Aerosol generator and extractor with molded cavity

Abstract

An aerosol generating system comprising an aerosol generating device (10), an extractor (30) for the aerosol generating device, and a cavity (20) for receiving an aerosol-forming substrate (52), the cavity (20) having a first end and an opposing second end, a length between the first end and the second end, and a cross-section perpendicular to the length, wherein the cross-sectional shape of the cavity (20) varies along the length of the cavity (20), the cross-sectional surface area of ​​the cavity (20) varies along the length of the cavity (20), and / or the cross-sectional dimension of the cavity (20) varies along the length of the cavity (20).

Description

[Technical field]

[0001] The present invention relates to an aerosol generating device, an extractor for an aerosol generating device, and an aerosol generating system comprising an aerosol generating device and an aerosol-generating article. [Background technology]

[0002] Some known aerosol generating systems include an aerosol generating device having a power source, such as a battery, a controller, and a heating element for heating the aerosol-forming substrate. In some embodiments, the aerosol-forming substrate comprises a tobacco rod or a tobacco plug disposed within the aerosol-generating article. In use, the aerosol-generating article is inserted into a cavity of the aerosol generating device, and the heating element penetrates the aerosol-forming substrate or is disposed around the outside of the aerosol-forming substrate. Power is supplied from the power source to the heating element to heat the aerosol-forming substrate, causing volatile components of the aerosol-forming substrate to be vaporized and released, condensing to form an aerosol that is inhaled by the user. Summary of the Invention [Problem to be solved by the invention]

[0003] In some such aerosol generating systems, the aerosol-generating article resembles a conventional cigarette with a similar cylindrical stick-like configuration. This similarity to a conventional cigarette is often desirable for users of the aerosol generating system who may be familiar with the manner of smoking a cigarette. However, such a configuration of the aerosol-generating article may not be optimal for the purpose of efficiently or evenly heating the aerosol-forming substrate using the heating element of the aerosol generating device. Such a configuration of the aerosol-generating article may result in areas of the aerosol-forming substrate being heated to a lower temperature than desired. This may also lead to an excess of the aerosol-forming substrate being provided to the aerosol-generating article in order for the aerosol generating system to generate the desired amount of aerosol.

[0004] It would be desirable to provide an aerosol generating device that provides improved heat transfer from a heating element to the aerosol-forming substrate.It would be desirable to provide an aerosol generating device that allows for even heating across the aerosol-forming substrate.It would be desirable to provide an aerosol generating device that allows for a minimum mass of aerosol-forming substrate to be used to generate a desired amount of aerosol. [Brief description of the drawings]

[0005] [Figure 1] 1 shows a schematic cross-sectional view through an aerosol generating device according to one embodiment of the present disclosure, the aerosol generating device comprising a cavity having a first end with a circular cross-section and a second end with an oval cross-section. [Diagram 2] 2 shows a schematic diagram of a cross section through a portion of the aerosol generating device of FIG. 1 rotated 90 degrees relative to FIG. [Diagram 3] 2 shows a schematic diagram of a top view of the aerosol generating device of FIG. 1, looking into the cavity of the device from the open first end of the cavity. [Figure 4] FIG. 2 shows a schematic diagram of an aerosol-generating article comprising an aerosol-forming substrate, the aerosol-generating article being suitable for use with the aerosol generating device of FIG. 1 to form an aerosol generating system according to one embodiment of the present disclosure. [Diagram 5] FIG. 5 shows a schematic diagram of an aerosol generation system comprising the aerosol generating device of FIG. 1 and the aerosol generating article of FIG. 4, a portion of which is received within a cavity of the aerosol generating device. [Figure 6] FIG. 1 shows a schematic cross-sectional view through an aerosol generating device according to another embodiment of the present disclosure, the aerosol generating device comprising an extractor defining a cavity having a first end with a circular cross-section and a second end with an oval cross-section. [Figure 7] 7 shows a schematic diagram of an extractor for the aerosol generating device of FIG. 6. [Figure 8]A schematic diagram of the aerosol generating device of Figure 6 is shown in which the extractor is received on the housing of the aerosol generating device and the extractor is disposed in a second position in which the heating element of the device does not extend into the cavity of the extractor. [Figure 9] 7 shows a schematic diagram of an aerosol generating system comprising the aerosol generating device of FIG. 6 and the aerosol generating article of FIG. 4, in which the extractor is received on the housing of the aerosol generating device and the extractor is disposed in a first position in which the heating element of the device extends into a cavity of the extractor and a portion of the aerosol generating device is received within the cavity of the extractor. [Figure 10] (a) shows a schematic diagram of a plan view of the extractor of the aerosol generating device of Figure 6, looking into the cavity of the extractor from the open first end of the cavity, (b) shows a schematic diagram of a side view of the extractor of the aerosol generating device of Figure 6, and (c) shows a schematic diagram of another side view of the extractor of the aerosol generating device of Figure 6, rotated 90 degrees relative to Figure 10b. [Figure 11] FIG. 7( a ) shows a schematic diagram of a plan view of another embodiment of an extractor according to the present disclosure, suitable for use in the aerosol generating device of FIG. 6 , looking into a cavity of the extractor from the open first end of the cavity; FIG. 7( b ) shows a schematic diagram of a side view of the extractor of (a); and FIG. 7( c ) shows a schematic diagram of another side view of the extractor of (a), rotated 90 degrees relative to (b). [Figure 12] FIG. 7( a ) shows a schematic diagram of a plan view of another embodiment of an extractor according to the present disclosure, suitable for use in the aerosol generating device of FIG. 6 , looking into a cavity of the extractor from the open first end of the cavity; FIG. 7( b ) shows a schematic diagram of a side view of the extractor of (a); and FIG. 7( c ) shows a schematic diagram of another side view of the extractor of (a), rotated 90 degrees relative to (b). [Figure 13] FIG. 7( a ) shows a schematic diagram of a plan view of another embodiment of an extractor according to the present disclosure, suitable for use in the aerosol generating device of FIG. 6 , looking into a cavity of the extractor from the open first end of the cavity; FIG. 7( b ) shows a schematic diagram of a side view of the extractor of (a); and FIG. 7( c ) shows a schematic diagram of another side view of the extractor of (a), rotated 90 degrees relative to (b). [Figure 14] FIG. 7( a ) shows a schematic diagram of a plan view of another embodiment of an extractor according to the present disclosure, suitable for use in the aerosol generating device of FIG. 6 , looking into a cavity of the extractor from the open first end of the cavity; FIG. 7( b ) shows a schematic diagram of a side view of the extractor of (a); and FIG. 7( c ) shows a schematic diagram of another side view of the extractor of (a), rotated 90 degrees relative to (b). [Figure 15] FIG. 7( a ) shows a schematic diagram of a plan view of another embodiment of an extractor according to the present disclosure, suitable for use in the aerosol generating device of FIG. 6 , looking into a cavity of the extractor from the open first end of the cavity, and FIG. 7( b ) shows a schematic diagram of a side view of the extractor of ( a ). [Figure 16] FIG. 7( a ) shows a schematic diagram of a plan view of another embodiment of an extractor according to the present disclosure, suitable for use in the aerosol generating device of FIG. 6 , looking into a cavity of the extractor from the open first end of the cavity, and FIG. 7( b ) shows a schematic diagram of a side view of the extractor of ( a ). [Figure 17] FIG. 7( a ) shows a schematic diagram of a plan view of another embodiment of an extractor according to the present disclosure, suitable for use in the aerosol generating device of FIG. 6 , looking into a cavity of the extractor from the open first end of the cavity, and FIG. 7( b ) shows a schematic diagram of a side view of the extractor of ( a ). DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0006] According to the present disclosure, there is provided an aerosol generating device comprising a cavity for receiving an aerosol-forming substrate. The cavity may have a first end. The cavity may have a second end opposite the first end. The cavity may have a length between the first end and the second end. The cavity may have a cross-section perpendicular to the length. The shape of the cross-section of the cavity may vary along the length of the cavity. The surface area of ​​the cross-section of the cavity may vary along the length of the cavity. The dimensions of the cross-section of the cavity may vary along the length of the cavity.

[0007] In some embodiments, the cross-sectional shape of the cavity varies along the length of the cavity. In some embodiments, the cross-sectional surface area of ​​the cavity varies along the length of the cavity. In some embodiments, the cross-sectional dimension of the cavity varies along the length of the cavity. In some embodiments, one or more of the cross-sectional shape of the cavity, the cross-sectional surface area of ​​the cavity, and the cross-sectional dimension of the cavity vary along the length of the cavity.

[0008] At least one of the cross-sectional shape of the cavity and the dimensions of the cavity along its length may allow the aerosol-forming substrate to deform when it is provided in a first configuration and then inserted into the cavity in a second configuration. In particular, when the aerosol-forming substrate is provided within an aerosol-generating article, the aerosol-generating article may be provided with a configuration similar to a conventional cigarette that is familiar and desirable to users, and the aerosol-forming substrate within the aerosol-generating article may then deform when the aerosol-generating article is inserted into the cavity of the aerosol-generating device to optimize the morphology of the aerosol-forming substrate and improve the transfer of heat from the heating element to the aerosol-forming substrate. For example, the density of the aerosol-forming substrate may be modified by the deformation of the aerosol-forming substrate to minimize peripheral portions of the aerosol-forming substrate located away from the heating element of the aerosol-generating device that are difficult to heat to the desired temperature. Advantageously, optimizing the morphology of the aerosol-forming substrate in an aerosol-generating device to improve heat transfer from a heating element to the aerosol-forming substrate may increase the amount of aerosol that can be generated from a particular mass of aerosol-forming substrate. Thus, optimizing the morphology of the aerosol-forming substrate in an aerosol-generating device may allow a desired amount of aerosol to be produced using a minimum mass of aerosol-forming substrate.

[0009] As used herein, "aerosol-generating device" refers to a device that interacts with an aerosol-forming substrate to generate an aerosol.

[0010] As used herein, "aerosol-forming substrate" refers to a substrate capable of releasing volatile compounds that can be cooled to form an aerosol. Such volatile compounds can be released by heating the aerosol-forming substrate. The aerosol formed by heating the aerosol-forming substrate can contain fewer known harmful components than those produced by combustion or pyrolysis of the aerosol-forming substrate.

[0011] The aerosol-forming substrate may be part of an aerosol-generating article.

[0012] As used herein, "aerosol-generating article" refers to an article comprising an aerosol-forming substrate capable of releasing a volatile compound capable of forming an aerosol. For example, the aerosol-generating article may be an article that generates an aerosol that can be directly inhaled through the mouth of a user into the lungs of the user. The aerosol-generating article may be disposable. The aerosol-generating article is preferably a heated aerosol-generating article, which is an aerosol-generating article that includes an aerosol-forming substrate that is intended to be heated, rather than burned, to release a volatile compound capable of forming an aerosol. The aerosol-generating article may be or include a tobacco stick.

[0013] The cavity of the aerosol generating device may have any suitable shape and size. The cavity has a first end and a second end opposite the first end. The cavity has a length extending between the first end and the second end. The cavity also has a cross-section extending in a direction perpendicular to the length of the cavity. The cavity has a cross-section at each point along the length of the cavity.

[0014] Each cross-section of a cavity is formed by a plane extending in a direction perpendicular to the length of the cavity. Each cross-section of a cavity may have a width or diameter, a surface area, and a perimeter. As used herein, the width of a cross-section of a cavity is the distance between two opposite sides of the cavity on the plane that forms the cross-section. As used herein, the perimeter of a cross-section of a cavity is the length of the line that forms the boundary of the cavity on the plane that forms the cross-section. As used herein, the surface area of ​​a cross-section of a cavity is the size of the area defined by the perimeter of the cross-section.

[0015] The cross-sectional dimension of the cavity may vary along the length of the cavity. The cross-sectional dimension of the cavity is preferably the cross-sectional width of the cavity. If the cross-section is circular, the cross-sectional dimension may be the cross-sectional diameter of the cavity. If the cross-section is not circular, the dimension may be the major cross-sectional width of the cavity. The major cross-sectional width is the maximum cross-sectional width. If the cross-section is not circular, the dimension may be the minor cross-sectional width of the cavity. The minor cross-sectional width is the minimum cross-sectional width.

[0016] If the shape of a cross-section of a cavity does not vary along the length of the cavity, the dimension that varies along the length of the cavity may be the same dimension as the cross-section of the cavity. For example, the dimension may be the minor width of the cross-section. The dimension that varies along the length of the cavity may extend in the same direction for each cross-section of the cavity.

[0017] If the cross-sectional shape of the cavity varies along the length of the cavity, the dimension of the cross-section of the cavity that varies along the length of the cavity may be the minimum width of the cross-section of the cavity. For example, if the cavity includes a portion having a circular cross-section and a portion having an oval cross-section, the dimension of the circular cross-section may be the diameter of the circle and the dimension of the oval cross-section may be the minor axis of the oval. If the cross-sectional shape of the cavity varies along the length of the cavity, the dimension that varies along the length of the cavity may be the maximum dimension of the cross-section of the cavity.

[0018] In some embodiments, the cross-sectional dimension at the first end of the cavity is larger than the cross-sectional dimension at the second end of the cavity. In other words, the cross-sectional dimension at the second end of the cavity may be less than the cross-sectional dimension at the first end of the cavity. For example, the cross-sectional width at the first end of the cavity may be larger than the cross-sectional width at the second end of the cavity. In these embodiments, when the aerosol-forming substrate is inserted into the cavity at the first end and moved to the second end, the aerosol-forming substrate may be compressed as it moves from the first end to the second end. Compressing the aerosol-forming substrate increases the density of the aerosol-forming substrate at the second end of the cavity and promotes heat transfer from the heating element to all parts of the aerosol-forming substrate, which may advantageously result in uniform heating across the aerosol-forming substrate.

[0019] In some embodiments, the cross-sectional surface area of ​​the cavity varies along the length of the cavity. In some preferred embodiments, the cross-sectional surface area of ​​the cavity at the first end of the cavity is greater than the cross-sectional surface area of ​​the cavity at the second end of the cavity. In other words, the cross-sectional surface area of ​​the cavity at the second end may be less than the cross-sectional surface area of ​​the cavity at the first end. Advantageously, such a configuration may lead to compression of the aerosol-forming substrate when moving from the first end to the second end of the cavity, facilitating heat transfer from the heating element to all parts of the aerosol-forming substrate.

[0020] It is preferred that the perimeter of each cross-section of the cavity along its length remains substantially constant. In other words, the length of the line forming the boundary of the cross-section of the cavity may remain substantially constant at each point along its length. The perimeter of the cross-section at the first end of the cavity and the perimeter of the cross-section at the second end of the cavity may be the same. The cross-section at the first end of the cavity and the cross-section at the second end of the cavity may be equiperimeter. It is preferred that the perimeter of the cross-section of the cavity along its length is substantially the same as the perimeter of the cross-section of the aerosol-forming substrate or the aerosol-generating article.

[0021] In some embodiments, the cross-sectional dimension at the second end of the cavity is greater than the cross-sectional dimension at the first end of the cavity to ensure that the perimeter of the cross-sectional dimension at the second end of the cavity is the same as the perimeter of the cross-sectional dimension at the first end of the cavity. For example, if the cross-section at the first end of the cavity is circular and the cross-section at the second end of the cavity is oval, the major axis of the oval cross-section at the second end of the cavity may be greater than the diameter of the circular cross-section at the first end of the cavity.

[0022] When the aerosol-generating article includes an outer wrapper, such as an outer wrapper formed from paper, the outer wrapper may crimp or wrinkle when the aerosol-generating article is inserted into the cavity if the perimeter of the cross-section of the cavity at any point along the length of the cavity is less than the perimeter of the cross-section of the aerosol-generating article. Advantageously, by providing the cavity with a cross-section having a perimeter along the length of the cavity that is substantially the same as or greater than the perimeter of the cross-section of the aerosol-generating article, crimp or wrinkle of the outer wrapper of the aerosol-generating article may be substantially prevented or inhibited when the aerosol-generating article is inserted into the cavity. Advantageously, maintaining a substantially constant perimeter for the cross-section of the cavity along the length of the cavity may substantially prevent or inhibit crimp or wrinkle of the outer wrapper of the aerosol-generating article when the aerosol-generating article is inserted into the cavity and moved from the first end to the second end.

[0023] If the cross-sectional perimeter of the cavity at any point along its length is less than the cross-sectional perimeter of the aerosol-generating article and the aerosol-generating article comprises an outer wrapper, the outer wrapper of the aerosol-generating article may include one or more cuts or slits to prevent or inhibit crimping and wrinkling of the outer wrapper when the aerosol-generating article is received within the cavity. The one or more cuts or slits may extend substantially along the length of the aerosol-generating article.

[0024] According to some preferred embodiments of the present disclosure, an aerosol generating device is provided that includes a cavity for receiving an aerosol-forming substrate. The cavity has a first end and an opposing second end, a length between the first end and the second end, and a cross-section perpendicular to the length. In these preferred embodiments, the surface area of ​​the cross-section of the cavity varies along the length of the cavity, and the perimeter of the cross-section of the cavity remains substantially constant along the length of the cavity. In some of these preferred embodiments, the shape of the cross-section of the cavity varies along the length of the cavity.

[0025] The cross-section of the cavity at the first end may have any suitable shape. For example, the cross-section of the cavity at the first end may be substantially circular, elliptical, square, triangular, or hexagonal. The cross-section of the cavity at the first end may have any polygonal shape. If the cross-sectional shape of the cavity at the first end has corners, the corners may be rounded. It is preferred that the cross-section of the cavity at the first end is substantially circular.

[0026] The cross-section of the cavity at the second end may have any suitable shape. For example, the cross-section of the cavity at the second end may be substantially circular, elliptical, square, triangular, or hexagonal. The cross-section of the cavity at the second end may have any polygonal shape. If the cross-sectional shape of the cavity at the second end has corners, the corners may be rounded.

[0027] In some embodiments, the cross-sectional shape of the cavity at the second end comprises a plurality of coincident shapes. In other words, the cross-sectional shape of the cavity at the second end is made up of a plurality of shapes having the same shape and dimensions. In some preferred embodiments, the cross-sectional shape at the second end comprises two coincident circles. In some embodiments, the cross-sectional shape at the second end comprises two coincident ovals or ellipses. In some embodiments, the multiple coincident shapes overlap. For example, if the cross-sectional shape of the cavity at the second end comprises two coincident circles, the cross-sectional shape of the cavity at the second end may form a figure eight.

[0028] In some preferred embodiments, the cross-sectional shape of the cavity at the first end is substantially circular and the cross-sectional shape of the cavity at the second end comprises two coincident circles.

[0029] In some embodiments, the cross-sectional shape of the cavity at the first end is substantially similar to the cross-sectional shape of the cavity at the second end. The cross-sectional shape of the cavity at the first end may be the same as the cross-sectional shape of the cavity at the second end.

[0030] In some embodiments, the cross-sectional shape of the cavity at the first end is different from the cross-sectional shape of the cavity at the second end. In some preferred embodiments, the cross-sectional shape at the first end is substantially circular and the cross-sectional shape at the second end is substantially triangular, preferably forming an equilateral triangle. In some preferred embodiments, the cross-sectional shape at the first end is substantially circular and the cross-sectional shape at the second end is substantially oval or elliptical. In some embodiments, the cross-sectional shape at the first end is substantially circular and the cross-sectional shape at the second end is substantially square or rectangular.

[0031] When the cross-sectional shape of the cavity includes corners, the corners may be rounded. For example, when the cross-sectional shape of the cavity is a triangle, three corners of the triangle may be rounded. Rounding the corners of the cross-sectional shape of the cavity may make it easier to clean the cavity.

[0032] Where the cross-sectional shape of the cavity at the first end differs from the cross-sectional shape of the cavity at the second end, it is preferred that the perimeter of the cross-section of the cavity remains substantially constant along the length of the cavity, in other words, the cross-section of the cavity at the first end and the cross-section of the cavity at the second end are isoperimetric.

[0033] In some embodiments, the cavity at the second end includes one or more protrusions. The one or more protrusions may facilitate retention of the aerosol-forming substrate within the cavity. In some preferred embodiments, the one or more protrusions may include a ridge. The ridge may extend substantially along the length of the cavity. The ridge may extend around the perimeter of the cavity.

[0034] Preferably, the cross section of the first end of the cavity may delimit the cross section of the second end of the cavity. In other words, the cross section of the second end of the cavity may fit completely within the cross section of the first end of the cavity. For example, if the first end of the cavity has a substantially circular cross section and the second end of the cavity has a substantially triangular cross section, the triangular cross section of the second end of the cavity may be truncated at the corners by the circular cross section of the first end of the cavity. The triangular cross section of the second end of the cavity may have rounded corners, and each rounded corner may have a radius equal to the radius of the circular cross section of the first end of the cavity.

[0035] The cross-section of the first end of the cavity and the cross-section of the second end of the cavity are preferably coaxially disposed on the central longitudinal axis.

[0036] The cavity may include a first end portion extending from a first end of the cavity. The cavity may include a second end portion extending from a second end of the cavity. The first end portion may extend to an intersection between the first end portion and the second end portion. The second end portion may extend to an intersection between the first end portion and the second end portion. The first end portion may terminate at the intersection between the first end portion and the second end portion. The second end portion may terminate at the intersection between the first end portion and the second end portion.

[0037] The first end portion of the cavity and the second end of the cavity are preferably coaxially disposed on the central longitudinal axis.

[0038] The cross-sectional shape of the cavity may be substantially the same between the first end and the intersection between the first end portion and the second end portion. The cross-sectional dimension of the cavity may be substantially the same between the first end and the intersection between the first end portion and the second end portion. In other words, the cross-section of the cavity may remain constant between the first end portion and the intersection between the first end portion and the second end portion.

[0039] The cross-sectional shape of the cavity may be substantially the same between the second end and the intersection between the first end portion and the second end portion. The cross-sectional dimension of the cavity may be substantially the same between the second end and the intersection between the first end portion and the second end portion. In other words, the cross-section of the cavity may remain constant between the second end portion and the intersection between the first end portion and the second end portion.

[0040] The cross-sectional shape of the cavity may change at the intersection between the first end portion and the second end portion. The cross-sectional shape of the cavity may change stepwise at the intersection between the first end portion and the second end portion. The cross-sectional dimensions of the cavity may change at the intersection between the first end portion and the second end portion. The cross-sectional dimensions of the cavity may change stepwise at the intersection between the first end portion and the second end portion. Stated differently, the intersection between the first end portion and the second end portion may be chamfered. Such a stepwise change, or chamfer, may facilitate deformation of the aerosol-forming substrate as it moves from the first end of the cavity to the second end of the cavity.

[0041] The intersection between the first and second end portions may be an intersection region. The intersection region may extend along a portion of the length of the cavity. The cross-sectional shape of the cavity may vary over the length of the intersection region. The cross-sectional shape of the cavity may vary stepwise over the length of the intersection region. The cross-sectional dimensions of the cavity may vary over the length of the intersection region. The cross-sectional dimensions of the cavity may vary stepwise over the length of the intersection region. Advantageously, the cross-section of the cavity at the intersection region may vary stepwise from the first end portion to the second end portion to facilitate deformation of an aerosol-forming substrate inserted into the cavity at the first end and moved to the second end portion.

[0042] In some embodiments, the aerosol generating device comprises a heating element, which may take any suitable form.

[0043] In some embodiments, the heating element may comprise a resistive heating element. During use, an electrical current is supplied to the resistive heating element to generate heat by resistive heating.

[0044] Suitable materials for forming the resistive heating element include, but are not limited to, semiconductors such as doped ceramics, "conductive" ceramics (such as, for example, molybdenum disilicide), carbon, graphite, metals, metal alloys, and composites made of ceramic and metallic materials. Such composites may include doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals. Examples of suitable metal alloys include stainless steel, nickel-containing, cobalt-containing, chromium-containing, aluminum-containing, titanium-containing, zirconium-containing, hafnium-containing, niobium-containing, molybdenum-containing, tantalum-containing, tungsten-containing, tin-containing, gallium-containing, manganese-containing, and iron-containing alloys, as well as nickel-, iron-, cobalt-, and stainless steel-based superalloys, Timetal®, and iron-manganese-aluminum-based alloys.

[0045] In some embodiments, the resistive heating element comprises one or more stamped sections of an electrically resistive material (such as stainless steel), or may comprise a heating wire or filament (e.g., Ni-Cr (nickel-chromium), platinum, tungsten, or alloy wire).

[0046] The heating element may comprise an electrically insulating substrate, and the resistive heating element is provided on the electrically insulating substrate. The electrically insulating substrate may be a ceramic material, such as zirconia or alumina. Preferably, the electrically insulating substrate has a thermal conductivity of about 2 watts per meter per kelvin or less.

[0047] In some embodiments, the heating element may include an induction heating element. The induction heating element may include a susceptor material. In use, a changing magnetic field is supplied to the induction heating element, which generates heat via eddy current induction and hysteresis losses upon penetration of the induction heating element with the changing magnetic field. In these embodiments, typically an inductor coil surrounds the induction heating element, and a changing current is supplied to the inductor coil to generate the changing magnetic field. The inductor coil may surround the cavity. The inductor coil may surround a second end portion of the cavity.

[0048] As used herein, "susceptor material" refers to a material that has the ability to convert electromagnetic energy into heat. When the susceptor material is penetrated by an alternating electromagnetic field, the susceptor heats up. Heating of the susceptor element can be the result of at least one of hysteresis losses and eddy currents induced in the susceptor, depending on the electrical and magnetic properties of the susceptor material.

[0049] The induction heating element may comprise any suitable material. The induction heating element may be formed from any material that can be inductively heated to a temperature sufficient to release the volatile compound from the aerosol-forming substrate. Suitable materials for the induction heating element include graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, nickel, nickel-containing compounds, titanium, and composites of metallic materials. The induction heating element may preferably comprise metal or carbon. Advantageously, the induction heating element may comprise or consist of ferromagnetic materials, such as ferritic iron, ferromagnetic alloys such as ferromagnetic steel or stainless steel, ferromagnetic particles, and ferrites.

[0050] In some preferred embodiments, the heating element is configured to penetrate the aerosol-forming substrate. In these embodiments, the heating element preferably extends into the cavity. The heating element preferably extends into the cavity at the second end. In some embodiments, the heating element may be an elongated heating element. The heating element may be blade-shaped. The heating element may be pin-shaped. The heating element may be cone-shaped.

[0051] In some embodiments, the heating element may be arranged to extend around an outer surface of the aerosol-forming substrate received within the cavity. The heating element may have a tubular shape. The heating element may include an electrically insulating substrate and at least one resistive heating track on the electrically insulating substrate. The electrically insulating substrate may comprise a flexible sheet. For example, the heating element may be formed flat and then rolled into a tubular shape. The electrically insulating substrate may comprise a polyimide film. The at least one resistive heating track may comprise at least one metal or metal alloy. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals. Examples of suitable metal alloys include stainless steels, nickel-containing, cobalt-containing, chromium-containing, aluminum-containing, titanium-containing, zirconium-containing, hafnium-containing, niobium-containing, molybdenum-containing, tantalum-containing, tungsten-containing, tin-containing, gallium-containing, manganese-containing, and iron-containing alloys, as well as nickel-, iron-, cobalt-, stainless steel-based superalloys, Timetal®, and iron-manganese-aluminum-based alloys.

[0052] If the cavity comprises a first end portion and a second end portion, the length of the heating element is preferably substantially similar to or less than the length of the second end portion of the cavity. The length of the heating element may be substantially the same as the length of the second end portion of the cavity. The length of the heating element may be less than the length of the second end portion of the cavity. If the heating element extends from the second end into the cavity, it preferably extends into the second end portion of the cavity. The heating element may extend into the second end portion of the cavity and may terminate at or around the intersection between the first and second end portions. If the heating element surrounds the cavity, it preferably surrounds the second end portion of the cavity. The heating element may surround the second end portion of the cavity and not the first end portion of the cavity.

[0053] In some embodiments, the aerosol generating device comprises a pin heating element extending into the cavity at the second end. The pin heating element may be an elongated heating element extending primarily in one direction and having a point at one end for piercing the aerosol-forming substrate. The pin heating element may extend into the cavity substantially along the length of the cavity. The pin heating element may be configured to penetrate an aerosol-forming substrate received within the cavity.

[0054] In some preferred embodiments comprising a pin heating element, the cross-sectional shape at the first end of the cavity is substantially circular and the cross-sectional shape at the second end of the cavity is substantially triangular. The circular cross-section at the first end of the cavity preferably bounds a triangular cross-section at the second end of the cavity. The circular cross-section at the first end of the cavity and the triangular cross-section at the second end of the cavity may be coaxially disposed on the central longitudinal axis. The pin heating element may extend along the central longitudinal axis.

[0055] Advantageously, providing a cavity with a second end having a substantially triangular cross section may improve the transfer of heat from the pin heating element to the aerosol-forming substrate, as compared to a cavity with a second end having a substantially circular cross section with similar dimensions. This is because the proportion of the aerosol-forming substrate disposed furthest from the pin heating element is reduced for a cavity with a triangular cross section, as compared to a cavity with a circular cross section. Furthermore, the density of the aerosol-forming substrate is redistributed to the second end of the cavity, providing a higher density between the pin heating element and the flat side of the triangular cross section, and a lower density at the corner of the triangular cross section furthest from the pin heating element. Advantageously, providing a cavity with a second end having a triangular cross section may allow a reduction in the mass of the aerosol-forming substrate required to generate a desired amount of aerosol.

[0056] In some preferred embodiments, the aerosol generating device comprises two pin heating elements extending into the cavity at the second end. Each pin heating element may extend into the cavity substantially the length of the cavity. Each pin heating element may be configured to penetrate an aerosol-forming substrate received within the cavity.

[0057] In some preferred embodiments having two pin heating elements, the cross-sectional shape at the first end of the cavity is substantially circular and the cross-sectional shape at the second end of the cavity is substantially oval or elliptical. The circular cross-section at the first end of the cavity preferably bounds an oval or elliptical cross-section at the second end of the cavity. The circular cross-section at the first end of the cavity and the oval or elliptical cross-section at the second end of the cavity may be coaxially disposed on a central longitudinal axis. The pin heating elements may extend parallel to the central longitudinal axis.

[0058] The oval or elliptical cross-section of the cavity at the second end may have a major axis. When the oval or elliptical cross-section of the cavity at the second end has a major axis, the two pin heating elements may extend through the major axis. Advantageously, this arrangement of the pin heating elements may allow for improved heat transfer from the pin heating elements to an aerosol-forming substrate disposed at the second end of the cavity.

[0059] The oval or elliptical cross-section of the cavity at the second end may have two foci. When the oval or elliptical cross-section has two foci, each pin heating element may extend through one of the foci. Advantageously, this arrangement of the pin heating elements may allow for improved heat transfer from the pin heating elements to an aerosol-forming substrate disposed at the second end of the cavity.

[0060] In some preferred embodiments, the aerosol generating device comprises a plurality of pin heating elements. Each of the plurality of pin heating elements may extend into the cavity at the second end. When the aerosol generating device comprises a plurality of heating elements, the cross-sectional shape of the cavity at the second end may comprise a plurality of coincident shapes. The number of pin heating elements may be the same as the number of coincident shapes that comprise the cross-sectional shape of the cavity at the second end. In these embodiments, it is preferred that each of the plurality of pin heating elements extends through the center of one of the plurality of coincident shapes. For example, the aerosol generating device may comprise two pin heating elements extending into the cavity at the second end, the cross-sectional shape of the cavity at the second end may comprise two coincident circles, and each of the pin heating elements may extend through the center of one of the coincident circles.

[0061] In some preferred embodiments, the aerosol generating device comprises a blade heating element extending into the cavity at a second end. The blade heating element may be an elongated heating element extending primarily in one plane and having a point at one end for piercing the aerosol-forming substrate. The blade heating element may extend into the cavity substantially along the length of the cavity. The blade heating element may be configured to penetrate an aerosol-forming substrate received within the cavity.

[0062] In some preferred embodiments comprising a blade heating element, the cross-sectional shape at the first end of the cavity is substantially circular and the cross-sectional shape at the second end of the cavity is substantially oval or elliptical. The circular cross-section at the first end of the cavity preferably bounds an oval or elliptical cross-section at the second end of the cavity. The circular cross-section at the first end of the cavity and the oval or elliptical cross-section at the second end of the cavity may be coaxially disposed on a central longitudinal axis. The blade heating element may extend along the central longitudinal axis.

[0063] Advantageously, providing a cavity with a second end having a substantially oval or elliptical cross section may improve the transfer of heat from the blade heating element to the aerosol-forming substrate, as compared to a cavity with a second end having a substantially circular cross section with similar dimensions. This is because the proportion of the aerosol-forming substrate disposed furthest from the blade heating element is reduced for a cavity with an oval or elliptical cross section, as compared to a cavity with a circular cross section. Furthermore, the density of the aerosol-forming substrate is redistributed at the second end of the cavity, providing a higher density between the blade heating element and the long side of the oval cross section, and a lower density at the short side of the oval cross section furthest from the pin heating element. Advantageously, providing a cavity with a second end having an oval or elliptical cross section may allow a reduction in the mass of the aerosol-forming substrate required to generate a desired amount of aerosol.

[0064] The oval or elliptical cross section of the cavity at the second end may have a major axis. When the oval or elliptical cross section of the cavity at the second end has a major axis, the blade heating element may extend through the major axis. Preferably, the blade heating element has a length that extends substantially in the direction of the length of the cavity and a width that extends substantially in the direction of the major axis of the cross section of the cavity at the second end. Advantageously, this arrangement of the blade heating element may allow improved heat transfer from the blade heating element to an aerosol-forming substrate disposed at the second end of the cavity.

[0065] The oval or elliptical cross section of the cavity at the second end may have two foci. When the oval or elliptical cross section has two foci, the blade heating element may extend through both foci. Advantageously, this arrangement of the blade heating element may allow for improved heat transfer from the blade heating element to an aerosol-forming substrate disposed at the second end of the cavity.

[0066] In some preferred embodiments, the aerosol generating device further comprises an extractor. The extractor may facilitate extraction of the aerosol-forming substrate from the aerosol generating device. In these preferred embodiments, the extractor comprises a body defining a cavity for receiving the aerosol-forming substrate.

[0067] The extractor may include a tubular body. The tubular body of the extractor may define a cavity for receiving the aerosol-forming substrate. A first end of the cavity may be open for insertion of the aerosol-forming substrate into the cavity. The tubular body of the extractor may include an open first end defining the open first end of the cavity. A second end of the cavity may be substantially closed. The tubular body of the extractor may include a substantially closed second end defining the substantially closed second end of the cavity. The substantially closed second end of the extractor may include one or more openings allowing one or more heating elements to extend from the second end into the cavity.

[0068] Where the aerosol generating device comprises a housing, the extractor may be movable relative to the housing. The extractor may be movable relative to the housing in any suitable manner. For example, the extractor may be rotatable, pivotable or slidable relative to the housing. Preferably, the extractor is slidable relative to the housing.

[0069] When the aerosol generating device comprises a heating element, the extractor is preferably movable relative to the heating element. In some preferred embodiments, the extractor is movable relative to the heating element between a first position and a second position. In the first position, the heating element may extend into the cavity. In the second position, the heating element may not extend into the cavity. The extractor may be movable relative to the heating element in any suitable manner. For example, the extractor may be rotatable, pivotable, or slidable relative to the heating element. The extractor is preferably slidable relative to the heating element.

[0070] The aerosol generating device preferably comprises a power source. The power source may be a DC power source. In a preferred embodiment, the power source is a battery. The power source may be a nickel metal hydride battery, a nickel cadmium battery, or a lithium-based battery (e.g., lithium cobalt, lithium iron phosphate, or lithium polymer battery). However, in some embodiments, the power source may be another form of charge storage device, such as a capacitor. The power source may be rechargeable and may have a capacity that allows for the storage of sufficient energy for one or more user operations, such as one or more aerosol generating experiences. For example, the power source may have a capacity sufficient to allow continuous heating of the aerosol-forming substrate for about six minutes, or a multiple of six minutes, corresponding to the typical time it takes to smoke one conventional cigarette. In some embodiments, the power source may have a capacity sufficient to allow continuous heating of the aerosol-forming substrate for about four minutes, or a multiple of four minutes. In another example, the power source may have a capacity sufficient to allow a predetermined number of puffs, or discontinuous activation of the heating element.

[0071] The aerosol generating device preferably comprises a controller. The controller may be configured to control the power supply from the power source to the heating element. The controller may comprise a microprocessor, which may be a programmable microprocessor, a microcontroller, or an application specific integrated circuit chip (ASIC) or other electronic circuit capable of providing control. The control device may comprise further electronic components.

[0072] The aerosol generating device preferably comprises a housing. If the aerosol generating device does not comprise an extractor, the tubular portion of the housing may at least partially define a cavity for receiving the aerosol-forming substrate. The housing may have a first end and a second end. The cavity may be disposed at the first end of the device.

[0073] The housing may be elongated. The housing is preferably cylindrical. The housing may comprise any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics, or composites containing one or more of these materials, or thermoplastics suitable for food or pharmaceutical applications, such as polypropylene, polyetheretherketone (PEEK), and polyethylene. Preferably, the material is light and not brittle.

[0074] The aerosol generating device is preferably portable. The aerosol generating device may have a length of about 70 mm to about 120 mm. The aerosol generating device may be a handheld device. In other words, the aerosol generating device may be sized and shaped to be held in a user's hand.

[0075] The aerosol generating device may comprise at least one air inlet in fluid communication with the cavity. In embodiments in which the aerosol generating device comprises a housing, the housing preferably at least partially defines the at least one air inlet. Preferably, the at least one air inlet is in fluid communication with the second end of the cavity. In embodiments in which the heating element extends into the cavity, the heating element preferably extends into the cavity from the second end of the cavity.

[0076] According to the present disclosure, there is provided an extractor for extracting an aerosol-forming substrate from an aerosol generating device. The extractor may include a body defining a cavity for receiving the aerosol-forming substrate. The cavity may have a first end. The cavity may have a second end opposite the first end. The cavity may have a length between the first end and the second end. The cavity may have a cross-section perpendicular to the length. At least one of: a cross-sectional shape of the cavity may vary along the length of the cavity; a cross-sectional surface area of ​​the cavity may vary along the length of the cavity; and a cross-sectional dimension of the cavity may vary along the length of the cavity.

[0077] The extractor cavity may have any suitable shape and size. The cavity has a first end and a second end opposite the first end. The cavity has a length extending between the first end and the second end. The cavity also has a cross-section extending in a direction perpendicular to the length of the cavity. The cavity has a cross-section at each point along the length of the cavity.

[0078] Each cross-section of the cavity is defined by a plane extending perpendicular to the length of the cavity. Each cross-section of the cavity may have a width or diameter, a surface area, and a perimeter.

[0079] The cross-sectional dimension of the cavity may vary along the length of the cavity. The cross-sectional dimension of the cavity is preferably the cross-sectional width of the cavity. If the cross-section is circular, the cross-sectional dimension may be the cross-sectional diameter of the cavity. If the cross-section is not circular, the dimension may be the major cross-sectional width of the cavity. If the cross-section is not circular, the dimension may be the minor cross-sectional width of the cavity.

[0080] If the shape of a cross-section of a cavity does not vary along the length of the cavity, the dimension that varies along the length of the cavity may be the same dimension as the cross-section of the cavity. For example, the dimension may be the minor width of the cross-section. The dimension that varies along the length of the cavity may extend in the same direction for each cross-section of the cavity.

[0081] If the cross-sectional shape of the cavity varies along the length of the cavity, the dimension of the cross-section of the cavity that varies along the length of the cavity may be the minimum width of the cross-section of the cavity. For example, if the cavity includes a portion having a circular cross-section and a portion having an oval cross-section, the dimension of the circular cross-section may be the diameter of the circle and the dimension of the oval cross-section may be the minor axis of the oval. If the cross-sectional shape of the cavity varies along the length of the cavity, the dimension that varies along the length of the cavity may be the maximum dimension of the cross-section of the cavity.

[0082] In some embodiments, the cross-sectional dimension of the cavity at the first end is greater than the cross-sectional dimension of the cavity at the second end. In other words, the cross-sectional dimension of the cavity at the second end may be less than the cross-sectional dimension of the cavity at the first end. For example, the cross-sectional width of the cavity at the first end may be greater than the cross-sectional width of the cavity at the second end.

[0083] In some embodiments, the cross-sectional surface area of ​​the cavity varies along the length of the cavity. In some preferred embodiments, the cross-sectional surface area of ​​the cavity at a first end of the cavity is greater than the cross-sectional surface area of ​​the cavity at a second end of the cavity. In other words, the cross-sectional surface area of ​​the cavity at the second end may be less than the cross-sectional surface area of ​​the cavity at the first end.

[0084] Preferably, the perimeter of the cross-section of the cavity remains substantially constant along the length of the cavity. In other words, the length of the line forming the boundary of the cross-section of the cavity may remain substantially constant along the length of the cavity. The perimeter of the cross-section at the first end of the cavity and the perimeter of the cross-section at the second end of the cavity may be the same. The cross-section at the first end of the cavity and the cross-section at the second end of the cavity may be equiperimeter. Preferably, the perimeter of the cross-section of the cavity is substantially the same as the perimeter of the cross-section of the aerosol-generating article or is greater than the perimeter of the cross-section of the aerosol-generating article along the length of the cavity.

[0085] In some embodiments, the cross-sectional dimension at the second end of the cavity is greater than the cross-sectional dimension at the first end of the cavity to ensure that the perimeter of the cross-sectional dimension at the second end of the cavity is the same as the perimeter of the cross-sectional dimension at the first end of the cavity. For example, if the cross-section at the first end of the cavity is circular and the cross-section at the second end of the cavity is oval, the major axis of the oval cross-section at the second end of the cavity may be greater than the diameter of the circular cross-section at the first end of the cavity.

[0086] According to some preferred embodiments of the present disclosure, an extractor is provided for extracting an aerosol-forming substrate from an aerosol generating device. The extractor may include a body defining a cavity for receiving the aerosol-forming substrate. The cavity may have a first end. The cavity may have a second end opposite the first end. The cavity may have a length between the first end and the second end. The cavity may have a cross-section perpendicular to the length. In these preferred embodiments, the cross-sectional surface area of ​​the cavity varies along the length of the cavity, and the cross-sectional perimeter of the cavity remains substantially constant along the length of the cavity. In some of these preferred embodiments, the cross-sectional shape of the cavity varies along the length of the cavity.

[0087] The cross-section of the cavity at the first end may have any suitable shape. For example, the cross-section of the cavity at the first end may be substantially circular, elliptical, square, triangular, or hexagonal. The cross-section of the cavity at the first end may have any polygonal shape. If the cross-sectional shape of the cavity at the first end has corners, the corners may be rounded. It is preferred that the cross-section of the cavity at the first end is substantially circular.

[0088] The cross-section of the cavity at the second end may have any suitable shape. For example, the cross-section of the cavity at the second end may be substantially circular, elliptical, square, triangular, or hexagonal. The cross-section of the cavity at the second end may have any polygonal shape. If the cross-sectional shape of the cavity at the second end has corners, the corners may be rounded.

[0089] In some embodiments, the cross-sectional shape of the cavity at the second end comprises a plurality of coincident shapes. In other words, the cross-sectional shape of the cavity at the second end is made up of a plurality of shapes having the same shape and dimensions. In some preferred embodiments, the cross-sectional shape at the second end comprises two coincident circles. In some embodiments, the cross-sectional shape at the second end comprises two coincident ovals or ellipses. In some embodiments, the multiple coincident shapes overlap. For example, if the cross-sectional shape of the cavity at the second end comprises two coincident circles, the cross-sectional shape of the cavity at the second end may form a figure eight.

[0090] In some preferred embodiments, the cross-sectional shape of the cavity at the first end is substantially circular and the cross-sectional shape of the cavity at the second end comprises two coincident circles.

[0091] In some embodiments, the cross-sectional shape of the cavity at the first end is substantially similar to the cross-sectional shape of the cavity at the second end. The cross-sectional shape of the cavity at the first end may be the same as the cross-sectional shape of the cavity at the second end.

[0092] In some embodiments, the cross-sectional shape of the cavity at the first end is different from the cross-sectional shape of the cavity at the second end. In some preferred embodiments, the cross-sectional shape at the first end is substantially circular and the cross-sectional shape at the second end is substantially triangular, preferably forming an equilateral triangle. In some preferred embodiments, the cross-sectional shape at the first end is substantially circular and the cross-sectional shape at the second end is substantially oval or elliptical. In some embodiments, the cross-sectional shape at the first end is substantially circular and the cross-sectional shape at the second end is substantially square or rectangular.

[0093] When the cross-sectional shape of the cavity includes corners, the corners may be rounded. For example, when the cross-sectional shape of the cavity is a triangle, three corners of the triangle may be rounded. Rounding the corners of the cross-sectional shape of the cavity may make it easier to clean the cavity.

[0094] Where the cross-sectional shape of the cavity at the first end differs from the cross-sectional shape of the cavity at the second end, it is preferred that the perimeter of the cross-section of the cavity remains substantially constant along the length of the cavity, in other words, the cross-section of the cavity at the first end and the cross-section of the cavity at the second end are isoperimetric.

[0095] In some embodiments, the cavity at the second end includes one or more protrusions. The one or more protrusions may facilitate retention of the aerosol-forming substrate within the cavity. In some preferred embodiments, the one or more protrusions may include a ridge. The ridge may extend substantially along the length of the cavity. The ridge may extend around the perimeter of the cavity.

[0096] Preferably, the cross section of the first end of the cavity may delimit the cross section of the second end of the cavity. In other words, the cross section of the second end of the cavity may fit completely within the cross section of the first end of the cavity. For example, if the first end of the cavity has a substantially circular cross section and the second end of the cavity has a substantially triangular cross section, the triangular cross section of the second end of the cavity may be truncated at the corners by the circular cross section of the first end of the cavity. The triangular cross section of the second end of the cavity may have rounded corners, and each rounded corner may have a radius equal to the radius of the circular cross section of the first end of the cavity.

[0097] The cross-section of the first end of the cavity and the cross-section of the second end of the cavity are preferably coaxially disposed on the central longitudinal axis.

[0098] The cavity may include a first end portion extending from a first end of the cavity. The cavity may include a second end portion extending from a second end of the cavity. The first end portion may extend to an intersection between the first end portion and the second end portion. The second end portion may extend to an intersection between the first end portion and the second end portion. The first end portion may terminate at the intersection between the first end portion and the second end portion. The second end portion may terminate at the intersection between the first end portion and the second end portion.

[0099] The first end portion of the cavity and the second end of the cavity are preferably coaxially disposed on the central longitudinal axis.

[0100] The cross-sectional shape of the cavity may be substantially the same between the first end and the intersection between the first end portion and the second end portion. The cross-sectional dimension of the cavity may be substantially the same between the first end and the intersection between the first end portion and the second end portion. In other words, the cross-section of the cavity may remain constant between the first end portion and the intersection between the first end portion and the second end portion.

[0101] The cross-sectional shape of the cavity may be substantially the same between the second end and the intersection between the first end portion and the second end portion. The cross-sectional dimension of the cavity may be substantially the same between the second end and the intersection between the first end portion and the second end portion. In other words, the cross-section of the cavity may remain constant between the second end portion and the intersection between the first end portion and the second end portion.

[0102] The cross-sectional shape of the cavity may change at the intersection between the first end portion and the second end portion. The cross-sectional shape of the cavity may change stepwise at the intersection between the first end portion and the second end portion. The cross-sectional dimensions of the cavity may change at the intersection between the first end portion and the second end portion. The cross-sectional dimensions of the cavity may change stepwise at the intersection between the first end portion and the second end portion. Stated differently, the intersection between the first end portion and the second end portion may be chamfered. Such a stepwise change, or chamfer, may facilitate deformation of the aerosol-forming substrate as it moves from the first end of the cavity to the second end of the cavity.

[0103] The intersection between the first and second end portions may be an intersection region. The intersection region may extend along a portion of the length of the cavity. The cross-sectional shape of the cavity may vary over the length of the intersection region. The cross-sectional shape of the cavity may vary stepwise over the length of the intersection region. The cross-sectional dimensions of the cavity may vary over the length of the intersection region. The cross-sectional dimensions of the cavity may vary stepwise over the length of the intersection region. Advantageously, the cross-section of the cavity at the intersection region may vary stepwise from the first end portion to the second end portion to facilitate deformation of an aerosol-forming substrate inserted into the cavity at the first end and moved to the second end portion.

[0104] According to the present disclosure, there is provided an aerosol generating system comprising an aerosol-forming substrate and an aerosol generating device as described above.

[0105] In some preferred embodiments, there is provided an aerosol generation system comprising an aerosol-forming substrate and an aerosol generating device including a cavity for receiving the aerosol-forming substrate. The cavity of the aerosol generating device has a first end and an opposing second end, a length between the first end and the second end, and a cross-section perpendicular to the length. At least one of: a shape of the cross-section of the cavity varies along the length of the cavity; a surface area of ​​the cross-section of the cavity varies along the length of the cavity; and a dimension of the cross-section of the cavity varies along the length of the cavity.

[0106] In some embodiments, the aerosol-forming substrate has a first end and an opposing second end, a length between the first and second ends, and a cross-section perpendicular to the length.

[0107] Before the aerosol-forming substrate is received in the cavity of the aerosol-generating device, the cross-sectional shape of the aerosol-forming substrate may be substantially constant along the length of the aerosol-forming substrate. The cross-sectional shape of the aerosol-forming substrate may be substantially similar to the cross-sectional shape of the cavity of the aerosol-generating device at a first end of the cavity. The cross-sectional shape of the aerosol-forming substrate is preferably substantially circular.

[0108] Before the aerosol-forming substrate is received within the cavity of the aerosol generating device, the cross-sectional dimension of the aerosol-forming substrate may be substantially constant along the length of the aerosol-forming substrate. The cross-sectional dimension of the aerosol-forming substrate may be substantially similar to the cross-sectional shape of the cavity at a first end of the cavity.

[0109] The length of the aerosol-forming substrate is preferably the same as or less than the length of the cavity of the aerosol-generating device, and may be one of the following: 90% or less of the length of the cavity, 80% or less of the length of the cavity, 70% or less of the length of the cavity, 60% or less of the length of the cavity, and 50% or less of the length of the cavity.

[0110] When the cavity comprises a first end portion and a second end portion, the length of the aerosol-forming substrate is preferably substantially similar to or less than the length of the second end portion of the cavity. The length of the aerosol-forming substrate may be substantially the same as the length of the second end portion of the cavity. The length of the aerosol-forming substrate may be less than the length of the second end portion of the cavity.

[0111] The aerosol generating device is configured to receive an aerosol-forming substrate. The aerosol-forming substrate is preferably a solid aerosol-forming substrate. The aerosol-forming substrate preferably comprises tobacco. The aerosol-forming substrate is preferably a solid aerosol-forming substrate comprising tobacco. The aerosol-forming substrate may comprise a tobacco-containing material containing volatile tobacco flavour compounds which are released from the substrate upon heating.

[0112] The solid aerosol-forming substrate may include a tobacco plug. The tobacco plug may include, for example, one or more of powder, granules, pellets, pieces, strands, strips, or sheets, including one or more of herb leaves, tobacco leaves, tobacco stems, expanded tobacco, and homogenized tobacco. As used herein, "homogenized tobacco material" refers to a material formed by agglomerating particulate tobacco. Providing homogenized tobacco material may improve aerosol generation and the nicotine content and flavor profile of the aerosol generated during heating of the aerosol-generating article. Specifically, the process of making homogenized tobacco involves grinding tobacco leaves, which allows for more efficient release of nicotine and flavor upon heating. When the tobacco plug includes homogenized tobacco material, the homogenized tobacco material may be in the form of a sheet. As used herein, "sheet" refers to a layered element having a width and length substantially greater than its thickness.

[0113] The solid aerosol-forming substrate may comprise homogenized tobacco material. The solid aerosol-forming material may comprise pieces, strands, or strips of homogenized tobacco material. The solid aerosol-forming substrate may comprise a sheet of homogenized tobacco material.

[0114] The homogenized tobacco material sheet may be formed by agglomerating particulate tobacco obtained by grinding or otherwise comminuted one or both of tobacco lamina and tobacco stems. The homogenized tobacco material sheet may also include one or more of tobacco dust, tobacco fines, and other particulate tobacco by-products formed, for example, during tobacco processing, handling, and transportation. The homogenized tobacco material sheet is preferably formed by a casting process of the type that generally involves casting a slurry including particulate tobacco and one or more binders onto a conveyor belt or other supporting surface, drying the cast slurry to form a homogenized tobacco material sheet, and removing the homogenized tobacco material sheet from the supporting surface.

[0115] The solid aerosol-forming substrate may comprise an aggregate of a crimped sheet of homogenized tobacco material. As used herein, the term "aggregated" is used to describe a sheet that is rolled, folded, or otherwise compressed or pinched in a direction substantially transverse to the longitudinal axis of the aerosol-generating article.

[0116] In some preferred embodiments, the aerosol-forming substrate comprises an assembly of textured sheets of homogenized tobacco material. As used herein, "textured sheets" refers to sheets that have been crimped, embossed, debossed, perforated, or otherwise modified. The use of textured sheets of homogenized tobacco material may advantageously facilitate assembling the sheets of homogenized tobacco material to form the aerosol-forming substrate. The aerosol-forming substrate may comprise an assembly of textured sheets of homogenized tobacco material that include a plurality of spaced indentations, protrusions, perforations, or combinations thereof.

[0117] In a particularly preferred embodiment, the aerosol-forming substrate comprises an assembly of crimped sheets of homogenized tobacco material. As used herein, "crimped sheet" means a sheet having a plurality of substantially parallel ridges or corrugations. The substantially parallel ridges or corrugations preferably extend along or parallel to the longitudinal axis of the aerosol-generating article. This conveniently facilitates assembly of the crimped sheets of homogenized tobacco material to form the aerosol-generating article. However, it is recognized that a 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 disposed at an acute or obtuse angle to the longitudinal axis of the aerosol-generating article.

[0118] The aerosol-forming substrate may include tobacco-containing and non-tobacco-containing materials.

[0119] The aerosol-forming substrate may include an aerosol former. The aerosol-forming substrate may include a single aerosol former or a combination of two or more aerosol formers. As used herein, the term "aerosol former" is used to describe any suitable known compound or mixture of compounds that facilitates the formation of an aerosol when used and is substantially resistant to thermal decomposition at the operating temperature of the aerosol-generating article. Suitable aerosol formers include, but are not limited to, polyhydric alcohols (such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dimethyl dodecanedioate and dimethyl tetradecanedioate). Preferred aerosol formers are polyhydric alcohols (such as propylene glycol, triethylene glycol, 1,3-butanediol, and most preferably glycerin) or mixtures thereof. The content of the aerosol former in the aerosol-forming substrate may be greater than 5% on a dry weight basis. The aerosol-forming substrate may have an aerosol former content of about 5 percent to about 30 percent on a dry weight basis.The aerosol-forming substrate may have an aerosol former content of about 20 percent on a dry weight basis.

[0120] The aerosol-forming substrate preferably comprises homogenized tobacco material, an aerosol former, and water.

[0121] The homogenized tobacco material may be provided in a sheet that is folded, crimped, or cut into strips. In a particularly preferred embodiment, the sheet is cut into strips having a width of about 0.2 millimeters to about 2 millimeters, more preferably about 0.4 millimeters to about 1.2 millimeters. In one embodiment, the strips have a width of about 0.9 millimeters.

[0122] In some preferred embodiments, the aerosol-generating system comprises an aerosol-generating article that includes an aerosol-forming substrate.

[0123] The aerosol-generating article may comprise an aerosol-forming substrate and one or more additional components. For example, the aerosol-generating article may comprise at least one of a filter, a hollow tube, and an aerosol cooling element. The aerosol-forming substrate and the one or more additional components are preferably arranged end-to-end in the form of a rod. The aerosol-generating article preferably comprises a wrapper surrounding the aerosol-forming substrate and the one or more additional components.

[0124] In some embodiments, the aerosol-generating article has a first end and an opposing second end. The aerosol-forming substrate may be disposed at the second end. The cavity of the aerosol-generating device may be configured to receive at least the aerosol-forming substrate at the second end of the aerosol-generating article. The aerosol-generating article may comprise a mouthpiece. The mouthpiece may be in the form of a filter, such as a cellulose acetate plug. The mouthpiece may be disposed at the first end of the aerosol-generating article opposite the aerosol-forming substrate.

[0125] Prior to insertion of the aerosol-generating article into the cavity of the aerosol-generating device, the cross-section of the second end of the aerosol-generating article preferably has substantially the same shape as the cross-section of the first end of the cavity of the aerosol-generating device.

[0126] Prior to insertion of the aerosol-generating article into the cavity of the aerosol-generating device, the cross-section of the second end of the aerosol-generating article preferably has substantially the same dimensions as the cross-section of the first end of the cavity of the aerosol-generating device.

[0127] The aerosol-generating article may have a total length of from about 30 millimeters to about 100 millimeters.

[0128] The aerosol-generating article may have an outer diameter of from about 5 millimeters to about 13 millimeters.

[0129] The aerosol-forming substrate may have a length of approximately 10 millimeters. The tobacco plug may have a length of approximately 12 millimeters. The diameter of the aerosol-forming substrate may be from approximately 5 millimeters to approximately 12 millimeters.

[0130] Where the aerosol-generating article includes a mouthpiece, the mouthpiece is approximately 7 millimeters in length, but may have a length between approximately 5 millimeters and approximately 10 millimeters.

[0131] In a preferred embodiment, the aerosol-generating article has an overall length of between about 40 millimeters and about 50 millimeters. Preferably, the aerosol-generating article has an overall length of about 45 millimeters. Preferably, the aerosol-generating article has an outer diameter of about 7.2 millimeters.

[0132] Preferably, the aerosol-generating article has a similar shape to a conventional cigarette, in particular a similar circular cross-sectional shape with a similar outer diameter. Such a shape may be desirable for users. Advantageously, varying the cross-section of the cavity of the aerosol-generating device in which the aerosol-forming substrate of the aerosol-generating article is received may allow the shape of the aerosol-generating article before insertion into the aerosol-generating device to be maintained similar to a conventional cigarette, while also allowing the shape of the aerosol-forming substrate when inserted into the aerosol-generating device to be optimized for heating. Optimizing the shape of the aerosol-forming substrate for heating may allow the mass of the aerosol-forming substrate to be minimized without reducing the amount of aerosol generated from the aerosol-forming substrate. Minimizing the mass of the aerosol-forming substrate in the aerosol-generating article while maintaining the shape of the aerosol-generating article before insertion into the cavity of the aerosol-generating device may require reducing the density of the aerosol-forming substrate in the aerosol-generating article before insertion into the cavity of the aerosol-generating device. Reducing the density of the aerosol-forming substrate in the aerosol-generating article may also facilitate deformation of the aerosol-forming substrate when it is inserted into a cavity of an aerosol-generating device.

[0133] In some embodiments, the aerosol-generating article comprises an induction heating element, which may comprise a susceptor material. In use, a changing magnetic field is supplied to the induction heating element, which generates heat through eddy current induction and hysteresis losses upon penetration of the induction heating element with the changing magnetic field.

[0134] The induction heating element may comprise any suitable material. The induction heating element may be formed from any material that can be inductively heated to a temperature sufficient to release the volatile compound from the aerosol-forming substrate. Suitable materials for the induction heating element include graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, nickel, nickel-containing compounds, titanium, and composites of metallic materials. The induction heating element may preferably comprise metal or carbon. Advantageously, the induction heating element may comprise or consist of ferromagnetic materials, such as ferritic iron, ferromagnetic alloys such as ferromagnetic steel or stainless steel, ferromagnetic particles, and ferrites. EXAMPLES

[0135] The present invention is defined in the claims. However, below is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of any other examples, embodiments, or aspects described herein.

[0136] Example 1. 1. An aerosol generating device comprising a cavity for receiving an aerosol-forming substrate, the cavity comprising: a first end and an opposing second end; A length between the first end and the second end; a cross section perpendicular to the length; The cross-sectional shape of the cavity varies along the length of the cavity; the cross-sectional surface area of ​​the cavity varies along the length of the cavity; and a cross-sectional dimension of the cavity varies along the length of the cavity. Example 2. 2. An aerosol generating device according to embodiment 1, wherein the cross-sectional dimension at the first end of the cavity is greater than the cross-sectional dimension at the second end of the cavity. Example 3. 3. An aerosol generating device according to embodiment 1 or 2, wherein the cross-sectional surface area of ​​the cavity varies along the length of the cavity. Example 4. An aerosol generating device according to example 3, wherein a cross-sectional surface area of ​​the cavity at a first end of the cavity is greater than a cross-sectional surface area of ​​the cavity at a second end of the cavity. Example 5. An aerosol generating device according to any one of Examples 1 to 4, wherein the cross-sectional perimeter of the cavity remains substantially constant along the length of the cavity. Example 6. 6. An aerosol generating device according to any one of Examples 1 to 5, wherein the cross-sectional shape at the first end is substantially circular and the cross-sectional shape at the second end is substantially triangular. Example 7. An aerosol generating device according to any one of Examples 1 to 5, wherein the cross-sectional shape at the first end is substantially circular and the cross-sectional shape at the second end is substantially oval or elliptical. Example 8. An aerosol generating device according to any one of Examples 1 to 5, wherein the cross-sectional shape at the first end is substantially circular and the cross-sectional shape at the second end is substantially square or rectangular. Example 9. An aerosol generating device according to any one of Examples 1 to 5, wherein the cross-sectional shape of the cavity at the first end is substantially circular and the cross-sectional shape of the cavity at the second end includes a plurality of matching shapes, optionally, the plurality of matching shapes partially overlapping. Example 10. An aerosol generating device according to any one of Examples 1 to 5, wherein the cross-sectional shape of the cavity at the first end is substantially circular and the cross-sectional shape of the cavity at the second end comprises two coincident circles, optionally, the two coincident circles partially overlap. Example 11. An aerosol generating device according to any one of Examples 1 to 5, wherein the cross-sectional shape of the cavity at the first end is substantially circular and the cross-sectional shape of the cavity at the second end includes two coinciding ellipses or ovals, and optionally, the two coinciding ellipses or ovals partially overlap. Example 12. An aerosol-generating apparatus according to any one of Examples 1 to 11, comprising a heating element. Example 13. 13. An aerosol generating device according to embodiment 12, wherein the heating element extends into the cavity. Example 14. 14. An aerosol generating device according to embodiment 12 or 13, wherein the heating element extends into the cavity at the second end. Example 15. The aerosol generating apparatus according to any one of Examples 12 to 14, wherein the heating element is a pin heating element. Example 16. The aerosol generating apparatus according to any one of Examples 12 to 14, wherein the heating element is a blade heating element. Example 17. 7. An aerosol generating device according to example 6, wherein the aerosol generating device further comprises a pin heating element extending into the cavity at the second end. Example 18. 18. An aerosol generating device according to embodiment 17, wherein the pin heating element extends into the cavity substantially along the length of the cavity. Example 19. An aerosol generating device according to example 7, wherein the aerosol generating device further comprises two pin heating elements extending into the cavity at the second end. Example 20. 20. An aerosol generating device according to example 19, wherein each pin heating element extends into the cavity substantially along the length of the cavity. Example 21. An aerosol generating device according to embodiment 19 or 20, wherein the oval or elliptical cross-section of the cavity at the second end has a major axis and the two pin heating elements extend through the major axis. Example 22. An aerosol generating device according to any one of Examples 19 to 21, wherein the oval or elliptical cross-section of the cavity at the second end has two foci, and each pin heating element extends through one of the foci. Example 23. 8. An aerosol generating device according to example 7, wherein the aerosol generating device further comprises a blade heating element extending into the cavity at the second end. Example 24. 24. An aerosol generating device according to embodiment 23, wherein the blade heating element extends into the cavity substantially along the length of the cavity. Example 25. An aerosol generating device according to embodiment 23 or 24, wherein the oval or elliptical cross-section of the cavity at the second end has a major axis and the blade heating element extends through the major axis. Example 26. 26. An aerosol generating device according to embodiment 25, wherein the blade heating element has a length extending substantially in the direction of the length of the cavity and a width extending substantially in the direction of the major axis of the cross-section of the cavity at the second end. Example 27. An aerosol generating device according to any one of Examples 23 to 26, wherein the oval or elliptical cross-section of the cavity at the second end has two foci and the blade heating element extends through the two foci. Example 28. 10. An aerosol generating device according to example 9, wherein the aerosol generating device further comprises a plurality of pin heating elements extending into the cavity at the second end. Example 29. An aerosol generating device according to Example 28, wherein the number of pin heating elements is the same as the number of matching shapes including the cross-sectional shape of the cavity at the second end, and each of the multiple pin heating elements extends through the center of one of the multiple matching shapes. Example 30. An aerosol generating device according to any one of Examples 1 to 29, wherein the aerosol generating device further comprises an extractor for extracting the aerosol-forming substrate from the aerosol generating device, the extractor comprising a body defining a cavity for receiving the aerosol-forming substrate. Example 31. An aerosol generating device according to Example 30, wherein the aerosol generating device further comprises a housing, and the extractor is movable relative to the housing. Example 32. An aerosol generating apparatus according to any one of Examples 12 to 29, wherein the aerosol generating apparatus further comprises an extractor for extracting the aerosol-forming substrate from the aerosol generating apparatus, the extractor comprising a body defining a cavity for receiving the aerosol-forming substrate, and the extractor being movable relative to the heating element. Example 33. An aerosol generating device according to Example 32, wherein the extractor is movable relative to the heating element between a first position in which the heating element extends into the cavity and a second position in which the heating element does not extend into the cavity. Example 34. 1. An extractor for extracting an aerosol-forming substrate from an aerosol generating device, the extractor comprising a body defining a cavity for receiving the aerosol-forming substrate, the cavity comprising: a first end and an opposing second end; A length between the first end and the second end; a cross section perpendicular to the length; The cross-sectional shape of the cavity varies along the length of the cavity; the cross-sectional surface area of ​​the cavity varies along the length of the cavity; and a cross-sectional dimension of the cavity varies along the length of the cavity. Example 35. An extractor according to embodiment 34, wherein the cross-sectional dimension at the first end of the cavity is greater than the cross-sectional dimension at the second end of the cavity. Example 36. An extractor according to embodiment 34 or 35, wherein the cross-sectional surface area of ​​the cavity varies along the length of the cavity. Example 37. An extractor according to embodiment 36, wherein a cross-sectional surface area of ​​the cavity at a first end of the cavity is greater than a cross-sectional surface area of ​​the cavity at a second end of the cavity. Example 38. The extractor according to any one of Examples 34-37, wherein the cross-sectional perimeter of the cavity remains substantially constant along the length of the cavity. Example 39. The extractor according to any one of Examples 34-38, wherein the cross-sectional shape at the first end is substantially circular and the cross-sectional shape at the second end is substantially triangular. Example 40. The extractor according to any one of Examples 34-38, wherein the cross-sectional shape at the first end is substantially circular and the cross-sectional shape at the second end is substantially oval or elliptical. Example 41. The extractor according to any one of Examples 34-38, wherein the cross-sectional shape at the first end is substantially circular and the cross-sectional shape at the second end is substantially square or rectangular. Example 42. An extractor according to any one of Examples 34-38, wherein the cross-sectional shape of the cavity at the first end is substantially circular and the cross-sectional shape of the cavity at the second end includes a plurality of matching shapes, optionally, the plurality of matching shapes partially overlapping. Example 43. An extractor according to any one of Examples 34-38, wherein the cross-sectional shape of the cavity at the first end is substantially circular and the cross-sectional shape of the cavity at the second end comprises two coinciding circles, optionally, the two coinciding circles partially overlap. Example 44. An extractor according to any one of Examples 34-38, wherein the cross-sectional shape of the cavity at the first end is substantially circular and the cross-sectional shape of the cavity at the second end comprises two matching ellipses or ovals, optionally, the two matching ellipses or ovals partially overlapping. Example 45. 1. An aerosol generation system comprising: an aerosol-forming substrate; An aerosol generating system comprising an aerosol generating device according to any one of Examples 1 to 33. Example 46. 1. An aerosol generation system comprising: an aerosol-forming substrate; and an aerosol generating device including a cavity for receiving the aerosol-forming substrate, the cavity comprising: a first end and an opposing second end; A length between the first end and the second end; a cross section perpendicular to the length; The cross-sectional shape of the cavity varies along the length of the cavity; the cross-sectional surface area of ​​the cavity varies along the length of the cavity; and a cross-sectional dimension of the cavity varies along the length of the cavity. Example 47. The aerosol-forming substrate is a first end and an opposing second end; A length between the first end and the second end; a cross section perpendicular to the length; Before the aerosol-forming substrate is received within the cavity of the aerosol generating device, a cross-sectional shape of the aerosol-forming substrate being substantially constant along the length of the aerosol-forming substrate and substantially similar to a cross-sectional shape of the cavity at a first end of the cavity; An aerosol-generating system according to Example 46, wherein the cross-sectional surface area of ​​the aerosol-forming substrate is substantially constant along the length of the aerosol-forming substrate and is substantially similar to the cross-sectional surface area of ​​the cavity at the first end of the cavity. Example 48. An aerosol-generating system according to Example 47, wherein the length of the aerosol-forming substrate is the same as or shorter than the length of the cavity of the aerosol-generating device. Example 49. The length of the aerosol-forming substrate is 90% or less of the cavity's length, 80% or less of the cavity's length, 70% or less of the cavity's length, 60% or less of the cavity's length, and The aerosol generating system according to Example 48, wherein the cavity length is less than 50%. Example 50. 50. The aerosol-generating system according to any one of Examples 35 to 49, wherein the aerosol-generating system comprises an aerosol-generating article comprising an aerosol-forming substrate. Example 51. An aerosol generating system according to Example 50, wherein the aerosol generating article comprises at least one of a filter, a hollow tube, and an aerosol cooling element. Example 52. An aerosol-generating system according to Example 51, wherein the aerosol-generating article comprises a wrapper surrounding the aerosol-forming substrate, and at least one of a filter, a hollow tube, and an aerosol cooling element. Example 53. An aerosol generating system according to any one of Examples 50 to 52, wherein the aerosol-forming substrate and at least one of the filter, hollow tube, and aerosol cooling element are arranged end-to-end in the form of a rod. Example 54. An aerosol-generating system according to any one of Examples 45 to 53, wherein a first end of the cavity of the aerosol-generating device is open for inserting an aerosol-forming substrate into the cavity. Example 55. An aerosol-generating system according to any one of Examples 45 to 54, wherein the aerosol-generating article has a first end and an opposing second end, and the aerosol-forming substrate is disposed at the second end. Example 56. An aerosol generating system according to Example 55, wherein the cavity of the aerosol generating device is configured to receive at least an aerosol-forming substrate at the second end of the aerosol-generating article. Example 57. An aerosol generating system according to any one of Examples 55 and 56, wherein prior to insertion of the aerosol generating article into the cavity of the aerosol generating device, the cross-section of the second end of the aerosol generating article has substantially the same shape as the cross-section of the first end of the cavity of the aerosol generating device. Example 58. An aerosol generating system according to any one of Examples 55 to 57, wherein prior to insertion of the aerosol generating article into the cavity of the aerosol generating device, the cross-section of the second end of the aerosol generating article has substantially the same dimensions as the cross-section of the first end of the cavity of the aerosol generating device. Example 59. An aerosol generating system according to any one of Examples 55 to 58, wherein prior to insertion of the aerosol generating article into the cavity of the aerosol generating device, the cross-section of the second end of the aerosol generating article has a shape substantially different from the shape of the cross-section of the second end of the cavity of the aerosol generating device. Example 60. An aerosol generating system according to any one of Examples 55 to 59, wherein prior to insertion of the aerosol generating article into the cavity of the aerosol generating device, the cross-section of the second end of the aerosol generating article has dimensions substantially different from the dimensions of the cross-section of the second end of the cavity of the aerosol generating device.

[0137] The embodiments will now be further described with reference to the figures.

[0138] 1 and 2 show an aerosol generation device 10 according to one embodiment of the present disclosure. The aerosol generation device 10 comprises a cavity 20 for receiving an aerosol-forming substrate. The aerosol generation device 10 further comprises a housing 11 having at one end a tubular portion 12 defining the cavity 20.

[0139] The aerosol generating device 10 further comprises a heating element 14 in the form of a blade extending into the cavity 20, a power source 15 in the form of a rechargeable lithium ion battery, and a controller 16 contained within the housing 11 on the side opposite the tubular portion 12 of the housing 11. The controller 16 is configured to control the supply of power from the power source 15 to the heating element 14 to heat an aerosol-forming substrate received within the cavity 20.

[0140] The cavity 20 includes a first end that is open for inserting an aerosol-forming substrate into the cavity 20 and a second end opposite the first end that is substantially closed. A first end portion 21 of the cavity 20 extends from the first end of the cavity 20 and a second end portion 22 of the cavity 20 extends from the second end of the cavity 20. The first end portion 21 extends to and terminates at an intersection between the first end portion 21 and the second end portion 22, and the second end portion 22 extends to and terminates at an intersection between the first end portion 21 and the second end portion 22.

[0141] The cavity 20 has a length extending between a first end and a second end. The cavity 20 also has a cross section perpendicular to the length. The shape of the cross section of the cavity 20 at the second end is different from the shape of the cross section of the cavity 20 at the first end. As shown in FIG. 3, at the first end of the cavity 20, the cross section of the cavity 20 is substantially circular, and at the second end of the cavity 20, the cross section of the cavity 20 is substantially oval. The major axis of the oval cross section at the second end of the cavity 20 is substantially the same as the diameter of the circular cross section at the first end of the cavity 20. In other words, the maximum dimension of the oval cross section at the second end of the cavity 20 is substantially the same as the diameter of the circular cross section at the first end of the cavity 20. The minor axis of the oval cross section at the second end of the cavity 20 is less than the diameter of the circular cross section at the first end of the cavity 20. The surface area of ​​the cross section of the cavity at the second end is less than the surface area of ​​the cross section of the cavity at the first end. However, the cross-sectional perimeter of the cavity 20 at the second end is substantially the same as the cross-sectional shape of the cavity 20 at the first end.

[0142] In this embodiment, the major axis of the oval cross-section at the second end of cavity 20 is the same as the diameter of the circular cross-section at the first end of cavity 20, but it will be appreciated that in other embodiments, the major axis of the oval cross-section at the second end of cavity 20 is greater than the diameter of the circular cross-section at the first end of cavity 20 to ensure that the circumference of the oval cross-section at the second end of cavity 20 is the same as the circumference of the circular cross-section at the first end of cavity 20.

[0143] The cross-sectional shape of cavity 20 is substantially circular along the length of first end portion 21, and the cross-sectional shape of cavity 20 is substantially oval along the length of second end portion 22. However, the cross-sectional shape of cavity 20 transitions gradually from circular to oval at the intersection between first end portion 21 and second end portion 22.

[0144] The heating element 14 extends from the second end into the cavity 20, through the second end portion 22, to the intersection between the second end portion 22 and the first end portion 21, but not into the first end portion 21. The heating element 14 is elongated and thin, having a length and a width substantially greater than its thickness. The heating element 14 also has a pointed end that allows the heating element to penetrate the aerosol-forming substrate. As shown in Figures 1, 2, and 3, the width of the heating element 14 extends substantially in the direction of the major axis of the oval cross-section of the second end of the cavity 20. In other words, the width of the heating element 14 extends substantially in the direction of the maximum dimension of the oval cross-section of the second end of the cavity 20. In this orientation, the oval cross-section of the cavity 20 at the second end complements the shape of the heating element 14.

[0145] Figure 4 shows an aerosol-generating article 50 for use in the aerosol-generating device 10 of Figure 1. The aerosol-generating article 50 comprises an aerosol-forming substrate 52, a hollow acetate tube 53, a polymeric filter 54, and a mouthpiece 55 arranged end-to-end with an outer wrapper 56. The aerosol-forming substrate 52 comprises a plug of tobacco and the mouthpiece 55 comprises a plug of cellulose acetate fibres. The aerosol-generating article generally forms a cylindrical rod having a circular cross-section having substantially the same shape and dimensions as the first end of the cavity 20 of the aerosol-generating device 10 of Figure 1.

[0146] In use, the end of the aerosol-generating article 50 including the aerosol-forming substrate 52 is inserted into the cavity 20 at the first end. The cross-sectional shape and dimensions of the aerosol-generating article 50 are substantially similar to the cross-sectional shape and dimensions of the first end portion 21 of the cavity 20, so that the aerosol-forming substrate 52 is not deformed when pushed through the first end portion 21 of the cavity. However, when the aerosol-generating article 50 is forced into the second end portion 22 of the cavity 20, the aerosol-forming substrate 52 is deformed by the tubular portion 12 of the housing 11 as the cross-sectional shape of the cavity 20 changes from circular to oval. The cross-sectional shape of the aerosol-forming substrate 52 changes when the aerosol-generating article 50 is forced into the second end portion 22 of the cavity 20, becoming substantially oval in shape to match the shape and dimensions of the second end portion 22 of the cavity 20. Additionally, as the aerosol-generating article 50 is forced into the second end portion 22 of the cavity 20 , the pointed tip of the heating element 14 pierces the aerosol-forming substrate 52 and the aerosol-forming substrate 52 is received on the heating element 14 .

[0147] As shown in FIG. 5, the length of the heating element 14 is substantially the same as the length of the aerosol-forming substrate 52 .

[0148] When the cross-sectional shape of the aerosol-forming substrate 52 changes from circular to oval, the aerosol-forming substrate is compressed around the heating element. The oval cross-sectional shape more closely resembles the cross-sectional shape of the heating element 14, which, together with the compression, results in improved heat transfer from the heating element 14 to the aerosol-forming substrate 52 and improved heat distribution through the aerosol-forming substrate 52 compared to when the cross-sectional shape of the aerosol-forming substrate 52 remains circular.

[0149] Figure 5 shows the aerosol-generating article 50 of Figure 4 inserted into the cavity 20 of the aerosol-generating device 10 of Figure 1. In use, a user activates the aerosol-generating device by pressing a button (not shown) on the housing 11, which provides power from the power source 15 to the heating element 14 to heat the aerosol-forming substrate 52. When a user inhales on the mouthpiece 55 of the aerosol-generating article 50, air is drawn through an inlet (not shown) in the tubular housing portion 12 of the housing 11 into the cavity 20 of the aerosol-generating device 10, through the aerosol-forming substrate 52 and into the aerosol-generating article 50. The heated aerosol-forming substrate 52 releases volatile compounds which are drawn into the acetate tube 53, cool in the acetate tube 53 and polymeric filter 54, condense to form an aerosol, and are inhaled by the user through the mouthpiece 55.

[0150] When the aerosol-generating article 50 is removed from the cavity 20 of the aerosol generating device 10, the aerosol-forming substrate 52 is no longer compressed. In some embodiments, the aerosol-forming substrate 52 may retain its deformed shape. However, in other embodiments, the aerosol-forming substrate may return to its undeformed shape (i.e., substantially circular cross-section).

[0151] Figure 6 shows an aerosol generation device 10 that is substantially similar to the aerosol generation device 10 of Figure 1, and like reference numerals are used to designate like features. The aerosol generation device 10 of Figure 6 is substantially the same as the aerosol generation device 10 of Figure 1, except that the aerosol generation device 10 of Figure 6 includes an extractor 30 to aid in removal of the aerosol-forming substrate from the aerosol generation device 10, and a cover 40.

[0152] The extractor 30 includes a tubular body defining a cavity 20 for receiving an aerosol-forming substrate. The cavity 20 has a size and shape substantially similar to the cavity 20 of the aerosol generating device 10 of FIG. 1. The cavity 20 includes a first end that is open for inserting the aerosol-forming substrate into the cavity 20 and a second end opposite the first end that is substantially closed. A first end portion 21 of the cavity 20 extends from the first end of the cavity 20 and a second end portion 22 of the cavity 20 extends from the second end of the cavity 20. The first end portion 21 extends to and terminates at the second end portion 22, and the second end portion 22 extends to and terminates at the first end portion 21.

[0153] The cavity 20 has a length extending between a first end and a second end and a cross-section perpendicular to the length. As shown in Figures 7 and 10, 10b and 10c, the shape of the cross-section of the cavity 20 at the second end is different from the shape of the cross-section of the cavity 20 at the first end. The cross-section of the first end of the cavity 20 is substantially circular. The cross-section of the second end of the cavity 20 is substantially oval. The surface area of ​​the cross-section of the cavity 20 at the second end is less than the surface area of ​​the cross-section of the cavity 20 at the first end. The perimeter of the cross-section of the cavity 20 at the second end is substantially the same as the shape of the cross-section of the cavity 20 at the first end.

[0154] The cross-sectional shape of cavity 20 is substantially circular along the length of first end portion 21, and the cross-sectional shape of cavity 20 is substantially oval along the length of second end portion 22. The cross-sectional shape of cavity 20 changes gradually at the intersection between first end portion 21 and second end portion 22.

[0155] The aerosol generating device 10 further comprises a housing 11 including a tubular portion 12 defining a cavity within which the extractor 30 is received. The aerosol generating device 10 also comprises a heating element 14 in the form of a blade. As shown in Figures 8 and 9, the extractor 30 is received within the tubular portion 12 of the housing 11 and is slidable relative to the tubular portion 12 and the heating element 14 between a first position and a second position. In the first position, as shown in Figure 9, the heating element 14 extends into the cavity 20 of the extractor 30. In the second position, as shown in Figure 8, the heating element 14 does not extend into the cavity 20. The extractor 30 has an opening at a substantially closed second end of the cavity 20 that allows the heating element 14 to extend from the second end into the cavity 20.

[0156] The aerosol generating device 10 further comprises a power source 15 in the form of a rechargeable lithium ion battery and a controller 16, both contained within the housing 11 on an opposite side of the housing 11 from the tubular portion 12. The controller 16 is configured to control the supply of power from the power source 15 to the heating element 14 for heating an aerosol-forming substrate received within the cavity 20 of the extractor 30 when the extractor 30 is in the first position.

[0157] A cover 40 is removably receivable over the tubular portion 12 and, in use, substantially encloses the tubular portion 12, as shown in FIG. 9, to further shield the user from the heat generated by the heating element 14.

[0158] Figure 9 shows the aerosol-generating article 50 of Figure 4 being inserted into the cavity 20 of the extractor 30, with the extractor 30 disposed in a first position and with the heating element 14 extending into the cavity 20. Insertion of the article 50 into the cavity 20 of the extractor 30 results in the same deformation of the article 50 and the aerosol-forming substrate 52 as described above with reference to Figure 5, with the cross-sectional shape of the aerosol-forming substrate 52 changing from circular to oval.

[0159] In use, a user activates the aerosol generating device by pressing a button (not shown) on the housing 11, which provides power from the power source 15 to the heating element 14 to heat the aerosol-forming substrate 52. When the user inhales on the mouthpiece 55 of the aerosol-generating article 50, air is drawn through an inlet (not shown) in the tubular housing portion 12 of the housing 11 into the cavity 20 of the aerosol generating device 10, and through the aerosol-forming substrate 52 into the aerosol-generating article 50. The heated aerosol-forming substrate 52 releases volatile compounds which are drawn into the acetate tube 53, cool within the acetate tube 53 and polymeric filter 54, condense to form an aerosol, and are inhaled by the user through the mouthpiece 55.

[0160] After use, a user may extract the aerosol-generating article 50 from the aerosol-generating device 10 of FIG. 6 by first moving the extractor 30 from a first position to a second position. This removes the aerosol-forming substrate 52 from the heating element 14 without creating friction on the outer surface of the aerosol-generating article 50. The user may then remove the aerosol-generating article 50 from the extractor 30. This two-step process reduces the momentary frictional forces experienced by the aerosol-generating article 50 when being removed from the device 10, compared to removing the aerosol-generating article 50 from the device 10 without the extractor. As a result, the extractor 30 helps to reduce the likelihood of the aerosol-generating article 50 being damaged during removal from the aerosol-generating device.

[0161] Figures 11a, 11b and 11c show an extractor 30 according to another embodiment of the present disclosure. The extractor 30 of Figures 11a, 11b and 11c is similar to the extractor 30 of Figures 6 and 10, and like reference numbers are used to designate like features.

[0162] The extractor 30 of Figures 11a, 11b and 11c includes a tubular body defining a cavity 20 for receiving an aerosol-forming substrate. The cavity 20 includes a first end that is open for inserting the aerosol-forming substrate into the cavity 20 and a second end opposite the first end that is substantially closed. A first end portion 21 of the cavity 20 extends from the first end of the cavity 20 and a second end portion 22 of the cavity 20 extends from the second end of the cavity 20. The extractor 30 has an opening at the substantially closed second end of the cavity 20 that allows the blade heating element 14 to extend from the second end into the cavity 20.

[0163] Cavity 20 has a length extending between a first end and a second end and a cross-section perpendicular to the length. The shape of the cross-section of cavity 20 at the second end is different from the shape of the cross-section of cavity 20 at the first end. The cross-section of cavity 20 at the first end is substantially circular. The cross-section of cavity 20 at the second end is substantially oval.

[0164] The difference between the extractor of Figures 11a, 11b and 11c and the extractor of Figures 6-10 is that the major axis of the oval cross-section at the second end of the cavity 20 of the extractor of Figures 11a, 11b and 11c is less than the diameter of the circular cross-section at the first end of the cavity 20. In other words, the maximum dimension of the oval cross-section at the second end of the cavity 20 is less than the circular cross-section at the first end of the cavity 20. Reducing the length of the major axis of the oval cross-section at the second end of the cavity 20 provides further compression of the aerosol-forming substrate 52 around the heating element 14, which may provide improved heat transfer from the heating element 14 to the aerosol-forming substrate 52.

[0165] In this embodiment, the perimeter of the cross section of the cavity 20 at the second end is smaller than the perimeter of the cavity at the first end. As a result, when the aerosol-generating article 50 is inserted into the cavity 20 and moved to the second end, the outer wrapper 56 may crimp or wrinkle as the aerosol-forming substrate 52 is compressed into the second end of the cavity 20. To reduce crimping or wrinkling of the outer wrapper 56, a slit or cut may be provided in a portion of the outer wrapper surrounding the aerosol-forming substrate 52. The slit or cut preferably extends in the direction of the length of the aerosol-generating article 50. Advantageously, the slit or cut in the outer wrapper 56 may allow portions of the outer wrapper 56 to overlap without the outer wrapper 56 crimping or wrinkling when the aerosol-forming substrate is moved to the second end of the cavity 20.

[0166] Figures 12a, 12b and 12c show an extractor 30 according to another embodiment of the present disclosure. The extractor 30 of Figures 12a, 12b and 12c is similar to the extractor 30 of Figures 6 and 10, and like reference numbers are used to designate like features.

[0167] The extractor 30 of Figures 12a, 12b and 12c includes a tubular body defining a cavity 20 for receiving an aerosol-forming substrate. The cavity 20 includes a first end that is open for inserting the aerosol-forming substrate into the cavity 20 and a second end opposite the first end that is substantially closed. A first end portion 21 of the cavity 20 extends from the first end of the cavity 20 and a second end portion 22 of the cavity 20 extends from the second end of the cavity 20.

[0168] The cavity 20 has a length extending between a first end and a second end and a cross-section perpendicular to the length. The shape of the cross-section of the cavity 20 at the second end is different from the shape of the cross-section of the cavity 20 at the first end. The cross-section of the first end of the cavity 20 is substantially circular. The cross-section of the second end of the cavity 20 is substantially oval. The major axis of the oval cross-section of the cavity 20 at the second end of the extractor of Figures 12a, 12b and 12c is substantially the same as the diameter of the circular cross-section of the cavity 20 at the first end.

[0169] The difference between the extractor of Figures 12a, 12b and 12c and the extractor of Figures 6-10 is that the extractor 30 of Figures 12a, 12b and 12c has two openings at a substantially closed second end of the cavity 20 to allow two pin heating elements 14 to extend into the cavity 20 from the second end. The openings are arranged such that the pin heating elements extend into the cavity 20 at the focus of the oval shape of the cross section at the second end of the cavity 20.

[0170] Figures 13a, 13b and 13c show an extractor 30 according to another embodiment of the present disclosure. The extractor 30 of Figures 13a, 13b and 13c is similar to the extractor 30 of Figures 12a, 12b and 12c, and like reference numbers are used to designate like features.

[0171] The extractor 30 of Figures 13a, 13b and 13c includes a tubular body defining a cavity 20 for receiving an aerosol-forming substrate. The cavity 20 includes a first end that is open for inserting the aerosol-forming substrate into the cavity 20 and a second end opposite the first end that is substantially closed. A first end portion 21 of the cavity 20 extends from the first end of the cavity 20 and a second end portion 22 of the cavity 20 extends from the second end of the cavity 20. The extractor 30 has two openings at the substantially closed second end of the cavity 20 that allow the two pin heating elements 14 to extend from the second end into the cavity 20.

[0172] Cavity 20 has a length extending between a first end and a second end and a cross-section perpendicular to the length. The shape of the cross-section of cavity 20 at the second end is different from the shape of the cross-section of cavity 20 at the first end. The cross-section of cavity 20 at the first end is substantially circular. The cross-section of cavity 20 at the second end is substantially oval.

[0173] The difference between the extractor of Figures 13a, 13b and 13c and the extractor of Figures 12a, 12b and 12c is that the major axis of the oval cross-section at the second end of the cavity 20 of the extractor of Figures 13a, 13b and 13c is less than the diameter of the circular cross-section at the first end of the cavity 20.

[0174] Figures 14a, 14b, and 14c show an extractor 30 according to another embodiment of the present disclosure. The extractor 30 of Figures 14a, 14b, and 14c is similar to the extractor 30 of Figures 12a, 12b, and 12c, and like reference numbers are used to designate like features.

[0175] The extractor 30 of Figures 14a, 14b and 14c includes a tubular body defining a cavity 20 for receiving an aerosol-forming substrate. The cavity 20 includes a first end that is open for inserting the aerosol-forming substrate into the cavity 20 and a second end opposite the first end that is substantially closed. A first end portion 21 of the cavity 20 extends from the first end of the cavity 20 and a second end portion 22 of the cavity 20 extends from the second end of the cavity 20. The extractor 30 has two openings at the substantially closed second end of the cavity 20 that allow the two pin heating elements 14 to extend from the second end into the cavity 20.

[0176] The cavity 20 has a length extending between a first end and a second end and a cross-section perpendicular to the length, the shape of the cross-section of the cavity 20 at the second end being different from the shape of the cross-section of the cavity 20 at the first end.

[0177] The cross section of the first end of the cavity 20 is substantially circular. The difference between the extractor of Figures 14a, 14b and 14c and the extractor of Figures 12a, 12b and 12c is that the cross section of the second end of the cavity 20 of Figures 14a, 14b and 14c includes two coincident overlapping circles forming a two lobe shape similar to a figure eight. The circumference of the two lobe shape of the cross section at the second end of the cavity 20 is substantially the same as the circumference of the circular cross section at the first end of the cavity 20.

[0178] Each pin heating element 14 extends through the center of one of the two coincident circles into the second end of the cavity 20. The bilobal shape of the cross-section at the second end of the cavity 20 results in a higher percentage of the aerosol-forming substrate being received within the cavity 20 near the pin heating elements 14 than a circular cross-section in the first portion of the cavity 20, which may provide improved heat transfer from the pin heating elements 14 to the aerosol-forming substrate 52.

[0179] Figures 15a and 15b show an extractor 30 according to another embodiment of the present disclosure. The extractor 30 of Figures 15a and 15b is similar to the extractor 30 shown in Figures 6-10, and like reference numbers are used to designate like features.

[0180] The extractor 30 of Figures 15a and 15b includes a tubular body defining a cavity 20 for receiving an aerosol-forming substrate. The cavity 20 includes a first end that is open for inserting the aerosol-forming substrate into the cavity 20 and a second end opposite the first end that is substantially closed. A first end portion 21 of the cavity 20 extends from the first end of the cavity 20 and a second end portion 22 of the cavity 20 extends from the second end of the cavity 20. The extractor 30 has a single opening at the substantially closed second end of the cavity 20 that allows a single pin heating element 14 to extend from the second end into the cavity 20.

[0181] Cavity 20 has a length extending between a first end and a second end and a cross-section perpendicular to the length. The shape of the cross-section of cavity 20 at the second end is different from the shape of the cross-section of cavity 20 at the first end. The cross-section of cavity 20 at the first end is substantially circular. The cross-section of cavity 20 at the second end is substantially triangular.

[0182] The triangular cross-section at the second end of the cavity 20 is truncated at the corners such that the triangular cross-section at the second end of the cavity 20 does not extend beyond the circular cross-section at the first end of the cavity. The triangular cross-section at the second end of the cavity 20 allows a higher proportion of the aerosol-forming substrate to be received within the cavity 20 near the pin heating element 14 than the circular cross-section at the first portion of the cavity 20, which may provide improved heat transfer from the heating element 14 to the aerosol-forming substrate 52.

[0183] Figures 16a and 16b show an extractor 30 according to another embodiment of the present disclosure. The extractor 30 of Figures 16a and 16b is similar to the extractor 30 of Figures 15a and 15b, and like reference numbers are used to designate like features.

[0184] The extractor 30 of Figures 16a and 16b includes a tubular body defining a cavity 20 for receiving an aerosol-forming substrate. The cavity 20 includes a first end that is open for inserting the aerosol-forming substrate into the cavity 20 and a second end opposite the first end that is substantially closed. A first end portion 21 of the cavity 20 extends from the first end of the cavity 20 and a second end portion 22 of the cavity 20 extends from the second end of the cavity 20. The extractor 30 has a single opening at the substantially closed second end of the cavity 20 that allows a single pin heating element 14 to extend from the second end into the cavity 20.

[0185] The cavity 20 has a length extending between a first end and a second end and a cross-section perpendicular to the length. The shape of the cross-section of the cavity 20 at the second end is different from the shape of the cross-section of the cavity 20 at the first end. The cross-section of the cavity 20 at the first end is substantially circular. The cross-section of the cavity 20 at the second end is substantially triangular.

[0186] The difference between the extractor 30 of Figures 16a and 16b and the extractor 30 of Figures 15a and 15b is that the side length of the triangular cross-section of the second end of the cavity 20 of the extractor 30 of Figures 16a and 16b is less than the side length of the triangular cross-section of the second end of the cavity 20 of the extractor 30 of Figures 15a and 15b. This reduces the surface area of ​​the triangular cross-section of the second end of the cavity 20 of the extractor 30 of Figures 16a and 16b compared to the surface area of ​​the triangular cross-section of the second end of the cavity 20 of the extractor 30 of Figures 15a and 15b, which may provide improved heat transfer from the heating element 14 to the aerosol-forming substrate 52.

[0187] Figures 17a and 17b show an extractor 30 according to another embodiment of the present disclosure. The extractor 30 of Figures 17a and 17b is similar to the extractor 30 of Figures 6-10, and like reference numbers are used to designate like features.

[0188] The extractor 30 of Figures 17a and 17b includes a tubular body defining a cavity 20 for receiving an aerosol-forming substrate. The cavity 20 includes a first end that is open for inserting the aerosol-forming substrate into the cavity 20 and a second end opposite the first end that is substantially closed. A first end portion 21 of the cavity 20 extends from the first end of the cavity 20 and a second end portion 22 of the cavity 20 extends from the second end of the cavity 20. The extractor 30 has a single opening at the substantially closed second end of the cavity 20 that allows a single pin heating element 14 to extend from the second end into the cavity 20.

[0189] Cavity 20 has a length extending between a first end and a second end and a cross-section perpendicular to the length. The shape of the cross-section of cavity 20 at the second end is the same as the shape of the cross-section of cavity 20 at the first end. The cross-section of cavity 20 at the first end is substantially circular and the cross-section of cavity 20 at the second end is substantially circular.

[0190] The diameter of the circular cross-section of cavity 20 at the second end of cavity 20 is less than the diameter of the circular cross-section at the first end of cavity 20. This reduces the cross-sectional surface area of ​​cavity 20 at the second end compared to the cross-sectional surface area of ​​cavity 20 at the first end, which may provide improved heat transfer from pin heating element 14 to aerosol-forming substrate 52.

Claims

1. 1. An aerosol generating device comprising a cavity for receiving an aerosol-forming substrate, the cavity comprising: a first end and an opposing second end; a length between the first end and the second end; a cross section perpendicular to said length; the cross-sectional perimeter of the cavity remains substantially constant along the length of the cavity; the cross-sectional shape of the cavity varies along the length of the cavity; the cross-sectional surface area of ​​the cavity varies along the length of the cavity; and wherein the cross-sectional dimension of the cavity varies along the length of the cavity.

2. 2. The aerosol generating device of claim 1, wherein the dimension of the cross section at the first end of the cavity is greater than the dimension of the cross section at the second end of the cavity.

3. 3. The aerosol generating device of claim 1, wherein the surface area of ​​the cross section of the cavity at the first end of the cavity is greater than the surface area of ​​the cross section of the cavity at the second end of the cavity.

4. The cross-sectional shape at the first end is substantially circular, and the cross-sectional shape at the second end is Substantially triangular, Substantially oval or elliptical, and 3. An aerosol generating device according to claim 1 or 2, which is one of substantially square or rectangular.

5. 3. The aerosol generating device of claim 1, wherein the shape of the cross section of the cavity at the first end is substantially circular, the shape of the cross section of the cavity at the second end is substantially triangular, and the aerosol generating device comprises a pin heating element extending into the cavity at the second end.

6. 3. The aerosol generating device of claim 1, wherein the shape of the cross section of the cavity at the first end is substantially circular and the shape of the cross section of the cavity at the second end is substantially oval or elliptical, and the aerosol generating device comprises a blade heating element extending into the cavity at the second end or two pin heating elements extending into the cavity at the second end.

7. 3. The aerosol generating device according to claim 1, further comprising an extractor for extracting the aerosol-forming substrate from the aerosol generating device, the extractor comprising a body defining the cavity for receiving the aerosol-forming substrate.

8. An extractor for extracting an aerosol-forming substrate from an aerosol-generating device, the extractor comprising a body defining a cavity for receiving the aerosol-forming substrate, the cavity comprising: a first end and an opposing second end; a length between the first end and the second end; a cross section perpendicular to said length; the cross-sectional perimeter of the cavity remains substantially constant along the length of the cavity; the cross-sectional shape of the cavity varies along the length of the cavity; the cross-sectional surface area of ​​the cavity varies along the length of the cavity; and wherein the cross-sectional dimension of the cavity varies along the length of the cavity.

9. 9. The extractor of claim 8, wherein the dimension of the cross section at the first end of the cavity is greater than the dimension of the cross section at the second end of the cavity.

10. 10. An extractor according to claim 8 or 9, wherein the surface area of ​​the cross-section of the cavity at the first end of the cavity is greater than the surface area of ​​the cross-section of the cavity at the second end of the cavity.

11. The cross-sectional shape at the first end is substantially circular, and the cross-sectional shape at the second end is Substantially triangular, Substantially oval or elliptical, and 10. An extractor according to claim 8 or 9, which is one of substantially square or rectangular.

12. 1. An aerosol generating system comprising: an aerosol-forming substrate; An aerosol generating system comprising the aerosol generating device according to claim 1 or 2.

13. The aerosol-forming substrate is a first end and an opposing second end; a length between the first end and the second end; a cross section perpendicular to said length; Before the aerosol-forming substrate is received in the cavity of the aerosol-generating device, the cross-sectional shape of the aerosol-forming substrate is substantially constant along the length of the aerosol-forming substrate and is substantially similar to the shape of the cross-section of the cavity at the first end of the cavity; 13. The aerosol generating system of claim 12, wherein the cross-sectional dimensions of the aerosol-forming substrate are substantially constant along the length of the aerosol-forming substrate and are substantially similar to the shape of the cross-section of the cavity at the first end of the cavity.

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