by one or more surfaces 482s of the hinge knuckle 410, the aerosol generator 200 (e.g., the capsule connector 210), or any combination thereof. As shown, the torsion spring 440 may include a second leg 446 that may extend from an end of the spring coil 442 and further extending through at least a portion of the slot 480 to engage at least a portion of the latch structure 482. For example, as shown, the second leg 446 may include a second end structure 446a that may engage (e.g., contact) at least a portion of the latch structure 482 (e.g., one or more surfaces 482s). The torsion spring 440 may be configured to exert a spring force on the hinge knuckle 410 and/or the aerosol generator 200 (e.g., capsule connector 210) via the end structure 446a of the second leg 446 engaging the hinge knuckle 410 and/or the aerosol generator 200. In some example embodiments, based on the second leg 446 engaging the hinge knuckle 410 and/or the aerosol generator 200 (e.g., via end structure 446a engaging the latch structure 482), the filled hinge 400 may hold the torsion spring 440 in place and is configured to transfer spring forces exerted by the torsion spring 440 to the hinge knuckle and/or the aerosol generator 200.

In some example embodiments, the hinge knuckle 410 may at least partially define the latch structure 482. For example, as shown, the latch structure 482 may be an opening in at least a portion of the hinge knuckle 410, for example an opening in at least a portion of the first knuckle structure 412a defined by one or more surfaces 482s of the hinge knuckle 410. However, it will be understood that example embodiments are not limited thereto.

In some example embodiments, and as shown in at least FIGS. 13A and 13B, the two knuckle structures 412 may be defined by separate, respective portions of a single, unitary piece of material that further defines at least a portion of the aerosol generator 200, such that the single unitary piece of material defines both at least a portion of the aerosol generator 200 and at least a portion of the filled hinge 400 (e.g., at least a portion of the hinge knuckle 410). For example, as shown in FIGS. 13A and 13B, the aerosol-generating device 100 may include a single, unitary piece of material 1300 that defines at least a portion of the capsule connector 210, including at least the one or more inner surfaces 210s thereof that at least partially define the capsule-receiving cavity 212, and further defines at least a portion (e.g., an entirety) of the hinge knuckle 410 of the filled hinge 400. As shown, the single, unitary piece of material 1300 may be separate from the piece(s) of material that define the housing 120 (e.g., the outer housing 120a and/or the inner housing 120b). As a result, the filled hinge 400 may be understood to, in addition to being coupled to the aerosol generator 200, being integrated with the aerosol generator 200, separately from the housing 120 of the aerosol-generating device. Such integration, based on at least the two knuckle structures 412 being defined by separate, respective portions of a single, unitary piece of material 1300 that further defines at least a portion of the aerosol generator 200, may improve structural integrity and stability of the filled hinge 400 in relation to the remainder of the aerosol-generating device 100, and thus may improve the functionality of the aerosol-generating device 100.

In some example embodiments, the hinge knuckle 410 may be configured to define at least the first and second knuckle structures 412a and 412b, collectively referred to as the two knuckle structures 412 (and in some example embodiments, further including the first and/or second covers 450 and/or 470) to maintain a full continuous structure (e.g., the hinge knuckle 410 may define the two knuckle structures 412, the first cover 450, and/or the second cover 470 as separate portions of a single unitary piece of material). Such a structure of the hinge knuckle 410 may be configured to reduce or minimize contact gap 602 (shown in FIG. 6C) between the hinge knuckle 410 outer surfaces and inner lid surfaces (e.g., 110s) where the hinge knuckle 410 and the lid 110 interface, therefore reducing lid 110 play in the assembled state (e.g., in the assembled aerosol-generating device 100). The central cavity 420 can then be integrated into the center of the hinge knuckle 410 (e.g., between the two knuckle structures 412 along the axis of rotation 402 as shown) and optimized in size to accommodate a torsion spring 440 with an increased number of coil rotations (e.g., an increased number of spring coil rotations in the spring coil 442). Doing so will increase the cycle life of the torsion spring 440, thereby improving the life cycle of the aerosol-generating device 100 and thus improving the functionality of the aerosol-generating device 100.

As shown in at least FIG. 9D, the hinge knuckle 410 may include and/or define one or more additional structures 411 external to the two knuckle structures 412, the first cover 450, and/or the second cover 470, for example one or more additional structures 411 that extend between the two knuckle structures 412 adjacent to the capsule connector 210 as shown in FIG. 9D. The one or more additional structures 411 may join two or more structures of the hinge knuckle 410 externally of the portion of the aerosol generator 200 (e.g., the capsule connector 210) to which the hinge knuckle 410 is coupled and/or integrated as separate portions of a single unitary piece of material. For example, as shown in at least FIG. 9D, the hinge knuckle 410 may include one or more additional structures that may join the two knuckle structures 412 together separately from the capsule connector 210 to which the hinge knuckle 410 is coupled and/or integrated. The hinge knuckle 410 may define the two knuckle structures 412, the first cover 450, the second cover 470, and the one or more additional structures 411 as separate portions of a single unitary piece of material, but example embodiments are not limited thereto. In some example embodiments, the one or more additional structures 411 may be omitted.

In some example embodiments, including the example embodiments shown in at least FIGS. 6A, 6C, 7A-7B, 8A-8C, 9A-9E, 10A-10B, 11A-11B, 12A-12B, and 13A, based on at least the spring coil 442 being held within the central cavity 420 between the two knuckle structures 412 along the axis of rotation 402, and in some example embodiments between the first and second covers 450 and 470, the torsion spring 440 may be understood to be “nested” in the middle of the hinge geometry of the hinge knuckle 410 and thus of the filled hinge 400 itself. The hinge knuckle 410 may have a balanced amount of material at opposite sides along the axis of rotation 402 (e.g., the two knuckle structures 412 may comprise equal or substantially equal amounts (e.g., volume and/or mass) of material and may have equal or substantially equal contact surface area to contact the respective end portions 432a and 432b of the hinge dowel pin 430). As a result, the hinge dowel pin 430 may be supported equally or substantially equally at opposite end portions 432a and 432b by two knuckle structures 412 and thus may have “balanced” support by the hinge knuckle 410, thereby improving rigidity and durability of the filled hinge due to reduced “play” of the hinge dowel pin 430 in relation to the hinge knuckle 410 enabled by the balanced support thereof. Such reduction of “play” may be further enabled based on the hinge knuckle 410 contacting and thus supporting the hinge dowel pin 430 at opposite end portions 432a and 432b such that the hinge dowel pin 430 is supported at two separate portions that are spaced apart across a relatively great distance along the axis of rotation 402 and at opposite sides of the center of mass 436 of the hinge dowel pin 430, thereby further reducing the play of the hinge dowel pin 430 in relation to the hinge knuckle 410 and thus further reducing the play of the lid 110 in relation to the remainder portion 130 of the aerosol-generating device 100, thereby further improving the durability, reliability, and thus functionality of the aerosol-generating device 100.

The hinge knuckle 410 (and thus any structures defined thereby, including for example the two knuckle structures 412 (e.g., the first and second knuckle structures 412a and 412b), the first cover 450, the second cover 470, or any combination thereof) may comprise any plastic material (e.g., PEEK), any metal material (e.g., stainless steel), or the like. The hinge dowel pin 430 may comprise any plastic material (e.g., PEEK), any metal material (e.g., stainless steel), or the like. The torsion spring 440 may comprise any metal material (e.g., spring steel, stainless steel, etc.), any plastic material (e.g., PEEK), or the like.

Still referring to FIGS. 6A, 6C, 7A-7B, 8A-8C, 9A-9E, 10A-10B, 11A-11B, 12A-12B, 13A-13B, 14A-14E, and 15, in some example embodiments, the hinge knuckle 410 and one or more structures thereof (e.g., the two knuckle structures 412, the first and second covers 450 and 470, etc.) may at least partially define the central cavity 420 that is configured to receive and at least partially enclose the spring coil 442 of the torsion spring 440. In some example embodiments, based on the central cavity 420 (also referred to herein as a central “pocket”) being defined between at least the two knuckle structures 412 along the axis of rotation 402, and the slot 480 extending therefrom, may be at least partially defined by surfaces and/or structure at least partially defining a slot 480 that is angled 490 from the horizontal direction, although example embodiments are not limited thereto. As further shown, the hinge knuckle 410 and structures thereof (e.g., the first and second knuckle structures 412a and 412b, the first and second covers 450 and 470, etc.) may define the central cavity 420 as including an opening 428 facing away from the central longitudinal axis 202 of the aerosol-generating device 100 and/or of the aerosol generator 200. The hinge knuckle 410 may define the opening 428 to be sized to be sufficiently large and have sufficient area to be configured to receive at least the spring coil 442 of the torsion spring 440 into the central cavity 420 via the opening 428 in a direction extending perpendicular to the axis of rotation 402. As a result, the hinge knuckle 410 may be configured to enable the spring coil 442 of the torsion spring 440 to be received into the central cavity 420 via the opening 428 and thus received into the central cavity 420 in a direction extending perpendicular to the axis of rotation 402.

The hinge knuckle 410 may be configured to define a central cavity 420 that is larger than a central cavity that may be defined by a hinge knuckle that contacts the hinge dowel pin at only one side along the axis of rotation, based on the hinge knuckle 410 having two knuckle structures 412 configured to contact and structurally support the hinge dowel pin 430 at opposite end portions 432a and 432b thereof. As a result, the filled hinge 400 may be configured to receive and accommodate, within the central cavity 420, a spring coil 442 of a customized torsion spring 440 (e.g., an enlarged spring coil 442) that may be configured to increase cycle life of the torsion spring 440 (and thus of the filled hinge 400 and thus of the aerosol-generating device 100) while retaining and/or improving the spring force (e.g., opening force) exerted by the torsion spring to cause the lid 110 to move to the open position in relation to the remainder portion 130 of the aerosol-generating device 100. Accordingly, the functionality of the aerosol-generating device 100 may be improved.

During manufacture of the aerosol-generating device 100, the torsion spring 440 may be at least partially inserted into the central cavity 420 via the opening 428 in a direction extending perpendicular to the axis of rotation 402, to at least position the spring coil 442 within the central cavity 420 and surrounding the axis of rotation 402. The second leg 446 may further be extended through the slot 480, for example to engage the latch structure 482, based on the torsion spring 440 being inserted through the opening 428 and at least partially into the central cavity 420. The first leg 444 may remain external to the central cavity 420 and the slot 480, such that a proximate end of the first leg 444, that is opposite from the distal end that may include an end structure 444a, may extend through the opening 428 to couple with one end of the spring coil 442 within the central cavity 420. The hinge dowel pin 430 may then be inserted through one of the pin holes 414a or 414b, through the central cavity 420 along the axis of rotation 402, and further through the other one of the pin holes 414a or 414b, to secure the torsion spring 440 in the filled hinge 400 so that the spring coil 442 is secured withing the central cavity 420 by at least the hinge dowel pin 430. The lid 110 may subsequently be coupled to the hinge dowel pin 430 (e.g., at the opposite end portions 432a and 432b thereof). The first leg 444 may be engaged with an inner lid surface 110s of the lid 110 based on the lid 110 being coupled to the hinge dowel pin 430.

FIG. 16 is a block diagram of an aerosol-generating device according to some example embodiments. In some example embodiments, the aerosol-generating device shown in FIG. 16 may be the aerosol-generating device 100 shown in one or more of FIGS. 1A to 15.

As shown in FIG. 16, according to some example embodiments, an aerosol-generating device 100 may include a control subsystem 2100 which may include a controller 2105, a power supply 2110, actuator controls 2115, a capsule electrical/data interface 2120, device sensors 2125, input/output (I/O) interfaces 2130, aerosol indicators 2135, at least one antenna 2140, and/or a storage medium 2145, etc., but the example embodiments are not limited thereto. For example, the control subsystem 2100 may include additional elements. However, for the sake of brevity, the additional elements are not described. In some example embodiments, the capsule electrical/data interface 2120 may be an electrical interface only, etc. It will be understood that the control subsystem 2100 may omit any one or more of the controller 2105, the power supply 2110, the actuator controls 2115, the capsule electrical/data interface 2120, the device sensors 2125, the input/output (I/O) interfaces 2130, the aerosol indicators 2135, the at least one antenna 2140, and/or the storage medium 2145.

The controller 2105 may be hardware including logic circuits; a hardware/software combination such as a processor executing software; or a combination thereof. For example, the controller 2105 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.

In the event where the controller 2105 is, or includes, a processor executing software, the controller 2105 is configured as a special purpose machine (e.g., a processing device) to execute the software, stored in memory accessible by the controller 2105 (e.g., the storage medium 2145 or another storage device), to perform the functions of the controller 2105. The software may be embodied as program code including instructions for performing and/or controlling any or all operations described herein as being performed by the controller 2105.

As disclosed herein, the term “storage medium”, “computer readable storage medium” or “non-transitory computer readable storage medium” may represent one or more devices for storing data, including read only memory (ROM), random access memory (RAM), magnetic RAM, core memory, magnetic disk storage mediums, optical storage mediums, flash memory devices and/or other tangible machine readable mediums for storing information. The term “computer-readable medium” may include, but is not limited to, portable or fixed storage devices, optical storage devices, and various other mediums capable of storing, containing or carrying instruction(s) and/or data.

The controller 2105 communicates with the power supply 2110, the actuator control 2115, the capsule electrical/data interface 2120, the device sensors 2125, the input/output (I/O) interfaces 2130, the aerosol indicators 2135, on-product controls 2150, and/or the at least one antenna 2140, etc. According to at least some example embodiments, the on-product controls 2150 can include any device or devices capable of being manipulated manually by an adult operator to indicate a selection of a value. Example implementations include, but are not limited to, one or more buttons, a dial, a capacitive sensor, and a slider, etc.

The controller 2105 (or storage medium 2145) stores key material and proprietary algorithm software for the encryption. For example, encryption algorithms rely on the use of random numbers. The security of these algorithms depends on how truly random these numbers are. These numbers are usually pre-generated and coded into the processor or memory devices. Example embodiments may increase the randomness of the numbers used for the encryption by using the aerosol drawing parameters (e.g., durations of instances of aerosol drawing, intervals between instances of aerosol drawing, or combinations of them) to generate numbers that are more random and more varying from individual to individual than pre-generated random numbers. All communications between the controller 2105 and another device that is internal or external to the aerosol-generating device 100 may be encrypted.

The controller 2105 is configured to operate a real time operating system (RTOS), control the control subsystem 2100 and may be updated through reading and/or sensing update information from a tag, chip, and/or label (e.g., a security tag, a security chip, etc.) included on the capsule 300, through communicating with the NVM or CC-NVM, and/or when the control subsystem 2100 is connected with other devices (e.g., a smart phone) through the I/O interfaces 2130 and/or the antenna 2140. For example, the update information may include parameter information related to the corresponding capsule, such as heater parameter information and/or heater profile information tailored and/or directed towards the aerosol-forming substrate contained within the installed capsule 300, capsule authentication update information with information relevant to the capsule authentication method (e.g., security settings related to the capsules, updates to the security keys used during authentication, etc.), programming updates, etc. Additionally, the I/O interfaces 2130 and the antenna 2140 allow the control subsystem 2100 to connect to various external devices such as smart phones, tablets, and PCs, etc. For example, the I/O interfaces 2130 may include a USB-C connector, a micro-USB connector, etc. The USB-C connector (e.g., charging connector 170) may be used by the control subsystem 2100 to charge the power source 2110b (e.g., which may correspond to the power source 230), and may also be used to transmit and/or receive data from at least one external device, such as aerosol profiles, heater profiles, device performance log data (e.g., controller performance data, memory performance data, battery performance data, heater performance data, etc.), firmware upgrades, software upgrades, etc., but the example embodiments are not limited thereto.

The controller 2105 may include on-board RAM and flash memory to store and execute code including analytics, diagnostics and software upgrades. As an alternative, the storage medium 2145 may store the code. Additionally, in some example embodiments, the storage medium 2145 may be on-board the controller 2105.

The controller 2105 may further include on-board clock, reset and power management modules to reduce an area covered by a PCB in the device body housing.

The device sensors 2125 may include a number of sensor transducers that provide measurement information to the controller 2105. The device sensors 2125 may include a power supply temperature sensor, an external capsule temperature sensor, a current sensor for the heater, power supply current sensor, airflow sensor and an accelerometer to monitor movement and orientation. The power supply temperature sensor and external capsule temperature sensor may be a thermistor or thermocouple and the current sensor for the heater and power supply current sensor may be a resistive based sensor or another type of sensor configured to measure current. The air flow sensor (e.g., flow sensor 185) may be a pressure sensor (e.g., a capacitive pressure sensor, etc.) configured to detect positive or negative air pressure (e.g., a draw or a puff), a microelectromechanical system (MEMS) flow sensor, and/or another type of sensor configured to measure air flow such as a hot-wire anemometer. Further, instead of, or in addition to, measuring air flow using a flow sensor included in the device sensors 2125 of the control subsystem 2100 of the device body housing, air flow may be measured using a hot wire anemometer located in the capsule 300. According to some example embodiments, the device sensors 2125 further includes a capsule detection sensor for detecting the presence of the capsule in the aerosol-generating device 100, and/or a door detection sensor for detecting the closure of a door and/or lid of the aerosol-generating device, but the example embodiments are not limited thereto.

The data generated from one or more of the device sensors 2125 may be detected based on a binary signal (e.g., on/off signal) using a general purpose input/output (GPIO) circuit, etc., and/or may be sampled at a sample rate appropriate to the parameter being measured using, for example, a discrete, multi-channel analog-to-digital converter (ADC), etc.

Additionally, according to some example embodiments, the device sensors may further include a tag sensor, such as a barcode sensor, a secure element (SE) reader, an optical reader, a physical parameter reader, etc. The tag sensor and/or the tag antenna (e.g., RFID antenna, NFC antenna, etc.) may be used individually or in combination to detect information stored on a tag (e.g., a RFID tag, a NFC tag, a barcode tag, a SE, etc.) installed and/or attached to an exterior portion of the capsule 300, and/or may be used to detect and/or sense a physical parameter of the capsule 300, such as a resistance value of a heater included within the capsule 300, etc. The tag sensor and/or tag antenna may be arranged in physical proximity to a properly inserted capsule 300 such that information stored on the tag, such as electronic identity information, authentication information, hardware parameter information, aerosol-forming substrate information (such as aerosol-forming substrate expiration information, date of manufacture information, etc.), profile information, etc.

The controller 2105 may adapt heater profiles for an aerosol-forming substrate and other profiles based on the measurement information received from the controller 2105. For the sake of convenience, these are generally referred to as aerosol profiles. The heater profile identifies the power profile to be supplied to the heater during the few seconds when aerosol drawing takes place and/or the power profile to be supplied to the heater in between aerosol drawing instances in order to apply continual heating to the capsule (e.g., to provide an “oven mode” where a desired temperature is maintained within the capsule for a desired period of time). For example, a heater profile can deliver maximum power to the heater when an instance of aerosol drawing is initiated, but then after a second or so immediately reduce the power to halfway or a quarter way. According to at least some example embodiments, the modulation of electrical power provided to the heater may be implemented using pulse width modulation, but is not limited thereto.

In addition, a heater profile can also be modified based on a detected draw and/or application of negative pressure on the aerosol-generating device 100. The use of the flow sensor allows aerosol drawing strength to be measured and used as feedback to the controller 2105 to adjust the power delivered to the heater of the capsule 300, which may be referred to as heating or energy delivery.

According to at least some example embodiments, when the controller 2105 recognizes the capsule 300 which is currently installed (e.g., via SKU, via a unique identifier included in a tag (e.g., RFID tag, NFC tag, etc.), etc.), the controller 2105 matches an associated heating profile that is designed for that particular capsule. The controller 2105 and the storage medium 2145 will store data and algorithms that allow the generation of heating profiles for all SKUs, capsule types, aerosol-forming substrate types, etc. In some example embodiments, the controller 2105 may read the heating profile from the capsule. Additionally, the adult operators may also adjust heating profiles to suit their preferences using the on-product controls 2150, using an external device wirelessly paired with the aerosol-generating device 100 and/or connected to the aerosol-generating device 100 via the I/O interfaces 2130, etc. In other example embodiments, the controller 2105 may use the heating profile applied for a previously installed capsule, which has been stored in memory, to a currently installed capsule on the assumption that the current capsule is of a same type as the previously installed capsule, etc.

The controller 2105 may send data to and receive data from the power supply 2110. The power supply 2110 includes a power source 2110b (e.g., which may correspond to the power source 230) and a power controller 2110a to manage the power output by the power source 2110b.

The power source 2110b may be a lithium-ion battery or one of its variants, for example a lithium-ion polymer battery. Alternatively, the power source 2110b may be a nickel-metal hydride battery, a nickel cadmium battery, a lithium-manganese battery, a lithium-cobalt battery, or a fuel cell. Alternatively, the power source 2110b may be rechargeable and include circuitry allowing the battery to be chargeable by an external charging device. In that case, the circuitry, when charged, provides power for a desired (or alternatively a pre-determined) number of instances of aerosol drawing, after which the circuitry must be re-connected to an external charging device.

The power controller 2110a provides commands to the power source 2110b based on instructions from the controller 2105. For example, the power supply 2110 may receive a command from the controller 2105 to provide power to the capsule (through the capsule electrical/data interface 2120) when the capsule is detected and the adult operator activates the control subsystem 2100 (e.g., by activating a switch such as a toggle button, capacitive sensor, IR sensor). Additionally, according to some example embodiments, the controller 2105 may transmit the command to the power supply 2110 based on the proper authentication of the capsule, but the example embodiments are not limited thereto.

In addition to supplying power to the capsule, the power supply 2110 also supplies power to the controller 2105. Moreover, the power controller 2110a may provide feedback to the controller 2105 indicating performance of the power source 2110b.

The controller 2105 sends data to and receives data from the at least one antenna 2140. The at least one antenna 2140 may include an NFC modem and a Bluetooth Low Energy (LE) modem and/or other modems for other wireless technologies (e.g., WiFi, etc.). In some example embodiments, the communications stacks are in the modems, but the modems are controlled by the controller 2105. The Bluetooth LE modem is used for data and control communications with an application on an external device (e.g., smart phone, etc.). The NFC/Bluetooth LE/WiFi modem may be used for pairing of the aerosol-generating device 100 to the application and transmission of diagnostic information, data, profile information, capsule information, hardware parameter information, firmware updates, etc. Moreover, the Bluetooth LE/WiFi modem may be used to provide location information (for an adult operator to find the aerosol-generating device) or authentication during a purchase, etc.

As described above, the control subsystem 2100 may generate and adjust various profiles for aerosol generation. The controller 2105 uses the power supply 2110 and the actuator controls 2115 to regulate the profile for the adult operator.

The actuator controls 2115 include passive and active actuators to regulate a desired aerosol profile. For example, the device body housing may include actuators within an air inlet path and/or air inlet channel of the device body housing, such as within the air flow subsystem of the aerosol-generating device 100 (e.g., air passage 182, manifold 184, air inlet connection 216, etc.). The actuator controls 2115 may control the flow of air within the air inlet channel using the actuators based on commands from the controller 2105 associated with the desired aerosol profile.

Moreover, the actuator controls 2115 are used to energize the heater in conjunction with the power supply 2110. More specifically, the actuator controls 2115 are configured to generate a drive waveform associated with the desired aerosol profile. As described above, each possible profile is associated with a drive waveform. Upon receiving a command from the controller 2105 indicating the desired aerosol profile, the actuator controls 2115 may produce the associated modulating waveform for the power supply 2110.

The controller 2105 supplies information to the aerosol indicators 2135 to indicate statuses and occurring operations to the adult operator. The aerosol indicators 2135 include a power indicator displayed on the display panel (e.g., a communication screen that may be included in the consumer interface panel 140), a separate indicator light (e.g., a LED indicator light, etc.) that may be activated when the controller 2105 senses a button pressed by the adult operator. The aerosol indicators 2135 may also include a haptic feedback motor, speaker, an indicator for a current state of an adult operator-controlled aerosol parameter (e.g., generated aerosol volume), and other feedback mechanisms.

In some example embodiments the control subsystem 2100 may implement and/or may be implemented by one or more portions of the aerosol generator 200 as shown in at least FIGS. 1A to 15. For example, in some example embodiments, at least a portion of the control subsystem 2100, including but not limited to the controller 2105, the antenna 2140, the aerosol indicators 2135, the storage medium 2145, the I/O interfaces 2130, the actuator controls 2115, the on-product controls 2150, the power supply 2110, the device sensors 2125, the capsule electrical/data interface 2120, any combination thereof, or the like may be implemented by one or more of the control circuitry 220, the power source 230, the sensor 285, the consumer interface panel 140, the capsule connector 210, any combination thereof, or the like.

One or more non-limiting examples of different capsules are disclosed herein. It should be understood that the relevant teachings/variants with regard to one capsule may be applicable to the other capsules unless indicated otherwise.

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.

Example Embodiments

Example Embodiment 1

An aerosol-generating device, comprising:

• • an aerosol generator configured to generate an aerosol based on heating of an aerosol-forming substrate;
  • a housing enclosing a lower portion of the aerosol generator and exposing an upper portion of the aerosol generator;
  • a lid; and
  • a filled hinge fixedly coupling the lid to the aerosol generator independently of the housing, the filled hinge defining an axis of rotation between the aerosol generator and the lid, the axis of rotation crossing a central longitudinal axis of the aerosol generator, the filled hinge including
    • a hinge knuckle including two knuckle structures spaced apart from each other along the axis of rotation to at least partially define opposite axial ends of a central cavity between the two knuckle structures along the axis of rotation,
    • a hinge dowel pin coupled between the two knuckle structures, the hinge dowel pin extending along the axis of rotation through the central cavity between the two knuckle structures, and
    • a torsion spring configured to at least contact the lid, the torsion spring including a spring coil, the spring coil surrounding at least a portion of the hinge dowel pin between the two knuckle structures within the central cavity.

Example Embodiment 2

The aerosol-generating device of Example Embodiment 1, wherein the aerosol-generating device is a heated tobacco aerosol-generating device, and the aerosol generator is configured to generate the aerosol based on non-combustion heating of the aerosol-forming substrate.

Example Embodiment 3

The aerosol-generating device of Example Embodiment 1, wherein the hinge knuckle further includes

• • a first cover at least partially defining a first vertical end of the central cavity that extends at least partially between the opposite axial ends of the central cavity, the first cover overlapping a first coil section of the spring coil in a vertical direction, the vertical direction extending perpendicular to the axis of rotation and paraxial to the central longitudinal axis of the aerosol generator.

Example Embodiment 4

The aerosol-generating device of Example Embodiment 3, wherein

• • the first cover at least partially defines a groove extending in a direction extending toward the central longitudinal axis and crossing the central longitudinal axis, such that the groove exposes a portion of the central cavity in the vertical direction.

Example Embodiment 5

The aerosol-generating device of Example Embodiment 3, wherein the hinge knuckle further includes

• • a second cover at least partially defining a second vertical end of the central cavity that extends at least partially between the opposite axial ends of the central cavity, the second vertical end opposite to the first vertical end in the vertical direction, the second cover at least partially overlapping the spring coil in the vertical direction.

Example Embodiment 6

The aerosol-generating device of Example Embodiment 5, wherein

• • the first cover is an upper cover and the second cover is a lower cover, such that the lower cover is configured to be between the upper cover and a lowermost end of the aerosol-generating device in the vertical direction.

Example Embodiment 7

The aerosol-generating device of Example Embodiment 1, wherein

• • the hinge knuckle includes one or more inner surfaces at least partially defining a slot extending from the central cavity to a latch structure, and
  • the torsion spring includes
    • a first leg extending from one end of the spring coil to at least contact the lid, and
    • a second leg extending from an opposite end of the spring coil and further extending through at least a portion of the slot to engage the latch structure.

Example Embodiment 8

The aerosol-generating device of Example Embodiment 7, wherein the hinge knuckle defines the latch structure.

Example Embodiment 9

The aerosol-generating device of Example Embodiment 1, wherein the two knuckle structures are defined by separate, respective portions of a single unitary piece of material, the single unitary piece of material further defining at least a portion of the aerosol generator.

Example Embodiment 10

The aerosol-generating device of Example Embodiment 1, wherein

• • the two knuckle structures define separate, respective pin holes that are each coaxial with the axis of rotation, and
  • the hinge dowel pin extends through both the central cavity and at least a portion of each of the separate, respective pin holes of the two knuckle structures.

Example Embodiment 11

The aerosol-generating device of Example Embodiment 10, wherein

• • the hinge dowel pin extends entirely through each of the separate, respective pin holes, such that the two knuckle structures are between opposite ends of the hinge dowel pin along the axis of rotation, and
  • the lid is fixedly coupled to the hinge dowel pin at each of the opposite ends of the hinge dowel pin.

Example Embodiment 12

An aerosol-generating device, comprising:

• • an aerosol generator configured to generate an aerosol based on heating of an aerosol-forming substrate;
  • a housing enclosing a lower portion of the aerosol generator and exposing an upper portion of the aerosol generator;
  • a lid; and
  • a filled hinge fixedly coupling the lid to the aerosol generator independently of the housing, the filled hinge configured to enable the lid to pivot around an axis of rotation between
    • a closed position wherein the lid at least partially covers both the upper portion of the aerosol generator and the filled hinge in at least a vertical direction extending parallel to a central longitudinal axis of the aerosol generator, and
    • an open position wherein the lid exposes the upper portion of the aerosol generator to an external environment in at least the vertical direction,
  • wherein the filled hinge includes
    • a hinge dowel pin extending along the axis of rotation,
    • a hinge knuckle including two knuckle structures supporting the hinge dowel pin at each of opposite end portions of the hinge dowel pin, the two knuckle structures further at least partially defining opposite axial ends of a central cavity between the two knuckle structures along the axis of rotation, and
    • a torsion spring configured to at least contact the lid, the torsion spring including a spring coil, the spring coil surrounding at least a portion of the hinge dowel pin between the two knuckle structures within the central cavity.

Example Embodiment 13

The aerosol-generating device of Example Embodiment 12, wherein the aerosol-generating device is a heated tobacco aerosol-generating device, and the aerosol generator is configured to generate the aerosol based on non-combustion heating of the aerosol-forming substrate.

Example Embodiment 14

The aerosol-generating device of Example Embodiment 12, wherein

• • the vertical direction includes at least a first vertical direction, the first vertical direction extending toward the axis of rotation, and
  • the hinge knuckle further includes a first cover configured to at least partially shield the spring coil within the central cavity in at least the first vertical direction.

Example Embodiment 15

The aerosol-generating device of Example Embodiment 14, wherein

• • the filled hinge is configured to enable the lid to pivot around the axis of rotation such that at least a portion of the torsion spring moves azimuthally in relation to the axis of rotation from an open-lid position to a closed-lid position, the open-lid position azimuthally offset from the first cover, the closed-lid position at least partially overlapping the first cover in an axial direction that is paraxial to the axis of rotation.

Example Embodiment 16

The aerosol-generating device of Example Embodiment 14, wherein

• • the vertical direction includes a second vertical direction, the second vertical direction extending toward the axis of rotation, the second vertical direction extending opposite to the first vertical direction, and
  • the hinge knuckle further includes a second cover configured to at least partially shield the spring coil within the central cavity in at least the second vertical direction.

Example Embodiment 17

The aerosol-generating device of Example Embodiment 16, wherein

• • the first cover is an upper cover and the second cover is a lower cover, such that the upper cover is configured to be between the lower cover and a lowermost end of the aerosol-generating device.

Example Embodiment 18

The aerosol-generating device of Example Embodiment 12, wherein

• • the hinge knuckle includes one or more inner surfaces at least partially defining a slot extending from the central cavity to a latch structure, and
  • the torsion spring includes
    • a first leg extending from one end of the spring coil to at least contact the lid, and
    • a second leg extending from an opposite end of the spring coil and further extending through the slot to engage the latch structure.

Example Embodiment 19

The aerosol-generating device of Example Embodiment 18, wherein the hinge knuckle defines the latch structure.

Example Embodiment 20

The aerosol-generating device of Example Embodiment 12, wherein the two knuckle structures are defined by separate portions of a single unitary piece of material, the single unitary piece of material further defining at least a portion of the aerosol generator.

Example Embodiment 21

The aerosol-generating device of Example Embodiment 12, wherein

• • the two knuckle structures define separate, respective pin holes that are each coaxial with the axis of rotation, and
  • the hinge dowel pin extends through both the central cavity and at least a portion of each of the separate, respective pin holes of the two knuckle structures.

Example Embodiment 22

The aerosol-generating device of Example Embodiment 21, wherein

• • the hinge dowel pin extends entirely through each of the separate, respective pin holes, such that the two knuckle structures are between opposite ends of the hinge dowel pin along the axis of rotation, and
  • the lid is fixedly coupled to the hinge dowel pin at each of the opposite ends of the hinge dowel pin.