CN118284346A

CN118284346A - Flat consumable article comprising a support structure for an aerosol generating device

Info

Publication number: CN118284346A
Application number: CN202280070543.3A
Authority: CN
Inventors: J·麦克沃伊
Original assignee: JT International SA
Current assignee: JT International SA
Priority date: 2021-10-20
Filing date: 2022-10-20
Publication date: 2024-07-02
Also published as: KR20240088946A; WO2023067060A1; JP2024539039A; EP4418907A1

Abstract

The invention relates to a flat consumable product (12) for an aerosol generating device, which extends along a product axis and comprises: -a tobacco substrate (25) defining at least a first pair of opposite lateral surfaces extending along the axis of the article; -a support structure (26) comprising an outlet portion and a matrix portion, the outlet portion being arranged in sequence along the product axis with the tobacco matrix (25), the matrix portion extending from the outlet portion along the product axis and being configured to engage with the first pair of opposite lateral surfaces to hold the tobacco matrix with the support structure (26). The matrix portion includes a pair of legs configured to extend along at least a portion of the corresponding lateral surface.

Description

Flat consumable article comprising a support structure for an aerosol generating device

Technical Field

The present invention relates to a flat consumable article comprising a support structure for an aerosol generating device.

In particular, the flat consumable article according to the present invention is configured for use with an aerosol generating device (also referred to as a heating non-combustion device or HNB device). Aerosol-generating devices of this type are adapted to heat, rather than burn, an aerosol-generating substrate contained in the article.

Background

The popularity and use of devices (also known as vaporizers or aerosol generating devices) with reduced or altered risks has grown rapidly over the past few years as an aid to helping people with smoking habits to abstain from traditional tobacco products such as cigarettes, cigars, cigarillos and cigarettes. Rather than burning tobacco in conventional tobacco products, a variety of different devices and systems may be used to heat or raise the temperature of the vaporizable material.

Common devices with reduced risk or altered risk are devices in which the substrate is heated to produce an aerosol or heated non-flammable devices (also known as HNB devices). This type of device produces an aerosol or vapor by heating an aerosol-generating substrate, typically comprising wet tobacco leaves or other suitable vaporizable material, to a temperature typically in the range of 150 to 350 ℃. Heating the aerosol-generating substrate without burning or igniting it releases an aerosol that contains the user's desired ingredients but does not contain toxic and carcinogenic byproducts of combustion and ignition. In addition, aerosols produced by heating tobacco or other vaporizable materials typically do not contain burnt or bitter flavors that may be uncomfortable to the user resulting from combustion and ignition, and therefore, the substrate does not require the addition of sugar and other additives that would normally be added to such materials to make smoke and/or vapor more suitable for the taste of the user.

Some HNB devices may be suitable for use with reduced size consumable articles. Such articles may have, for example, a flat shape and form a substantially cuboid shape with a thickness of 1mm or 2 mm. The transverse and longitudinal dimensions of the article may be between 10 and 30 mm. Because of such shape and size, these consumable articles make the heat transfer by vapor more efficient than bar-type forms.

It is therefore apparent that it may be difficult for a user to handle these reduced-size consumable articles without bending or breaking them. The handling may be particularly difficult when inserting or removing such articles into HNB devices. Furthermore, it can be difficult to accurately position such articles within the device.

Disclosure of Invention

One of the objects of the present invention is to propose a flat consumable product for HNB devices, which can be easily handled by the user, placed inside the device to generate aerosols and removed from the device.

To this end, the invention relates to a flat consumable product for an aerosol-generating device, the flat consumable product extending along a product axis and comprising:

-a tobacco substrate defining at least a first pair of opposite lateral surfaces extending along the axis of the article;

-a support structure comprising an outlet portion and a substrate portion, the outlet portion being arranged in sequence with the tobacco substrate along the product axis, the substrate portion extending from the outlet portion along the product axis and being configured to engage with the first pair of opposed lateral surfaces to retain the tobacco substrate with the support structure, the outlet portion comprising an airflow pathway extending from the tobacco substrate;

the matrix portion includes a pair of legs, each leg configured to extend along at least a portion of a corresponding lateral surface.

Thanks to these features, the tobacco substrate can be held by the support structure. The support structure increases the stiffness of the article to facilitate handling and reduce deformation of the article. This retention is ensured in particular by the feet extending along at least a portion of the consumable article. In particular, each leg may extend along the entire length of the tobacco substrate or along a portion of the length of the tobacco substrate. The portion may for example constitute at least 1/4, advantageously at least 1/2, more advantageously at least 3/4 of the total length of the tobacco substrate. Thus, the user may simply use the support structure (e.g., to form a solid element) to operate when inserting or removing the consumable article from the device. Thus, bending or breakage of the tobacco substrate can be avoided. Furthermore, by using a support structure, the consumable product can be placed just inside the device in order to generate an aerosol. In particular, the consumable product can be more easily guided into the device, such as into a complementary heating chamber of the device. In addition, the height of the feet can be adjusted to prevent excessive deformation/collapse of the tobacco substrate and obstruction of the flow channels. Thus, the user's experience may be improved.

In some embodiments, the tobacco substrate may be assembled to the support structure during the manufacture of the article. In some cases, the tobacco substrate may be secured (e.g., glued) to the support structure, particularly to the feet that hold the tobacco substrate. In some other embodiments, the support structure may be provided separately from the tobacco substrate. In this case, the user may engage the tobacco substrate with the support structure prior to use of the consumable article with the aerosol-generating device. In both embodiments, the support structure may be recyclable.

According to some embodiments, the tobacco substrate further defines a second pair of opposite lateral surfaces extending along the axis of the article, the second pair of opposite lateral surfaces having a width, for example at least 5 times, advantageously 10 times, the width of the first pair of lateral surfaces.

Due to these features, the tobacco substrate forms a substantially rectangular parallelepiped shape. The shape is particularly suitable for being at least partially accommodated inside an aerosol-generating device.

According to some embodiments, each leg defines an inner surface configured to engage with a corresponding lateral surface of the tobacco substrate.

According to some embodiments, the inner surface of each leg defines a cross-sectional shape complementary to the cross-sectional shape of the corresponding lateral surface of the tobacco substrate.

Advantageously, the cross-sectional shape of the inner surface of each leg has a concave circular shape and the cross-sectional shape of the corresponding lateral surface has a convex circular shape.

Thanks to these features, the tobacco substrate can be guided by the feet during its insertion into the support structure. For example, the feet may act as rails and the tobacco substrate may simply slide between these rails as it is inserted. Furthermore, the complementary cross-sectional shape of the legs and the corresponding lateral surface of the tobacco substrate may ensure better contact between these elements and a more secure retention of the tobacco substrate between the legs.

According to some embodiments, each leg defines a tapered portion extending up to a leg end and defining a taper angle at the leg end.

Because of these features, the distance between the legs at the leg ends is greater than the distance between the legs in any other area of the legs. Thus, insertion of the tobacco substrate from the leg end may be facilitated. Further, each leg may define a straight portion extending between an outlet portion of the support structure and a corresponding tapered portion. Along the straight portion, the distance between the legs may be constant. The distance is adapted to hold the tobacco substrate between the feet.

According to some embodiments, the support structure is made of a single piece.

Because of these features, the support structure can be easily manufactured using, for example, injection molding or any other available technique.

According to some embodiments, the support structure is made of pulp material injection molded. In other words, the support structure is made of injection molded pulp material.

Pulp is a particularly advantageous material because it is inexpensive and heat resistant. In addition, the pulp ensures good stiffness and compatibility with tobacco products.

According to some embodiments, the support structure comprises tobacco powder and/or flavoring.

In particular, the tobacco powder may be added as a filler during the manufacturing of the support structure. For example, when the support structure is formed by injection moulding, the ground tobacco, or a powder of ground tobacco, or at least particles thereof, may be added to the material forming the support structure like pulp. Tobacco is added to the support structure for enhancing the sensory perception of the user. For example, when the support structure is heated with the tobacco substrate, the ground tobacco may release the tobacco flavor, thereby thus enhancing the user's experience. Flavoring agents may be used instead of or in addition to the ground tobacco. Such flavoring agents may also be adapted to release flavor upon heating. For example, flavoring agents with polysaccharide carriers as described in EP 2279677, EP 2682007, EP 2682008, EP 2682009 or EP 3533348 may be used.

According to some embodiments, a wrapper is included that wraps around the tobacco substrate or wraps the tobacco substrate with at least a portion of the support structure.

Because of these features, the wrapper can ensure that the taste of the tobacco and/or flavour released during the smoking process is retained. In addition, the wrap can prevent condensate or vapor leakage and can efficiently direct airflow along the entire area of the tobacco substrate to the outlet portion. The wrapper may be formed of any suitable material, such as aluminum or paper. In some embodiments, the wrap may cover only the tobacco substrate with the feet of the support structure. In some embodiments, the wrap may also cover the entire support structure including the outlet portion. In this last case, the wrapper may be formed from a single sheet or from different sheets covering the tobacco substrate and the leg and outlet portions, respectively. In some other cases, the wrapper may cover only the tobacco substrate, separate from the legs of the support structure. In this case, the tobacco substrate is wrapped before being inserted between the legs. The wrap may include a tearable portion such that at least a portion of the wrap can be easily removed prior to insertion.

According to some embodiments, the outlet portion is hollow and preferably hollow or comprises a support element arranged inside the outlet portion.

The hollow structure may facilitate air flow within the outlet portion. When the hollow structure is substantially hollow, the air flow is not impeded and thus the pressure resistance is reduced. When the hollow structure comprises supporting elements such as ribs, struts or additional walls, the rigidity of the hollow structure may be increased. Further, in some cases, the support element may act as an airflow guide and/or a cooler. Thus, the air streams directed to the user may be mixed and/or cooled, for example, in a particular manner to enhance the user's experience. Furthermore, in some embodiments, the support element may act as a stop to prevent insertion of the tobacco substrate inside the outlet portion.

According to some embodiments, the tobacco substrate comprises at least one, preferably a plurality of flow channels extending along the article axis and formed on at least one of the second pair of opposing lateral surfaces.

Because of these features, the available surface of the tobacco substrate for heat transfer is increased over a flat surface. The air flow can also be easily directed through the tobacco substrate. The flow channels may be formed on only one of the lateral surfaces or on each of the lateral surfaces. In this last case, in each section, the flow channels arranged on the different lateral surfaces may be staggered between these lateral surfaces.

According to some embodiments, the outlet portion comprises at least two edges extending perpendicular to the axis of the article, at least a portion of each edge being for contact with the tobacco substrate.

In particular, the edges of the outlet portion may be in close contact with the tobacco substrate such that the air flow directed by the flow channels formed in the substrate may pass entirely into the interior of the outlet portion. In particular, the edge is in contact with at least one projection of the tobacco substrate between the flow channels, preferably with a plurality of projections.

According to some embodiments, each edge comprises a recessed portion arranged to face the corresponding flow channel.

In other words, the flow channels are aligned with the corresponding recessed portions, and each recessed portion lengthens the corresponding flow channel. Thanks to these features, the concave portion can ensure aerosol cooling and good mouthfeel for the user. In addition, the size of these recessed portions and/or alignment with corresponding flow channels may be adjusted to adjust the cooling effect.

According to some embodiments, the support structure includes at least one visual characteristic (e.g., color, logo or image) to define the flavor of the tobacco substrate.

Thanks to these features, the support structure makes it possible to distinguish the consumable product from other consumable products having, for example, different tastes and/or flavors.

According to some embodiments, the visual characteristic is a color obtained by mixing pulp material with one or more dyes during injection molding.

Thus, the support structure may be at least partially or fully colored to indicate different tastes and/or flavors of the consumable article. The or each dye used to colour the pulp material is advantageously a food dye.

For example, one or a mixture of any of the following dyes may be used to color the pulp: red dye, green dye, blue dye, and yellow dye.

The red dye is, for example, an allure red AC, also known as E129 dye. The chemical formula is C ₁₈H₁₄N₂Na₂O₈S₂, and the full name is 6-hydroxy-5- [ (2-methoxy-5-methyl-4-sulfophenyl) diazenyl ] naphthalene-2-sulfonic acid disodium.

The green dye is, for example, fast green FCF, also known as E143 dye. The chemical formula is C ₃₇H₃₄N₂Na₂O₁₀S₃, the full name of which is ethyl- [4- [ [4- [ ethyl- [ (3-sulfophenyl) methyl ] amino ] phenyl ] - (4-hydroxy-2-sulfophenyl) methylene ] -1-cyclohexyl-2, 5-dienylidene ] - [ (3-sulfophenyl) methyl ] ammonium nitrogen.

The blue dye is, for example, brilliant blue FCF, also known as E133 dye. The chemical formula is C ₃₇H₃₄N₂Na₂O₉S₃, and the full name of the chemical formula is disodium 2- [ [4- [ ethyl- [ (3-sulfophenyl) methyl ] amino ] phenyl ] - [4- [ ethyl- [ (3-sulfophenyl) methyl ] nitrous subunit ] cyclohexyl-2, 5-diene-1-subunit ] methyl ] benzenesulfonate.

Yellow dyes are, for example, tartrazine, also known as E102 dyes. The chemical formula is C ₁₆H₉N₄Na₃O₉S₂, the full name of which is trisodium 5-hydroxy-1- (4-sulfophenyl) -4- [ (E) - (4-sulfophenyl) diazenyl ] -1H-pyrazole-3-carboxylate.

The or each dye in the pulp material may for example be between 0.1% and 5% by weight.

In one aspect, the present invention relates to a flat consumable article for an aerosol generating device, the flat consumable article extending along an article axis and comprising:

Wherein the support structure is made of injection molded pulp material.

Preferably, the support structure comprises tobacco powder and/or flavourant. Preferably, the support structure may include at least one visual characteristic (e.g., color, logo or image) to define the flavor of the tobacco substrate. Preferably, the visual characteristic is a color obtained by mixing the pulp material with one or more dyes during injection molding.

Drawings

The invention and its advantages will be better understood by reading the following description, which is given by way of non-limiting example only and made with reference to the accompanying drawings, in which:

fig. 1 is a perspective view of an aerosol-generating assembly comprising an aerosol-generating device and a flat consumable article according to the invention, which can be used with the aerosol-generating device;

fig. 2 is a perspective view of the flat consumable article of fig. 1, comprising a wrapper, according to an example of a first embodiment of the present invention;

FIG. 3 is a perspective view of the flat consumable product of FIG. 1 according to an example of a first embodiment that differs from the example of FIG. 2;

FIG. 4 is a view similar to the view of FIG. 2, wherein the consumable article is free of a wrapper;

FIG. 5 is a perspective view of the tobacco substrate of the consumable article of FIG. 4;

FIG. 6 is a perspective view of the support structure of the consumable article of FIG. 4;

FIG. 7 is a perspective view of the support structure of the consumable article of FIG. 4 according to an alternative example;

FIG. 8 is a partial view of the support structure of FIG. 6;

fig. 9 (a) is a cross-sectional view taken along plane VII-a of fig. 8, and (B) is a cross-sectional view taken along plane VII-B of fig. 8;

Fig. 10 is a perspective view of a flat consumable product according to a second embodiment of the present invention; and

Fig. 11 is a perspective view of a support structure comprised in the consumable article of fig. 10.

Detailed Description

Before the present invention is described, it is to be understood that this invention is not limited in its application to the details of construction set forth in the following description. It will be apparent to those skilled in the art having the benefit of this disclosure that the present invention is capable of other embodiments and of being practiced or of being carried out in various ways.

As used herein, the term "aerosol generating device" or "device" may include an inhalation device that delivers an aerosol (including aerosol for inhalation) to a user via a heater element as described in further detail below. The device may be portable. "portable" may mean that the device is used while held by a user. The device may be adapted to generate a variable amount of aerosol (as opposed to a metered amount of aerosol), for example by activating the heater element for a variable period of time, which may be controlled by a trigger. The trigger may be user-activated, such as a suction button and/or a suction sensor. The inhalation sensor may be sensitive to inhalation intensity and duration to be able to provide a variable amount of vapour (in order to simulate the effect of smoking a conventional combustible smoking article such as a cigarette, cigar or pipe). The apparatus may include a temperature adjustment control to drive the temperature of the heater and/or heated aerosol-generating substrate (aerosol precursor) to a specified target temperature and thereafter maintain the temperature at a target temperature effective to generate an aerosol.

As used herein, the term "aerosol" may include suspensions of vaporizable materials (e.g., one or more of solid particles, droplets, gas). The suspension may be in a gas (including air). An aerosol herein may generally refer to/include a vapor. The aerosol may comprise one or more components of the vaporisable material.

As used herein, the term "vaporizable material" or "precursor" may refer to a smokable material that may, for example, include nicotine or tobacco and aerosol former. The tobacco may take the form of various materials, such as cut filler, particulate tobacco, tobacco leaf, and/or reconstituted tobacco. Suitable aerosol formers include: polyols such as sorbitol, glycerol, and glycols (e.g., propylene glycol or triethylene glycol); non-polyols (such as monohydric alcohols), acids (such as lactic acid), glycerol derivatives, esters (such as triacetin, triethylene glycol diacetate, triethyl citrate, glycerol or vegetable glycerol). In some embodiments, the aerosol generating agent may be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. The matrix may further comprise at least one of a gelling agent, a binder, a stabilizer, and a wetting agent.

As used herein, the term "wider" in relation to two surfaces is used to compare the dimensions of these surfaces in the lateral direction (i.e., the direction perpendicular to the direction of extension of these surfaces). When at least one of these surfaces has a non-planar shape, the dimension is measured from a plane passing through at least two points, which limit the surface in the transverse direction.

First embodiment of the invention

Fig. 1 shows an aerosol-generating assembly 10 comprising an aerosol-generating device 11 and a flat consumable article 12 (hereinafter referred to as consumable article 12) according to a first embodiment of the present invention. The aerosol generating device 11 is intended to operate with a consumable article 12 (shown in more detail in fig. 2 to 9).

Referring to fig. 1, the aerosol-generating device 11 comprises a device body 15 extending along a device axis Y. The device body 15 includes a suction nozzle 16 and a housing 17 arranged in order along a device axis Y. According to the example of fig. 1, the suction nozzle 16 and the housing 17 form two different components. In particular, according to this example, the mouthpiece 16 is designed to be fixed on or housed in an insertion opening formed at one of the ends of the housing 17. In this case, the consumable product 12 may be inserted inside the device 11 when the mouthpiece 16 is removed from the housing 17. According to another example (not shown), the suction nozzle 16 and the housing 17 form one single piece. In this case, the consumable product 12 may be inserted inside the device 11 (e.g., through a flow outlet). According to both examples, the mouthpiece 16 defines a through-hole adapted to at least partially receive the consumable product 12. In particular, the through-hole may be adapted to receive at least an outlet portion of the consumable product 12, as will be described in further detail below. According to a further embodiment (not shown), the aerosol-generating device 11 is not provided with a suction nozzle 16. In this case, the outlet portion of the consumable product 12 may form a mouth end designed to contact the lips and/or mouth of a user during the period of inhalation.

The housing 17 defines an interior space of the device 11 that accommodates a plurality of different elements designed to perform different functions of the device 11. The interior space may, for example, house a battery for powering the device 11, a control module for controlling the operation of the device 11, a heating chamber for heating the consumable product 12, and the like. In particular, the heating chamber is designed to accommodate at least the tobacco substrate of the consumable article 12 and heat the tobacco substrate using a suitable heater. In the example of fig. 1, the heating chamber may be arranged, for example, along the device axis Y in an extension of the through-hole of the suction nozzle 16.

Referring to fig. 2, the consumable product 12 is, for example, a flat rectangular parallelepiped extending along a product axis X between an inlet end 18 and an outlet end 19, and has an external dimension lxwxh. The consumable product 12 is adapted to direct an airflow from an inlet end 18 to an outlet end 19, as will be described in further detail below. In a typical example, the article 12 has a length L on the article axis X substantially equal to 25 to 35mm (e.g., 33 mm), a width W between 8 and 15mm (e.g., substantially equal to 12 mm), and a height H between 0.8 and 2mm (e.g., substantially equal to 1.2 mm). According to different examples, the values of L, W and H may be selected within a range of +/-40%, for example.

In the example of fig. 2, the consumable article 12 is wrapped by a common wrapper 21. In other words, in this example, wrapper 21 is formed from a single sheet of material wrapped around article axis X over substantially the entire length of consumable article 12. In other examples, wrapper 21 extends along only a portion of the length of consumable article 12. For example, the wrapper 21 may extend only along and advantageously only wrap the tobacco substrate of the consumable article 12, as shown in the alternative embodiment of fig. 3. According to another example, the wrapper 21 is formed from two different sheets of material that individually wrap, for example, the tobacco substrate and the support structure of the consumable article 12. Wrap 21 may be made of aluminum and/or paper. The paper may be coated with an impermeable coating to prevent liquid absorption like cooking/backing paper. In some embodiments, when wrap 21 is made of aluminum, the wrap may only wrap the tobacco substrate to prevent condensate leakage and/or vapor leakage. In addition, aluminum achieves better heat transfer.

Fig. 4 shows the consumable article 12 without the wrapper 21. In some embodiments, consumable articles 12 without wraps 21 may be provided and used, as shown in fig. 4. Referring to fig. 4, the consumable article 12 includes a tobacco substrate 25 for generating an aerosol and a support structure 26 for holding the tobacco substrate 25. The support structure 26 may also be used to collect and direct the aerosol flow from the tobacco substrate 25 into the mouth of the user.

The tobacco substrate 25 is shown in more detail in fig. 5. The tobacco substrate 25 defines the inlet end 18 of the consumable article 12 and contains a vaporizable or smokeable material as defined above. The vaporizable material is compressed, for example, to form a solid structure capable of releasing an aerosol upon heating. Examples of tobacco substrates and methods for their manufacture are described in WO/2021/094365 and WO/2021/094366. In particular, referring to fig. 5, the tobacco substrate 25 defines, for example, a substantially flat cuboid, defining a first pair of opposing lateral surfaces 33A, 33B (represented in fig. 5 as the right and left sides of the substrate) and a second pair of opposing lateral surfaces 34A, 34B (represented in fig. 5 as the top and bottom sides of the substrate), the pairs of lateral surfaces extending along the article axis X. The width of the second pair of opposite lateral surfaces 34A, 34B is for example at least 5 times, advantageously 10 times, the width of the first pair of lateral surfaces 33A, 33B. The first pair of opposing lateral surfaces 33A, 33B are designed to contact the support structure 26, as will be described in further detail below. Each of the first pair of lateral surfaces 33A, 33B may define a generally flat shape that may define a rounded edge in each cross-section. In particular, in each section, each of the first pair of lateral surfaces 33A, 33B may have a convex shape. The second pair of lateral surfaces 34A, 34B are designed to be heated by conduction and/or convection by the heating chamber of the device 11. According to another embodiment, the tobacco substrate 25 comprises a susceptor and is designed to be further heated by sensing the magnetic interaction of the susceptor with the magnetic coil.

Each of the second pair of lateral surfaces 34A, 34B defines a plurality of flow channels extending along the article axis X and is designed to direct an airflow along the tobacco substrate 25. In the example of fig. 5, two flow channels 36A are formed on the lateral surface 34A, and three flow channels 36B are formed on the lateral surface 34B. In each cross-section of the tobacco substrate 25, the flow channels disposed on the different lateral surfaces 34A, 34B may be arranged in a staggered manner, as shown in fig. 5. In particular, in this case, the tobacco substrate 25 may be formed in each cross-section in a wave shape, with valleys between the protrusions forming the flow channels 36A, 36B on each lateral surface 34A, 34B. The shape may be formed, for example, by stamping. In an alternative mode (not shown), the cross section is not wave-shaped, but the protrusion thickness widens and the flow channel thickness decreases.

Fig. 6 shows in more detail the support structure 26 for holding the tobacco substrate 25. In a preferred embodiment of the present invention, the support structure 26 is formed from a single piece using, for example, an injection molding process. The support structure 26 may be made of or include a pulp material. In some embodiments, the support structure 26 may include ground tobacco or flavoring that may be released upon heating. The support structure 26 may also be recyclable. The support structure 26 may also include at least one visual characteristic (e.g., color, logo or image) to define the flavor of the tobacco substrate.

When the visual characteristic is color, the color may be obtained by mixing the pulp material with one or more dyes during injection molding. Thus, the support structure 26 may be at least partially or fully colored to indicate a different taste and/or flavor of the consumable article 12. The or each dye used to colour the pulp material is advantageously a food dye. For example, one or a mixture of any of the following dyes may be used to color the pulp: red dye, green dye, blue dye, and yellow dye.

Referring to fig. 6, the support structure 26 comprises an outlet portion 41 designed to be arranged in sequence with the tobacco substrate 25 along the product axis X, and a substrate portion 42 extending from the outlet portion 41 along the product axis X and configured to engage with the first pair of opposite lateral surfaces 33A, 33B to retain the tobacco substrate 25 with the support structure 26.

The outlet portion 41 defines an airflow path extending from the tobacco substrate 25 to the outlet end 19 of the consumable article 12 formed by the outlet portion 41. Thus, the outlet portion 41 serves to extend the flow channels 36A, 36B of the tobacco substrate 25 and direct the airflow from each of these flow channels 36A, 36B up to the outlet end 19 of the consumable article 12. As shown in fig. 6, the outlet portion 41 may have a rectangular cross section and may be hollow internally or define support elements such as ribs, struts or additional walls. In some embodiments, the outlet portion 41 may comprise a filter element. The filter element may comprise paper or cellulose acetate tow. The thickness of the outer wall defining the outlet portion 41 may be between 0.01mm and 0.5mm, preferably between 0.05mm and 0.2 mm. At the end opposite the outlet end 19, the outlet portion 41 comprises two edges 46A, 46B extending perpendicular to the product axis X, at least a portion of each edge 46A, 46B being intended to be in contact with the tobacco substrate 25, as shown in fig. 4. In particular, these edges 46A, 46B, or at least a portion thereof, are intended to be in close contact with the projections of the tobacco substrate 25 and extend substantially along a straight line according to the first embodiment of the invention. The thickness of the outlet portion 41 may be equal to or less than the maximum height of the tobacco substrate 25. Preferably, the maximum height of the tobacco substrate 25 is between 0.05mm and 0.2mm greater than the thickness of the outlet portion. Thus, in this case, the edges 46A, 46B may act as a stop when inserting the tobacco substrate 25 into the substrate portion 42. The maximum height of the tobacco substrate 25 is preferably measured as the distance between two planes parallel to the article axis X and tangential to the projections arranged on the opposite lateral surfaces 34A, 34B. In other words, when there are protrusions, the maximum height is measured as the distance between the protrusions. According to an alternative example of the support structure 26 shown in fig. 7, the edges 46A, 46B may comprise a stop 47, preventing the tobacco substrate 25 from sliding inside the outlet portion 41. These stops 47 may protrude from the edges 46A, 46B inside the outlet portion 41, as shown in fig. 7.

The base portion 42 includes a pair of feet 53A, 53B extending along the product axis X from the outlet portion 41 toward the inlet end 18 of the consumable product 12. In particular, each leg 53A, 53B is configured to extend along at least a portion of a corresponding lateral surface 33A, 33B of the first pair of lateral surfaces of tobacco substrate 25. In the example of the figures, the feet 53A, 53B extend along the overall length of the tobacco substrate 25. According to other examples, the feet 53A, 53B extend accordingly for at least 1/2, advantageously 3/4, of the total length (along the axis X) of the tobacco substrate 25. For example, the legs 53A, 53B are symmetrical with respect to a central plane passing along the product axis X midway between the two legs 53A, 53B. In further description, only the leg 53B will be described in detail with reference to fig. 8 and 9.

As shown in fig. 8, the leg 53B includes a straight portion 55 adjacent to the outlet portion 41 and a tapered portion 56 extending from the straight portion 55 to a leg end 57. The tapered portion 56 extends for example between 10% and 50% of the total length of the leg 53B and forms a taper angle at the leg end 57 of for example between 1 ° and 5 °. For example, the straight portion 55 defines a substantially constant cross-sectional shape as shown in section a of fig. 9. The shape is for example formed by two branches 61, 62 extending towards the centre plane and an intermediate element 63 extending between the branches 61, 62. For example, the tapered portion 56 defines a variable cross-sectional shape that gradually changes from the cross-sectional shape of the straight portion 55 to the cross-sectional shape of the leg end 57 as shown in section B of fig. 9. In particular, as shown in fig. 9, the extension of the branches 61, 62 decreases gradually from the straight portion 55 to the foot end 57. In some embodiments (not shown), the leg end 57 may further define a blocking portion that blocks the tobacco substrate 25 once it is received between the legs 53A, 53B. The blocking portion may protrude from the leg end 57 of each leg 53A, 53B toward the space formed between the legs 53A, 53B.

The straight portion 55 and the tapered portion 56 together form an inner surface 64 configured to contact the lateral surface 33B of the tobacco substrate 25. In particular, the cross-sectional shape defined by the inner surface 66 may be complementary to the cross-sectional shape of the corresponding lateral surface 33B, and may thus define a concave circular shape. In some embodiments, each leg may also be divided into two separate elongated sections that access the outlet portion 41. The feet may also extend over a small portion (e.g., less than 5% of the lateral surfaces) of the opposing lateral surfaces 34A, 34B.

The use of the consumable product 12 according to the present invention will now be described. In one embodiment, the consumable product 12 is considered assembled. In other words, in this case, the tobacco substrate 25 is inserted into the support structure 26, as explained above. When the user intends to use the consumable article 12, he/she inserts the tobacco substrate 25 into the heating cavity and then installs the mouthpiece 16 on the outlet portion 41. Alternatively, when the mouthpiece 16 is not required, the user performs only the step of inserting the tobacco substrate 25 into the heating chamber, and the outlet portion 41 acts as a mouthpiece. The user then initiates operation of the aerosol-generating device 11, which heats the tobacco substrate 25. When a user sucks on, an air flow is created inside the consumable product 12 and from the inlet end 18 first through the flow channels 36A, 36B and then through the outlet portion 41 to the outlet end 19.

According to another embodiment, the consumable product 12 is unassembled. In this case, the user first inserts the tobacco substrate 25 between the feet 53A, 53B and then performs the steps described above.

Second embodiment of the invention

A flat consumable article 112 according to a second embodiment of the present invention will now be described with reference to fig. 10 and 11.

As in the previous cases, the consumable article 112 includes a tobacco substrate 125, a support structure 126, and (in some examples) a wrapper (not shown in fig. 10). The tobacco substrate 125 is similar to the tobacco substrate 25 described with reference to the first embodiment of the present invention. The support structure 126 is also similar to the support structure 26 described above, and in particular includes an outlet portion 141 and a matrix portion 142 (similar to the matrix portion 42 described above). The outlet portion 141 according to the second embodiment of the invention differs from the outlet portion 41 according to the first embodiment of the invention only in the edges 146A, 146B for contact with the tobacco substrate 125.

In particular, as shown in fig. 11, each edge 146A, 146B of the outlet portion 141 includes a recessed portion 136A, 136B disposed on a corresponding lateral surface of the tobacco substrate 125 for each flow channel. Thus, the recessed portions 136A, 136B are arranged to face the corresponding flow passages and elongate them. Each recessed portion 136A, 136B may form a semi-circular shape and may extend from the tobacco substrate 125 to a maximum extension length, for example, between 0.1mm and 5mm (preferably, between 0.5mm and 2.5 mm). The recessed portions 136A, 136B may act as vents to cool the airflow inside the outlet portion 126. When provided and covering the outlet portion 141, the wrap may also define apertures facing the recessed portions 136A, 136B.

Claims

1. A flat consumable product (12; 112) for an aerosol generating device (11), the flat consumable product (12; 112) extending along a product axis (X) and comprising:

-a tobacco substrate (25; 125) defining at least a first pair of opposite lateral surfaces (33 a,33 b) extending along the article axis (X);

-a support structure (26; 126) comprising an outlet portion (41; 141) and a substrate portion (42; 142) arranged in sequence with the tobacco substrate (25; 125) along the article axis (X), the substrate portion extending from the outlet portion (41; 141) along the article axis (X) and being configured to engage with said first pair of opposite lateral surfaces (33 a,33 b) to retain the tobacco substrate (25; 125) with the support structure (26; 126), the outlet portion (41; 141) comprising an airflow path extending from the tobacco substrate (25; 125);

The matrix portion (42; 142) includes a pair of legs (53A, 53B), each leg (53A, 53B) configured to extend along at least a portion of a corresponding lateral surface (33A, 33B).

2. The flat consumable article (12; 112) according to claim 1, wherein the tobacco substrate (25; 125) further defines a second pair of opposite lateral surfaces (34 a,34 b) extending along the article axis (X), the second pair of opposite lateral surfaces (34 a,34 b) having a width at least 5 times, advantageously 10 times, the width of the first pair of lateral surfaces (33 a,33 b).

3. The flat consumable article (12; 112) according to any one of the preceding claims, wherein each leg (53 a,53 b) defines an inner surface (64) configured to engage with a corresponding lateral surface (33 a,33 b) of the tobacco substrate (25; 125).

4. A flat consumable article (12; 112) according to claim 3, wherein the inner surface (64) of each leg (53 a,53 b) defines a cross-sectional shape complementary to the cross-sectional shape of the corresponding lateral surface (33 a,33 b) of the tobacco substrate (25; 125);

advantageously, the cross-sectional shape of the inner surface (64) of each leg (53 a,53 b) has a concave circular shape, and the cross-sectional shape of the corresponding lateral surface (33 a,33 b) has a convex circular shape.

5. The flat consumable article (12; 112) according to any one of the preceding claims, wherein each leg (33 a,33 b) defines a tapered portion (56) extending up to a leg end (57) and defining a taper angle at the leg end (57).

6. The flat consumable article (12; 112) according to any one of the preceding claims, wherein the support structure (26; 126) is made of one piece.

7. The flat consumable article (12; 112) according to any one of the preceding claims, wherein the support structure (26; 126) is made of injection molded pulp material.

8. The flat consumable article (12; 112) according to any one of the preceding claims, wherein the support structure (26; 126) comprises tobacco powder or flavouring.

9. The flat consumable article (12; 112) according to any one of the preceding claims, further comprising a wrapper (21) wrapping the tobacco substrate (25; 125) or wrapping the tobacco substrate together with at least a portion of the support structure (26; 126).

10. Flat consumable article (12; 112) according to any one of the preceding claims, wherein the outlet portion (41; 141) is hollow and preferably empty or comprises a support element arranged inside the outlet portion (41; 141).

11. The flat consumable article (12; 112) according to any one of the preceding claims in combination with claim 2, wherein the tobacco substrate (25; 125) comprises at least one, preferably a plurality of flow channels (36 a,36 b) extending along the article axis (X) and formed on at least one lateral surface of the second pair of opposite lateral surfaces (34 a,34 b).

12. The flat consumable article (12; 112) according to claim 11, wherein the outlet portion (41; 141) comprises at least two edges (46 a,46b;146a,146 b) extending perpendicular to the article axis (X), at least a portion of each edge (46 a,46b;146a,146 b) being for contact with the tobacco substrate (25; 125).

13. The flat consumable article (112) of claim 12, wherein each edge (146 a,146 b) comprises a recessed portion (136 a,136 b) arranged to face the corresponding flow channel (36 a,36 b).

14. The flat consumable article (12; 112) according to any one of the preceding claims, wherein the support structure (26; 126) comprises at least one visual property such as a color, logo or image, thereby defining the flavor of the tobacco substrate.

15. The flat consumable article (12; 112) according to claim 14 in combination with claim 7, wherein the visual characteristic is a color obtained by mixing the pulp material with one or more dyes during injection molding.