RU2811176C2 - Aerosol-generating device with insulation of heating zone and aerosol-generating system - Google Patents

Abstract

FIELD: aerosol-generating systems.

SUBSTANCE: invention relates to an aerosol-generating device for heating an aerosol-generating substrate. The device provided in the cylindrical aerosol-generating product includes a longitudinally extending cavity for receiving a distal portion of the aerosol-generating product. The longitudinally extending cavity has a longitudinal axis and is formed by a base, side walls extending from the base, and an opening at the end of the cavity opposite the base. The inner surfaces of the side walls form a stabilizing part of the cavity having a first diameter, and a heating part of the cavity located between the stabilizing part and the base. The heating part has a second diameter that is larger than the first diameter. The inner walls of the cavity further form a mounting part located at the far end of the cavity, a heating part located between the stabilizing part and the mounting part. The installation part of the cavity has a third diameter, which is equal to the first diameter of the stabilizing part.

EFFECT: improved thermal insulation of the aerosol-generating substrate.

25 cl, 16 dwg

Description

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

A number of prior art documents disclose aerosol generating devices that include, for example, heated aerosol generating systems and electrically heated aerosol generating systems. An example of a heated aerosol generating system is disclosed in WO 2013/076098, which describes embodiments in which an aerosol generating substrate of an aerosol generating article is penetrated by a heating element of the aerosol generating device to generate a respirable aerosol. The heating element is in contact with the aerosol-forming substrate and increases the temperature of the substrate, thereby evaporating the volatile components of the substrate. When the aerosol-forming substrate is consumed, the aerosol-generating article containing the aerosol-forming substrate is removed from the aerosol-generating device and discarded. The aerosol generating article disclosed in WO 2013/076098 has a tight fit in the cavity of the extractor portion of the aerosol generating device. This provides an interference fit that holds the product in the cavity. Heat applied to the aerosol-forming substrate rapidly increases the temperature of the substrate due to direct contact between the heating element and the substrate. However, heat is also quickly removed from the product by conduction to the cavity walls, which can act as a heat sink.

WO 2018/050735 discloses an embodiment of an aerosol generating device in which the cavity of the aerosol generating article is provided with ribs to provide improved retention of the aerosol generating article in the cavity. The fins are spaced apart to provide channels for air flow between adjacent fins and possibly also between discontinuous fins. The fins are preferably arranged in an inclined manner to allow the user to remove the aerosol generating article by applying an axial force along with a torque to facilitate removal. However, important contact points between the aerosol generating article and the cavity fins still exist, and the air flow between the longitudinal fins also helps to cool the aerosol generating substrate.

The disclosure presented herein relates to an aerosol generating device for heating a substrate to form an aerosol. The aerosol-generating substrate may be provided with an aerosol-generating article. The aerosol generating article may be a substantially cylindrical aerosol generating article. The aerosol generating device may include 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 formed by a base, side walls extending from the base, and an opening at the end of the cavity opposite the base. The inner surfaces of the side walls form a first cavity portion having a first diameter. The first part of the cavity may be a stabilizing part. A second cavity portion having a second diameter may be located between the stabilizing portion and the base. The second part may be a heating part. The second diameter may be larger than the first diameter.

In a preferred embodiment, an aerosol generating device is provided for heating an aerosol generating substrate provided in a substantially cylindrical aerosol generating article. The aerosol generating device includes a longitudinally extending cavity for receiving a distal portion of the aerosol generating article. The longitudinally extending cavity has a longitudinal axis and is formed by a base, side walls extending from the base, and an opening at the end of the cavity opposite the base. The inner surfaces of the side walls form a stabilizing part of the cavity having a first diameter. The heating part of the cavity is located between the stabilizing part and the base. The heating part has a second diameter that is larger than the first diameter.

The diameter of the stabilizing part is such that the distal part of the aerosol generating article can be inserted through it. Preferably, when the distal portion of the aerosol generating article is inserted through the stabilizing portion, there is a minimum space between the outer surface of the aerosol generating article and the inner surface of the stabilizing portion. Preferably, there is a tight or sliding fit between the aerosol generating article and the stabilizing part. Preferably, there is no gap between the outer surface of the aerosol generating article and the inner surface of the stabilizing part when the aerosol generating article is housed in the cavities. The outer surface of the aerosol generating article may contact the inner surface of the stabilizing portion when the article is inserted or accommodated therein. Thus, it is preferable that the inner diameter of the stabilizing portion is substantially the same size as the outer diameter of the aerosol generating article. For example, the inner diameter of the stabilizing portion may be the same diameter as the outer diameter of the aerosol generating article, plus or minus 10%, or plus or minus 5%. In some embodiments, the inner diameter of the stabilizing portion may be 0-5% larger than the outer diameter of the aerosol generating article, such as 1-4% larger or 2-3% larger. Preferably, the dimensions are such that the article can be inserted into and removed from the cavity while maintaining a pattern of interaction, such as contact or loose seal, between the article and the inner diameter of the stabilizing portion 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 significant 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 located at or adjacent to the base of the cavity. Preferably, when the aerosol generating article is fully inserted into the cavity, at least a portion of the aerosol generating article is located within the heating portion of the cavity. Preferably, the aerosol generating article is configured such that the aerosol generating substrate of the aerosol generating article is accommodated inside the heating portion of the cavity when the aerosol generating article is fully inserted into the cavity. The diameter of the inner surface of the heating part is larger than the diameter of the stabilizing part. Therefore, there is a gap between the outer part of the aerosol generating article and the inner surface of the heating part. Preferably, the air gap is present entirely or substantially entirely around the outer surface of the aerosol generating portion of the article located within the heating portion of the cavity. Preferably, the air gap provides a layer of air insulation between the aerosol generating portion of the article and the inner surface of the heating portion.

The cross-section of the cavity on the stabilizing part has preferably or substantially the same shape as the cross-section of the cavity on the heating part. Preferably the cross-sectional shape is round or oval. Preferably, the stabilizing part of the cavity and the heating part of the cavity are coaxial.

In some embodiments, the diameter of the stabilizing portion may vary to the diameter of the heating portion at the step in the inner wall of the cavity. In some embodiments, the diameter of the stabilizing portion may be changed to the diameter of the heating portion through a series of steps. In some embodiments, the diameter of the stabilizing portion may be changed to the diameter of the heating portion by means of an inclined interior portion of the cavity wall.

The aerosol generating article contains an aerosol generating substrate that can be heated to generate the aerosol. Preferably, the aerosol-generating substrate is located at or adjacent to a distal end of the aerosol-generating article. Therefore, at least a portion of the aerosol-generating substrate is located within the heating portion when the aerosol-generating article is fully inserted into the cavity of the device. The heating means for heating the aerosol-generating substrate is arranged to heat a portion of the aerosol-generating substrate, an aerosol-generating article, which is located inside the heating part. 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 means may comprise a susceptor and an inductor. The heating means preferably comprises a heating element or current collector configured to penetrate a distal end of the aerosol generating article and come into contact with the aerosol generating substrate when the aerosol generating article is fully inserted into the cavity of the aerosol generating device. In some embodiments, a susceptor may be provided as part of the aerosol generating article. In some embodiments, a susceptor may be provided as part of the aerosol generating device and as part of the aerosol generating article.

In some embodiments, a heating element may be provided as part of the aerosol generating device. The heating element may be provided to at least partially penetrate a portion of the aerosol-forming substrate when the aerosol-forming substrate is housed within the heating portion. The heating element may be an elongated heating element. The heating element may include a tapered or pointed end. The tapered or pointed end advantageously facilitates penetration of the heating element into the substrate, generating an aerosol. The heating element may be a plate-shaped heating element. The heating element may be a pin-shaped heating element. The heating element may contain only one heating element. The heating element may be provided along the central longitudinal axis of the heating portion. The heating element may comprise multiple heating elements. Several heating elements can have the same properties. One or more of the plurality of heating elements may have one or more different properties compared to the remainder of the plurality of heating elements. The specified property can be, for example, size, shape, dimensional characteristic, operating temperature.

In some embodiments, a heating element may be provided as part of the aerosol generating article and may be operable in combination with one or more features of the device. The heating element may be a current collector provided as part of the aerosol generating article. The heating element may be a current collector provided in the region of the aerosol-forming substrate. The heating element may be a current collecting element having any of a variety of shapes. The current collecting element may be rod-shaped, cube-shaped, cuboid-shaped, or any other shape included in the aerosol generating article. The current collecting element may be centrally located along the central longitudinal axis of the aerosol generating article. The heating element may be a current-receiving material included in the aerosol-generating substrate portion of the aerosol-generating article. The current collecting material may be provided in the form of, for example, any of: particles, strips, pieces, powder, sheets or mesh.

As used herein, the term "susceptor" refers to a material that can convert electromagnetic energy into heat. When placed within a changing electromagnetic field, eddy currents induced in the pantograph cause the pantograph to heat up. Since the susceptor is located in thermal contact with, or at least close to, the aerosol-forming substrate, the aerosol-forming substrate is heated by the susceptor.

As used herein, the term "inductor" refers to a component that can generate a varying electromagnetic field to heat a current collector located within the varying electromagnetic field. In use, the aerosol generating article may be engaged with the aerosol generating device such that the current collector is placed within the changing electromagnetic field generated by the inductor.

As used herein, the term “aerosol generating device” refers to a device that interacts with an aerosol-forming substrate to generate an aerosol. The aerosol-generating substrate may be a component of the aerosol-generating article. The aerosol generating device may include one or more components for supplying energy from a power supply to the aerosol generating substrate to generate the 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 that interacts with an aerosol generating substrate of the aerosol generating article to generate an aerosol that can be directly inhaled into the user's lungs through the user's mouth.

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

As used herein, the term "aerosol-generating article" refers to an article containing an aerosol-forming substrate that is capable of releasing volatile compounds, which compounds are capable of forming an aerosol. For example, an aerosol generating product may be capable of generating an aerosol that is inhaled directly into the user's lungs through the user's mouth. The aerosol-generating product may be disposable. An aerosol generating product is a heated aerosol generating product that is designed to be heated, rather than burned, to release volatile compounds that are capable of forming an aerosol. The aerosol generated by heating the aerosol-forming substrate may contain fewer known harmful constituents than would be produced by combustion or pyrolytic degradation of the aerosol-forming substrate. In some embodiments, the aerosol generating article may comprise an aerosol generating substrate. In some embodiments, the aerosol-forming substrate may be formed from or contain processed tobacco, such as homogenized tobacco or molded sheet 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.

In the context of this document, the terms “upstream”, “downstream”, “near” and “distant” are used to describe the relative positions of elements or parts of elements of aerosol generating products, aerosol generating devices and aerosol generating systems , according to the present invention.

Aerosol generating articles as described herein include a proximal end through which aerosol exits the aerosol generating article when in use. The proximal end may also be called the mouth end. In use, the user puffs from the proximal or mouth end of the aerosol generating article to inhale the aerosol generated by the aerosol generating article. In some embodiments, the aerosol generating device and the aerosol generating article are configured such that at least a portion of the mouthpiece end is not contained 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 mouthpiece end extends outwardly beyond the cavity opening of the aerosol generating device. Thus, the user can puff at the mouthpiece end of the aerosol generating article. In some embodiments, the aerosol generating device and the aerosol generating article are configured such that the entire length of the aerosol generating article is contained within a longitudinally extending cavity of the device when the article is fully inserted into the cavity. In some embodiments, a mouthpiece element may be provided comprising an air flow path configured to align with the mouthpiece end of the aerosol generating article. Thus, the user can alternatively puff on the mouthpiece. In some embodiments, the mouthpiece element may be a separate mouthpiece element. The separate mouthpiece may be configured to engage 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 an aerosol generating device.

The aerosol generating article includes a distal end opposite the proximal 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 parts of components of an aerosol generating article may be described as being upstream or downstream of each other based on their respective positions between the proximal or downstream end and the distal or upstream end aerosol generating product.

As used herein, the term “diameter” is used to refer to the maximum lateral dimension of elements or parts of elements of aerosol generating articles, aerosol generating devices, and aerosol generating systems according to the present invention. For the avoidance of doubt, the term "diameter" as used herein may refer to the "width" of elements or portions of elements of aerosol-generating articles, aerosol-generating devices, and aerosol-generating systems of non-circular cross-section.

As used herein, the term “longitudinal” is used to describe the direction between the downstream or proximal end and the opposite upstream or distal end of aerosol generating articles, aerosol generating devices and aerosol generating systems according to the present invention , and the term "transverse" is used to describe the direction perpendicular to the longitudinal direction.

For the avoidance of doubt, the term "heating element" as used herein may include one or more heating elements.

There are prior art aerosol generating systems in which a cylindrical aerosol generating article is designed to be inserted into a cavity of the aerosol generating device to be penetrated by a heating agent, for example as disclosed in WO 2013/076098. The heating means in WO 2013/076098 is a heating element that penetrates into the aerosol-forming substrate to sufficiently heat the substrate to form an aerosol. However, the effectiveness of the device may be affected by the contact between the walls of the cavity and the product 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 that is configured 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 that is in contact therewith. In some embodiments, it is preferable to heat the aerosol-forming substrate to a temperature of 150°C to 450°C, such as 200°C to 400°C, or 250°C to 350°C, or 300°C to 350°C C. Thermal transfer within the aerosol-forming substrate results in heating of the entire aerosol-forming substrate, but there may be a time lag in temperature toward the outside of the aerosol-forming substrate to reach the temperatures required for aerosol formation. The present aerosol generating device minimizes or eliminates contact between the outer surface of the aerosol generating article, at least in the heating portion of the aerosol generating article, and the internal walls of the article housing the cavity of the aerosol generating device. This helps prevent thermal transfer between the aerosol-generating article and the cavity walls. The dissipation of thermal energy within the heated aerosol-generating substrate can be minimized as a result of reduced contact between the outer surface of the aerosol-generating article containing the aerosol-forming substrate, at least in the heating portion of the aerosol-generating article, and the internal walls of the article containing the cavity , a device that generates an aerosol. As a result, a greater proportion of the heat from the heating means can be retained within the aerosol-forming substrate, and the entire substrate can be brought to operating temperature more quickly. Air between the outer walls of the cavity in the heating portion and the aerosol generating article may provide thermal insulation to the aerosol generating article as a thermal barrier.

The present invention can reduce the time delay between the heating element starting to operate and the aerosol-forming substrate reaching operating temperature. The operating temperature may be the temperature at or above which one or more volatile compounds are released from the aerosol-forming substrate. Advantageously, the time between the user starting to operate the aerosol generating system and the aerosol generating device being ready for the user to take the first puff, also referred to as TT1P, can be reduced. Advantageously, the initial aerosol delivery provided by the aerosol generating device described herein can be improved. In this way, the user's smoking session during the first few puffs can be improved.

As an additional benefit, the reduced thermal transfer between the outer surface of the aerosol generating article and the cavity walls of the aerosol generating device means that less thermal energy is dissipated from the aerosol generating article when heated. In this way, the aerosol-forming substrate can remain at operating temperature longer, for example between puffs. Once operating temperature is reached, less power may be required to maintain the aerosol-forming substrate at that operating temperature. This helps ensure a consistent user experience while consuming the product. This may also mean that the total amount of energy required to consume the aerosol generating product is lower. Thus, the device may be configured to operate with a smaller power source, such as a smaller battery, than would otherwise be required. The device may be able to handle more duty cycles without the need for a larger battery.

As an additional benefit, reducing or eliminating contact points between the aerosol-generating article and the cavity walls may help prevent the formation of cold spots in the aerosol-generating substrate. Cold spots are areas of the aerosol-generating substrate that do not reach the optimal operating temperature during device consumption due to localized heat dissipation. If cold spots occur, the aerosol-forming substrate may not be completely consumed during use. Thus, by minimizing or preventing the occurrence of cold spots in the aerosol-forming substrate, the total amount of substrate required for a user's satisfactory smoking session can be lower.

As an additional benefit, reducing the amount of heat dissipated from the aerosol generating article can reduce the maximum temperature that the heating element needs to reach for a satisfactory smoking session for the user. In addition to lower energy requirements, this may also reduce the likelihood of heating portions of the aerosol-forming substrate in areas that are in significant contact with the heating element, which can cause unpleasant tastes and odors.

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

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

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

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

Preferably, the difference in diameter between the stabilizing portion and the heating portion provides one or more insulating air pockets surrounding the outer surface of the aerosol generating article, the distal portion of which is fully inserted into the longitudinally extending cavity. If more than one air pocket is present, there is preferably no through air flow between the air pockets. In some embodiments, the air pocket is preferably annular and extends around the aerosol generating article when the aerosol generating article is contained within the cavities. Two or more semi-annular air pockets may be formed. If more than one air pocket is formed, then in some embodiments the air pockets are separated by a rib, such as a longitudinal rib or an annular rib. Air flow within the air pocket or air pockets may contribute to thermal dissipation from the aerosol generating article. Thus, it is highly preferable that the device does not have air inlets or air outlets formed in the heating portion, which would otherwise allow air to flow into or out of the air pocket or pockets formed by the gap between the aerosol generating article, and the inner walls of the heating part when the product is inserted into the cavity. In particular, it is preferable that the air inlets or air outlets are not formed extending through the side wall of the cavity extending into the heating portion.

It may be advantageous for the air inlet to be formed extending through the base of the cavity. Such an inlet may provide an air source allowing air to be drawn into a distal end of the aerosol generating article along the length of the article and into the user's mouth through the proximal end, or mouthpiece end, of the aerosol generating article. Such an air inlet through the base of the cavity may be provided by a single opening at the center point of the base or within a small radius of that center point. Such an inlet may be positioned such that when the aerosol generating article is inserted into the cavity of the aerosol generating device, the air inlet is aligned with the end surface of the aerosol generating article. That is, the air inlet is not located in the gap diameter region.

In preferred embodiments, the inner walls of the cavity may further define a mounting portion located at the distal end of the cavity. The heating part may be located between the stabilizing part and the installation part. The cavity mounting portion may have a third diameter that is substantially equal to the first diameter of the stabilizing portion. The mounting portion is preferably aligned coaxially with the stabilizing portion. Thus, the cylindrical product may be capable of passing through the stabilizing portion, and the distal end of the product may be capable of being accommodated in the mounting portion. Thus, the distal end of the article may be limited in the radial direction. Preferably, when the article is fully inserted into the cavity, the article is held by contact with the inner walls of both the stabilizing portion and the inner walls of the mounting portion. Preferably, the dimensions of the mounting portion and the aerosol generating article are such that the article can be inserted into and removed from the cavity while maintaining a pattern of interaction, such as contact or loose seal, between the article and the inside diameter of the mounting portion when inserted into the cavity. Advantageously, in such a configuration, one or more closed air pockets may be formed by a gap between the outer surface of the aerosol generating article and the inner surface of the cavity. Thus, the outer boundaries of the circumferential or annular air pocket, when the aerosol generating article is fully inserted into the cavity, may be formed by (1) the outer surface of the aerosol generating article, (2) the inner surface of the heating portion of the cavity, (3) a radially extending step or a slope passing between the inner surface of the heating part and the inner surface of the stabilizing part, and (4) a radially extending step or slope passing between the inner surface of the heating part and the inner surface of the mounting part.

In some embodiments, the diameter of the heating portion may vary to the diameter of the mounting portion on the step in the inner wall of the cavity. Alternatively, in some embodiments, the diameter of the heating portion may be changed to the diameter of the mounting portion through a series of steps. In some embodiments, the diameter of the heating portion may be changed to the diameter of the mounting portion by means of an inclined interior portion of the cavity wall. In some embodiments, the inner walls of the cavity may define a tapered region in which the diameter of the cavity varies from a second diameter to a third diameter. Advantageously, the cone can help align the aerosol generating article when the aerosol generating article is inserted into the cavity. The cone-shaped area may act as a funnel to guide the distal end of the aerosol-generating article into the mounting portion of the cavity.

It is preferable that there be minimal contact between the product and the cavity wall in the heating part. For example, it may be preferable to have a circumferential air gap formed around the article inserted into the cavity. However, it may be desirable to include one or more edges. One or more ribs may help guide and stabilize the aerosol generating article inserted into the cavity. In some embodiments, only one rib is provided. In some embodiments, multiple fins are provided. In some embodiments, there are 3 fins. In some embodiments, 6 fins are provided. If more than one fin is provided, it is preferred that the fins be substantially evenly spaced around the circumference of the cavity. One or more ribs may be longitudinally extending ribs. Such fins may extend radially into the cavity from the inner wall of the heating portion of the cavity. Preferably, any such fins extend radially over a distance substantially equal to the air gap. The inner side walls of the cavity may define one or more ribs extending longitudinally in the heating portion. The ribs may have a radial size equal to half the diameter of the gap. A plurality of individual partially annular air pockets may be formed by such fins. For example, two longitudinally extending fins may separate a heating portion of the cavity to allow semi-circular air pockets to form when the article is inserted into the cavity. In some embodiments, the ribs may be circular. In some embodiments, the ribs may be a combination of longitudinal and circumferential ribs. The combination of longitudinal and annular ribs can form several air cavities.

In some embodiments, the aerosol generating device may include a first housing portion and a second housing portion that is movable relative to the first housing portion. The first housing portion may include a power source, control electronics, and at least a portion of means for heating the aerosol generating device. A longitudinally extending cavity may be formed in the second body portion. The second housing portion may be capable of functioning 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 assist in peeling the aerosol-forming substrate away from the heating element. In some embodiments, the extractor may assist in the removal of the aerosol-generating article following consumption of the article. For example, the aerosol generating device may include heating means that is 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 the aerosol-generating substrate, aerosol-generating article, housed in the cavities of the second body portion of the aerosol-generating device from the heating means. The first body portion and the second body portion may be removably attached and detached from each other. In this way, the second housing portion can be easily removed from the first housing portion, for example to facilitate cleaning.

In some embodiments, the second body portion may be movable between a first position and a second position. The first position may be an operating position defined by heating means, such as a heating element or inductor, configured to engage the aerosol-generating substrate of the aerosol-generating article. The first position may be an operating position formed by a heating element inserted into and in contact with the aerosol-generating substrate of the aerosol-generating article. The first position may be an operating position formed by the aerosol-generating substrate of the aerosol-generating article located within the alternating magnetic field generated by the inductor. The second position may be an extraction position formed by the aerosol-forming substrate that is at least partially disconnected from or disengaged from the heating means. At least partial separation may involve physical separation or simply separation because the bond or interface between the heating agent and the aerosol-forming substrate is broken. For example, during and after heating, the aerosol-forming substrate may adhere to the heating medium. The second extraction position may be a position in which the aerosol-forming substrate is released from the heating means. The second extraction position may be a position in which the aerosol-forming substrate is moved away from the alternating magnetic field generated by the inductor. Advantageously, such an extractor helps 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 generating substrate is in contact with a heating element of the aerosol generating device and a second position in which the aerosol generating substrate is the aerosol-forming element is at least partially separated from the heating element. Preferably, the extractor remains connected to the aerosol generating device if it is in the first position. Preferably, the extractor remains connected to the aerosol generating device in the second position. In some embodiments, the extractor remains coupled to the aerosol generating device at any intermediate point between the first position and the second position. The extractor may be attached to or detachable from the aerosol generating device.

The extractor may include a sliding reservoir. The sliding reservoir may define a cavity for receiving an aerosol generating article. The sliding reservoir is preferably slidable between a first position and a second position. In some embodiments, the entire extractor, including the sliding reservoir, can be moved to pass the sliding reservoir between a first position and a second position. Alternatively, only the sliding extractor reservoir may be configured to slide between a first position and a second position.

In preferred embodiments, the heating element may extend into the heating portion of the cavity of the aerosol generating device. The heating element may be substantially plate-shaped for insertion into the aerosol-forming substrate of the aerosol-forming article. The heating element can have a length from 10 mm to 60 mm. The heating element can have a width from 2 mm to 10 mm. The heating element can have a thickness from 0.2 mm to 1 mm. A preferred length may be from 15 mm to 50 mm, for example from 18 mm to 30 mm. A preferred length may be about 19 mm or about 20 mm. A preferred width may be from 3 mm to 7 mm, for example from 4 mm to 6 mm. A preferred width may be approximately 5 mm. A preferred thickness may be from 0.25 mm to 0.5 mm. A preferred thickness may be approximately 0.4 mm. The heating element may comprise an electrically insulating substrate and an electrically resistive heating element. In some embodiments, the electrically resistive heating element includes one or more traces. In some embodiments, the electrically resistive heating element is provided on or integrated into the electrically insulating substrate. The electrically resistive heating element may be supported by an electrically insulating substrate. Alternatively or in addition, the heating element may surround the heating portion of the cavity.

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

The aerosol generating product may be any product suitable for consumption using such a device. For example, the aerosol generating product may be any product described herein. For example, in some embodiments, the aerosol generating article may comprise multiple coaxially aligned components. The plurality of coaxially aligned components may comprise an aerosol-forming substrate collected in a wrapper to form a substantially cylindrical article. The aerosol-generating product may have a longitudinal axis and a diameter of the product. The aerosol generating article may have a proximal portion terminating at a proximal end and a distal portion terminating at a distal end. The aerosol-forming substrate is preferably located on or adjacent to a distal portion of the article. In some embodiments, the aerosol-forming substrate may be a tobacco plug, such as a cylindrical tobacco plug.

The aerosol generating article may have an overall length of from about 30 mm to about 100 mm, preferably from 40 mm to 60 mm, or from 42 mm to 52 mm, such as about 45 mm. The aerosol generating article may have an outer diameter of from about 5 mm to about 12 mm, such as from 6 mm to 9 mm, or from 7 mm to 8 mm.

The aerosol generating article may include a filter element. The filter element may include a filter plug. The filter element may be located at the downstream end of the aerosol generating article. The filter element may be a cellulose acetate filter plug. In some embodiments, the filter element is approximately 7 mm in length. The filter element may have a length of from about 5 mm to about 10 mm.

In some embodiments, the aerosol generating article has an overall length of approximately 45 mm. The aerosol generating article may have an outer diameter of from about 7 mm, such as from 6.8 mm to 7.2 mm. The aerosol-forming substrate may have a length of from about 8 mm to 14 mm, such as 10 mm, or 11 mm, or 12 mm.

The diameter of the aerosol-forming substrate can range from about 5 mm to about 12 mm. The aerosol generating article may comprise an outer paper wrapper. The aerosol generating article may include a barrier between the aerosol generating substrate and the filter plug. The spacer may range from about 5 mm to about 25 mm. Preferably the spacer is approximately 18 mm. The spacer may include one or more spacer components.

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-like aerosol-forming substrate. In some embodiments, the aerosol-forming substrate contains both solid and liquid components. In some embodiments, the aerosol-forming substrate contains both solid and gel components. In some embodiments, the aerosol-forming substrate contains both liquid and gel components.

The aerosol-forming substrate is preferably a solid aerosol-forming substrate. The aerosol-forming substrate may contain tobacco-containing material containing volatile compounds that are released from the substrate when heated. Volatile compounds may include volatile tobacco flavor compounds. The aerosol-forming substrate may contain an aerosol-forming agent that promotes the formation of a dense and stable aerosol. Examples of suitable aerosol-forming substances are glycerin 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 tobacco material and optionally 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, granules, beads, pieces, thin tubes, strips, or sheets. In some embodiments, the aerosol-forming substrate comprises one or more of: grass leaves, tobacco leaves, tobacco stem fragments, reconstituted tobacco, homogenized tobacco, extruded tobacco, molded sheet tobacco, and expanded tobacco. In some embodiments, the solid aerosol-forming substrate may be in particulate form. In some embodiments, the aerosol-forming substrate may be provided in a suitable container or cartridge. Optionally, the solid aerosol-forming substrate may contain additional tobacco or non-tobacco volatile compounds, such as volatile flavor compounds to be released when the substrate is heated. The aerosol-forming solid substrate may contain capsules that, for example, contain additional tobacco or non-tobacco volatile compounds. In some embodiments, such capsules may melt during heating of the solid substrate forming the aerosol. In some embodiments, such capsules may comprise a frangible membrane. The fragile membrane may be crushed, for example, by the user before or during use to release volatile compounds.

As used herein, the term “homogenized tobacco” refers to a material formed by agglomeration of particulate tobacco. Homogenized tobacco may be in leaf form. The aerosol-forming agent content of the homogenized tobacco material may be greater than 5% on a dry weight basis. Alternatively, the aerosol-forming agent content of the homogenized tobacco material may range from 5% to 30% by weight on a dry weight basis. Sheets of homogenized tobacco material may be formed by agglomerating bulk tobacco obtained by grinding or otherwise combining one or both of tobacco leaf blades and tobacco leaf stems. Alternatively or additionally, the sheets of homogenized tobacco material may contain one or more of tobacco dust, tobacco fines and other bulk tobacco by-products generated, for example, during tobacco processing, handling and shipping. The sheets of homogenized tobacco material may contain one or more internal binders, ie tobacco endogenous binders, one or more external binders, ie tobacco exogenous binders, or a combination thereof to promote agglomeration of the bulk tobacco; alternatively or additionally, the sheets of homogenized tobacco material may contain other additives, including, but not limited to, tobacco and non-tobacco fibers, aerosol formers, humectants, plasticizers, flavoring agents, fillers, aqueous and non-aqueous solvents, and combinations thereof.

In a particularly preferred embodiment, the aerosol-forming substrate comprises an assembled corrugated sheet of homogenized tobacco material. As used herein, the term “corrugated sheet” means a sheet having multiple substantially parallel folds or corrugations. Preferably, when the aerosol generating article is assembled, substantially parallel folds or corrugations extend along or parallel to the longitudinal axis of the aerosol generating article. This advantageously facilitates the collection of the corrugated sheet of homogenized tobacco material to form an aerosol-forming substrate. However, it should be appreciated that the corrugated sheets of homogenized tobacco material for inclusion in the aerosol generating article may alternatively or additionally have multiple substantially parallel folds or corrugations that are located at an acute or obtuse angle to the longitudinal axis of the aerosol generating article when the article aerosol generating agent was collected. In some embodiments, the aerosol-forming substrate may comprise an assembled sheet of homogenized tobacco material that is substantially uniformly textured over substantially the entire surface. For example, the aerosol-forming substrate may comprise an assembled corrugated sheet of homogenized tobacco material containing multiple substantially parallel folds or corrugations that are substantially evenly spaced across the width of the sheet.

Optionally, the solid aerosol-forming substrate may be provided on or embedded in a thermally stable carrier. The carrier may be in the form of powder, granules, beads, pieces, thin tubes, strips or sheets. Alternatively, the carrier may be a tubular carrier having a thin layer of solid substrate deposited on its internal surface, or on its external surface, or on both its internal and external surfaces. Such a tubular carrier may be formed, for example, from paper or paper-like material, non-woven carbon fiber mat, lightweight open cell metal mesh, or perforated metal foil, or any other heat-stable polymer matrix.

The solid aerosol-forming substrate may be applied to the surface of the carrier in the form of, for example, a sheet, foam, gel 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 to provide non-uniform delivery of the flavor 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 include additional components, such as, for example, a charging unit for recharging the built-in electrical power supply in the electrically controlled or electrical aerosol generating device.

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

in fig. 1 is a schematic illustration of an aerosol generating article suitable for use with an aerosol generating device according to the present invention;

in fig. 2 is a schematic illustration of a cavity of an aerosol generating device according to one aspect of the present invention, the cavity defining an article housing cavity for receiving a suitable aerosol generating article;

in fig. 3 is a schematic diagram showing the aerosol generating article shown in FIG. 1, which is inserted into the cavity housing the product shown in FIG. 2;

in fig. 4 is a schematic cross-sectional view of FIG. 3, showing an aerosol generating article located inside the heating part of the cavity;

in fig. 5 is a schematic diagram showing an extractor containing the cavity shown in FIG. 2 connected to the main body of the aerosol generating device according to the present invention;

in fig. 6 is a schematic view showing the aerosol generating article shown in FIG. 1, which is completely inserted into the cavity of the aerosol generating device shown in FIG. 5;

in fig. 7 is a schematic illustration of a cavity of an aerosol generating control device not in accordance with an aspect of the present invention, the cavity defining an article housing cavity for receiving a suitable aerosol generating article;

in fig. 8 is a schematic view showing the aerosol generating article shown in FIG. 1, which is completely inserted into the cavity of the aerosol generating device shown in FIG. 7;

in fig. 9 is a graph comparing nicotine delivery per puff between an aerosol generating device in accordance with the present invention and a control device;

in fig. 10 is a graph comparing glycerin delivery per puff between the aerosol generating device of the present invention and the control device;

in fig. 11 is a schematic illustration of a further embodiment of a cavity of an aerosol generating device according to an aspect of the present invention, the cavity including fins extending longitudinally across a heating portion;

in fig. 12 is a schematic cross-sectional view of the heating portion of the cavity, showing two fins;

in fig. 13 is a schematic cross-sectional view of the heating portion of the cavity showing three fins;

in fig. 14 is a schematic longitudinal sectional view of the heating part of the cavity showing six fins;

in fig. 15 is a schematic longitudinal sectional view of the extractor showing some of its six fins; And

in fig. 16 is a schematic illustration of a further embodiment of an aerosol generating device according to an aspect of the present invention, wherein the aerosol generating device includes an inductor and an aerosol generating article suitable for use with the device including a susceptor.

In fig. 1 illustrates an aerosol generating article 10 suitable for use with an aerosol generating device according to one embodiment of the present invention. The aerosol generating article 10 includes four coaxially aligned elements: an aerosol generating substrate 20, a support member 30, a transfer section 40, and a mouthpiece 50. These four elements are arranged in series and surrounded by an outer wrap 60 to form the aerosol generating article 10. The aerosol generating article 10 has a mouthpiece end 70 that the user inserts into his mouth during use, and a distal end 80 located at the opposite end of the aerosol generating article 10 from the mouthpiece end 70.

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

The aerosol generating substrate 20 is located at the outermost or upstream end of the aerosol generating article 10. In the embodiment illustrated in FIG. 1, the aerosol-forming substrate 20 comprises an assembled sheet of corrugated homogenized tobacco material surrounded by a wrapper. The corrugated sheet of homogenized tobacco material contains glycerin as an aerosol-forming agent.

The support member 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 member 30 places the aerosol generating substrate 20 at the extreme distal end 80 of the aerosol generating article 10 such that it can come into contact with the heating element of the aerosol generating device. The support member 30 has the function of preventing the aerosol generating substrate 20 from being forced downstream within the aerosol generating article 10 toward the transfer element 40 when the internal heating element of the aerosol generating device is inserted into the aerosol generating substrate 20. The support member 30 also acts as a separator to separate the transmission member 40 of the aerosol generating article from the aerosol generating substrate 20.

The transfer element 40 is located immediately downstream of the support element 30 and abuts the support element 30. In use, volatiles released from the aerosol-generating substrate 20 pass along the transfer section 40 towards the mouthpiece end 70 of the aerosol-generating article 10. The volatile substances may be cooled within the transfer section 40 to form an aerosol that is inhaled by the user. In the embodiment illustrated in FIG. 1, the transfer element 40 is an aerosol cooling element. The aerosol cooling element comprises a corrugated and assembled polylactic acid sheet surrounded by a wrapper 90. The corrugated and assembled polylactic acid sheet defines a plurality of longitudinal channels that extend 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 illustrated in FIG. 1, the mouthpiece 50 contains a traditional cellulose acetate fiber tow filter with low filtration efficiency.

To assemble the aerosol generating article 10, the four elements described above are aligned and tightly wrapped in the outer wrap 60. In the embodiment illustrated in FIG. 1, The outer wrapper is traditional cigarette paper.

The aerosol generating article illustrated in FIG. 1 is designed to engage with an aerosol generating device including an internal heating element for consumption by a user. In use, the internal heating element of the aerosol generating device heats the aerosol generating substrate 20 of the aerosol generating article 10 to a sufficient temperature to generate an aerosol. The aerosol is drawn downstream through the aerosol generating article 10 and inhaled by the user. The aerosol generating article illustrated in FIG. 1 is substantially cylindrical and has a diameter of approximately 7 mm and an overall length of approximately 45 mm.

In fig. 2 shows a longitudinally extending cavity 110. In the embodiment illustrated in FIG. 2, cavity 110 is provided with an extractor 100 of an aerosol generating device in accordance with one aspect of the present invention. The extractor 100 is a component that can be detachably coupled to the main apparatus portion to form an aerosol generating apparatus. The longitudinally extending cavity 110 of the extractor 100 is configured to receive a distal end and distal portion of an aerosol generating article, such as an aerosol generating article 10, as described with respect to FIG. 1.

The extractor 100 has a base 102 and side walls 103 that extend from the base 102. A longitudinally extending cavity 110 is formed by the internal surfaces of the base 102 and the side walls 103 and has an opening 111 at the end of the cavity 110 opposite the base 102. The cavity is circular in cross section and has three separate longitudinally divided parts, the diameter of the cavity varying between adjacent parts.

The first portion, or stabilizing portion 120, of the cavity 110 has a first diameter. This diameter is sized to closely match the outer diameter of the aerosol generating article for use with the aerosol generating device. Thus, if the aerosol generating article shown in FIG. 1 to be used with the apparatus, the first diameter may be approximately the same as the outer diameter of the aerosol generating article or be slightly larger in diameter than the outer diameter of the aerosol generating article. Thus, in a particular embodiment, the first diameter may be approximately 7.2 mm.

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

The first downwardly 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 portion or mounting portion 140 has a third diameter. The third diameter is preferably substantially the same as or identical to the first diameter. Thus, in the present example, the third diameter may be 7.2 mm. A second downwardly flared or inclined portion 145 of the inner surface of the cavity provides a transition between the heating portion 120 and the mounting portion 130. The second inclined portion is a region in which the diameter of the cavity decreases from a second diameter to a third diameter. The slope may operate to guide the distal end of the aerosol generating article into the mounting portion 140.

An opening or slot 150 is formed by a radially central portion of the base 102. This opening 150 allows a heating element attached to the main part of the aerosol generating device to be inserted into the cavity 110 when the extractor 100 is connected to the main part of the device. The opening 150 also allows air to flow into the cavity 110.

The outer surfaces of the walls of the extractor may include features designed to facilitate connection with the main part of the aerosol generating device. Such features may include, for example, grooves, slots, ridges and latches. The extractor is designed to be slidably engaged with the main body of the aerosol generating device. The extractor portion may slide into a corresponding housing on the main body of the aerosol generating device.

The extractor 100 is formed from injection molded polyetheretherketone (PEEK). However, extractor 100 may be formed from any suitable material, such as other polymeric materials such as polyethylene or polypropylene.

In fig. 3 shows an aerosol generating article 10 as described in relation to FIG. 1, which is fully inserted into the cavity 110 of the extractor 100, as described in relation to FIG. 2. The distal end of the aerosol generating article was inserted through the opening 111 and pushed through the stabilizing portion 120 and the heating portion 130 to be placed inside the mounting portion 140. The distal end 80 of the article 10 rests on the inner surface of the base 102. Since the outer diameter of the article 10 is being substantially the same as the first cavity diameter in the stabilizing portion 120 and the third cavity diameter in the mounting portion 140, there is close contact between the product and the cavity walls at these points. However, the cavity diameter of the heating portion 130 is larger than that of the stabilizing portion and the mounting portion. Since the aerosol generating article 10 is substantially cylindrical, there is an air gap 160 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 this gap can be determined by subtracting the first diameter of the stabilizing portion (and aerosol generating article) from the second diameter of the heating portion and dividing by two. The longitudinal size of the heating part is similar to the longitudinal size of the aerosol-forming substrate or product. The aerosol-forming substrate of the article is substantially contained within the heating portion when the article is fully inserted into the extractor cavity.

Inlet openings passing through the side walls of the cavity are not formed. Thus, when the article is positioned within the cavity, the air gap 160 forms an annular air pocket. This air pocket helps to isolate the aerosol-generating substrate during use of the aerosol-generating device.

The ability to insulate an aerosol-generating product is a result of the difference in thermal conductivity between the air and the cavity sidewall material, such as PEEK. At preferred operating temperatures (e.g., 300 to 600 degrees Kelvin), the thermal conductivity of air ranges from 0.0262 Watts per meter-Kelvin (V.m ^-1 .K ^-1 ) and 0.0457 V.m ^-1 .K ^-1 . In contrast, the thermal conductivity of PEEK at 300 degrees Kelvin is approximately 0.25 V.m ^-1 .K ^-1 . Thus, air is approximately ten times less conductive than PEEK. If, preferably, through-flow of air within the air gap is prevented, the air gap 160 may function to help prevent heat dissipation from the aerosol-generating substrate of the aerosol-generating article.

In fig. 4 shows a cross-section of the heating part of the extractor with an inserted aerosol-generating product. The side walls 103 can be considered to be circular in cross section. The cavity 110 is formed by the inner surface 131 of the side walls 103. The aerosol generating article 10 passes through the heating portion. In cross-section, the aerosol generating substrate 20 of the aerosol generating article fills the central portion of the cavity. The air gap 160 can be considered as an annular gap extending completely around the aerosol generating article. The air gap creates an air pocket when the product is inserted.

The extractor 100 is an integral part of the aerosol generating device 500. The extractor may be detachably coupled to the main body to form an aerosol generating device. Thus, the main part, which can be called the first housing part 501, contains a power supply, control electronics and a heating element. The extractor, which may be referred to as the second body portion 100, includes a cavity 110 that receives the product.

As can be seen in FIG. 5, in a specific embodiment, the main body/second body portion 501 includes a shell 510 for connection to the extractor/second body part 100 and a heating element 520 for insertion into a cavity 110 of the extractor 100. The extractor 100 and the main body 501 are coupled together through relative longitudinal movement. The heating element 520 extends into the cavity 110 through an opening 150 formed through the base 102. Thus, the opening 150 also allows the extractor to be moved relative to the heating element 520.

In 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 generating substrate 20.

When in use, the heating element is activated and raises the temperature of the aerosol-forming substrate to an operating temperature, for example from 300°C to 350°C. This causes substances within the substrate to volatilize, forming an aerosol. When a user inhales at the proximal end of the aerosol generating article 10, the aerosol formed from these volatile components may be inhaled. The presence of the air gap 160 helps to minimize heat loss through the outer walls of the aerosol generating article. In tests conducted on aerosol-generating products containing homogenized tobacco as the aerosol-forming substrate, delivery of nicotine and other aerosol-forming substances was greater during initial puffs compared to a control device that did not have an air gap.

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

Fig. 7 and 8 are presented to illustrate the control extractor 700 and the control device 800 containing such an extractor. It should be noted that FIG. 7 and 8 are presented for comparison purposes only and do not illustrate embodiments of the present invention.

The control extractor 700 is different from the extractor 100 shown in FIG. 2, in that the cavity 710 of the control extractor 700 does not form separate stabilizing, heating and mounting parts. Instead, a cavity 710 is formed by inner walls 760 that extend uniformly between the cavity opening 711 and the cavity base 702. The diameter of the cavity 710 is substantially uniform along the length of the cavity, which is approximately 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 part of the extractor shown in FIG. 2. From other points of view, the control extractor and the extractor shown in FIG. 2 are the same.

In fig. 8 illustrates an aerosol generating article operably coupled to an extractor 700 of a control device 800. The aerosol generating article is tightly seated within a 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.

Identical aerosol generating products were tested under identical conditions. The only difference is that one set of products was tested using the extractor and apparatus described in relation to FIG. 2-6, and the control set of products was tested using the control extractor and control device described in relation to FIGS. 7 and 8. Fourier transform infrared spectroscopy (FTIR) was performed on aerosols obtained from these experiments.

In fig. 9 is a graph showing nicotine delivery (measured in milligrams on the y-axis) versus the number of puffs on the aerosol-generating product (x-axis). Results obtained using the extractor shown in FIG. 2-6, containing an air gap that surrounds part of the product, are shown by solid line (a). Results obtained using the control extractor shown in FIG. 7 and 8, without the air gap that surrounds the part of the product, are shown by the dotted line (b). It can be seen that nicotine delivery is approximately the same for the first two puffs, but after that, nicotine delivery is significantly improved using the extractor shown in FIG. 2, compared to the control extractor. It can be assumed that the air gap 160 does provide an insulating effect and reduces heat dissipation from the aerosol substrate of the article, thereby improving nicotine delivery.

In fig. 10 is a graph showing glycerol delivery (measured in milligrams on the y-axis) versus the number of puffs on the aerosol generating product (x-axis). Results obtained using the extractor shown in FIG. 2-6, containing an air gap that surrounds part of the product, are shown by solid line (a). Results obtained using the control extractor shown in FIG. 7 and 8, without the air gap that surrounds the part of the product, are shown by the dotted line (b). It can be seen that glycerol delivery is approximately the same for the first two or three puffs, but after that glycerol delivery is significantly improved using the extractor shown in FIG. 2, compared to the control extractor. This result mirrors the nicotine delivery results presented in FIG. 9.

Although it is preferable that the extractor 100 be configured to provide a completely annular air gap between the aerosol generating article and the heating portion of the cavity, circumstances may arise in which one or more fins may be required. Such ribs may help stabilize the aerosol generating article within the longitudinally extending cavity 110. Such ribs may provide a strengthening effect for the extractor. Such ribs may help guide the distal end of the aerosol generating article toward the mounting portion when inserted into the cavity. Such fins may help prevent radial deformation of the aerosol generating article when a heating element is inserted into the aerosol generating substrate of the aerosol generating article.

For example, referring now to FIG. 11, the extractor 100 may include one or more fins 790. The one or more fins preferably extend along the heating portion 130. Preferably, the one or more fins extending along the heating portion 130 extend from the beginning or downstream end 736 of the transition 735 between the stabilizing portion 120 and the heating portion 130 along the end or upstream end 746 of the transition 745 from the heating portion 130 to the mounting portion 140. Such fins 790 should not protrude into the cavity beyond the walls of the stabilizing portion so as not to obstruct the passage of the aerosol generating article . Although continuous fins are illustrated extending along the entire length of the heating portion 130, it should be understood that other structures may be used that still serve the function of stabilizing the aerosol generating article 10 within the chamber with minimal contact. It is preferred that any fins have a relatively small width dimension, for example a width of from 0.5 mm to 1.5 mm in a dimension that can contact the aerosol-generating article.

In fig. 12 is a cross-sectional view of an extractor 800 having two longitudinally extending ribs 890 extending along a heating portion between a stabilizing portion and a mounting portion. The cross-sectional view is taken from the heating part. When the aerosol generating article 10 is inserted into the cavity, the fins 890 help define a first air pocket 860A and a second air pocket 860B. There is very little contact between the article 10 and the fins 890, and only a small amount of heat is lost at these contact points. Isolation of the aerosol-forming substrate is provided by two semi-annular air pockets 890A, 890B.

In fig. 13 is a cross-sectional view of an extractor 900 having three longitudinally extending ribs 990 extending along the heating portion, between the stabilizing portion and the mounting portion. The cross-sectional view is taken from the heating part. When the aerosol generating article 10 is inserted into the cavity, the fins help define a first air pocket 960A, a second air pocket 960B, and a third air pocket 960C. There is very little contact between the article 10 and the fins 990, and only a small amount of heat is lost at these contact points. Isolation of the aerosol-forming substrate is provided by three partially annular air pockets 960A, 960B, 960C.

In fig. 14 is a cross-sectional view of an extractor 1400 having six longitudinally extending fins 1490 extending along the heating portion, between the stabilizing portion and the mounting portion. The cross-sectional view is taken from the heating part. When the aerosol generating article 10 is inserted into the cavity, the fins help define a first air pocket 1460A, a second air pocket 1460B, a third air pocket 1460C, a fourth air pocket 1460D, a fifth air pocket 1460E, and a sixth air pocket 1460F. There is very little contact between the article 10 and the fins 1490, and only a small amount of heat is lost at these contact points. Isolation of the aerosol-forming substrate is provided by six partially annular air pockets 1460A, 1460B, 1460C, 1460D, 1460E, and 1460F.

In fig. 15 is a longitudinal 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 mounting portion 1440. Such longitudinally extending ribs 1490 may provide a strengthening effect for the extractor. Such longitudinally extending ribs 1490 may help guide the distal end of the aerosol generating article toward the mounting portion when inserted into the cavity. Such longitudinally extending fins 1490 may help prevent radial deformation of the aerosol generating article if a heating element is inserted into the aerosol generating 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 including an extractor for housing the aerosol generating article 10. The disclosed heating element is a resistive heating element. However, there may be alternative embodiments of the invention. For example, the heating means may comprise induction heating means. The heating element may include a plate-type susceptor and an inductor so that an induction coil can be positioned around the cavity 110. Alternatively, the aerosol generating article 110 may include a susceptor, and the aerosol generating device may include an inductor for heating the susceptor.

In fig. 16 schematically illustrates such an aerosol generating system driven by induction. In this system, the aerosol generating article 1000 is similar to the article 10 described in relation to FIG. 1. One difference in the system shown in FIG. 16, compared to the systems described above, for example in relation to FIG. 2-6 is that the aerosol-forming substrate 1025 of the article 1000 contains or is associated with a current collector 1020. The current collector in this example is a longitudinal strip of stainless steel. This strip acts as a current collector 1020 that can be heated to heat the aerosol-forming substrate. In one specific embodiment, the current collector 1020 may be in the form of a strip of 430 stainless steel having dimensions of 12 mm by 4 mm by 35 micrometers.

The aerosol generating device 1500 is similar to the device described in relation to FIG. 2-6. However, there is no heating element associated with the device. Instead, the pantograph 1020 is located in thermal communication with the aerosol-generating substrate of the aerosol-generating article, and heat can be generated in the pantograph by induction heating when the pantograph is located in a changing magnetic field generated by the aerosol-generating device. Thus, the aerosol generating device 1500 includes an inductor in the form of an induction coil 1600, as well as a power supply such as a battery, and control electronics. The induction coil 1600 is capable of generating a varying magnetic field within the extractor cavity. The current collector and the induction coil may, in combination, form a heating means for the aerosol-forming substrate.

Induction heating is a well-known phenomenon described by Faraday's law of induction and Ohm's law. More specifically, Faraday's law of induction states that if the magnetic induction in a conductor changes, then an alternating electric field is created in the conductor. Since this electric field is created in a conductor, a current known as eddy current will flow in the conductor according to Ohm's law. Eddy current will generate heat in proportion to the current density and resistivity of the conductor. A conductor that can be inductively heated is known as a current collector. The aerosol generating device is an induction heating device equipped with an induction heating source, such as, for example, an induction coil 1600, which is capable of generating an alternating electromagnetic field from an alternating current source, such as an LC circuit. Eddy currents are generated in the pantograph 1020, generating heat, thereby increasing the temperature of the pantograph so that it can function as a heating element.

The aerosol generating device 1500 includes a battery and electronics (not shown) that enable activation of the inductor 1600. Such actuation may be performed manually or may occur automatically in response to the user tightening the aerosol generating product 1000 inserted into the cavity. , containing the substrate, the aerosol generating device 1500. The battery supplies constant current. The electronics include a DC-to-AC inverter to supply high-frequency AC current to the inductor.

When the device is operated, a high frequency alternating current flows through the turns of wire that form part of the induction coil 1600. This causes the induction coil 1600 to generate a varying electromagnetic field within the substrate housing portion of the device. The electromagnetic field preferably varies at a frequency of 1 to 30 MHz, preferably 2 to 10 MHz, for example 5 to 7 MHz. When the aerosol generating article 1000 is properly positioned in the substrate receiving cavity, as illustrated in FIG. 16, the current collector 1020 of the product 1000 is located within this changing electromagnetic field. The changing field generates eddy currents inside the pantograph, which heats up as a result. Additional heating is provided through magnetic hysteresis losses inside the current collector. The heated current collector heats the aerosol generating substrate 1020 of the aerosol generating article 1000 to a sufficient temperature to generate 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 minimized by the air gap 160 provided on the heating portion of the cavity. As a result, processes for delivering the aerosol to the user can be improved.

Claims (29)

1. An aerosol generating device for heating an aerosol generating substrate provided in a cylindrical aerosol generating article, the aerosol generating device comprising; a longitudinally extending cavity for housing a distal portion of the aerosol generating article, wherein the longitudinally extending cavity has a longitudinal axis and is formed by a base, side walls extending from the base, and an opening at an end of the cavity opposite the base, wherein the inner surfaces of the side walls form a stabilizing portion of the cavity, having a first diameter, and a cavity heating portion located between the stabilizing portion and the base, the heating portion having a second diameter that is larger than the first diameter, wherein the inner walls of the cavity additionally form a mounting part located at the far end of the cavity, a heating part located between the stabilizing part and the mounting part, wherein the mounting part of the cavity has a third diameter, which is equal to the first diameter of the stabilizing part. 2. The aerosol generating device according to claim 1, characterized in that the cross-sectional area of the cavity in the heating part is 110-300% larger than the cross-sectional area of the cavity in the stabilizing part. 3. The aerosol generating device according to claim 2, characterized in that the cross-sectional area of the cavity in the heating part is 130-200% larger than the cross-sectional area of the cavity in the stabilizing part. 4. An aerosol generating device according to claim 2 or 3, characterized in that the cross-sectional area of the cavity in the heating part is 140-160% larger than the cross-sectional area of the cavity in the stabilizing part. 5. An aerosol generating device according to any of the previous paragraphs, characterized in that the second diameter is 105-170% larger than the first diameter. 6. An aerosol generating device according to any of the previous paragraphs, characterized in that the second diameter is 110-150% larger than the first diameter. 7. An aerosol generating device according to any of the previous paragraphs, characterized in that the second diameter is 125-130% larger than the first diameter. 8. The aerosol generating device of any one of the preceding claims, characterized in that the difference in diameter between the stabilizing portion and the heating portion provides one or more insulating air pockets surrounding the outer surface of the aerosol generating article when the distal portion of the aerosol generating article is inserted into a longitudinally extending cavity. 9. An aerosol generating device according to any of the preceding claims, characterized in that it has an air inlet opening through the base. 10. An aerosol generating device according to any of the previous claims, characterized in that the inner walls of the cavity form a cone-shaped region in which the diameter of the cavity changes with a constant gradient from the second diameter to the third diameter. 11. The aerosol generating device according to any one of the preceding claims, characterized in that the difference in diameter between the first diameter on the stabilizing part and the second diameter on the heating part is a gap diameter, the gap diameter being from 0.5 mm to 5 mm. 12. The aerosol generating device according to claim 11, characterized in that the gap diameter is 1-4 mm. 13. The aerosol generating device according to claim 11 or 12, characterized in that the inner side walls comprise one or more fins extending longitudinally in the heating portion and extending radially from the inner side walls. 14. The aerosol generating device according to claim 13, characterized in that the ribs have a radial size equal to the diameter of the gap. 15. The aerosol generating device according to claim 13 or 14, characterized in that one or more ribs are configured to guide and stabilize the aerosol generating article inserted into the cavity. 16. An aerosol generating device according to any one of paragraphs. 13-15, characterized in that it contains a combination of longitudinal and annular ribs. 17. An aerosol generating device according to any of the previous paragraphs, characterized in that it comprises a first housing part containing a power source, control electronics and at least part of the heating means, and a second housing part, which is configured to move relative to the first housing part, while a longitudinally extending cavity is formed in the second body part. 18. The aerosol generating device according to claim 17, characterized in that the second housing portion is connected to the first housing portion so as to be movable between a first position and a second position, wherein the first position is an operating position formed by a heating means configured to engagement with the aerosol generating article, and the second position is an extraction position formed by the aerosol generating article being at least partially removed from the longitudinally extending cavity. 19. The aerosol generating device according to claim 17 or 18, characterized in that the first body part and the second body part are detachable and detachable from each other. 20. An aerosol generating device according to any of the previous paragraphs, characterized in that the heating element is configured to pass into the heating part of the cavity. 21. An aerosol-generating device according to any of the previous paragraphs, characterized in that the outer boundaries of the circumferential or annular air pocket, when the aerosol-generating product is fully inserted into the cavity, are formed by (1) the outer surface of the aerosol-generating product, (2) the inner the surface of the cavity heating portion, (3) a radially extending step or slope passing between the inner surface of the heating portion and the inner surface of the stabilizing portion, and (4) a radially extending step or slope passing between the inner surface of the heating portion and the inner surface of the mounting portion. 22. 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 to accommodate a distal portion of the aerosol-generating article, the aerosol-generating device being longitudinally the passing cavity has a longitudinal axis and is formed by a base, side walls extending from the base, and an opening at the end of the cavity opposite the base, wherein the inner surfaces of the side walls form a stabilizing part of the cavity having a first diameter, and a heating part of the cavity located between the stabilizing part and the base, wherein the heating part has a second diameter that is larger than the first diameter, wherein the inner walls of the cavity additionally form a mounting part located at the far end of the cavity, a heating part located between the stabilizing part and the mounting part, wherein the mounting part of the cavity has a third diameter, which is equal to the first diameter of the stabilizing part. 23. The aerosol generating system according to claim 22, characterized in that the aerosol generating product is a cylindrical aerosol generating product to be heated with the device, wherein the aerosol generating product has a longitudinal axis and a diameter of the product, wherein the first the diameter of the longitudinally extending cavity of the aerosol-generating device is equal to the diameter of the product. 24. The aerosol generating system of claim 22 or 23, wherein the aerosol generating article comprises a plurality of coaxially aligned components, including an aerosol generating substrate assembled within the wrapper to form a cylindrical article having a longitudinal axis and a diameter an article, wherein the aerosol-generating article has a proximal portion terminating in a proximal end and a distal portion terminating in a distal end, and wherein the aerosol-generating substrate is located in the distal portion of the article. 25. An aerosol generating system according to any one of claims. 22-24, characterized in that the aerosol generating device is a device defined according to any one of claims. 2-21.

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