Flat consumable article for aerosol-generating device

Abstract

A flat consumable article (30) extends along an article axis (Y) and along an article plane (A) parallel to the article axis (Y) and includes a tobacco portion and a mouthpiece portion arranged along the article axis (Y). The nozzle portion (34) comprises a corrugated core (50) and at least one planar support (60) supporting the corrugated core (50), the corrugated core (50) being attached to the at least one planar support (60).

Description

Technical Field

[0001] The present invention relates to a flat consumable article for an aerosol generating device, for example, the flat consumable article presents a solid substrate capable of forming an aerosol when heated.

[0002] The flat consumable article according to the present invention is configured to operate with an aerosol generating device. This type of aerosol generating device (also known as a heat-not-burn device) is adapted to heat, but not burn, a substrate by conduction, convection and / or radiation to generate an aerosol for inhalation. Background Art

[0003] In contrast to tobacco burning devices, various devices are available that heat or warm the vaporizable material in conventional tobacco products.

[0004] For example, such devices are heated substrate aerosol generating devices or heating but not burning devices. This type of device generates an aerosol or vapor by heating an aerosol substrate, typically including moist tobacco leaves or other suitable vaporizable materials, to a temperature typically in the range of 150°C to 350°C. Heating the aerosol substrate, but not burning or burning it, releases an aerosol that includes the ingredients desired by the user but does not include toxic and carcinogenic combustion and burning byproducts. In addition, the aerosol generated by heating tobacco or other vaporizable materials typically does not include burnt or bitter tastes that may be uncomfortable to the user due to combustion and burning, and therefore, the substrate does not need sugars and other additives that are typically added to such materials to make the smoke and / or vapor more suitable for the user's taste.

[0005] For example, the aerosol substrate used is a flat consumable product comprising a tobacco portion and a mouthpiece portion. The flat consumable product is intended to be at least partially received in a heating chamber of an aerosol generating device. The mouthpiece portion allows vapor to cool and pass from the tobacco portion to an outlet of the consumable product.

[0006] It is important that the flat consumable article does not collapse during handling, when inserted into an aerosol generating device or during use in a device. Collapse of the flat consumable article may block or impede the flow of vapour. Summary of the invention

[0007] One of the objects of the present invention is to provide a flat consumable product article which has a greater resistance to deformation and is easier to manufacture.

[0008] To this end, the present invention relates to a flat consumable article for an aerosol generating device, the flat consumable article extending along an article axis and along an article plane parallel to the article axis, the flat consumable article comprising a tobacco portion and a mouthpiece portion arranged along the article axis,

[0009] The nozzle portion comprises a corrugated core and at least a planar support supporting the corrugated core, the corrugated core being attached to the at least one planar support.

[0010] Due to these features, the flat consumable product exhibits greater resistance to deformation and is easier to manufacture. The corrugated core increases the compression resistance of the nozzle portion. In fact, the corrugations of the core increase the bending strength of the core in a direction perpendicular to the corrugations. The planar support further increases the resistance of the consumable product to deformation.

[0011] According to some embodiments, the corrugated core together with the at least one planar support defines a plurality of flow channels extending substantially parallel to the axis of the article.

[0012] Due to these features, the corrugated core enables efficient and consistent flow of vapor through the mouthpiece portion.

[0013] According to some embodiments, the corrugated core comprises a sheet comprising two opposing non-planar surfaces formed by generatrixes, which are straight lines substantially parallel to the axis of the article, extending from a directrix corresponding to a non-zero periodic function.

[0014] Due to these features, the corrugated core assumes a shape that enhances both the resistance to deformation of the consumable article and the flow of vapor through the mouthpiece portion.

[0015] According to some embodiments, each non-planar surface of the sheet includes a longitudinal edge extending longitudinally along the axis of the article, and at least one planar support is in contact with the longitudinal edge of the corresponding non-planar surface.

[0016] Due to these features, the planar support supports the corrugated core along regularly spaced lines.Deformation resistance is uniformly enhanced throughout the nozzle portion.

[0017] According to some embodiments, an orthogonal projection of the corrugated core on the plane of the article is included within an orthogonal projection of the at least one planar support on the plane of the article.

[0018] Due to these features, the corrugated core is completely supported by the planar support members. Deformation resistance is enhanced throughout the nozzle portion.

[0019] According to some embodiments, the corrugated core is glued or welded to the at least one planar support.

[0020] Due to these features, the deformation resistance of the consumable article is further increased. In addition, since the corrugated core and the planar support are connected together, the manufacture of the consumable article is further made easier. Movement of the corrugated core relative to the planar support is prevented.

[0021] According to some embodiments, at least one planar support is made of paper, cardboard or film.

[0022] Thanks to these characteristics, the planar support is made of a common material which has satisfactory resistance to deformation and is not hazardous to the user.

[0023] According to some embodiments, the flat consumable product further comprises a wrapper wrapping at least the nozzle portion.

[0024] Due to these features, the generation of condensation inside the aerosol generating device is prevented. In fact, the wrap prevents the generated vapor from escaping from the product inside the device and condensing inside the heater. The corrugated core and the planar support prevent the wrap from collapsing. On the contrary, the wrap keeps the corrugated core and the support or plate in place in the consumable product.

[0025] According to some embodiments, at least one planar support is attached to the wrap.

[0026] Due to these features, the resistance of the consumable article to deformation is further increased, since the corrugated core, the planar support and the wrapping are mechanically linked together. For the same reasons, the manufacture of the consumable article is further made easier.

[0027] According to some embodiments, a flat consumable article includes at least two planar supports configured to support a corrugated core.

[0028] Due to these features, flat consumable articles exhibit even greater resistance to deformation.

[0029] According to some embodiments, each planar support is in contact with a longitudinal edge of a corresponding non-planar surface.

[0030] Due to these features, the corrugated core is supported by the planar supports along regularly spaced lines on each side. The deformation resistance of the entire nozzle portion is further uniformly enhanced on both sides of the corrugated core.

[0031] The present invention also relates to a method for manufacturing a flat consumable product as described above, the method comprising the following steps:

[0032] - Provide tobacco parts;

[0033] - producing the nozzle part such that the corrugated core is attached to at least one planar support;

[0034] - arranging the tobacco portion and the mouthpiece portion along the axis of the article; and

[0035] - Attaching the tobacco portion and the mouthpiece portion together.

[0036] Due to these features, the planar support makes it easier to manufacture the consumable article, as the planar support can support the corrugated core during the assembly process of the consumable article.

[0037] According to some embodiments, the step of producing the nozzle part comprises attaching the corrugated core and at least one planar support to form the nozzle part.

[0038] Due to these features, flat consumable products are easy to manufacture.

[0039] According to some embodiments, the step of producing the nozzle portion comprises forming the nozzle portion by simultaneously extruding together a corrugated core and at least one planar support member.

[0040] Due to these features, the nozzle part is produced in one extrusion step. The manufacture of flat consumable articles is even easier. The manufacture can also be carried out faster because the nozzle part can be produced continuously by continuous extrusion.

[0041] According to some embodiments, the step of attaching the tobacco portion and the mouthpiece portion together comprises wrapping at least the mouthpiece portion with a wrapper.

[0042] Thanks to these features, wrapping of the mouthpiece part is made easier, since the planar support constitutes a support for the corrugated core during wrapping. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] The invention and its advantages will be better understood on reading the following description, given by way of non-limiting example only and made with reference to the accompanying drawings, in which:

[0044] - Figure 1 is a perspective view of an aerosol generating assembly comprising an aerosol generating device and a flat consumable product according to the present invention;

[0045] - Figure 2 yes Figure 1 A simplified three-dimensional view of a flat consumable product;

[0046] - Figure 3 is a partial three-dimensional view of a flat consumable product according to a first embodiment of the present invention;

[0047] - Figure 4 yes Figure 3 A front view of a flat consumable product;

[0048] - Figure 5 yes Figure 3 A partial three-dimensional view of a corrugated core of a flat consumable product;

[0049] - Figure 6is a partial three-dimensional view of a flat consumable according to a second embodiment of the present invention;

[0050] - Figure 7 FIG. 1 is a partial perspective view of a flat consumable product according to a third embodiment of the present invention. DETAILED DESCRIPTION

[0051] Before describing the present invention, it should be understood that the present invention is not limited to the construction details set forth in the following description. For those skilled in the art who benefit from this disclosure, it is obvious that the present invention is capable of other embodiments and can be practiced or implemented in a variety of different ways.

[0052] As used herein, the term "aerosol generating device" or "device" can include an inhalation device that delivers an aerosol (including an aerosol for inhalation) to a user by a heater element described in further detail below. The device can be portable. "Portable" can refer to that the device is used when held by a user. The device can be suitable for, for example, generating a variable amount of aerosol (different from a quantitative aerosol) by enabling a heater element for a variable period of time, which can be controlled by a trigger. The trigger can be user-enabled, such as an inhalation button and / or an inhalation sensor. The inhalation sensor can be sensitive to inhalation intensity and inhalation duration, so as to provide a variable amount of vapor (so as to simulate the effect of conventional combustible smoking articles such as cigarettes, cigars or pipes). The device can include a temperature control component to drive the temperature of the heater and / or heated aerosol-generating material (aerosol precursor) to reach a specified target temperature and thereafter the temperature is maintained at a target temperature that can effectively generate an aerosol.

[0053] As used herein, the term "aerosol" may include a suspension of vaporizable material such as one or more of the following: solid particles; liquid droplets; gas. The suspension may be in a gas (including air). Aerosol herein may generally refer to / include vapor. Aerosol may contain one or more components of vaporizable material.

[0054] As used herein, the term "vaporizable material" or "precursor" may refer to a material that can be ignited and smoked, which can, for example, include nicotine or tobacco and an aerosol former. Tobacco can take the form of a variety of different materials, such as shredded tobacco, granulated tobacco, tobacco leaves and / or reconstituted tobacco. Suitable aerosol formers include: polyols, such as sorbitol, glycerol, and glycols (such as 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 glycerin). In some embodiments, the aerosol generator can be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. The matrix can also include at least one of a gelling agent, a binder, a stabilizer, and a wetting agent.

[0055] First embodiment of the present invention

[0056] Figure 1 An aerosol generating assembly 1 according to the present invention is shown. The aerosol generating assembly 1 comprises an aerosol generating device 10 and an aerosol generating substrate 30 (also referred to as a flat consumable article 30). The aerosol generating device 10 is intended to operate with the flat consumable article 30 according to the first embodiment of the present invention. Figures 2 to 5 is shown in more detail in .

[0057] Reference again Figure 1 , the aerosol generating device 10 comprises a device body 12. The device body 12 extends along the device axis X and comprises at least one side wall 14. The device body 12 further comprises a mouthpiece 16 and a shell 18 arranged in sequence along the device axis X. For example, the mouthpiece 16 and the shell 18 are two different parts.

[0058] For example, the nozzle 16 includes a cavity 20 extending along the device axis X. In particular, the cavity 20 is designed to receive a flat consumable product 30 so that the device axis X coincides with the product axis Y, which will be described in further detail below. For example, the cavity 20 has a cross-sectional shape that is substantially similar to the flat consumable product 30. The cavity 20 is, for example, a through hole extending along the device axis X.

[0059] The housing 18 defines an interior space of the device 10 that receives a variety of different elements designed to perform different functions of the device 10. The interior space may, for example, receive a battery for powering the device 10, a control module for controlling the operation of the device 10, a heating chamber (not shown) for heating the flat consumable article 30, and at least one heating element (not shown) for heating the heating chamber.

[0060] refer to Figure 2, the flat consumable product 30 is, for example, a flat rectangular parallelepiped. The flat consumable product 30 extends substantially along the product axis Y and in the product plane A parallel to the product axis Y. The consumable product 30 has a length L, a width W and a height H. The length L is measured between the two opposite ends of the product 30 along the product axis Y. The width W is measured perpendicular to the product axis Y, in the product plane A, between the two opposite ends of the product 30. The height H is measured perpendicular to the product axis Y and perpendicular to the product 30, between the two opposite ends of the product plane A. For example, flat means that the height H is much smaller than the length L and the width W. In particular, the height H is 5 to 50 times smaller than the length L or the width W. In a typical example, the length L of the consumable product 30 is substantially equal to 33 mm, while its width W and height H are substantially equal to 12 mm and 1.2 mm, respectively. According to different examples, for example, the values ​​of L, W and H can be selected within the range of + / -40% of the above values.

[0061] The flat consumable product 30 includes a tobacco portion 32 and a nozzle portion 34 arranged along the product axis Y. In other words, the tobacco portion 32 and the nozzle portion 34 are arranged along the product axis Y. The tobacco portion 32 and the nozzle portion 34 can be arranged continuously along the product axis Y. Alternatively, an intermediate element (not shown in the drawings) can be arranged between the tobacco portion 32 and the nozzle portion 34. For example, the intermediate element is a filter plug. For example, the consumable product 30 further includes a wrapper 70. Along the product axis Y, the flat consumable product 30 includes an abutment end 40 intended to be inserted into the cavity 20 of the nozzle 16 of the device 10, in particular into the heating chamber of the device 10, and a nozzle end 42 opposite to the abutment end 40. For example, the length L of the product 30 is measured between the abutment end 40 and the nozzle end 42.

[0062] The tobacco portion 32 comprises a tobacco matrix. The tobacco portion 32 is intended to be heated by a heater (in this example, a heating chamber is used) and comprises a vaporizable material as defined above. Figure 2 As shown, tobacco portion 32 includes a side wall 33 extending substantially parallel to the axis of the article.

[0063] For example, the nozzle portion 34 is intended to be received within the nozzle 16 (eg, Figure 1 In some examples not shown, the nozzle portion 34 itself forms a nozzle intended to come into contact with the mouth and / or lips of a user. Figure 2 As shown, the mouthpiece portion 34 includes a planar side 35 that is flush with the side wall 33 of the tobacco portion 32. Figures 3 to 5As shown, the nozzle part 34 comprises a corrugated core 50 and at least a planar support 60, advantageously at least two planar supports 60, configured to support the corrugated core 50. According to an example not shown, the nozzle part 34 comprises one planar support 60. Figure 3 and Figure 4 In the example shown, the nozzle portion 34 comprises two planar supports 60 which are advantageously arranged on either side of the corrugated core 50 relative to the plane A of the product.

[0064] The corrugated core 50 is attached to at least one planar support 60. Figure 4 As shown, the corrugated core 50 defines a first bounding plane P1 and a second bounding plane P2, both planes P1 and P2 extending substantially parallel to the article plane A. The corrugated core 50 extends between the first bounding plane P1 and the second bounding plane P2. Figure 4 As shown, the orthogonal projection of the corrugated core 50 on the product plane A is included in the orthogonal projection of the at least one planar support 60 on the product plane A. The corrugated core 50 and the at least one planar support 60 together define a plurality of flow channels 51, which extend substantially parallel to the product axis Y. Figures 3 to 5 In the example shown, the corrugated core 50 comprises a sheet 52. For example, the corrugated core 50 is made of paper or cardboard. Advantageously, the corrugated core 50 is glued to at least one planar support 60. According to a specific example, the corrugated core 50 is made of paper or cardboard laminated with thermoplastic. In this specific example, the corrugated core 50 can be welded to at least one planar support 60.

[0065] For example, the flow channel 51 is defined by the corrugated core 50 and the planar support 60, or by the corrugated core 50 and the wrap 70. The flow channel 51 forms a passage for the vapor to flow toward the user's mouth.

[0066] Advantageously, the sheet 52 of the corrugated core 50 extends between two bounding planes P1, P2. The sheet 52 comprises two opposite non-planar surfaces 54 (or corrugated surfaces). For example, each of the non-planar surfaces 54 is characterized by a directrix D ( Figure 4 and Figure 5 ) and a straight generatrix G substantially parallel to the axis Y of the product ( Figure 5 In particular, each non-planar surface 54 is formed by a generatrix G extending from a directrix D. For example, the directrix D corresponds to a sine wave function, a square wave function, a triangle wave function, or a sawtooth wave function. Figures 3 to 5In the example of , the criterion D corresponds to a truncated triangular wave function. "Truncation of triangular wave function" means that the criterion D corresponds to a triangular wave function whose ordinate is limited between a truncated maximum value and a truncated minimum value, the truncated maximum value is less than the corresponding triangular wave function maximum value and the truncated minimum value is less than the corresponding triangular wave function minimum value. In other words, in this example, Figures 3 to 5 As shown, the directrix D corresponds to a trapezoidal wave function. Advantageously, the period of the function of the directrix D is not constant. In particular, the directrix D may present a first portion of a function having a first period and a second portion of a function having a second period, the second period being different from the first period.

[0067] Each non-planar surface 54 of the sheet 52 includes a longitudinal edge 56 extending longitudinally along the axis Y of the article.

[0068] The longitudinal edge 56 of the non-planar surface 54 corresponds to a line or sub-surface of the non-planar surface 54 that extends substantially parallel to the article axis Y. For example, Figure 4 As shown, the longitudinal edge 56 of the first non-planar surface 54 of the sheet 52 extends within a first defined plane P1, and the longitudinal edge 56 of the second non-planar surface 54 of the sheet extends within a second defined plane P2. Figures 3 to 5 According to an example, the longitudinal edges 56 are planar surfaces substantially parallel to the article axis A. According to an example not shown, the longitudinal edges 56 are straight lines substantially parallel to the article axis A, in particular when the directrix D corresponds to a sine wave function, a triangular wave function or a sawtooth wave function. Advantageously, the longitudinal edges 56 are glued or welded to the planar support 60 they face.

[0069] Advantageously, at least one planar support 60 is in contact with the longitudinal edge 56 of the first non-planar surface 54. Figure 3 and Figure 4 In the example shown, the first planar support 60 is in contact with the longitudinal edge 56 of the first non-planar surface 54, and the second planar support is in contact with the longitudinal edge of the second non-planar surface 54. For example, at least one planar support is attached to the wrapping 70, in particular glued or welded to the wrapping 70. For example, at least one planar support 60 is essentially made of paper, paperboard or a film (such as an adhesive film, an anti-fouling film or a moisture-proof film). According to a specific example, at least one planar support 60 is made of paper or paperboard laminated with thermoplastic. In this specific example, the corrugated core 50, in particular the longitudinal edge 56, can be welded to the at least one planar support 60. As shown in FIG. Figure 3 As shown in the example of , the corrugated core 50 and at least one planar support 60 (here two planar support 60) are different parts. At least one planar support 60 can present a flat or ridged surface.

[0070] like Figure 2, Figure 3 and Figure 4 As shown, the wrapper 70 at least wraps the nozzle portion 34. In particular, as Figure 2 As shown, the wrapper 70 wraps both the tobacco portion 32 and the mouthpiece portion 34. For example, the wrapper 70 attaches the tobacco portion 32 and the mouthpiece portion 34 together. In an example not shown, the wrapper 70 includes two separate parts, which are a first part that wraps the tobacco portion 32 and a second part that wraps the mouthpiece portion 34. The first part of the wrapper 70 is not integral with the second part of the wrapper 70. The tobacco portion 32 and the mouthpiece portion 34 are then fixed to each other by other suitable means.

[0071] The wrapper 70 can be made of paper and / or nonwoven fabric and / or aluminum. For example, the wrapper 70 is made of a single layer. In a variant, the wrapper 70 is made of at least two layers. Preferably, the portion of the wrapper 70 that wraps the tobacco portion 32 includes an outer paper layer and an inner aluminum layer. The outer paper layer can extend to wrap the mouthpiece portion 34, and the inner aluminum layer can be shorter so as to only wrap the tobacco portion 32. Alternatively, the wrapper 70 includes an inner paper layer and an outer aluminum layer. In this case, the inner paper layer can be longer than the outer aluminum layer. In a variant, the aluminum layer (whether inner or outer) wraps the entire mouthpiece portion.

[0072] The wrapper 70 can be porous or airtight. In an embodiment, at least a portion of the wrapper 70 can be made of airtight material. The wrapper 70 can include a dedicated ventilation area. The ventilation area can be positioned in the part of the wrapper that wraps the nozzle portion 34. The ventilation area can be formed by an air orifice arranged through the wrapper 70. The air orifice can be further formed through a flat or planar support 60. For example, the air orifice can be formed as a series of perforations, which extend along the direction perpendicular to the product plane A of the consumable product 30 or along the direction parallel to the product plane A and perpendicular to the product axis Y. The air orifice (for example, each diameter or longer dimension is 0.2mm to 0.6mm) can be formed by laser cutting or any other suitable technology. Because the plane side 35 of the nozzle portion 34 is flush with the sidewall 33 of the tobacco portion 32, when both the tobacco portion 32 and the nozzle portion 34 are wrapped by a wrapper 70, the product 30 seems to be one-piece to the touch. This makes the product 30 easier to produce and comfortable to the user to touch.

[0073] A method for manufacturing a flat consumable product 30 will now be described. Initially, the method includes the step of providing a tobacco portion 32. Then, the method includes the step of producing a mouthpiece portion 34 so that the corrugated core is attached to at least one planar support 60. For example, the step of producing the mouthpiece portion 34 includes the sub-step of attaching the corrugated core 50 and at least one planar support 60. The corrugated core 50 is preferably glued or welded to at least one planar support 60. Due to the rigidity imparted by the support 60, the mouthpiece portion 34 can be handled without the risk of deformation. According to a specific example, for reasons of productivity, the mouthpiece portion 34 can be formed by providing an elongated corrugated core element and an elongated support element attached (e.g., glued or welded) together and then cutting into sections corresponding to individual mouthpiece portions 34. "Elongated" means that the size of the elongated corrugated core element and the elongated support element is greater than the size intercepted along the product axis Y of the mouthpiece portion 34 to be produced. In other words, both the elongated corrugated core element and the elongated support element are formed by continuous elongated sheets and then attached together to form an elongated whole. The elongated whole is then cut into the mouthpiece portion 34 at the desired length. According to another example, the corrugated core 50 and at least one planar support member 60 are produced by extrusion. For example, the corrugated core 50 is formed by providing, for example, an initially planar elongated sheet 52, and then by wrinkling the elongated sheet 52 to obtain a corrugated elongated sheet 52. According to another example, the corrugated core 50 is formed by providing an elongated sheet 52 that is already corrugated, in particular by extrusion. Then, the method includes the steps of continuously arranging the tobacco portion 32 and the mouthpiece portion 34 along the product axis Y. Finally, the method includes the steps of attaching the tobacco portion 32 and the mouthpiece portion 34 together. For example, the steps of attaching the tobacco portion 32 and the mouthpiece portion 34 together include wrapping at least the mouthpiece portion 34 with a wrapper 70. In particular, both the tobacco portion 32 and the mouthpiece portion 34 are wrapped by the wrapper 70 .

[0074] Second embodiment of the present invention

[0075] Figure 6 A flat consumable product article 130 according to a second embodiment of the present invention is shown. The flat consumable product article 130 of the second embodiment is similar to the flat consumable product article 30 of the first embodiment, except that the corrugated core 150 and at least one planar support member 160 (here, two planar support members 160) are made in one piece. For example, the corrugated core 150 and the at least one planar support member 160 are formed by a single continuous sheet 152. In particular, the sheet 152 includes at least one end portion 152A corresponding to the at least one planar support member 160 and a corrugated portion 153 corresponding to the corrugated core 150. Figure 6In the example of FIG. 1 , the sheet 152 includes a first end portion 152A corresponding to the first planar support 160, a second end portion 152B corresponding to the second planar support 160, and a corrugated portion 153 arranged between the first end portion 152A and the second end portion 152B and corresponding to the corrugated core 150. Advantageously, as Figure 6 As shown, the opposite lateral ends of the corrugated core 150 are formed as integral parts of the first and second planar support members 160, respectively. Figure 6 As shown, the first end portion 152A and the second end portion 152B are folded relative to the corrugated portion 153 so that each planar support 160 contacts the longitudinal edge 156 of the corresponding non-planar surface 154. This further enhances the deformation resistance of the flat consumable product 130. In addition, since the corrugated core 150 and the at least one planar support 160 are made in one piece, it is easier to wrap the corrugated core 150 and the at least one planar support 160 with the wrap 170.

[0076] The method for manufacturing the flat consumable article 130 according to the second embodiment of the present invention is similar to the above-mentioned method. Advantageously, the step of producing the nozzle portion 34 also includes a sub-step of folding a single continuous sheet 152 before the attachment sub-step, so that at least one planar support 160 is in contact with the longitudinal edge 156 of the corresponding non-planar surface 154. For example, before the folding sub-step, the corrugated core 150 and the at least one planar support 160 are produced by extrusion. Advantageously, the corrugated core 150 and the at least one planar support 160 are extruded together at the same time. According to a specific example, for reasons of productivity, the nozzle portion 34 can be formed by providing a long continuous sheet 152, which is cut into sections corresponding to the individual nozzle portions 34 after the folding and attachment sub-steps.

[0077] Third embodiment of the present invention

[0078] Figure 7A flat consumable article 230 according to a third embodiment of the present invention is shown. The flat consumable article 230 of the third embodiment is similar to the flat consumable article 130 of the second embodiment, except that the longitudinal edge 256 is formed as an integral part of at least one planar support 260. In other words, in the third embodiment, the non-planar surface 254 and at least a portion of the longitudinal edge 256 are virtual. In particular, there is no physical boundary between the longitudinal edge 256 and the portion of the non-planar surface 254 extending opposite to the longitudinal edge. Therefore, the corrugated core 250 and the at least one planar support 260 are attached because they are made in one piece and because the longitudinal edge 256 is formed as an integral part of at least one planar support 260. In the third embodiment, "the corrugated core 250 includes a sheet 252" means that the corrugated core 250 includes a portion of the sheet 52, 152 similar to the first and second embodiments, except that the sheet 252 is made integrally with at least one support 260 at the level of each longitudinal edge 256. This further enhances the deformation resistance of the flat consumable article 230. Furthermore, wrapping the corrugated core 250 and the at least one planar support 260 with the wrap 270 is made easier due to the presence of a plurality of continuous joints between the corrugated core 250 and the at least one planar support 260 .

[0079] The method for manufacturing a flat consumable product 130 according to the second embodiment of the present invention is similar to the method of the first embodiment, except that the step of producing the nozzle portion 34 includes a sub-step of extruding the corrugated core 250 and at least one planar support 260 together to form the nozzle portion 34. In other words, the corrugated core 250 and at least one planar support 260 are simultaneously formed by extruding one piece. That is, the nozzle portion 34 is formed by extruding the corrugated core 250 and at least one planar support 260 together at the same time. Advantageously, in this third embodiment, compared with the first and second embodiments, it is not necessary to attach the corrugated core 250 to at least one planar support 260. According to a specific example, for reasons of productivity, the nozzle portion 34 can be formed by extruding a continuous elongated single piece (in the third embodiment, the single piece is made of an elongated core element and an elongated support element), and then the single piece is cut into sections corresponding to the individual nozzle portions 34.

Claims

1. A flat consumable product (30; 130; 230) for an aerosol generating device (10), the flat consumable product (30; 130; 230) extending along a product axis (Y) and along a product plane (A) parallel to the product axis (Y), the flat consumable product (30; 130; 230) comprising a tobacco portion (32) and a mouthpiece portion (34) arranged along the product axis (Y), The nozzle portion (34) comprises a corrugated core (50; 150; 250) and at least one planar support (60; 160; 260) supporting the corrugated core (50; 150; 250), the corrugated core (50; 150; 250) being attached to the at least one planar support (60; 160; 260).

2. The flat consumable product (30; 130; 230) according to claim 1, wherein: The corrugated core (50; 150; 250) defines, together with the at least one planar support (60; 160; 260), a plurality of flow channels (51) extending substantially parallel to the article axis (Y).

3. The flat consumable product (30; 130; 230) according to claim 1 or 2, wherein: The corrugated core (50; 150; 250) comprises a sheet (52; 152; 252), wherein the sheet (52; 152; 252) comprises two opposite non-planar surfaces (54), wherein the non-planar surfaces (54) are formed by a generatrix (G), which is a straight line substantially parallel to the axis (Y) of the article, and which extends from a directrix (D) corresponding to a non-zero periodic function.

4. The flat consumable product (30; 130; 230) according to claim 3, wherein: Each non-planar surface (54) of the sheet (52; 152; 252) includes a longitudinal edge (56; 156; 256) extending longitudinally along the axis (Y) of the article, and at least one planar support member (60; 160; 260) is in contact with the longitudinal edge (56; 156; 256) of the corresponding non-planar surface (54).

5. The flat consumable product (30; 130; 230) according to claim 3 or 4, wherein: The orthogonal projection of the corrugated core (50; 150; 250) on the plane (A) of the article is included within the orthogonal projection of the at least one planar support (60; 160; 260) on the plane (A) of the article.

6. A flat consumable product article (30; 130) according to any one of the preceding claims, wherein: The corrugated core (50; 150) is glued or welded to the at least one planar support (60; 160).

7. A flat consumable product article (30; 130; 230) according to any one of the preceding claims, wherein: The at least one planar support (60; 160; 260) is made of paper, cardboard or film.

8. The flat consumable product (30; 130; 230) according to any one of the preceding claims, further comprising a wrapper (70; 170; 270) which wraps at least the nozzle portion (34).

9. The flat consumable product (30; 130; 230) according to claim 8, wherein: The at least one planar support (60; 160; 260) is attached to the wrap (70; 170; 270).

10. The flat consumable article (30; 130; 230) according to any one of the preceding claims, comprising at least two planar supports (60; 160; 260), the at least two planar supports being configured to support the corrugated core (50; 150; 250).

11. The flat consumable product (30; 130; 230) according to claim 10 in combination with claim 4, wherein: Each planar support (60; 160; 260) contacts a corresponding longitudinal edge (56; 156; 256) of the non-planar surface (54).

12. A method for manufacturing a flat consumable article (30; 130; 230) according to any one of the preceding claims, the method comprising the steps of: - providing said tobacco portion (32); - producing the nozzle part (34) such that the corrugated core (50; 150; 250) is attached to the at least one planar support (60; 160; 260); - arranging the tobacco portion (32) and the mouthpiece portion (34) along the article axis (Y); and - Attaching the tobacco portion (32) and the mouthpiece portion (34) together.

13. The method according to claim 12, wherein: The step of producing the nozzle portion (34) comprises attaching the corrugated core (50; 150) and the at least one planar support (60; 160) to form the nozzle portion (34).

14. The method according to claim 12, wherein: The step of producing the nozzle portion (34) includes forming the nozzle portion (34) by simultaneously extruding the corrugated core (250) and the at least one planar support member (260) together.

15. The method according to any one of claims 12 to 14, wherein: The step of attaching the tobacco portion (32) and the mouthpiece portion (34) together includes wrapping at least the mouthpiece portion (34) with a wrapper (70; 170; 270).

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