Aerosol products

Abstract

An aerosol product article (1, 2, 3, 4, 5) for use in an aerosol generating device (102) comprises a substantially flat aerosol-generating substrate (14), at least one air flow channel (16) extending along the substantially flat aerosol-generating substrate (14), and a packaging member (22) surrounding the substantially flat aerosol-generating substrate (14) and the at least one air flow channel (16).

Description

[Technical field]

[0001] The present disclosure relates generally to aerosol product articles, and more particularly to aerosol product articles for use in an aerosol generating device that heats the aerosol product article to generate an aerosol for inhalation by a user. The present disclosure is particularly applicable to aerosol product articles for use in portable (handheld) aerosol generating devices. [Background technology]

[0002] Risk reduction or risk modification devices (also known as aerosol generating devices or vapour generating devices) have grown rapidly in popularity and use in recent years as an alternative to the use of traditional tobacco products. A variety of devices and systems are available that heat or warm an aerosol generating material to generate an aerosol for inhalation by the user.

[0003] A commonly available risk-reducing or risk-modifying device is the heated substrate aerosol-generating device or so-called heated non-combustion device. This type of device generates an aerosol or vapour by heating an aerosol-generating substrate, typically to a temperature in the range 150° C. to 300° C. Heating the aerosol-generating substrate to a temperature in this range, without burning the aerosol-generating substrate, typically generates vapour which cools and condenses to form an aerosol for inhalation by a user of the device.

[0004] Currently available aerosol-generating devices can use one of many different approaches to supply heat to the aerosol-generating substrate, including resistive heating, which utilizes a resistive heating element, and inductive heating, which utilizes an induction coil and an inductively heatable susceptor. Summary of the Invention [Problem to be solved by the invention]

[0005] Regardless of which approach is used to heat the aerosol-generating substrate, the characteristics of the aerosol generated by the aerosol generating device will depend on many factors, including the structure of the aerosol product article used in the aerosol generating device. It is therefore desirable to provide an aerosol product article that allows for optimizing the characteristics of the aerosol generated during use of the article, while at the same time being easy to use in combination with the aerosol generating device. [Means for solving the problem]

[0006] According to a first aspect of the present disclosure there is provided an aerosol product article for use in an aerosol generating device, the aerosol product article comprising: a substantially flat aerosol-generating substrate; at least one air flow channel extending along a substantially flat aerosol-generating substrate; a packaging member enclosing a substantially flat aerosol-generating substrate and at least one air flow channel; Includes.

[0007] The aerosol production article is for use in an aerosol generating device that heats an aerosol-generating substrate, without burning the aerosol-generating substrate, to volatilize at least one component of the aerosol-generating substrate, thereby producing a heated vapor that cools and condenses to form an aerosol that is inhaled by a user of the aerosol generating device. The aerosol generating device is a handheld, portable device.

[0008] Generally, a vapor is a substance that is in the gas phase below its critical temperature, meaning that the vapor can be condensed into a liquid by increasing the pressure without decreasing the temperature, whereas an aerosol is a suspension of fine solid particles or liquid droplets in air or another gas. However, it should be noted that, in this specification, the terms "aerosol" and "vapor" may be used interchangeably, particularly with respect to the form of inhalable medium that is produced for inhalation by a user.

[0009] By surrounding at least one air flow channel with a packaging member, the vapor and / or aerosol generated during use of the aerosol product article in the aerosol generating device flows inside the article along at least one air flow channel before being inhaled by the user. This may bring about many advantages, since the formation of condensation material on the inner surface of the aerosol generating device is substantially eliminated or at least minimized. For example, it may help to reduce the accumulation of residues in the aerosol generating device, and thus the number of cleaning and maintenance operations that the user of the device must perform. It may also help to ensure that the maximum amount of vapor and / or aerosol possible is delivered to the user, and that the delivered vapor and / or aerosol has optimal properties.

[0010] The aerosol product article may include a distal end, a mouth end, and a longitudinal axis that may extend between the mouth end and the distal end. The mouth end is located at an end of the aerosol product article opposite the distal end. More specifically, the mouth end is located downstream of the distal end with respect to an airflow direction through the aerosol product article during use of the aerosol product article, for example, in an aerosol generating device. The at least one airflow channel may extend in a first direction that may be substantially parallel to the longitudinal axis. Because air flows along the at least one airflow channel from the distal end to the mouth end during use of the aerosol product article, it is ensured that a maximum amount of volatile components is released from the heated aerosol-generating substrate into the air as the air flows along the airflow channel. This, in turn, ensures that a maximum amount of vapor and / or aerosol possible is generated and delivered to a user during use of the aerosol product article.

[0011] The at least one air flow channel may include at least one groove. The at least one groove may be formed in a surface of the substantially flat aerosol-generating substrate. The at least one groove may be readily formed during manufacture of the aerosol product, for example by pressing the surface of the substantially flat aerosol-generating substrate.

[0012] The aerosol-generating substrate may include a plurality of said grooves, which may be arranged, for example, side-by-side to form a grooved surface. The provision of a plurality of grooves may allow for an increased amount of vapour and / or aerosol to be generated and delivered to a user during use of the aerosol product article in an aerosol generating device.

[0013] The at least one airflow channel may include at least one air flow passage formed internally within the aerosol-generating substrate. The air flow passage may be readily formed during manufacture of the aerosol product article. Because the air flow passage is completely surrounded by the aerosol-generating substrate, a maximum amount of volatile components may also be released into the air from the heated aerosol-generating substrate as air flows along the air flow passage, thus ensuring that a maximum amount of vapour and / or aerosol possible is generated and delivered to a user during use of the aerosol product article in an aerosol generating device.

[0014] In one example, a single air flow passage may be formed internally within the aerosol-generating substrate, for example at a substantially central location within a cross-section of the aerosol-generating substrate. In another example, multiple air flow passages may be formed internally within the aerosol-generating substrate, for example arranged side-by-side in a second direction perpendicular to the first direction (longitudinal direction). By providing multiple air flow passages, increased amounts of vapour and / or aerosol may be generated and delivered to a user during use of the aerosol product article in the aerosol generating device.

[0015] The aerosol-generating substrate may comprise a plurality of aerosol-generating strips. The aerosol-generating strips may, for example, extend in a first direction substantially parallel to the longitudinal axis and be intermittently arranged in a second direction, which may be substantially perpendicular to the first direction. The aerosol product article may comprise a plurality of said airflow channels, and one of said airflow channels may be formed between each pair of intermittently arranged aerosol-generating strips. Each airflow channel is in fluid communication with the pair of intermittently arranged aerosol-generating strips that form a particular airflow channel. The vapour or aerosol generated during heating of the aerosol-generating strips thus flows into the adjacent airflow channel, ensuring that the generated vapour or aerosol is entrained in the air flowing through the airflow channel and can be delivered to the user during inhalation when the aerosol product article is heated during use in the aerosol generating device. The aerosol-generating strip has at least one side extending in the first direction that is directly exposed to and in fluid communication with the adjacent airflow channel. This arrangement allows a large surface area of ​​each aerosol-generating strip to be directly exposed to at least one adjacent airflow channel, thereby increasing the delivery of vapour or aerosol through the airflow channels for inhalation by a user. In addition, this arrangement allows the airflow channels to be easily formed during manufacture of the aerosol product article, for example, by spacing the aerosol-generating strips in the second direction to form the airflow channels. The aerosol product article can therefore be efficiently manufactured and relatively easily mass produced.

[0016] The aerosol-generating strips may all comprise the same aerosol-generating material. Alternatively, at least some of the aerosol-generating strips may comprise different aerosol-generating materials from each other. For example, at least one aerosol-generating strip may comprise a first aerosol-generating material and at least another of the aerosol-generating strips may comprise a second aerosol-generating material different from the first aerosol-generating material. One or more aerosol-generating strips may comprise a flavoring. Thus, aerosols with improved properties and / or consumer appeal may be generated during use of the aerosol product article in the aerosol generating device. The use of aerosol-generating strips provides the further advantage that different regions of the aerosol-generating substrate may be heated in different ways to generate a desired aerosol during use of the aerosol product article in the aerosol generating device, for example by heating different aerosol-generating strips to different temperatures and / or at different heating rates. This is particularly advantageous in embodiments in which the aerosol-generating strips comprise different materials and / or one or more (but not all) aerosol-generating strips comprise a fragrance, because vapors or aerosols having different properties (e.g., different temperatures, densities, compositions, active ingredients, fragrances, etc.) may be emitted into different airflow channels. When these vapors or aerosols are mixed, for example, in the portion of the aerosol product downstream of the aerosol-generating substrate formed by the aerosol-generating strip, the properties of the resulting vapor or aerosol may be improved, and an aerosol with improved consumer appeal may be produced.

[0017] The substantially flat aerosol-generating substrate may have a flat rectangular shape that may have a pair of major surfaces. The packaging member may include a pair of rectangular sheets that may be attached to the pair of major surfaces, respectively. The aerosol product article may have a pleasing aesthetic appearance due to the flat rectangular shape of the aerosol-generating substrate. The aerosol-generating substrate may be easily covered by the packaging member, ensuring that the user does not directly touch the aerosol-generating substrate during handling of the aerosol product article. The flat rectangular shape may also facilitate packaging and storage of multiple aerosol product articles.

[0018] In some embodiments where the aerosol-generating substrate comprises a plurality of aerosol-generating strips, the upper and lower surfaces of the aerosol-generating strips may define major surfaces of the aerosol-generating substrate. The packaging member may be adhered (e.g., by a pharma-ceutically acceptable adhesive) in contact with the upper and lower surfaces of the aerosol-generating strips. Thus, the aerosol-generating strips are secured to the packaging member in a relative position to one another to define airflow channels between the intermittently arranged (i.e., spaced) aerosol-generating strips.

[0019] The aerosol product article may include a support member that may form the mouth end portion of the article. The support member may have a tubular shape, for example a rectangular tubular shape, to receive the downstream end of the aerosol-generating substrate and at least one airflow channel. The support member may be self-supporting and may include, for example, cardboard or plastic material. The support member may advantageously deliver the vapor and / or aerosol generated during use of the article directly to the mouth of the user. The support member allows the heated vapor generated during use of the aerosol product article to cool and condense to form an aerosol with optimal characteristics for inhalation by the user.

[0020] The packaging member may comprise a substantially non-conductive and non-magnetically permeable material, such as a paper wrapper, which may facilitate the manufacture and handling of the aerosol product and may increase the efficiency of aerosol generation.

[0021] The packaging member may have a porous inner surface that may face towards the aerosol generating substrate for absorbing condensation. The porous inner surface may help to substantially eliminate or at least minimise the formation of condensation material on the inner surface of the aerosol generating device. The packaging member may have an anti-stick outer surface that may face away from the aerosol generating substrate. For example, the packaging member may include an anti-stick coating on the outer surface. The anti-stick outer surface may help to ensure that the packaging member does not stick to the surface of the aerosol generating device when heated. The porous inner surface and the anti-stick outer surface together may reduce the build-up of residues within the aerosol generating device and therefore reduce the number of cleaning and maintenance tasks that must be performed by users of the device.

[0022] The aerosol-generating substrate may comprise a non-liquid aerosol-generating material, such as any type of solid or semi-solid material. Exemplary types of aerosol-generating solids include powders, granules, pellets, flakes, strands, particles, gels, strips, loose-leaf, cut-leaf, cut-filler, porous materials, foamed materials, or sheets. The aerosol-generating substrate may comprise a plant-derived material, in particular tobacco. It may advantageously comprise, for example, reconstituted tobacco, which comprises tobacco and any one or more of cellulose fibers, tobacco stem fibers, and inorganic fillers, such as CaCO3.

[0023] As a result, aerosol-generating devices intended for use with the aerosol-producing articles may be referred to as "heated tobacco devices," "heated non-combustible tobacco devices," "devices for vaporizing tobacco products," etc., and are understood to be devices suitable for achieving these effects. The features disclosed herein are equally applicable to devices designed to vaporize any aerosol-generating substrate.

[0024] The aerosol-forming substrate may include an aerosol-forming agent. Examples of aerosol-forming agents include polyhydric alcohols, such as glycerin or propylene glycol, and mixtures thereof. Typically, the aerosol-forming substrate may include an aerosol-forming agent content of about 5% to about 50% by dry weight. In some embodiments, the aerosol-forming substrate may include an aerosol-forming agent content of about 10% to about 20% by dry weight, and in some cases about 15% by dry weight.

[0025] The aerosol product article may be configured for use in an electrically operated aerosol generating device that includes a heater. The heater may be a resistive heater or an inductive heater. Upon heating, the aerosol-generating substrate may release volatile compounds. The volatile compounds may include flavor compounds such as nicotine or tobacco flavors. [Brief description of the drawings]

[0026] [Figure 1] FIG. 1 is a schematic longitudinal cross-sectional view of a first example of an aerosol product. [Diagram 2] FIG. 2 is a schematic cross-sectional view taken along line AA in FIG. [Diagram 3] FIG. 3 is a schematic cross-sectional view similar to FIG. 2 of a second example of an aerosol product. [Figure 4] FIG. 11 is a schematic longitudinal cross-sectional view of a third example of an aerosol product. [Diagram 5] FIG. 11 is a schematic longitudinal sectional view of a fourth example of an aerosol product. [Figure 6] FIG. 6 is a schematic cross-sectional view taken along line BB in FIG. 5. [Figure 7] FIG. 11 is a schematic longitudinal sectional view of a fifth example of an aerosol product. [Figure 8] FIG. 8 is a schematic cross-sectional view taken along line CC in FIG. 7. [Figure 9] 1 is a schematic cross-sectional view of an aerosol generation system including an aerosol generating device and an aerosol product according to the present disclosure. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0027] Several embodiments of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0028] 1 and 2, a first example of an aerosol product article 1 for use in an electrically operated aerosol generation device 102 is shown, an example of which is described later in this specification with reference to FIG. 9. The aerosol product article 1 is substantially flat and has a distal end 10 and an oral end 12 (or proximal end) at an opposite end of the aerosol product article 1. The oral end 12 is downstream of the distal end 10 with respect to the direction of airflow through the aerosol product article 1, as shown by the three arrows in FIG. 1. A longitudinal axis extends between the distal end 10 and the oral end 12 and defines the longitudinal direction of the aerosol product article 1.

[0029] The aerosol product article 1 comprises a substantially flat aerosol-generating substrate 14. The aerosol-generating substrate 14 comprises a bulk or mass of aerosol-generating material and has a flat rectangular shape having a pair of oppositely disposed major surfaces 14a, 14b. The aerosol product article 1 is a consumable or disposable item in which the aerosol-generating substrate 14 may comprise tobacco or tobacco material.

[0030] The aerosol product 1 includes a plurality of air flow channels, which in the illustrated example include a plurality of grooves 18 formed in the major surface 14a of the aerosol-generating substrate 14. The grooves 18 are arranged side-by-side and parallel to one another, and the grooves 18 extend longitudinally between the distal end 10 and the oral end 12 substantially parallel to the longitudinal axis. Together, the grooves 18 form a grooved surface 20. The grooves 18 may be formed in any suitable manner, for example by pressing the major surface 14a of the aerosol-generating substrate 14 with a suitably shaped pressing tool. Although three grooves 18 are shown in the example of Figures 1 and 2, it will be understood that any suitable number of grooves 18 may be provided depending, for example, on the desired tensile resistance of the aerosol product 1. It is also noted that the grooves 18 may have any suitable cross-sectional shape, including, but not limited to, a square, rectangular, trapezoidal, or semicircular shape as shown in Figure 2.

[0031] The aerosol product article 1 further comprises a wrapping member 22 which surrounds the aerosol-generating substrate 14 and the groove 18. The aerosol-generating substrate 14 and the groove 18 are thus completely surrounded by the wrapping member 22 which may comprise, for example, tobacco paper or a similar material. The wrapping member 22 comprises a pair of rectangular sheets 24, 26 attached respectively to major surfaces 14a, 14b of the aerosol-generating substrate 14. The rectangular sheets 24, 26 are typically formed by a single sheet of material which is wrapped around the aerosol-generating substrate 14 and which may have overlapping edges which are bonded together to secure the wrapping member 22 in place around the aerosol-generating substrate 14 and the groove 18.

[0032] In an illustrative and non-limiting example, the aerosol-generating substrate 14 may have a length (in the longitudinal direction of the aerosol product article 1) of about 18.0 mm, a width of about 11.8 mm, and a thickness (or depth) of about 1.2 mm. The aerosol-generating substrate 14 may be spaced inward from the distal end 10 of the aerosol product article 1 by a small distance, for example about 3.0 mm, as shown in FIG. 1. The aerosol product article 1 may have a width of about 12.0 mm and a thickness (or depth) of about 1.4 mm to accommodate the aerosol-generating substrate 14 within the packaging member 22. The aerosol product article 1 may have any suitable length between the distal end 10 and the mouth end 12 by varying the length of the portion of the packaging member 22 that extends between the downstream end of the aerosol-generating substrate 14 and the mouth end 12. During use of the aerosol product 1 in the aerosol generating device 102, as the vapor flows through this portion of the packaging member 22, the vapor can cool and condense to form an aerosol that is inhaled by the user. Thus, the length of the portion of the packaging member 22 that extends between the downstream end of the aerosol-generating substrate 14 and the mouth end 12 of the aerosol product 1 can be selected at the time of manufacture to provide an aerosol having desired characteristics.

[0033] In some embodiments, the packaging member 22 includes a porous inner surface 22a that faces towards the aerosol-generating substrate 14 and that can absorb condensation that may form during the heating process. Alternatively or additionally, the packaging member 22 may include an anti-stick outer surface 22b that faces away from the aerosol-generating substrate 14 to reduce the risk of the packaging member 22 sticking to a surface of the aerosol-generating device 102 when heated. The anti-stick outer surface 22b may include an anti-stick coating on the outer surface 22b of the packaging member 22.

[0034] Referring now to Figure 3, there is shown a second example of an aerosol product 2. Aerosol product 2 is similar to aerosol product 1 described above with reference to Figures 1 and 2, and corresponding features are identified using the same reference numbers.

[0035] The aerosol product article 2 includes a plurality of air flow channels 16 in the form of air passages 30 formed internally within the aerosol-generating substrate 14. Similar to the grooves 18, the air passages 30 extend longitudinally between the distal end 10 and the oral end 12 substantially parallel to the longitudinal axis. The air passages 30 are positioned side-by-side at approximately the midpoint between the major faces 14a, 14b of the aerosol-generating substrate 14, although different locations may be adopted, provided that each air passage 30 is completely surrounded by the aerosol-generating material forming the aerosol-generating substrate 14. It should also be noted that the air passages 30 may have a variety of cross-sectional shapes, including, but not limited to, a square, rectangular, circular, elliptical or triangular shape as shown in FIG. 3.

[0036] Referring now to Figure 4, there is shown a third example of an aerosol product 3. The aerosol product 3 is similar to the aerosol product 1 described above with reference to Figures 1 and 2, and corresponding features are identified using the same reference numbers.

[0037] The aerosol product article 3 includes a support member 28 that is disposed at the oral end 12 of the aerosol product article 3 to form an oral end portion 34 that may be held by a user's lips during use of the aerosol product article 3 in the aerosol generating device 102. The support member 28 typically comprises a self-supporting material, such as cardboard or a plastic material, and has a tubular form with a rectangular cross section to receive the downstream end of the aerosol-generating substrate 14 and the groove 18 formed in the surface 14a. The packaging member 22 also encloses the support member 28.

[0038] 5 and 6, there is shown a fourth example of an aerosol product 4. The aerosol product 4 is similar to the aerosol product 2 described above with reference to FIG. 3, and corresponding features are identified using the same reference numerals.

[0039] The aerosol product article 4 includes an air flow channel 16 in the form of a single air passage 30 formed internally within the aerosol-generating substrate 14. The air passage 30 extends longitudinally between the distal end 10 and the oral end 12 substantially parallel to the longitudinal axis. The air passage 30 is centrally located within and surrounded on all sides by the aerosol-generating substrate 14, ensuring that during use of the aerosol product article 4 in the aerosol generating device 102, volatile components may be released from the aerosol-generating substrate 14 and entrained in the air flowing through the air passage 30.

[0040] The aerosol product article 4 is shown without the support member 28 at the oral end 12. However, a support member 28 may also be provided at the oral end 12 of the aerosol product article 4, as described above in connection with the aerosol product article 3 of FIG.

[0041] 7 and 8, there is shown a fifth example of an aerosol product 5. Aerosol product 5 is similar to aerosol products 1, 2, 3 and 4 described above with reference to Figures 1 to 6, and corresponding features are identified using the same reference numerals.

[0042] Within the aerosol product article 5, the aerosol-generating substrate 14 includes a plurality of aerosol-generating strips 32 extending between the distal end 10 and the oral end 12 in a first direction substantially parallel to the longitudinal direction of the aerosol product article 5. The aerosol-generating strips 32 are laterally spaced apart, in other words arranged intermittently and spaced apart in a second direction perpendicular to the first direction. Due to this intermittent arrangement (or spacing) of the aerosol-generating strips 32, an airflow channel 16 is formed with an airflow channel 16 formed between each adjacent pair of the aerosol-generating strips 32. Each airflow channel 16 is directly exposed to or in fluid communication with the adjacent aerosol-generating strip 32 that forms the airflow channel 16, which means that when the aerosol product article 5 is used in the aerosol generating device 102 as described below, vapour or aerosol generated during use of the aerosol product article 5 can flow into the airflow channel 16, be entrained in the airflow through the airflow channel 16 and delivered to the user during inhalation.

[0043] Each of the aerosol-generating strips 32 has an in-use upper and lower surface, which together define the major surfaces 14a, 14b of each of the aerosol-generating substrates 14. The packaging member 22 may be attached to the upper and lower surfaces of the aerosol-generating strips 32 by, for example, a pharma- ceutically acceptable adhesive. In this manner, the aerosol-generating strips 32 are secured to the packaging member 22 and in fixed positions relative to one another to define airflow channels 16 between the intermittently arranged (i.e., spaced) aerosol-generating strips 32.

[0044] In the illustrated example, the aerosol-generating strips 32 all include the same aerosol-generating material. However, in other examples, at least some of the aerosol-generating strips 32 may include different aerosol-generating materials. For example, at least one aerosol-generating strip 32 may include a first aerosol-generating material and at least another aerosol-generating strip 32 may include a second aerosol-generating material that is different from the first aerosol-generating material. In both examples, at least one aerosol-generating strip 32 may include a flavoring. By providing aerosol-generating strips 32 that include different aerosol-generating materials and / or aerosol-generating strips 32 that include a flavoring, an aerosol having improved consumer appeal may be generated during use of the aerosol product article 5.

[0045] The aerosol product article 5 is shown without the support member 28 at the oral end 12. However, a support member 28 may also be provided at the oral end 12 of the aerosol product article 5, as described above in relation to the aerosol product article 3 of FIG.

[0046] Referring now to Figure 9, there is shown an aerosol generation system 100 including an aerosol generation device 102 and a first example of the aerosol product article 1 described above with reference to Figures 1 and 2. It will be appreciated that the aerosol generation device 102 may be used in combination with alternative aerosol product articles according to the present disclosure, such as the second, third, fourth or fifth examples of the aerosol product articles 2, 3, 4, 5 described above with reference to Figures 3-8.

[0047] The aerosol generating device 102 includes a receiving chamber 106 and a heater 104 disposed within a device body 108 for providing heat to the receiving chamber 106. The heater 104 can be a resistive heater or an inductive heater including an electromagnetic field generator including a susceptor and an induction coil.

[0048] In use, a user inserts the aerosol product item 1 into the receiving chamber 106. The aerosol generating device 102 may include a cover 110 and a pivot 112 that allows the cover 110 to move between a closed position shown in Figure 9 and an open position (not shown). As will be understood by one of ordinary skill in the art, a user must pivot the cover 110 to the open position to allow insertion of the aerosol product item 1 into the receiving chamber 106 and then pivot the cover back to the closed position shown in Figure 9 to hold the aerosol product item 1 in place within the receiving chamber 106.

[0049] The aerosol generating device 102 includes a power source 114, e.g., a rechargeable battery, and a controller 116, both of which are connected to the heater 104. The heater 104 may be activated manually, for example, via a user interface, such as a button, on the aerosol generating device 102, or automatically in response to a user drawing on the mouthpiece 118 of the aerosol generating device 102. The aerosol generating device 102 includes one or more air inlets 120 that allow air to flow into the aerosol product article 1 and through grooves 18 formed in the surface of the aerosol generating substrate 14. The direction of air flow is indicated by the arrows in FIG.

[0050] With the aerosol product 1 placed in the receiving chamber 106, power is applied from the power source 114 to the heater 104 (either by manual or automatic activation of the heater 104 as described above), which heats the aerosol-generating substrate 14 without combustion, thereby liberating one or more volatile components. The volatile components are entrained in air flowing through the channels 18, thereby forming a vapor. As the vapor flows through the channels 18, it cools and condenses to form an aerosol, which is inhaled by the user through the mouthpiece 118 of the aerosol-generating device 102.

[0051] When the aerosol generating substrate 14 becomes depleted and no longer emits sufficient volatile components to generate an aerosol of acceptable quality, the aerosol product item 1 can be removed from the receiving chamber 106 after the cover 110 is pivoted to an open position and a replacement aerosol product item 1 can be inserted in its place.

[0052] When the aerosol generating device 102 is used in combination with an aerosol product having a support member 28, such as the third example of aerosol product 3 described above with reference to Figure 4, the support member 28 can protrude from the open end 106a of the receiving chamber 106, thereby enabling the user's lips to hold the mouth end portion 34 of the aerosol product 3 formed by the support member 28.

[0053] Although exemplary embodiments have been described in the preceding paragraphs, it should be understood that various modifications to these embodiments may be made without departing from the scope of the appended claims, and thus, the breadth and scope of the claims should not be limited to the above-described exemplary embodiments.

[0054] All possible combinations of the features described above in any possible variations are encompassed by this disclosure unless otherwise indicated herein or otherwise contradicted by context.

[0055] Unless the context otherwise requires, throughout this specification and the claims, the words "comprise", "including", and the like are intended to be construed in their inclusive sense, i.e., "including but not limited to," rather than in their exclusive or exhaustive sense.

Claims

1. An aerosol product (1, 2, 3, 4, 5) for use in an aerosol generating device (102), comprising: a substantially flat aerosol-generating substrate (14); at least one air flow channel (16) extending along said substantially flat aerosol-generating substrate (14); a packaging member (22) surrounding the substantially flat aerosol-generating substrate (14) and the at least one air flow channel (16); An aerosol product comprising (1, 2, 3, 4, 5).

2. 2. The aerosol product article of claim 1, comprising a distal end (10), an oral end (12) and a longitudinal axis extending between the oral end (12) and the distal end (10), and wherein the at least one air flow channel (16) extends in a first direction substantially parallel to the longitudinal axis.

3. 2. The aerosol product article of claim 1, wherein the at least one air flow channel (16) comprises at least one groove (18) formed in a surface (14a) of the substantially flat aerosol-generating substrate (14).

4. 4. The aerosol product article of claim 3, wherein the aerosol-generating substrate (14) includes a plurality of the grooves (18) arranged side-by-side to form a grooved surface (20).

5. 2. The aerosol product article of claim 1, wherein the at least one air flow channel (16) comprises at least one air passage (30) formed internally within the aerosol-generating substrate (14).

6. The aerosol-generating substrate (14) includes a plurality of aerosol-generating strips (32) extending in a first direction and intermittently arranged in a second direction perpendicular to the first direction; 2. The aerosol product article of claim 1, wherein the aerosol product article includes a plurality of the air flow channels (16), and one of the air flow channels (16) is formed between each pair of the intermittently arranged aerosol generating strips (32) and is in fluid communication with the pair of the intermittently arranged aerosol generating strips (32).

7. 7. The aerosol product article of claim 6, wherein the aerosol-forming strips (32) all comprise the same aerosol-forming material.

8. 7. The aerosol product article of claim 6, wherein at least one of the aerosol-generating strips (32) comprises a first aerosol-generating material, and at least one of the aerosol-generating strips (32) comprises a second aerosol-generating material different from the first aerosol-generating material.

9. 7. The aerosol product article of claim 6, wherein at least one of the aerosol-generating strips (32) includes a flavoring.

10. 10. The aerosol product article of any one of claims 1 to 9, wherein the substantially flat aerosol-generating substrate (14) has a flat rectangular shape having a pair of major surfaces (14a, 14b), and the packaging member (22) comprises a pair of rectangular sheets (24, 26) respectively attached to the pair of major surfaces (14a, 14b).

11. The aerosol product article of any one of claims 1 to 9, comprising a support member (28) forming a mouth end portion (34) of the aerosol product article, and the support member (28) having a tubular configuration for receiving the downstream end of the aerosol-generating substrate (14) and the at least one air flow channel (16).

12. The aerosol product article according to any one of claims 1 to 9, wherein the packaging member (22) has a perforated inner surface (22a) facing towards the aerosol-generating substrate (14) for absorbing condensation, and an anti-stick outer surface (22b) facing away from the aerosol-generating substrate (14).

13. 13. The aerosol product article of claim 12, wherein the packaging member (22) includes an anti-stick coating on the anti-stick outer surface (22b).

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