REPLACEABLE FILTRATION SYSTEM AND APPARATUS

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/728,875 filed on Dec. 6, 2024, the entire disclosure of which is incorporated herein by reference in its entirety.

BACKGROUND

Field

The present disclosure relates to a replaceable filtration system for a heat-not-burn (HNB) aerosol-generating device.

SUMMARY

At least one example embodiment relates to an apparatus for filtration of an aerosol-generating device.

In at least one example embodiment, the apparatus includes a filter carriage and a filter. The filter carriage includes a base defining an opening, a lid configured to be removably coupled to the base such that the lid is moveable between an open position and a closed position, a hinge between the base and the lid, and a handle coupled to at least a portion of the lid. The filter is configured to be inserted into the opening of the filter carriage. The filter includes a first layer defining a central opening, a second layer, and a third layer including a plurality of discs. The plurality of discs includes a plurality of depressions. The second layer is between the first layer and the third layer.

In at least one example embodiment, the filter carriage includes a plurality of interconnected structures defining a plurality of open spaces.

In at least one example embodiment, the filter carriage includes a polymer substrate.

In at least one example embodiment, the first layer includes a high-density cotton in a range of 2.5 g/cm³ to 8.5 g/cm³.

In at least one example embodiment, the second layer includes a plurality of cotton fibers wrapped in a spiral shape.

In at least one example embodiment, the plurality of depressions includes 5 depressions.

In at least one example embodiment, the plurality of discs includes 4 discs.

In at least one example embodiment, the plurality of depressions includes a first set of depressions about a perimeter of the plurality of discs and at least one depression at a center of the plurality of discs. The plurality of discs includes a first disc, a second disc, a third disc, and a fourth disc. The first set of depressions of the first disc and the third disc are configured to be aligned and the first set of depressions of the second disc and the fourth disc are configured to be aligned.

In at least one example embodiment, each of the plurality of discs are configured to be offset from an adjacent one of the plurality of discs by 45°.

In at least one example embodiment, the filter has a cylindrical shape.

In at least one example embodiment, each of the plurality of depressions are 60% less thick than a thickness of each of the plurality of discs.

At least one example embodiment relates to a system for filtration of an aerosol-generating device.

In at least one example embodiment, the system includes a housing defining a cavity configured to receive a capsule; a lid removably coupled to the housing, the lid including a mouthpiece defining a channel between a first end of the mouthpiece and a second end of the mouthpiece; and a filter assembly configured to be at least partially inserted into the channel at the first end of the mouthpiece. The filter assembly includes a filter carriage defining an opening and a filter configured to be inserted into the opening of the filter carriage. The filter carriage includes a base, a lid configured to be removably coupled to the base such that the lid is moveable between an open position and a closed position, a first hinge between the base and the lid, and a handle coupled to at least a portion of the lid. The filter includes a first layer defining a central opening, a second layer, and a third layer including a plurality of discs. The plurality of discs includes a plurality of depressions. The second layer is between the first layer and the third layer.

In at least one example embodiment, the system includes a hinge between the lid and the housing. The lid is moveable between an open position and a closed position. The open position provides access to the channel at the first end of the mouthpiece.

In at least one example embodiment, the mouthpiece includes at least one protrusion extending from a portion of the channel adjacent the first end. The filter carriage defines at least one recess configured to engage the at least one protrusion and secure the filter carriage within the mouthpiece.

In at least one example embodiment, the housing further comprises a gasket between the capsule and the filter assembly.

In at least one example embodiment, the handle of the filter extends from a first end to a second end. The first end is coupled to at least a portion of the lid of the filter carriage and the second end includes an end member. A bottom surface of the mouthpiece at the second end of the mouthpiece defines a recess configured to receive the end member of the handle and secure the handle within the mouthpiece.

In at least one example embodiment, a shape of the end member includes a circular, oval, square, rectangular, or polygonal shape.

In at least one example embodiment, the filter carriage includes a plurality of interconnected structures defining a plurality of open spaces.

In at least one example embodiment, the filter carriage includes a polymer substrate.

In at least one example embodiment, the first layer includes a high-density cotton in a range of 2.5 g/cm³ to 8.5 g/cm³.

In at least one example embodiment, the second layer includes a plurality of cotton fibers wrapped in a spiral shape.

In at least one example embodiment, the plurality of depressions includes 5 depressions.

In at least one example embodiment, the plurality of discs includes 4 discs.

In at least one example embodiment, the plurality of depressions includes a first set of depressions about a perimeter of each of the plurality of discs and at least one depression at a center of the plurality of discs. The plurality of discs includes a first disc, a second disc, a third disc, and a fourth disc. The first set of depressions of the first disc and the third disc are configured to be aligned and the first set of depressions of the second disc and the third disc are configured to be aligned.

In at least one example embodiment, each of the plurality of discs are configured to be offset from an adjacent one of the plurality of discs by 45°.

In at least one example embodiment, the filter includes a cylindrical shape.

In at least one example embodiment, each of the plurality of depressions are 60% less thick than a thickness of each of the plurality of discs.

BRIEF DESCRIPTION OF THE DRAWINGS

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

FIG. 1A is a front perspective view of an aerosol-generating device in accordance with at least one example embodiment.

FIG. 1B is a rear perspective view of the aerosol-generating device of FIG. 1 in accordance with at least one example embodiment.

FIG. 1C is a front view of the aerosol-generating device of FIG. 1 in accordance with at least one example embodiment.

FIG. 2A is a front view of a filter assembly in accordance with at least one example embodiment.

FIG. 2B is a front view of the filter assembly of FIG. 2A in an open position in accordance with at least one example embodiment.

FIG. 3A is a front perspective view of a filter of the filter assembly of FIGS. 2A-2B in accordance with at least one example embodiment.

FIG. 3B is a cross-sectional view of the filter of FIG. 3A along line III-III in accordance with at least one example embodiment.

FIG. 4 is a front perspective view of a first layer of the filter of FIG. 3 in accordance with at least one example embodiment.

FIG. 5 is a front perspective view of a second layer of the filter of FIG. 3 in accordance with at least one example embodiment.

FIG. 6A is a front perspective view of a third layer of the filter of FIG. 3 in accordance with at least one example embodiment.

FIG. 6B is a top view of a plurality of discs of the third layer of the filter of FIG. 6A in accordance with at least one example embodiment.

FIG. 7 is a cross-sectional view of the filter assembly within a lid and mouthpiece of the aerosol-generating device of FIG. 1A along line VII-VII in accordance with at least one example embodiment.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

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

Accordingly, while example embodiments are capable of various modifications and alternative forms, example embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit an example embodiment to the particular forms disclosed, but to the contrary, example embodiments are to cover all modifications, equivalents, and alternatives falling within the scope of an example embodiment. 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, region, layer, or section discussed below could be termed a second element, region, layer, or section without departing from the teachings of example embodiment.

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,” when used in this specification, specify the presence of stated features, integers, steps, operations, and/or elements, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements and/or groups thereof.

Example embodiments are described herein with reference to cross-sectional illustrations that are schematic illustrations of example embodiment. As such, variations from the shapes of the illustrations are to be expected. Thus, example embodiment should not be construed as limited to the shapes of regions illustrated herein but are to include deviations and variations in shapes.

When the words “about” and “substantially” are used in this specification in connection with a numerical value, it is intended that the associated numerical value include a tolerance of ±10% around the stated numerical value, unless otherwise explicitly defined. 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 embodiment 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.

FIG. 1A is a front perspective view of an aerosol-generating device in accordance with at least one example embodiment. FIG. 1B is a rear perspective view of the aerosol-generating device of FIG. 1 in accordance with at least one example embodiment. FIG. 1C is a front view of the aerosol-generating device of FIG. 1 in accordance with at least one example embodiment.

At least one example embodiment relates to an aerosol-generating device 100 including a housing 105 and a lid 110 coupled to the housing. In at least one example embodiment, the lid 110 may also include a mouthpiece 115 extending from at least a portion of the lid 110. In at least one example embodiment, the lid 110 may be removably coupled to the housing 105. For example, the lid 110 may be coupled to the housing by a hinge 120. The lid may be configured to move between a closed position, shown in FIGS. 1A-1B, and an open position, shown in FIG. 1C, at the hinge 120.

In at least one example embodiment, the housing 105 may include a capsule receiving cavity 130 configured to receive a capsule. The capsule may be configured to contain an aerosol-forming substrate. The capsule may also contain a heater for heating the aerosol-forming substrate and generating an aerosol in some example embodiments. In at least one example embodiment, the lid 110 defines a lid cavity 125. The lid cavity 125 may be configured to receive a filter assembly, as will be discussed below in relation to FIGS. 2A-9. In at least one example embodiment, the housing 105 includes a gasket between the capsule and the filter assembly. The gasket may be configured to create a seal between the capsule and the filter assembly when the lid 110 is in the closed position. The device and capsule may include features as set forth in application Ser. No. 17/151,327, filed on Jan. 18, 2021, which published as US 2022/0225672, and application Ser. No. 17/947,436, filed on Sep. 19, 2022, the entire contents of each of which are incorporated herein by reference thereto.

In at least one example embodiment, the aerosol-generating device 100 is configured to heat a capsule inserted into the capsule receiving cavity 130 to generate an aerosol. The aerosol-generating device 100 and method of generating an aerosol may be similar or analogous to the device and methods as also set forth in application Ser. No. 17/947,436, published as US 2024/0090574, and filed on Sep. 19, 2022, the entire contents of which is incorporated herein by reference thereto.

In at least one example embodiment, a method of generating an aerosol may include initially loading the capsule into the aerosol-generating device 100. To load the capsule 200, the lid 110 is pivoted to the open position, shown in FIG. 1C, and the capsule is inserted into the capsule-receiving cavity 130. Next, the lid 110 is pivoted to the closed position, shown in FIGS. 1A-1B.

In at least one example embodiment, the aerosol-generating device 100 may be activated using an interface panel 135, such as by pressing a power button 137, or upon detection of a draw event. For example, the aerosol-generating device 100 may include a flow sensor configured to detect a draw event or a puff. Upon activation, a heater is configured to heat the capsule within the capsule receiving cavity 130. For example, the aerosol-generating device may include control circuitry configured to instruct a power source within the housing 105 to supply an electrical current from a power supply to a heater within the housing 105. In at least one example embodiment, the capsule may undergo resistive heating. As a result of the heating of the capsule, the temperature of the aerosol-forming substrate within the capsule will increase such that volatiles are released so as to generate an aerosol.

In at least one example embodiment, the heating of the aerosol-forming substrate within the capsule may be below a 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). Thus, in at least one example embodiment, pyrolysis does not occur during the heating and resulting production of aerosol. In other instances, there may be some pyrolysis and combustion byproducts, but the extent may be considered relatively minor and/or merely incidental. The method of heating/control may be as described in U.S. application Ser. No. 17/151,375, published as US 2022/0225685 and titled “Heat-Not-Burn (HNB) Aerosol-Generating Devices Including Energy Based Heater Control, And Methods Of Controlling A Heater”, filed Jan. 18, 2021; and U.S. application Ser. No. 17/151,409, issued as U.S. Pat. No. 11,789,476 and titled “Heat-Not-Burn (HNB) Aerosol-Generating Devices Including Intra-Draw Heater Control, and Methods of Controlling a Heater”, filed Jan. 18, 2021, the entire contents of each of which are incorporated herein by reference thereto.

Upon a draw or application of negative pressure to the aerosol-generating device 100, such as via the mouthpiece 115, ambient air is drawn into the aerosol-generating device 100. Once inside, the air flows through at least one air channel within the housing 105 and through the capsule within the capsule receiving cavity 130. The airflow travels through the capsule and through the aerosol-forming substrate within the capsule so as to entrain the volatiles released by the aerosol-forming substrate, which results in an aerosol. The resulting air exits the capsule and then flows through a filtration system within the lid cavity 125, as will be discussed below with respect to FIGS. 2A-7, before exiting the aerosol-generating device 100 through the mouthpiece 115.

FIG. 2A is a front view of a filter assembly in accordance with at least one example embodiment. FIG. 2B is a front view of the filter assembly of FIG. 2A in an open position in accordance with at least one example embodiment.

In at least one example embodiment, the lid cavity 125 of the lid 110 is configured to receive a filtration system, such as a filter assembly 200. The filter assembly 200 may include a filter carriage 205 having a base 210 and a carriage lid 215. The carriage lid 215 may be removably coupled to the base 210. For example, the carriage lid may be moveable between a closed position, shown in FIG. 2A, and an open position, shown in FIG. 2B, at a hinge 220. The hinge 220 may include a living hinge, a knife hinge, an overlay hinge, a concealed hinge, a barrel door hinge, a counter flip hinge or any other kind of hinge. In at least one example embodiment, the filter carriage 205 comprises a substantially cylindrical shape. In other example embodiments, the filter carriage 205 comprises a trapezoidal, circular, ovular, rectangular, or polygonal shape in cross-section. In at least one example embodiment, the filter carriage 205 comprises a polymer substrate. For example, the filter carriage may comprise a polymer plastic.

In at least one example embodiment, the filter assembly 200 includes a filter handle 225 (shown in FIG. 2B) coupled to the carriage lid 215. The filter handle 225 may be coupled to the carriage lid 215 opposite the hinge 220. In at least one example embodiment, the filter handle 225 includes an extension 230 extending from the carriage lid 215 and an end member 235 coupled to an end of the extension 230 opposite the carriage lid 215. The extension 230 and/or the end member 235 may be gripped or held by an adult consumer to move the carriage lid 215 from the closed position to the open position. In at least one example embodiment, pulling the filter handle 225 may also disengage and remove the filter carriage 205 from the lid cavity 125 of the lid 110.

In at least one example embodiment, the filter carriage 205 includes a plurality of interconnected structures 240. The plurality of interconnected structures 240 define an exterior of the filter carriage 205 and include a plurality of open spaces 245 between each of the plurality of interconnected structures 240. The plurality of open spaces 245 between the plurality of interconnected structures 240 may be configured to allow air flow through the filter carriage 205. In at least one example embodiment, the filter carriage 205 defines a cavity configured to receive a filter 250, which will be described below in relation to FIGS. 3-8. In at least one example embodiment, the filter 250 is replaceable. For example, the filter 250 may be removed from the filter carriage 205 after use, by opening the carriage lid 215 using the filter handle 225 as discussed above, and replaced with a new filter 250. In other example embodiments, the filter assembly 200 may be replaceable. For example, the filter assembly 200, including the filter carriage 205 and the filter 250, may be removed from the lid cavity 125 and replaced. In at least one example embodiment, the filter 250 is configured to remove compounds from an aerosol generated by the capsule in the capsule receiving cavity 130, as set forth above with respect to FIG. 1C, through the filter 250 of the filter assembly 200, and to the mouthpiece 115.

In at least one example embodiment, the filter carriage 205 defines at least two recesses 255 adjacent a first end 260 of the base 210 of the filter carriage 205. The at least two recesses 255 may be configured to engage an interior portion of the lid 110, as will be discussed below with respect to FIG. 7. The at least two recesses 255 may comprise a trapezoidal, circular, ovular, rectangular, or polygonal shape in cross-section. In at least one other example embodiment, the at least two recesses 255 may be defined by at least two of the open spaces 245 between the interconnected structures 240 adjacent the first end 260 of the base 210.

In at least one example embodiment, the filter carriage 205 may also define at least one engagement edge 265 adjacent a second end 270 of the filter carriage 205. For example, at least a portion of the carriage lid 215 may define the at least one engagement edge 265. The at least one engagement edge may extend about a periphery of the carriage lid 215 in at least one example embodiment. In other example embodiments, the at least one engagement edge 265 comprises at least two engagement edges 265 on opposing sides of the carriage lid 215. The at least one engagement edge may be configured to engage a portion of the interior of the lid 110, as will be discussed below with respect to FIG. 7.

FIG. 3A is a front perspective view of a filter of the filter assembly of FIGS. 2A-2B in accordance with at least one example embodiment. FIG. 3B is a cross-sectional view of the filter of FIG. 3A along line III-III in accordance with at least one example embodiment.

In at least one example embodiment, as shown in FIG. 3A, the filter 250 includes a plurality of layers. For example, the filter 250 may include a first layer 300, a second layer 305, and a third layer 310. In at least one example embodiment, the filter 250 may be in the form of a rod. For example, the filter may have a height extending from a bottom end 315 to a top end 320. In at least one example embodiment, the first layer 300 may be adjacent the bottom end 315, the third layer 310 may be adjacent the top end 320, and at least the second layer 305 may be between the first layer 300 and the third layer 310. In at least one example embodiment, the filter 250 comprises a cylindrical shape. In at least one example embodiment, the third layer 310 comprises a plurality of discs 600, which will be described below with respect to FIG. 6A.

In at least one example embodiment, as shown in FIG. 3B, the first layer 300 defines a first opening 400, which will be discussed below with respect to FIG. 4. The first opening 400 extends through a center of the first layer 300. In at least one example embodiment, the second layer 305 includes a plurality of cotton fibers wrapped into a spiral, which will be described below with respect to FIG. 5, such the second layer 305 may comprise an accordion or bellows-type shape, as shown in FIG. 3B.

FIG. 4 is a front perspective view of a first layer of the filter of FIGS. 3A and 3B in accordance with at least one example embodiment.

In at least one example embodiment, the first layer 300 defines the first opening 400. The first opening 400 may extend through a center of the first layer 300, as shown in FIG. 3B. The first layer 300 may be configured to direct air flow into the filter 250 through the first opening 400. The first layer 300 may also be configured to prevent and/or reduce air flow, aerosol, and/or or gas from leaking out of the filter 250. The filter carriage may sit on the gasket that is slightly above the capsule and the two will form a seal forcing gas through an area of low pressure (e.g., a hole in a center of the first filter material). In at least one example embodiment, the first layer 300 comprises a cylindrical shape. In at least one example embodiment, the first layer 300 comprises a high-density cotton. In other example embodiments, the first layer 300 may include any organic fiber such as corn, coconut husk, jute, flax, coir, hemp, or any combination thereof. For example, the first layer 300 may comprise a high-density cotton between about 2.5 g/cm³ to about 8.5 g/cm³. In at least one example embodiment, the first layer 300 has a thickness of about 0.7 mm to about 1.0 mm.

FIG. 5 is a front perspective view of a second layer of the filter of FIG. 3 in accordance with at least one example embodiment.

In at least one example embodiment, the second layer 305 comprises a material wrapped or wound into a spiral 500, as shown in FIG. 5. For example, the second layer 305 comprises a plurality of cotton fibers wrapped into the spiral 500. The cotton fibers may be a long sheet that is bent back and forth upon itself and then curved into a roll so as to establish long channels along the second layer 305. In cross-section, the second layer 305 may comprise an accordion or bellows-type shape, as shown in FIG. 3B. The bellows-type shape of the second layer 305 may allow any excess oils to be collected without obstructing air flow through the filter 250, which may result from an adhesion effect of long vertical filters and the filter material. Any oil passing through the first filter may be absorbed by the second filer. In at least one example embodiment, the first layer 300 comprises a cylindrical shape. In at least one example embodiment, the material of the second layer 305 comprises any synthetic or organic fiber. In at least one example embodiment, the second layer 305 may include cotton. In at least one example embodiment, the second layer 305 comprises a thickness between about 1.5 mm and about 2.2 mm when rolled out. The second layer 305 may also comprise a density between about 6.0 g/cm³ and about 8.0 g/cm³.

FIG. 6A is a front perspective view of a third layer of the filter of FIG. 3 in accordance with at least one example embodiment. FIG. 6B is a top view of a plurality of discs of the third layer of the filter of FIG. 6A in accordance with at least one example embodiment.

In at least one example embodiment, the third layer 310 includes the plurality of discs 600. For example, the third layer 310 may include at least four discs, as shown in FIGS. 6A-6B. In other example embodiments, the third layer 310 may include between 2-6 of the discs 600. The disc layers may depend on a size of a cavity in a mouthpiece. In at least one example embodiment, the number of discs will be chosen to allow for a 0 to 0.2 mm gap between a top of the mouthpiece and the filter housing. Each of the discs 600 include a thickness 605. In at least one example embodiment, the thickness 605 of each of the discs 600 may be uniform. For example, the thickness 605 of each of the discs 600 may be between about 0.1 mm and about 3.0 mm and a density of about 1.0 g/cm³ to about 4.0 g/cm³. In other example embodiments, the thickness 605 of one or more of the discs 600 may vary.

In at least one example embodiment, each of the plurality of discs 600 include one or more depressions or dimples. The one or more depressions or dimples may extend partially through a thickness of each of the plurality of discs 600. Each of the plurality of discs 600 may include at least one center dimple 603 in a center portion and a set of dimples, such as a plurality of peripheral dimples 610, in a peripheral portion. In at least one example embodiment, each of the discs 600 may include four of the peripheral dimples 610 adjacent the periphery of each of the discs 600. The peripheral dimples 610 may surround the center dimple 603. In at least one example embodiment, each of the peripheral dimples 610 may be evenly spaced apart about the periphery of each disc 600 and/or about the center dimple 603. In other example embodiments, each of the peripheral dimples 610 may be unevenly spaced apart about the periphery of each of the discs 600 and/or the center dimple 603. In at least one example embodiment, placement on each disc for the dimples may be in any configuration without limitation to any particular orientation. However, in at least one example embodiment, the dimples are in a Metatron's cube formation with one central dimple and 5-6 additional dimples extending from the central dimple at about 60 degrees. A thickness of the dimples should be reduced by about 60% of the overall disc thickness. For example, if the disc has a thickness of about 1.5 mm, the dimple should be about 0.9 mm.

In at least one example embodiment, each of the discs 600 are stacked, as shown in FIG. 6A. The discs 600 may be stacked such that each center dimple 603 is aligned with another center dimple 603 of an adjacent one of the discs 600. In at least one example embodiment, the discs 600 may be stacked such that the peripheral dimples 610 of one of the discs 600 is misaligned or offset from an adjacent one of the discs 600. Each of the discs 600 may be rotated about 45-90° in some example embodiments. For example, each of the discs 600 may be rotated about 45°, as shown in FIG. 6B, such that the peripheral dimples 610 of every other one of the discs 600 in the stack are aligned. For example, the peripheral dimples 610 of a first one of the discs 600 and a third one of the discs 600 may be aligned and the peripheral dimples 610 of a second one of the discs 600 and a fourth one of the discs 600 may be aligned. In other example embodiments, each of the discs 600 may be rotated about 90° relative to an adjacent one of the discs 600.

In at least one example embodiment, each of the center dimples 603 and the peripheral dimples 610 are configured to be less thick than the thickness 605 of each of the plurality of discs 600. For example, each of the center dimples 603 and the peripheral dimples 610 may be about 60% less thick than the thickness 605 of each of the plurality of discs 600. In at least one example embodiment, each of the center dimples 603 and the peripheral dimples 610 are also configured to reduce resistance-to-draw (RTD), such that the RTD is about 15 mmWG to about 230 mmWG. For example, a size and number of each of the center dimples 603 and/or the peripheral dimples 610 may be adjusted to control the resistance-to-draw of the filter 250 and the filter assembly 200.

FIG. 7 is a cross-section view of the filter assembly within a lid and mouthpiece of the aerosol-generating device of FIG. 1A along line VII-VII in accordance with at least one example embodiment.

The lid cavity 125 of the lid 110 is configured to removably receive the filter carriage 205. In at least one example embodiment, an interior of the lid 110 may include at least two protrusions 700 configured to engage the at least two recesses 255 and/or the at least one engagement edge 265 of the filter carriage 205. The at least two protrusions 700 may comprise a trapezoidal, circular, ovular, rectangular, or polygonal shape in cross-section. The at least two protrusions 700 may have a beveled or tapered edge to facilitate engagement with the at least two recesses 255 and/or the at least one engagement edge 265 of the filter carriage 205. In at least one example embodiment, the at least two recesses 255 and/or the at least one engagement edge 265 of the filter carriage 205 are configured to engage the at least two protrusions 700 of the lid 110 in a snap-fit. In other example embodiments, the filter may friction fit within the filter carriage 205.

In at least one example embodiment, the filter handle 225 may be configured to engage at least a portion of the interior of the lid 110. For example, a portion of the interior of the lid 110 may define a notch or recess configured to receive at least the end member 235 of the filter handle 225 and to secure the filter handle 225 within the lid 110.

In at least one example embodiment, the lid 110 and the mouthpiece 115 define a channel extending from an inlet end 715 of the lid 110 to the outlet end 710 of the mouthpiece 115. The filter carriage 205 is at least partially received within the channel within the lid cavity 125. Aerosol generated within the capsule of the capsule receiving cavity 130, as discussed above with respect to FIG. 1C, is configured to be drawn through the filter 250 within the filter carriage 205 and into the mouthpiece 115 where the aerosol my exit through the outlet end 710.

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.

Illustrative embodiment 1. An apparatus for filtration of an aerosol-generating device, comprising: a filter carriage including, a base defining an opening, a lid configured to be removably coupled to the base such that the lid is moveable between an open position and a closed position, a hinge between the base and the lid, and a handle coupled to at least a portion of the lid; and a filter configured to be inserted into the opening of the filter carriage, the filter including, a first layer defining a central opening, a second layer, and a third layer including a plurality of discs, the plurality of discs including a plurality of depressions, the second layer between the first layer and the third layer.

Illustrative embodiment 2. The apparatus of claim 1, wherein the filter carriage includes a plurality of interconnected structures defining a plurality of open spaces.

Illustrative embodiment 3. The apparatus of Illustrative embodiment 1, wherein the filter carriage includes a polymer substrate.

Illustrative embodiment 4. The apparatus of Illustrative embodiment 11, wherein the first layer includes a high-density cotton in a range of 2.5 g/cm³ to 8.5 g/cm³.

Illustrative embodiment 5. The apparatus of Illustrative embodiment 1, wherein the second layer includes a plurality of cotton fibers wrapped in a spiral shape.

Illustrative embodiment 6. The apparatus of Illustrative embodiment 1, wherein the plurality of depressions includes 5 depressions.

Illustrative embodiment 7. The apparatus of Illustrative embodiment 1, wherein the plurality of discs includes 4 discs.

Illustrative embodiment 8. The apparatus of Illustrative embodiment 1, wherein the plurality of depressions includes a first set of depressions about a perimeter of the plurality of discs and at least one depression at a center of the plurality of discs.

Illustrative embodiment 9. The apparatus of Illustrative embodiments 1-8, wherein the plurality of discs includes a first disc, a second disc, a third disc, and a fourth disc.

Illustrative embodiment 10. The apparatus of Illustrative embodiments 1-9, wherein the first set of depressions of the first disc and the third disc are configured to be aligned.

Illustrative embodiment 11. The apparatus of Illustrative embodiments 1-10, wherein the first set of depressions of the second disc and the fourth disc are configured to be aligned.

Illustrative embodiment 12. The apparatus of Illustrative embodiment 1, wherein each of the plurality of discs are configured to be offset from an adjacent one of the plurality of discs by 45°.

Illustrative embodiment 13. The apparatus of Illustrative embodiment 1, wherein the filter includes a cylindrical shape.

Illustrative embodiment 14. The apparatus of Illustrative embodiment 1, wherein each of the plurality of depressions are 60% less thick than a thickness of each of the plurality of discs.

Illustrative embodiment 15. A system for filtration of an aerosol-generating device, comprising: a housing defining a cavity configured to receive a capsule; a lid removably coupled to the housing, the lid including a mouthpiece defining a channel between a first end of the mouthpiece and a second end of the mouthpiece; and a filter assembly configured to be at least partially inserted into the channel at the first end of the mouthpiece, the filter assembly including, a filter carriage defining an opening, the filter carriage including, a base, a lid configured to be removably coupled to the base such that the lid is moveable between an open position and a closed position, a first hinge between the base and the lid, and a handle coupled to at least a portion of the lid, and a filter configured to be inserted into the opening of the filter carriage, the filter including, a first layer defining a central opening, a second layer, and a third layer including a plurality of discs, the plurality of discs including a plurality of depressions, the second layer between the first layer and the third layer.

Illustrative embodiment 16. The system of Illustrative embodiment 15, further comprising: a second hinge between the lid and the housing, the lid being moveable between an open position and a closed position, and the open position providing access to the channel at the first end of the mouthpiece.

Illustrative embodiment 17. The system of Illustrative embodiment 15, wherein the mouthpiece includes at least one protrusion extending from a portion of the channel adjacent the first end.

Illustrative embodiment 18. The system of any one of Illustrative embodiments 15-17, wherein the filter carriage defines at least one recess configured to engage the at least one protrusion and secure the filter carriage within the mouthpiece.

Illustrative embodiment 19. The system of Illustrative embodiment 15, wherein the housing further comprises a gasket between the capsule and the filter assembly.

Illustrative embodiment 20. The system of Illustrative embodiment 15, wherein the handle of the filter extends from a first end to a second end, the first end coupled to at least a portion of the lid of the filter carriage and the second end including an end member.

Illustrative embodiment 21. The system of any one of Illustrative embodiments 15-20 wherein a bottom surface of the mouthpiece at the second end of the mouthpiece defines a recess configured to receive the end member of the handle and secure the handle within the mouthpiece.

Illustrative embodiment 22. The system of any one of Illustrative embodiments 15-21, wherein a shape of the end member includes a circular, oval, square, rectangular, or polygonal shape.

Illustrative embodiment 23. The system of Illustrative embodiment 15, wherein the filter carriage includes a plurality of interconnected structures defining a plurality of open spaces.

Illustrative embodiment 24. The system of Illustrative embodiment 15, wherein the filter carriage includes a polymer substrate.

Illustrative embodiment 25. The system of Illustrative embodiment 15, wherein the first layer includes a high-density cotton in a range of 2.5 g/cm³ to 8.5 g/cm³.

Illustrative embodiment 26. The system of Illustrative embodiment 15, wherein the second layer includes a plurality of cotton fibers wrapped in a spiral shape.

Illustrative embodiment 27. The system of Illustrative embodiment 15, wherein the plurality of depressions includes 5 depressions.

Illustrative embodiment 28. The system of Illustrative embodiment 15, wherein the plurality of discs includes 4 discs.

Illustrative embodiment 29. The system of Illustrative embodiment 15, wherein the plurality of depressions include a first set of depressions about a perimeter of the plurality of discs and at least one depression at a center of the plurality of discs.

Illustrative embodiment 30. The system of any one of Illustrative embodiments 15-29, wherein the plurality of discs includes a first disc, a second disc, a third disc, and a fourth disc.

Illustrative embodiment 31. The system of any one of Illustrative embodiments 15-30, wherein the first set of depressions of the first disc and the third disc are configured to be aligned.

Illustrative embodiment 32. The system of any one of Illustrative embodiments 15-31, wherein the first set of depressions of the second disc and the third disc are configured to be aligned.

Illustrative embodiment 33. The system of Illustrative embodiment 15, wherein each of the plurality of discs are configured to be offset from an adjacent one of the plurality of discs by 45°.

Illustrative embodiment 34. The system of Illustrative embodiment 15, wherein the filter includes a cylindrical shape.

Illustrative embodiment 35. The system of Illustrative embodiment 15, wherein each of the plurality of depressions are 60% less thick than a thickness of each of the plurality of discs.

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.