阅读说明：本技术 具有加热区隔热的气溶胶生成装置 (Aerosol-generating device with heating zone insulation ) 是由 S·卡佩利 R·埃米特 E·萨迪·拉托雷 于 2020-04-22 设计创作，主要内容包括：用于加热设置在气溶胶生成制品(10)中的气溶胶形成基质(20)的气溶胶生成装置(100)包括用于接收气溶胶生成制品的远侧部分的纵向延伸腔(110)。所述纵向延伸腔具有纵向轴线,并且由基部(102)、从所述基部延伸的侧壁(103)和在所述腔的与所述基部相对的端部处的开口(111)限定。所述侧壁的内表面限定：所述腔的稳定部分(120),所述稳定部分具有第一直径；以及所述腔的位于所述稳定部分与所述基部之间的加热部分(130),所述加热部分具有大于所述第一直径的第二直径。第一直径与第二直径之间的差提供将气溶胶生成制品与腔的侧壁分开的间隙(160)。该间隙可有助于防止在使用中从气溶胶形成基质中耗散热并改善气溶胶递送。此外,腔的内壁还限定设置于腔的远侧端处的定位部分(140),所述加热部分设置于稳定部分与定位部分之间,所述腔的定位部分具有基本上等于所述稳定部分的第一直径的第三直径。(An aerosol-generating device (100) for heating an aerosol-forming substrate (20) disposed in an aerosol-generating article (10) comprises a longitudinally extending cavity (110) for receiving a distal portion of the aerosol-generating article. The longitudinally extending cavity has a longitudinal axis and is defined by a base (102), a sidewall (103) extending from the base, and an opening (111) at an end of the cavity opposite the base. The inner surface of the sidewall defines: a stabilizing portion (120) of the cavity, the stabilizing portion having a first diameter; and a heating portion (130) of the cavity between the stabilizing portion and the base, the heating portion having a second diameter greater than the first diameter. The difference between the first diameter and the second diameter provides a gap (160) separating the aerosol-generating article from a sidewall of the cavity. The gap may help to prevent heat dissipation from the aerosol-forming substrate in use and improve aerosol delivery. Further, the inner wall of the cavity further defines a positioning portion (140) disposed at the distal end of the cavity, the heating portion being disposed between the stabilizing portion and the positioning portion, the positioning portion of the cavity having a third diameter substantially equal to the first diameter of the stabilizing portion.)

1. An aerosol-generating device for heating an aerosol-forming substrate disposed in a substantially cylindrical aerosol-generating article, the aerosol-generating device comprising;

a longitudinally extending cavity for receiving a distal portion of the aerosol-generating article, the longitudinally extending cavity having a longitudinal axis and being defined by a base, a sidewall extending from the base, and an opening at an end of the cavity opposite the base,

wherein an inner surface of the sidewall defines a stabilizing portion of the cavity having a first diameter and a heating portion of the cavity between the stabilizing portion and the base, the heating portion having a second diameter greater than the first diameter,

wherein the inner wall of the cavity further defines a positioning portion disposed at a distal end of the cavity, the heating portion being disposed between the stabilizing portion and the positioning portion, the positioning portion of the cavity having a third diameter that is substantially equal to the first diameter of the stabilizing portion.

2. An aerosol-generating device according to claim 1, wherein the cross-sectional area of the cavity in the heating portion is 110% to 300% greater than the cross-sectional area of the cavity in the stabilizing portion.

3. An aerosol-generating device according to any preceding claim, wherein the difference in diameter between the stabilizing portion and the heating portion provides one or more insulating air pockets around an outer surface of the aerosol-generating article when a distal portion of the aerosol-generating article is inserted into the longitudinally extending cavity.

4. An aerosol-generating device according to any preceding claim, wherein an air inlet is defined through the base.

5. An aerosol-generating device according to any preceding claim, wherein an inner wall of the cavity defines a tapered region, wherein the diameter of the cavity varies at a constant gradient between the second diameter and the third diameter.

6. An aerosol-generating device according to any preceding claim, wherein the difference in diameter between the first diameter at the stabilizing portion and the second diameter at the heating portion is a gap diameter, the gap diameter being between 0.5mm and 5 mm.

7. An aerosol-generating device according to claim 6, wherein inner sidewall comprises one or more ribs extending longitudinally in the heating portion and radially from the inner sidewall, the ribs having a radial dimension equal to the gap diameter.

8. An aerosol-generating device according to any preceding claim comprising: a first body portion housing at least a portion of a power source, control electronics, and a heating device; and a second body portion movable relative to the first body portion, wherein the longitudinally extending cavity is defined in the second body portion.

9. An aerosol-generating device according to claim 8, wherein the second body portion is movably coupled to the first body portion between a first position and a second position, the first position being an operating position defined by the heating device being engageable with the aerosol-generating article, and the second position being an extraction position defined by the aerosol-generating article being at least partially ejected from the longitudinally extending cavity.

10. An aerosol-generating device according to any preceding claim, wherein a heating element extends into the heating portion of the cavity.

11. An aerosol-generating system comprising an aerosol-generating article and an aerosol-generating device configured to heat the aerosol-generating article,

wherein the aerosol-generating device comprises a longitudinally extending cavity for receiving a distal portion of the aerosol-generating article, the longitudinally extending cavity having a longitudinal axis and being defined by a base, a sidewall extending from the base, and an opening at an end of the cavity opposite the base,

wherein an inner surface of the sidewall defines a stabilizing portion of the cavity having a first diameter, and a heating portion of the cavity between the stabilizing portion and the base, the heating portion having a second diameter greater than the first diameter,

wherein the inner wall of the cavity further defines a positioning portion disposed at a distal end of the cavity, the heating portion being disposed between the stabilizing portion and the positioning portion, the positioning portion of the cavity having a third diameter that is substantially equal to the first diameter of the stabilizing portion.

12. An aerosol-generating system according to claim 11, wherein the aerosol-generating article is a substantially cylindrical aerosol-generating article to be heated with the device, the aerosol-generating article having a longitudinal axis and an article diameter, wherein the first diameter of the longitudinally extending cavity of the aerosol-generating device is substantially equal to the article diameter.

13. An aerosol-generating system according to claim 11 or claim 12, wherein the aerosol-generating article comprises a plurality of coaxially aligned components, including an aerosol-forming substrate assembled within a package to form a substantially cylindrical article having a longitudinal axis and an article diameter, the aerosol-generating article having a proximal portion terminating in a proximal end and a distal portion terminating in a distal end, and wherein the aerosol-forming substrate is located in the distal portion of the article.

14. An aerosol-generating system according to claim 11, 12 or 13, wherein the aerosol-generating device is as defined in any one of claims 2 to 10.

Technical Field

The present invention relates to an aerosol-generating device for heating an aerosol-forming substrate. In particular, the aerosol-generating device is configured to provide improved thermal insulation of the aerosol-forming substrate.

Background

A number of prior art documents disclose aerosol-generating devices including, for example, heated aerosol-generating systems and electrically heated aerosol-generating systems. An example of a heated aerosol-generating system is disclosed in WO2013/076098, which describes embodiments in which an aerosol-forming substrate of an aerosol-generating article is penetrated by a heating element of an aerosol-generating device in order to produce an inhalable aerosol. The heating element is in contact with the aerosol-forming substrate and raises the temperature of the substrate, thereby causing the volatile components of the substrate to evaporate. When the aerosol-forming substrate is depleted, the aerosol-generating article containing the aerosol-forming substrate is removed from the aerosol-generating device and disposed of. The aerosol-generating article disclosed in WO2013/076098 fits closely within the cavity of the extractor portion of the aerosol-generating device. This provides a tight fit, which retains the article in the cavity. The heat supplied to the aerosol-forming substrate rapidly raises the temperature of the substrate due to the direct contact between the heating element and the substrate. However, heat can also be quickly removed from the article by conduction into the walls of the cavity, which can act as a heat sink.

WO2018/050735 discloses embodiments of aerosol-generating devices in which an aerosol-generating article cavity is provided with ribs to provide improved retention of an aerosol-generating article in the cavity. The ribs are spaced apart to define airflow channels between adjacent ribs and possibly also between discontinuous ribs. The ribs are preferably arranged in an inclined manner so that a user can extract the aerosol-generating article by applying an axial force together with a torque in order to facilitate removal. However, there are still a large number of contact points between the ribs of the aerosol-generating article and the cavity, and the airflow between the longitudinal ribs also contributes to the cooling of the aerosol-forming substrate.

Disclosure of Invention

The disclosure herein relates to an aerosol-generating device for heating an aerosol-forming substrate. The aerosol-forming substrate may be provided in an aerosol-generating article. The aerosol-generating article may be a substantially cylindrical aerosol-generating article. The aerosol-generating device may comprise a longitudinally extending cavity for receiving a distal portion of the aerosol-generating article. The longitudinally extending cavity may have a longitudinal axis. The longitudinal cavity may be defined by a base, a sidewall extending from the base, and an opening at an end of the cavity opposite the base. The inner surface of the sidewall defines a first portion of the cavity having a first diameter. The first portion of the cavity may be a stable portion. A second portion of the cavity having a second diameter may be located between the stabilizing portion and the base. The second portion may be a heating portion. The second diameter may be greater than the first diameter.

In a preferred embodiment, there is provided an aerosol-generating device for heating an aerosol-forming substrate disposed in a substantially cylindrical aerosol-generating article. The aerosol-generating device comprises a longitudinally extending cavity for receiving a distal portion of the aerosol-generating article. The longitudinally extending cavity has a longitudinal axis and is defined by a base, a sidewall extending from the base, and an opening at an end of the cavity opposite the base. The inner surface of the sidewall defines a stabilizing portion of the cavity having a first diameter. The heating portion of the cavity is located between the stabilizing portion and the base. The heating portion has a second diameter greater than the first diameter.

The diameter of the stabilizing portion is such that the distal portion of the aerosol-generating article can be inserted therethrough. When the distal portion of the aerosol-generating article is inserted through the stabilizing portion, there is preferably a minimum space between the outer surface of the aerosol-generating article and the inner surface of the stabilizing portion. Preferably, there is a close or snug fit between the aerosol-generating article and the stabilizing section. Preferably, there is no gap between the outer surface of the aerosol-generating article and the inner surface of the stabilizing portion when the aerosol-generating article is received in the cavity. The outer surface of the aerosol-generating article may contact the inner surface of the stabilizing portion when the article is inserted into or received within the cavity. It is therefore preferred that the inner diameter of the stabilising portion is substantially the same size as the outer diameter of the aerosol-generating article. For example, the inner diameter of the stabilizing section may be the same as, 10% or 5% of the diameter of the outer diameter of the aerosol-generating article. In some embodiments, the inner diameter of the stabilizing portion may be from 0% to 5% greater than the outer diameter of the aerosol-generating article, for example from 1% to 4% greater, or from 2% to 3% greater. Preferably, the dimensions are such that the article can be inserted into and removed from the cavity while maintaining interference, such as contact or a seal that is not tight, between the article and the inner diameter of the stabilizing section upon insertion. Preferably, the dimensions are such that the article can be inserted into and removed from the cavity without damaging the article. Preferably, the dimensions are such that the article is supported within the cavity without allowing any substantial movement in the radial direction.

When the aerosol-generating article is fully inserted into the cavity, the distal end of the article preferably abuts the base of the cavity. When the aerosol-generating article is fully inserted into the cavity, the distal end of the aerosol-generating article may abut an optional stop or end point at or near the base of the cavity. Preferably, at least a portion of the aerosol-generating article is located within the heated portion of the cavity when the aerosol-generating article is fully inserted into the cavity. Preferably, the aerosol-generating article is configured such that when the aerosol-generating article is fully inserted into the cavity, the aerosol-forming substrate of the aerosol-generating article is received within the heated portion of the cavity. The diameter of the inner surface of the heating portion is larger than the diameter of the stabilizing portion. Thus, there is a gap between the outer surface of the aerosol-generating article and the inner surface of the heating portion. Preferably, the air gap is present completely or substantially completely around the outer surface of the portion of the aerosol-generating article located within the heated portion of the cavity. Preferably, the air gap provides an air insulating layer between a portion of the aerosol-generating article and the inner surface of the heating portion.

The transverse cross-section of the cavity at the stabilizing section preferably has substantially the same shape as the transverse cross-section of the cavity at the heating section. Preferably, the cross-sectional shape is circular or elliptical. Preferably, the stabilizing portion of the cavity and the heating portion of the cavity are coaxial.

In some embodiments, the diameter of the stabilizing portion may change to the diameter of the heating portion at a step in the inner wall of the cavity. In some embodiments, the diameter of the stabilizing section may be changed to the diameter of the heating section by a series of steps. In some embodiments, the diameter of the stabilizing section may be changed to the diameter of the heating section by a sloped inner portion of the chamber wall.

An aerosol-generating article comprises an aerosol-forming substrate which can be heated to generate an aerosol. Preferably, the aerosol-forming substrate is positioned at or near the distal end of the aerosol-generating article. Thus, when the aerosol-generating article is fully inserted into the cavity of the device, at least a portion of the aerosol-forming substrate is positioned within the heating portion. The heating means for heating the aerosol-forming substrate is positioned to heat a portion of the aerosol-forming substrate of the aerosol-generating article located within the heating portion. The heating means may comprise a heating element. In some embodiments, the heating element may comprise a resistive heating element. In some embodiments, the resistive heating element may comprise one or more electrically conductive tracks on an electrically insulating substrate.

In some embodiments, the heating device may include a susceptor and an inductor. The heating device preferably comprises a heating element or susceptor arranged to penetrate the distal end of the aerosol-generating article and contact the aerosol-forming substrate when the aerosol-generating article is fully inserted into the cavity of the aerosol-generating device. In some embodiments, the susceptor may be provided as part of an aerosol-generating article. In some embodiments, the susceptor may be provided as part of an aerosol-generating article and as part of an aerosol-generating device.

In some embodiments, the heating element may be provided as part of an aerosol-generating device. The heating element may be arranged to at least partially penetrate a portion of the aerosol-forming substrate when the aerosol-forming substrate is received within the heating portion. The heating element may be an elongate heating element. The heating element may comprise a pointed or tapered end. The pointed or tapered end advantageously facilitates penetration of the heating element through the aerosol-forming substrate. The heating element may be a blade-shaped resistive heating element. The heating element may be a pin-shaped resistive heating element. The heating element may comprise only one heating element. The heating element may be arranged along a central longitudinal axis of the heating portion. The heating element may comprise a plurality of heating elements. The plurality of heating elements may have the same characteristics. One or more of the plurality of heating elements may have one or more different characteristics than the remainder of the plurality of heating elements. The characteristic may be, for example, size, shape, dimension, operating temperature.

In some embodiments, the heating element may be provided as part of an aerosol-generating article and may operate in combination with one or more features of the device. The heating element may be a susceptor which is part of the aerosol-generating article. The heating element may be a susceptor arranged in an area of the aerosol-forming substrate. The heating element may be a susceptor element having any of a variety of shapes. The susceptor element may be in the shape of a rod, a cube, a cuboid, or any other shape that is incorporated into the aerosol-generating article. The susceptor element may be arranged centrally along a central longitudinal axis of the aerosol-generating article. The heating element may be a susceptor material incorporated into an aerosol-forming substrate portion of an aerosol-generating article. The susceptor material may be provided, for example, in any of the following forms: granules, strips, chips, powders, sheets or webs.

As used herein, the term "susceptor" refers to a material that can convert electromagnetic energy into heat. When located within a fluctuating electromagnetic field, eddy currents induced in the susceptor cause heating of the susceptor. When the susceptor is positioned in thermal contact with, or at least in proximity to, the aerosol-forming substrate is heated by the susceptor.

As used herein, the term inductor refers to a component that can generate a fluctuating electromagnetic field for heating a susceptor located within the fluctuating electromagnetic field. In use, the aerosol-generating article may be engaged with the aerosol-generating device such that the susceptor is located within the fluctuating electromagnetic field generated by the inductor.

As used herein, an "aerosol-generating device" relates to a device that interacts with an aerosol-forming substrate to generate an aerosol. The aerosol-forming substrate may be a component part of an aerosol-generating article. The aerosol-generating device may comprise one or more components for supplying energy from a power source to the aerosol-forming substrate to generate an aerosol. For example, the aerosol-generating device may be a heated aerosol-generating device. The aerosol-generating device may be an electrically heated aerosol-generating device or a gas heated aerosol-generating device. The aerosol-generating device may be an aerosol-generating device which interacts with an aerosol-forming substrate of an aerosol-generating article to generate a gas which may be inhaled through a user's mouth directly into the user's lungs.

As used herein, the term "aerosol-forming substrate" relates to a substrate capable of releasing volatile compounds capable of forming an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may conveniently be used as part of an aerosol-generating article. The aerosol-forming substrate may be described as being located in a heating zone of an aerosol-generating article. The aerosol-generating article may be an elongate aerosol-generating article. The aerosol-generating article may be substantially rod-shaped. The aerosol-generating article may have a substantially constant diameter along the entire length of the aerosol-generating article.

As used herein, the term "aerosol-generating article" refers to an article comprising an aerosol-forming substrate capable of releasing volatile compounds capable of forming an aerosol. For example, aerosol-generating articles are capable of generating an aerosol that can be inhaled directly into the lungs of a user through the mouth of the user. The aerosol-generating article may be disposable. The aerosol-generating article is a heatable aerosol-generating article, which is intended to be heated rather than to burn in order to release volatile compounds capable of forming an aerosol. The aerosol formed by heating the aerosol-forming substrate may contain less known harmful constituents than known harmful constituents produced by combustion or thermal degradation of the aerosol-forming substrate. In some embodiments, the aerosol-generating article may comprise an aerosol-forming substrate. In some embodiments, the aerosol-forming substrate may be formed from or may comprise processed tobacco, such as homogenised tobacco or cast leaf tobacco.

As used herein, the term "aerosol-generating system" refers to an aerosol-generating device and at least one aerosol-generating article configured for use with the device.

As used herein, the terms "upstream", "downstream", "proximal" and "distal" are used to describe the relative positions of elements or portions of elements of aerosol-generating articles, aerosol-generating devices and aerosol-generating systems according to the invention.

The aerosol-generating article described herein comprises a proximal end through which, in use, aerosol exits the aerosol-generating article. The proximal end may also be referred to as a mouth end. In use, a user draws on the proximal end or mouth end of the aerosol-generating article in order to inhale an aerosol generated by the aerosol-generating article. In some embodiments, the aerosol-generating device and aerosol-generating article are configured such that at least a portion of the mouth end is not received within the longitudinally extending cavity of the device when the article is fully inserted into the cavity. That is, at least a portion of the mouth end extends outwardly beyond the opening of the cavity of the aerosol-generating device. In this way, a user can draw on the mouth end of the aerosol-generating article. In some embodiments, the aerosol-generating device and aerosol-generating article are configured such that when the article is fully inserted into the cavity, the entire length of the aerosol-generating article is received within the longitudinally extending cavity of the device. In some embodiments, a mouthpiece element comprising an airflow channel alignable with a mouth end of an aerosol-generating article may be provided. In this way, the user can instead draw on the mouthpiece. In some embodiments, the mouthpiece element may be a separate mouthpiece element. A separate mouthpiece may be engaged with one or both of the aerosol-generating device and the aerosol-generating article. In some embodiments, instead of a separate mouthpiece element, a mouthpiece element may be provided as part of the aerosol-generating device.

The aerosol-generating article includes a distal end opposite a proximal end or mouth end. The proximal or mouth end of the aerosol-generating article may also be referred to as the downstream end and the distal end of the aerosol-generating article may also be referred to as the upstream end. Components or portions of components of aerosol-generating articles may be described as being upstream or downstream of each other based on their relative position between a proximal or downstream end and a distal or upstream end of the aerosol-generating article.

As used herein, the term "diameter" is used to refer to the largest transverse dimension of an aerosol-generating article, an aerosol-generating device and a component or part of a component of an aerosol-generating system according to the present invention. For the avoidance of doubt, as used herein, the term "diameter" may refer to the "width" of a non-circular transverse cross-section of an aerosol-generating article, an aerosol-generating device and a component or part of a component of an aerosol-generating system.

As used herein, the term "longitudinal" is used to describe a direction between a downstream or proximal end and an opposite upstream or distal end of an aerosol-generating article, aerosol-generating device and aerosol-generating system according to the present invention, and the term "transverse" is used to describe a direction perpendicular to the longitudinal direction.

For the avoidance of doubt, in this description the term "heating element" is used to denote one or more heating elements.

Prior art aerosol-generating systems exist in which a cylindrical aerosol-generating article is arranged to be inserted into a cavity of an aerosol-generating device to be penetrated by a heating device, for example as disclosed in WO 2013/076098. The heating device in WO2013/076098 is a heating element that penetrates an aerosol-forming substrate to heat the substrate sufficiently to form an aerosol. However, the efficiency of the device may be affected by the contact between the walls of the cavity and the article inserted into the cavity. The use of the aerosol-generating device disclosed herein provides a number of advantages over this prior art.

A heating element arranged to be inserted into at least a portion of an aerosol-forming substrate of an aerosol-generating article may immediately deliver heat to that portion of the aerosol-forming substrate with which it is in contact. In some embodiments, it is preferred to heat the aerosol-forming substrate to a temperature of between 150 ℃ and 450 ℃, for example between 200 ℃ and 400 ℃, or between 250 ℃ and 350 ℃, or between 300 ℃ and 350 ℃. The heat transfer within the aerosol-forming substrate causes the entire aerosol-forming substrate to be heated, although there may be a time lag for the temperature towards the outer portion of the aerosol-forming substrate to reach the temperature required to form an aerosol. The present aerosol-generating device minimizes or avoids contact between the outer surface of the aerosol-generating article and the inner wall of the article-receiving cavity of the aerosol-generating device, at least in the heating portion of the aerosol-generating article. This helps to prevent heat transfer between the aerosol-generating article and the walls of the cavity. Dissipation of thermal energy within a heated aerosol-forming substrate may be minimised due to reduced contact between the outer surface of an aerosol-generating article comprising the aerosol-forming substrate and the inner wall of the article-receiving cavity of the aerosol-generating device, at least in the heating portion of the aerosol-generating article. Thus, a greater proportion of the heat from the heating means may be retained within the aerosol-forming substrate and the entire substrate may be brought to the operating temperature more quickly. Air between the outer wall of the cavity in the heating portion and the aerosol-generating article may provide thermal insulation of the aerosol-generating article as a thermal barrier.

The invention may reduce the time delay between the start of operation of the heating element and the arrival of the aerosol-forming substrate at the operating temperature. The operating temperature may be a temperature at or above which one or more volatile compounds are released from the aerosol-forming substrate. Advantageously, the time between operation of the aerosol-generating system being activated by a user and the aerosol-generating device being ready for the user to take a first puff, also referred to as TT1P, may be reduced. Advantageously, the initial aerosol delivery provided by the aerosol-generating device described herein may be improved. Thus, the user experience in the first few puffs may be improved.

In another advantage, the reduced heat transfer between the outer surface of the aerosol-generating article and the wall of the cavity of the aerosol-generating device means that less thermal energy is dissipated from the aerosol-generating article upon heating. Thus, the aerosol-forming substrate may be held at the operating temperature for a longer period of time, for example between puffs. Once at the operating temperature, a lower energy input may be required to maintain the aerosol-forming substrate at that operating temperature. This helps to provide a consistent user experience during consumption of the article. This may also mean that less total energy is required to consume the aerosol-generating article. Thus, the device may be operated with a smaller power source, such as a smaller battery, than would otherwise be required. The device may be able to perform a greater number of operating cycles without the need to provide a larger battery.

In another advantage, reducing or eliminating contact points between the aerosol-generating article and the walls of the cavity may help prevent cold spots from forming in the aerosol-forming substrate. Cold spots are areas of the aerosol-forming substrate which, due to local heat dissipation, do not reach an optimum operating temperature during consumption of the device. If cold spots occur, the aerosol-forming substrate may not be fully consumed during use. Thus, by minimising or preventing cold spots in the aerosol-forming substrate, the total substrate mass required for a satisfactory user experience may be lower.

In another advantage, the reduction in heat dissipated from the aerosol-generating article may reduce the maximum temperature that the heating element needs to reach in order to achieve a satisfactory user experience. In addition to the lower energy requirement, this may also reduce the chance of heating parts of the aerosol-forming substrate to a high temperature in the region contacting the heating element, which may result in unpleasant taste and odour.

A substantially cylindrical aerosol-generating article heated with the device may have a longitudinal axis and an article diameter. The first diameter is preferably substantially equal to the diameter of the article, such that the distal portion of the substantially cylindrical aerosol-generating article can be inserted through the stabilizing portion of the cavity. Preferably, the transverse cross-sectional shape of the aerosol-generating article is substantially the same as the transverse cross-sectional shape of the stabilizing portion of the cavity.

The diameter of the cavity in the heating portion may be 105% to 170%, for example 110% to 150%, larger than the diameter of the cavity in the stabilizing portion. Preferably, the diameter of the cavity in the heating portion may be 120% to 140%, for example 125% to 130%, larger than the diameter of the cavity in the stabilizing portion.

The cross-sectional area of the cavity in the heating portion may be 110% to 300% greater than the cross-sectional area of the cavity in the stabilizing portion. For example, the cross-sectional area of the cavity in the heating portion may be 115% to 280% greater than the cross-sectional area of the cavity in the stabilizing portion, for example 130% to 200% greater, preferably 140% to 160% greater.

Preferably, a diameter difference between the first diameter at the stabilizing portion and the second diameter at the heating portion is referred to as a gap diameter. Preferably, the gap diameter may be between 0.5mm and 5mm, for example between 1mm and 4 mm. In other words, the aerosol-generating device is configured such that when the aerosol-generating article is fully inserted into the cavity, there is an air gap between the outer surface of the aerosol-generating article and the inner surface of the heated portion of the cavity equal to half the diameter of the gap, for example between 0.25mm and 2.5 mm. Preferably, the air gap is between 0.25mm and 2.5mm, for example between 0.3mm and 2mm, or between 0.5mm and 1 mm. The air gap provides a layer of air insulation between the outer surface of the aerosol-generating article and the inner surface of the heating portion of the cavity.

Preferably, the difference in diameter between the stabilizing portion and the heating portion provides one or more insulating air pockets that are fully inserted around their distal portions into the outer surface of the aerosol-generating article in the longitudinally extending cavity. In case there is more than one air pocket, preferably there is no through-flow of air between the air pockets. In some embodiments, the air pocket is preferably annular, extending around the aerosol-generating article when received in the cavity. Two or more semi-annular air pockets may be defined. Where more than one air pocket is defined, in some embodiments the air pockets are separated by ribs, such as longitudinal ribs or annular ribs. The air flow within the one or several air pockets may contribute to the heat dissipation of the aerosol-generating article. It is therefore highly preferred that there is no defined air inlet or air outlet in the heating portion of the device when the article is inserted into the cavity, which may allow air to flow into or out of the air pocket or pockets defined by the gap between the aerosol-generating article and the inner wall of the heating portion. In particular, it is preferred that there is no air inlet or air outlet defined through the side wall of the cavity extending to the heating section.

Advantageously, the air inlet is defined by the base of the cavity. Such inlets may provide a source of air to allow air to be drawn into the distal end of the aerosol-generating article along the length of the article and into the mouth of a user through the proximal or mouth end of the aerosol-generating article. Such an air inlet through the base of the cavity may be provided by a single hole at the centre point of the base or within a small radius of the centre point. Such inlets may be positioned such that the air inlet is aligned with the end face of the aerosol-generating article when the aerosol-generating article is inserted into the cavity of the aerosol-generating device. That is, the air inlet is not located in the region of the gap diameter.

In a preferred embodiment, the inner wall of the cavity may further define a locating portion disposed at the distal end of the cavity. The heating portion may be disposed between the stabilizing portion and the positioning portion. The locating portion of the cavity may have a third diameter substantially equal to the first diameter of the stabilizing portion. The locating portion is preferably coaxially aligned with the stabilizing portion. In this way, the cylindrical article can pass through the stabilizing portion and the distal end of the article can be seated in the positioning portion. The distal end of the article may thus be radially constrained. Preferably, when the article is fully inserted into the cavity, the article is retained by contact with both the inner wall of the stabilising portion and the inner wall of the locating portion. Preferably, the positioning portion and the aerosol-generating article are dimensioned such that the article can be inserted into and removed from the cavity while maintaining interference, such as contact or a poor seal, between the article and the inner diameter of the positioning portion when inserted into the cavity. Advantageously, in such a configuration, the one or more closed air pockets may be defined by a gap between an outer surface of the aerosol-generating article and an inner surface of the cavity. Thus, the outer boundary of the circumferential or annular air pocket when the aerosol-generating article is fully inserted into the cavity may be formed by: (1) an outer surface of the aerosol-generating article, (2) an inner surface of the heating portion of the cavity, (3) a radially extending step or ramp extending between the inner surface of the heating portion and the inner surface of the stabilizing portion, and (4) a radially extending step or ramp extending between the inner surface of the heating portion and the inner surface of the positioning portion.

In some embodiments, the diameter of the heating portion may change to the diameter of the positioning portion at a step in the inner wall of the cavity. Alternatively, in some embodiments, the diameter of the heating portion may be varied to the diameter of the positioning portion by a series of steps. In some embodiments, the diameter of the heating portion may be changed to the diameter of the positioning portion by means of an inclined inner portion of the chamber wall. In some embodiments, the inner wall of the lumen may define a tapered region, wherein the diameter of the lumen varies between the second diameter and the third diameter. Advantageously, the taper may assist in the alignment of the aerosol-generating article when the aerosol-generating article is inserted into the cavity. The tapered region may act as a funnel to guide the distal end of the aerosol-generating article into the locating portion of the cavity.

Preferably, there is minimal contact between the article and the chamber walls in the heated portion. It may be preferred, for example, that there is a circumferential air gap defined around the article inserted into the cavity. However, it may be desirable to include one or more ribs. The one or more ribs may help guide and stabilize an aerosol-generating article inserted into the cavity. In some embodiments, only one rib is provided. In some embodiments, a plurality of ribs is provided. In some embodiments, 3 ribs are provided. In some embodiments, 6 ribs are provided. Where more than one rib is provided, preferably the ribs are substantially evenly spaced around the circumference of the cavity. The one or more ribs may be longitudinally extending ribs. Such ribs may extend radially into the cavity from an inner wall of the heating portion of the cavity. Preferably, any such ribs extend radially a distance substantially equal to the air gap. The interior sidewalls of the cavity may define one or more ribs extending longitudinally in the heating portion. The ribs may have a radial dimension equal to half the diameter of the gap. A plurality of individual part-annular air pockets may be formed by such ribs. For example, two longitudinally extending ribs may separate the heating portions of the cavity to allow two semi-annular air pockets to be defined when the article is inserted into the cavity. In some embodiments, the ribs may be annular. In some embodiments, the ribs may be a combination of longitudinal ribs and annular ribs. The combination of the longitudinal ribs and the annular ribs may define a plurality of air chambers.

In some embodiments, an aerosol-generating device may comprise a first body portion and a second body portion movable relative to the first body portion. The first body portion may house at least a portion of the power supply, control electronics, and heating means of the aerosol-generating device. A longitudinally extending cavity may be defined in the second body portion. The second body portion can act as an extractor. In some embodiments, the extractor may facilitate at least partial separation of the aerosol-forming substrate from the heating element. In some embodiments, the extractor may facilitate complete separation of the aerosol-forming substrate from the heating element. In some embodiments, the extractor may facilitate tearing the aerosol-forming substrate away from the heating element. In some embodiments, the extractor may facilitate removal of the aerosol-generating article after the article has been consumed. For example, the aerosol-generating device may comprise a heating device attached to, integrated into or part of the first body portion. Movement of the second body portion relative to the first body portion may act to separate an aerosol-forming substrate of an aerosol-generating article received in a cavity of the second body portion of the aerosol-generating device from the heating device. The first body portion and the second body portion may be removably coupled to each other. Thus, the second body portion may be easily removed from the first body portion to facilitate cleaning, for example.

In some embodiments, the second body portion is movable between a first position and a second position. The first position may be an operating position defined by the engagement of a heating device, such as a heating element or an inductor, with an aerosol-forming substrate of an aerosol-generating article. The first position may be an operating position defined by the insertion of the heating element into and contact with an aerosol-forming substrate of an aerosol-generating article. The first position may be an operating position defined by the aerosol-forming substrate of the aerosol-generating article being located within an alternating magnetic field generated by the inductor. The second position may be an extraction position defined by the aerosol-forming substrate being at least partially detached or separated from the heating means. At least partial separation may comprise physical separation, or simply separation, provided that the bond or interface between the heating means and the aerosol-forming substrate is broken. For example, the aerosol-forming substrate may adhere to the heating device during and after heating. The second extraction position may be a position in which the aerosol-forming substrate is released from the heating device. The second extraction position may be a position where the aerosol-forming substrate moves out of the alternating magnetic field generated by the inductor. Advantageously, such an extractor helps to facilitate removal of the aerosol-generating article from the aerosol-generating device. Thus, the extractor may be movably coupled to the aerosol-generating device and may be movable between a first position in which the aerosol-forming substrate is in contact with a heating element of the aerosol-generating device and a second position in which the aerosol-forming substrate is at least partially separated from the heating element. Preferably, the extractor remains coupled to the aerosol-generating device in the first position. Preferably, the extractor remains coupled to the aerosol-generating device in the second position. In some embodiments, the extractor remains coupled to the aerosol-generating device when at any intermediate point between the first position and the second position. The extractor may be removably coupled to the aerosol-generating device.

The extractor may comprise a slide container. The slide container may define a cavity for receiving the aerosol-generating article. The sliding container is preferably slidable between a first position and a second position. In some embodiments, the entire extractor, including the sliding receptacle, can be moved to translate the sliding receptacle between the first position and the second position. Alternatively, only the sliding container of the extractor can slide between the first and second positions.

In a preferred embodiment, the heating element may extend into a heating portion of the cavity of the aerosol-generating device. The heating element may be substantially blade-shaped for insertion into an aerosol-forming substrate of an aerosol-forming article. The heating element may have a length between 10mm and 60 mm. The heating element may have a width of between 2mm and 10 mm. The heating element may have a thickness between 0.2mm and 1 mm. Preferred lengths may be between 15mm and 50mm, for example between 18mm and 30 mm. Preferred lengths may be about 19mm or about 20 mm. Preferably the width may be between 3mm and 7mm, for example between 4mm and 6 mm. Preferably the width may be about 5 mm. Preferably the thickness may be between 0.25mm and 0.5 mm. Preferably the thickness may be about 0.4 mm. The heating element may comprise an electrically insulating substrate and a resistive heating element. In some embodiments, the resistive heating element comprises one or more rails. In some embodiments, the resistive heating element is disposed on or embedded in an electrically insulating substrate. The resistive heating element may be supported by an electrically insulating substrate. Alternatively or additionally, the heating element may surround a heated portion of the cavity.

The invention may provide an aerosol-generating system comprising an aerosol-generating article and an aerosol-generating device configured to heat an aerosol-forming substrate of the aerosol-generating article. The aerosol-generating device may be any device described herein.

The aerosol-generating article may be any article suitable for consumption using such a device. For example, the aerosol-generating article may be any article described herein. For example, in some embodiments, an aerosol-generating article may comprise a plurality of coaxially aligned components. The plurality of coaxial alignments may comprise an aerosol-forming substrate assembled within a package to form a substantially cylindrical article. The aerosol-generating article may have a longitudinal axis and an article diameter. The aerosol-generating article may have a proximal portion terminating in a proximal end and a distal portion terminating in a distal end. The aerosol-forming substrate is preferably located at or near a distal portion of the article. In some embodiments, the aerosol-forming substrate may be a tobacco rod, for example a cylindrical tobacco rod.

The aerosol generating article may have a total length of between about 30mm and about 100mm, preferably between 40mm and 60mm or between 42mm and 52mm, for example about 45 mm. The aerosol-generating article may have an outer diameter of between about 5mm and about 12mm, for example between 6mm and 9mm, or between 7mm and 8 mm.

The aerosol-generating article may comprise a filter element. The filter element may comprise a filter segment. The filter element may be located at a downstream end of the aerosol-generating article. The filter element may be a cellulose acetate filter segment. In some embodiments, the length of the filter element is about 7 mm. The filter element may have a length of between about 5mm and about 10 mm.

In some embodiments, the total length of the aerosol-generating article is about 45 mm. The aerosol-generating article may have an outer diameter of about 7mm, for example between 6.8mm and 7.2 mm. The aerosol-forming substrate may have a length of between about 8mm and 14mm, for example 10mm or 11mm or 12 mm.

The aerosol-forming substrate may have a diameter of between about 5mm and about 12 mm. The aerosol-generating article may comprise an outer wrapper. The aerosol-generating article may comprise a separation between the aerosol-forming substrate and the filter segment of the filter. The separation may be in the range of about 5mm to about 25 mm. Preferably, the separation is about 18 mm. The separation may include one or more spacer members.

In some embodiments, the aerosol-forming substrate is a solid aerosol-forming substrate. In some embodiments, the aerosol-forming substrate is a liquid aerosol-forming substrate. In some embodiments, the aerosol-forming substrate is a gel aerosol-forming substrate. In some embodiments, the aerosol-forming substrate comprises both solid and liquid components. In some embodiments, the aerosol-forming substrate comprises both solid and gel components. In some embodiments, the aerosol-forming substrate comprises both liquid and gel components.

The aerosol-forming substrate is preferably a solid aerosol-forming substrate. The aerosol-forming substrate may comprise a tobacco-containing material containing volatile compounds that are released from the substrate upon heating. The volatile compounds may include volatile tobacco flavor compounds. The aerosol-forming substrate may comprise an aerosol former which facilitates dense and stable aerosol formation. Examples of suitable aerosol formers are glycerol and propylene glycol. In some embodiments, the aerosol-forming substrate may comprise a non-tobacco material. In some embodiments, the aerosol-forming substrate may comprise a tobacco material and additionally a non-tobacco material.

If the aerosol-forming substrate is a solid aerosol-forming substrate, in some embodiments, the solid aerosol-forming substrate may comprise, for example, one or more of: powder, granule, pellet, chip, strand, ribbon, or sheet. In some embodiments, the aerosol-forming substrate may comprise one or more of the following: herbaceous plant leaves, tobacco vein segments, reconstituted tobacco, extruded tobacco, cast leaf tobacco, and expanded tobacco. In some embodiments, the solid aerosol-forming substrate may be in bulk form. In some embodiments, the aerosol-forming substrate may be provided in a suitable container or cartridge. Alternatively, the solid aerosol-forming substrate may comprise additional tobacco or non-tobacco volatile compounds, such as volatile flavour compounds, which are released upon heating of the substrate. The solid aerosol-forming substrate may comprise a capsule, for example comprising additional tobacco or non-tobacco volatile compounds. In some embodiments, such capsules may melt during heating of the solid aerosol-forming substrate. In some embodiments, such capsules may include a frangible membrane. The frangible membrane can be crushed to release the volatile compound, for example, by a user, before or during use.

As used herein, homogenized tobacco refers to a material formed by agglomerating particulate tobacco. The homogenized tobacco material may be in the form of a sheet. The homogenized tobacco material may have an aerosol former content of greater than 5% on a dry weight basis. Alternatively, the homogenized tobacco material may have an aerosol former in an amount of between 5 and 30 weight percent on a dry weight basis. Sheets of homogenized tobacco material may be formed by agglomerating particulate tobacco obtained by grinding or otherwise combining one or both of tobacco lamina and tobacco stem. Alternatively or additionally, the sheet of homogenized tobacco material may comprise one or more of tobacco dust, tobacco fines and other particulate tobacco by-products formed during, for example, processing, handling and transporting the tobacco. The sheet of homogenized tobacco material may comprise one or more intrinsic binders that are tobacco endogenous binders, one or more extrinsic binders that are tobacco exogenous binders, or a combination thereof, to help agglomerate the particulate tobacco; alternatively or additionally, the sheet of homogenized tobacco material may include other additives, including but not limited to tobacco and non-tobacco fibers, aerosol formers, humectants, plasticizers, flavorants, fillers, aqueous and non-aqueous solvents, and combinations thereof.

In a particularly preferred embodiment, the aerosol-forming substrate comprises a gathered crimped sheet of homogenised tobacco material. As used herein, the term "crimped sheet" means a sheet having a plurality of substantially parallel ridges or corrugations. Preferably, the substantially parallel ridges or corrugations extend along or parallel to the longitudinal axis of the aerosol-generating article when the aerosol-generating article has been assembled. This advantageously promotes aggregation of the crimped sheet of homogenised tobacco material to form the aerosol-forming substrate. However, it will be appreciated that the crimped sheet of homogenized tobacco material for inclusion in an aerosol-generating article may alternatively or additionally have a plurality of substantially parallel ridges or corrugations that are disposed at acute or obtuse angles to the longitudinal axis of the aerosol-generating article when the aerosol-generating article has been assembled. In certain embodiments, the aerosol-forming substrate may comprise a gathered sheet of homogenised tobacco material that is textured substantially uniformly over substantially its entire surface. For example, the aerosol-forming substrate may comprise a gathered crimped sheet of homogenised tobacco material comprising a plurality of substantially parallel ridges or corrugations that are substantially evenly spaced across the width of the sheet.

Optionally, the solid aerosol-forming substrate may be disposed on or embedded in a thermally stable carrier. The carrier may take the form of a powder, granules, pellets, chips, strands, ribbons or sheets. Alternatively, the support may be a tubular support having a thin layer of solid substrate deposited on its inner surface or its outer surface or both. Such tubular supports may be formed, for example, from paper, or paper-like materials, non-woven carbon fiber mats, low mass open mesh wire mesh, or perforated metal foil, or any other thermally stable polymer matrix.

The solid aerosol-forming substrate may be deposited on the surface of the carrier in the form of, for example, a sheet, foam, gum or slurry. The solid aerosol-forming substrate may be deposited over the entire surface of the carrier or, alternatively, may be deposited in a pattern so as to provide uneven flavour delivery during use.

An aerosol-generating system is a combination of an aerosol-generating device and one or more aerosol-generating articles for use with the device. However, the aerosol-generating system may comprise further components, such as a charging unit for recharging an onboard power source in an electrically operated aerosol-generating device or an aerosol-generating device.

Drawings

Specific embodiments of the present invention will now be described with reference to the accompanying drawings, in which:

figure 1 is a schematic view of an aerosol-generating article suitable for use with an aerosol-generating device according to the invention;

figure 2 is a schematic view of a cavity of an aerosol-generating device defining an article-receiving cavity for receiving a suitable aerosol-generating article, according to an aspect of the present invention;

figure 3 is a schematic diagram showing the aerosol-generating article of figure 1 when inserted into the article-receiving cavity of figure 2;

figure 4 is a schematic cross-section of figure 3 showing an aerosol-generating article positioned within the heated portion of the chamber;

figure 5 is a schematic diagram showing an extractor comprising the cavity of figure 2 coupled to a body portion of an aerosol-generating device according to the invention;

figure 6 is a schematic diagram showing the aerosol-generating article of figure 1 when fully inserted into the cavity of the aerosol-generating device of figure 5;

figure 7 is a schematic view of a cavity of a control aerosol-generating device, not in accordance with aspects of the present invention, defining an article-receiving cavity for receiving a suitable aerosol-generating article;

figure 8 is a schematic diagram showing the aerosol-generating article of figure 1 when fully inserted into the cavity of the aerosol-generating device of figure 7;

figure 9 is a graph comparing nicotine delivery per puff between an aerosol-generating device according to the invention and a control device;

figure 10 is a graph comparing glycerol delivery per puff between an aerosol-generating device according to the present invention and a control device;

figure 11 is a schematic view of a further embodiment of a cavity of an aerosol-generating device according to aspects of the present invention, the cavity comprising ribs extending longitudinally along a heated portion;

FIG. 12 is a schematic transverse cross-sectional view of a heating portion of a cavity showing two ribs;

FIG. 13 is a schematic transverse cross-sectional view of a heating portion of a cavity showing three ribs;

FIG. 14 is a schematic transverse cross-sectional view of a heating portion of a cavity showing six ribs;

fig. 15 is a schematic longitudinal cross-sectional view of the extractor showing some of its six ribs; and

figure 16 is a schematic view of another embodiment of an aerosol-generating device according to aspects of the present invention, the aerosol-generating device comprising a sensor and an aerosol-generating article suitable for use with a device comprising a susceptor.

Detailed Description

Figure 1 shows an aerosol-generating article 10 suitable for use with an aerosol-generating device according to an embodiment of the present invention. The aerosol-generating article 10 comprises four elements arranged in coaxial alignment: an aerosol-forming substrate 20, a support element 30, a transfer section 40 and a mouthpiece 50. These four elements are arranged in sequence and surrounded by an outer wrapper 60 to form the aerosol-generating article 10. The aerosol-generating article 10 has a mouth end 70 into which a user inserts his mouth during use, and a distal end 80 located at the end of the aerosol-generating article 10 opposite the mouth end 70.

In use, air is drawn through the aerosol-generating article from the distal end 80 to the mouth end 70 by the user. The distal end 80 of the aerosol-generating article may thus also be described as the upstream end of the aerosol-generating article 10, and the mouth end 70 of the aerosol-generating article 10 may also be described as the downstream end of the aerosol-generating article 10. Elements of the aerosol-generating article 10 positioned between the mouth end 70 and the distal end 80 may be described as being upstream of the mouth end 70, or alternatively downstream of the distal end 80.

The aerosol-forming substrate 20 is positioned at the very distal or upstream end of the aerosol-generating article 10. In the embodiment illustrated in figure 1, the aerosol-forming substrate 20 comprises an aggregated sheet of crimped homogenized tobacco material surrounded by a wrapper. The crimped sheet of homogenised tobacco material comprises glycerol as an aerosol former.

The support element 30 is located immediately downstream of the aerosol-forming substrate 20 and abuts the aerosol-forming substrate 20.

In the embodiment shown in fig. 1, the support element is a hollow cellulose acetate tube. The support element 30 positions the aerosol-forming substrate 20 at the distal extremity 80 of the aerosol-generating article 10 such that it can be brought into contact with a heating element of an aerosol-generating device. The support element 30 serves to prevent the aerosol-forming substrate 20 from being urged downstream within the aerosol-generating article 10 towards the transfer element 40 when a heating element of an aerosol-generating device is inserted into the aerosol-forming substrate 20. The support element 30 also acts as a spacer to space the transfer element 40 of the aerosol-generating article from the aerosol-forming substrate 20.

The transfer element 40 is positioned immediately downstream of the support element 30 and abuts the support element 30. In use, volatile materials released from the aerosol-forming substrate 20 pass along the transfer section 40 towards the mouth end 70 of the aerosol-generating article 10. The volatile materials can be cooled within the delivery section 40 to form an aerosol that can be inhaled by a user. In the embodiment shown in fig. 1, the transfer element 40 is an aerosol-cooling element. The aerosol-cooling element comprises a crimped and gathered polylactic acid sheet material defined by a wrapper 90. The crimped and gathered polylactic acid sheet defines a plurality of longitudinal channels extending along the length of the aerosol-cooling element 40.

The mouthpiece 50 is located immediately downstream of the transfer section 40 and abuts the transfer section 40. In the embodiment shown in figure 1, the mouthpiece 50 comprises a conventional cellulose acetate tow filter of low filtration efficiency.

To assemble the aerosol-generating article 10, the four elements are aligned and tightly wrapped within the outer wrapper 60. In the embodiment shown in figure 1, the outer wrapper is a conventional cigarette paper.

The aerosol-generating article illustrated in figure 1 is designed to engage with an aerosol-generating device comprising an internal heating element for consumption by a user. In use, the internal heating element of the aerosol-generating device heats the aerosol-forming substrate 20 of the aerosol-generating article 10 to a temperature sufficient to form an aerosol. The aerosol is drawn downstream through the aerosol-generating article 10 and is inhaled by the user. The aerosol-generating article shown in figure 1 is substantially cylindrical and has a diameter of about 7mm and a total length of about 45 mm.

Fig. 2 shows a longitudinally extending cavity 110. In the embodiment shown in fig. 2, the cavity 110 is provided in the extractor 100 of an aerosol-generating device according to aspects of the present invention. The extractor 100 is a component that is removably coupled to a main device portion to form an aerosol-generating device. The longitudinally extending cavity 110 of the extractor 100 is arranged for receiving distal ends and distal portions of aerosol-generating articles, such as the aerosol-generating article 10 described with respect to fig. 1.

Extractor 100 has a base 102 and a sidewall 103 extending from base 102. A longitudinally extending cavity 110 is defined by the base 102 and the inner surface of the sidewall 103, and has an opening 111 at an end of the cavity 110 opposite the base 102. The lumen is circular in cross-section and has three separate longitudinally separated portions, the diameter of the lumen varying between adjacent portions.

The first or stabilizing portion 120 of the lumen 110 has a first diameter. The diameter is sized to closely match the outer diameter of an aerosol-generating article used with the aerosol-generating device. Thus, if the aerosol-generating article of fig. 1 is used with a device, the first diameter may be substantially the same as, or slightly larger than, the outer diameter of the aerosol-generating article. Thus, in particular embodiments, the first diameter may be about 7.2 mm.

The second or heating portion 130 has a second diameter. This second diameter is larger than the first diameter to help minimize or prevent contact between the outer surface of the aerosol-generating article received in the cavity and the inner surface 131 of the cavity in the heating portion 130. For example, if the first diameter is about 7.2mm, the second diameter may be between about 8.8mm and about 9.2 mm. This will provide an air gap of about 1mm between the outer surface of the article fully inserted into the cavity and the inner surface 131 of the cavity wall in the heating section 130 of the cavity. The second portion extends longitudinally about 12 mm.

A first flared or inclined portion 135 of the inner surface of the cavity provides a transition between the stabilizing portion 120 and the heating portion 130.

The third or locating portion 140 has a third diameter. The third diameter is preferably substantially the same or the same as the first diameter. Thus, in this example, the third diameter may be 7.2 mm. A second flared or inclined portion 145 of the inner surface of the cavity provides a transition between the heating portion 120 and the positioning portion 130. This second inclined portion is the region where the diameter of the cavity decreases from the second diameter to the third diameter. The inclined portion may act to guide the distal end of the aerosol-generating article into the locating portion 140.

A hole or slot 150 is defined through a radially central portion of the base 102. This aperture 150 allows a heating element attached to the main portion of the aerosol-generating device to be inserted into the cavity 110 when the extractor 100 is coupled to the main portion of the device. The holes 150 also allow air to flow into the cavity 110.

The outer surface of the wall of the extractor may comprise features designed to assist in coupling with a main portion of the aerosol-generating device. Such features may include, for example, grooves, ridges, and snaps. The extractor is designed to slidingly engage with a main portion of the aerosol-generating device. A portion of the extractor may be slid into a corresponding sheath on the main portion of the aerosol-generating device.

Extractor 100 is formed from injection molded Polyetheretherketone (PEEK). However, the extractor 100 may be formed from any suitable material, such as other polymeric materials, for example, polyethylene or polypropylene.

Figure 3 shows the aerosol-generating article 10 as described in relation to figure 1 fully inserted into the cavity 110 of the extractor 100 as described in relation to figure 2. The distal end of the aerosol-generating article has been inserted through the opening 111 and pushed through the stabilizing and heating portions 120, 130 to rest within the locating portion 140. The distal end 80 of the article 10 rests against the inner surface of the base 102. Since the outer diameter of the article 10 is substantially the same as the first diameter of the cavity in the stabilizing section 120 and the third diameter of the cavity at the locating section 140, there is intimate contact between the article and the cavity walls at these points. However, the diameter of the cavity at the heating portion 130 is larger than the diameter at the stabilizing and positioning portions. Since the aerosol-generating article 10 is substantially cylindrical, an air gap 160 is formed between the outer surface 61 of the aerosol-generating article and the inner surface of the cavity in the heating portion. The width of the gap may be determined by subtracting the first diameter of the stabilizing section (and aerosol-generating article) from the second diameter of the heating section and dividing by two. The longitudinal dimension of the heating portion is similar to the longitudinal dimension of the aerosol-forming substrate of the article. When the article is fully inserted into the cavity of the extractor, the aerosol-forming substrate of the article is substantially within the heated portion.

No inlet is defined through the side wall of the chamber. Thus, when the article is positioned within the cavity, the air gap 160 forms an annular air pocket. This air pocket helps to insulate the aerosol-forming substrate during use of the aerosol-generating device.

The ability to insulate the aerosol-generating article is a result of the difference in thermal conductivity between the air and the material, e.g., PEEK, that forms the sidewalls of the cavity. At a preferred operating temperature (e.g., 300 to 600 kelvin), the thermal conductivity of air is at 0.0262 watts per meter kelvin (w.m.)^-1.K^-1) And 0.0457W.m^-1.K^-1In the meantime. In contrast, PEEK is at 3A thermal conductivity of about 0.25 W.m. at 00 Kelvin^-1.K^-1. Thus, air is about ten times less conductive than PEEK. If, as is preferred, air flow within the air gap is prevented, the air gap 160 may act to help prevent heat dissipation from the aerosol-forming substrate of the aerosol-generating article.

Figure 4 shows a cross-section of a heated portion of an extractor with an aerosol-generating article inserted. The side wall 103 is seen to be circular in transverse cross-section. The cavity 110 is defined by an inner surface 131 defined by the sidewall 103. The aerosol-generating article 10 extends through the heating section. In cross-section, the aerosol-forming substrate 20 of the aerosol-generating article fills a central portion of the cavity. The air gap 160 may be considered an annular gap that extends completely around the aerosol-generating article. When the article is inserted, the air gap forms an air pocket.

The extractor 100 is a component part of the aerosol-generating device 500. An extractor is removably coupled to the body portion to form an aerosol-generating device. Thus, the body portion, which may be referred to as the first body portion 501, includes a power source, control electronics, and a heating element. The extractor, which may be referred to as second body portion 100, includes an article receiving cavity 110.

As can be seen in fig. 5, in a particular embodiment, the main/second body portion 501 includes a sheath 510 for coupling with the extractor/second body portion 100 and a heating element 520 for insertion into the cavity 110 of the extractor 100. The extractor 100 and the main portion 501 are coupled together by relative longitudinal movement. The heating element 520 extends into the cavity 110 through an opening 150 defined through the base 102. Thus, the opening 150 also allows the extractor to move relative to the heating element 520.

Fig. 6 shows an aerosol-generating article 10 operably coupled to an aerosol-generating device 500. The heating element 520 penetrates the distal end of the aerosol-generating article 10 and contacts the aerosol-forming substrate 20.

In use, operation of the heating element is initiated and the temperature of the aerosol-generating forming substrate is raised to an operating temperature of, for example, between 300 ℃ and 350 ℃. This causes the evaporation of the material within the aerosol-forming substrate. The aerosol formed from these volatile components can be inhaled when the user inhales on the proximal end of the aerosol-generating article 10. The presence of the air gap 160 helps to minimise heat loss through the outer wall of the aerosol-generating article. In tests on aerosol-generating articles comprising homogenised tobacco as an aerosol-forming substrate, the delivery of nicotine and other aerosol-forming agents in the initial puff is greater compared to a control device in which no air gap is present.

Experiments have been conducted to compare aerosol delivery from an aerosol generating article as described in relation to figure 1 (a) when heated in a device having an extractor as described in relation to figures 2 to 6, and (b) when heated in a control device having an extractor without an air gap.

Fig. 7 and 8 are provided to illustrate a collation extractor 700 and a collation apparatus 800 including the extractor. It should be noted that fig. 7 and 8 are provided for comparison only, and do not illustrate embodiments of the present invention.

The comparison extractor 700 differs from the extractor 100 of fig. 2 in that the cavity 710 of the comparison extractor 700 does not define separate stabilizing, heating and positioning portions. Instead, chamber 710 is defined by an inner wall 760 that extends uniformly between chamber opening 711 and chamber base 702. The diameter of the lumen 710 is substantially uniform along the length of the lumen, about 7.2 mm. That is, the diameter of the entire cavity of the control extractor is approximately the same as the diameter of the stabilizing section of the extractor of fig. 2. In other respects, the control extractor is the same as the extractor of fig. 2.

Fig. 8 shows an aerosol-generating article operably coupled to an extractor 700 of a control device 800. The aerosol-generating article fits closely into the cavity 710 of the extractor 700, thereby providing significant contact between the outer surface of the aerosol-generating article and the inner surface 760 of the cavity 710.

The same aerosol-generating article was tested under the same conditions. The only difference is that one set of articles was tested using the extractor and apparatus described with respect to fig. 2 to 6, and a control set of articles was tested using the control extractor and control apparatus described with respect to fig. 7 and 8. The aerosols produced by these experiments were subjected to Fourier Transform Infrared (FTIR) spectroscopy.

Figure 9 is a graph plotting nicotine delivery (measured in mg on the y-axis) versus the number of puffs on an aerosol-generating article (on the x-axis). Using the extractor of fig. 2-6, including an air gap around a portion of the article, the results generated are shown with solid line (a). Using the control extractor of fig. 7 and 8, there was no air gap around a portion of the article, and the resulting results are shown by dashed line (b). It can be seen that nicotine delivery was about the same for the first two puffs, but then nicotine delivery was significantly improved using the extractor of figure 2 compared to using the control extractor. It is speculated that the air gap 160 does provide an insulating effect and reduces heat dissipation from the aerosol-forming substrate of the article, thereby improving nicotine delivery.

Figure 10 is a graph plotting glycerol delivery (measured in mg on the y-axis) versus the number of puffs on an aerosol-generating article (on the x-axis). Using the extractor of fig. 2-6, including an air gap around a portion of the article, the results generated are shown with solid line (a). Using the control extractor of fig. 7 and 8, there was no air gap around a portion of the article, and the resulting results are shown by dashed line (b). As can be seen, glycerol delivery was approximately the same for the first two or three puffs, but then glycerol delivery was significantly improved using the extractor of fig. 2 compared to using the control extractor. This result reflects the nicotine delivery results plotted in figure 9.

Although it is preferred that the extractor 100 is configured to provide a fully annular air gap between the aerosol-generating article and the heating portion of the cavity, there may be situations where one or more ribs are required. Such ribs may help to stabilize the aerosol-generating article within the longitudinally extending cavity 110. Such ribs may provide reinforcement to the extractor. Such ribs may help to direct the distal end of the aerosol-generating article towards the locating portion when inserted into the cavity. Such ribs may help prevent radial deformation of the aerosol-generating article if the heating element is inserted into an aerosol-forming substrate of the aerosol-generating article.

For example, turning now to fig. 11, the extractor 100 may include one or more ribs 790. One or more ribs preferably extend along the heating portion 130. Preferably, the one or more ribs extending along heating portion 130 extend from a beginning or downstream end 736 of transition 735 between stabilizing portion 120 and heating portion 130 all the way to an ending or upstream end 746 of transition 745 from heating portion 130 to positioning portion 140. Such ribs 790 should not protrude further into the cavity than the wall of the stabilizing portion so as not to impede passage of the aerosol-generating article. Although a continuous rib is shown extending along the entire length of the heating portion 130, it will be appreciated that other designs may be used which still serve to stabilize the aerosol-generating article 10 within the chamber with minimal contact. Preferably, any ribs have a relatively small width dimension, for example a width of between 0.5mm and 1.5mm in a dimension that can contact the aerosol-forming article.

Fig. 12 shows a transverse cross-sectional view of an extractor 800 having two longitudinally extending ribs 890 extending along the heating portion between the stabilizing portion and the positioning portion. The cross-sectional view is taken through the heated portion. The ribs 890 help define the first and second air pockets 860A, 860B when the aerosol-generating article 10 is inserted into the cavity. There is very little contact between the article 10 and the ribs 890 and only negligible heat is lost at these points of contact. Thermal insulation of the aerosol-forming substrate is provided by two semi-annular air pockets 890A, 890B.

Fig. 13 shows a transverse cross-sectional view of extractor 900 with three longitudinally extending ribs 990 extending along the heated portion between the stabilizing and positioning portions. The cross-sectional view is taken through the heated portion. The ribs help to define the first, second and third air pockets 960A, 960B, 960C when the aerosol-generating article 10 is inserted into the cavity. There is very little contact between the article 10 and the ribs 990 and only negligible heat is lost at these points of contact. The insulation of the aerosol-forming substrate is provided by three partial annular air pockets 960A, 960B, 960C.

Fig. 14 shows a transverse cross-sectional view of an extractor 1400 having six longitudinally extending ribs 1490 extending along the heating portion between the stabilizing and positioning portions. The cross-sectional view is taken through the heated portion. The ribs help define the first, second, third, fourth, fifth, and sixth air pockets 1460A, 1460B, 1460C, 1460D, 1460E, and 1460F when the aerosol-generating article 10 is inserted into the cavity. There is very little contact between the article 10 and the ribs 1490 and only negligible heat is lost at these points of contact. The insulation of the aerosol-forming substrate is provided by six part annular air pockets 1460A, 1460B, 1460C, 1460D, 1460E and 1460F.

Fig. 15 shows a longitudinal cross-sectional view of an extractor 1400 having six longitudinally extending ribs 1490 extending along a heating portion 1430 between a stabilizing portion 1420 and a positioning portion 1440. Such longitudinally extending ribs 1490 may provide an enhanced effect to the extractor. Such longitudinally extending ribs 1490 may help to direct the distal end of the aerosol-generating article towards the positioning portion when inserted into the cavity. Such longitudinally extending ribs 1490 may help prevent radial deformation of the aerosol-generating article if the heating element is inserted into an aerosol-forming substrate of the aerosol-generating article.

The above embodiments describe an aerosol-generating system comprising an aerosol-generating article 10 and an aerosol-generating device 500 comprising an extractor for receiving the aerosol-generating article 10. The disclosed heating element is a resistive heating element. However, alternative embodiments of the present invention are possible. For example, the heating device may comprise an induction heating device. The heating element may comprise a susceptor in the form of a blade and an inductor, for example an inductor coil may be disposed around the cavity 110. Alternatively, the aerosol-generating article 110 may comprise a susceptor and the aerosol-generating device may comprise an inductor arranged to heat the susceptor.

Figure 16 schematically illustrates such an inductively actuated aerosol-generating system. In this system, the aerosol-generating article 1000 is similar to the article 10 described with respect to fig. 1. One difference of the system of fig. 16 compared to the systems described above, for example with respect to fig. 2 to 6, is that the aerosol-forming substrate 1025 of the article 1000 incorporates or is associated with a susceptor 1020. In this example, the susceptor is a longitudinal strip of stainless steel. The strip acts as a susceptor 1020 which can be heated to heat the aerosol-forming substrate. In one particular embodiment, the susceptor 1020 may be in the form of a strip of grade 430 stainless steel having dimensions of 12mm x 4mm x 35 microns.

The aerosol-generating device 1500 is similar to the devices described with respect to fig. 2 to 6. However, there is no heating element associated with the device. Instead, the susceptor 1020 is positioned in thermal communication with the aerosol-forming substrate of the aerosol-generating article and heat may be generated in the susceptor by inductive heating when the susceptor is placed within a fluctuating magnetic field generated by the aerosol-generating device. Accordingly, the aerosol-generating device 1500 comprises an inductor in the form of an induction coil 1600, as well as power supply and control electronics, such as a battery. The induction coil 1600 is capable of generating a fluctuating magnetic field within the cavity of the extractor. The susceptor and the induction coil may in combination form a heating means for the aerosol-forming substrate.

Induction heating is a known phenomenon described by faraday's law of electromagnetic induction and ohm's law. More specifically, faraday's law of electromagnetic induction states that if the magnetic induction in a conductor changes, a changing electric field is created in the conductor. Since this electric field is generated in the conductor, a current called an eddy current will flow in the conductor according to ohm's law. Eddy currents generate heat proportional to current density and conductor resistivity. A conductor capable of being inductively heated is known as a susceptor. The aerosol-generating device is an induction heating device equipped with an induction heating source, such as an induction coil 1600, which is capable of generating an alternating electromagnetic field by an AC source, such as an LC circuit. Heat generating eddy currents are generated in the susceptor 1020, thereby raising the temperature of the susceptor so that it can act as a heating element.

The aerosol-generating device 1500 includes a battery and electronics (not shown) that allow the sensor 1600 to be actuated. Such actuation may be manual or may occur automatically in response to a user drawing on the aerosol-generating article 1000 inserted into the substrate-receiving cavity of the aerosol-generating device 1500. The battery supplies a direct current. The electronic device comprises a DC/AC inverter to supply the inductor with a high frequency alternating current.

When the device is actuated, a high frequency alternating current passes through the coil forming part of induction coil 1600. This results in the induction coil 1600 generating a fluctuating electromagnetic field within the portion of the substrate receiving cavity of the device. The electromagnetic field preferably fluctuates at a frequency between 1 and 30MHz, preferably between 2 and 10MHz, for example between 5 and 7 MHz. When the aerosol-generating article 1000 is correctly positioned in the substrate-receiving cavity, as shown in fig. 16, the susceptor 1020 of the article 1000 is located within this fluctuating electromagnetic field. The fluctuating field generates eddy currents within the susceptor, thus heating the susceptor. Further heating is provided by hysteresis losses within the susceptor. The heated susceptor heats the aerosol-forming substrate 1020 of the aerosol-generating article 1000 to a temperature sufficient to form an aerosol. The aerosol is drawn downstream through the aerosol-generating article 1000 and inhaled by the user. Heat dissipation from the aerosol-forming substrate 1025 is minimised by the air gap 160 provided at the heated portion of the chamber. Thus, aerosol delivery to the user may be improved.