Flat consumable article for an aerosol generating device, including a support structure

Abstract

The present invention relates to a flat consumable article (12) for an aerosol generating device, comprising: a tobacco substrate (25) extending along an article axis and defining at least a first pair of opposing side surfaces extending along the article axis; and a support structure (26) including an outlet portion disposed contiguous with the tobacco substrate (25) along the article axis, and a substrate portion extending from the outlet portion along the article axis and configured to engage with the first pair of opposing side surfaces to hold the tobacco substrate together with the support structure (26). The substrate portion includes a pair of legs configured to extend along at least a portion of the corresponding side surfaces.

Description

[Technical field]

[0001] The present invention relates to a flat consumable article for an aerosol generating device, comprising a support structure.

[0002] In particular, the flat consumable article according to the present invention is adapted to operate with an aerosol-generating device, also known as a heated non-burning device or HNB device, such type of aerosol-generating device being adapted to heat, rather than combust, an aerosol-generating substrate contained within the article. [Background technology]

[0003] The popularity and use of risk reduction or risk modification devices (also known as vaporizers or aerosol generating devices) has grown rapidly in recent years as aids to assist habitual smokers wishing to quit smoking traditional tobacco products such as cigarettes, cigars, cigarillos, and rolling tobacco. A variety of devices and systems are available that heat or warm a vaporizable material, as opposed to burning tobacco in traditional tobacco products.

[0004] A commonly available risk reduction or risk modification device is a heat-not-burn device, also known as a substrate heated aerosol generator or HNB device. This type of device generates an aerosol or vapor by heating an aerosol-generating substrate, typically containing moist tobacco or other suitable vaporizable material, to a temperature typically ranging from 150°C to 350°C. By heating, rather than burning or combusting, the aerosol-generating substrate, an aerosol is released that contains the ingredients desired by the user, but does not contain the toxic and carcinogenic by-products of combustion and burning. Furthermore, the aerosol generated by heating tobacco or other vaporizable material typically does not contain the burnt or bitter taste resulting from combustion and burning, which can be unpleasant to the user. Thus, the substrate does not require sugars and other additives that are typically added to such materials to make the smoke and / or vapor more palatable to the user.

[0005] Some HNB devices can be adapted to work with consumable articles of reduced dimensions. Such articles can, for example, have a flat plate shape and form a roughly rectangular parallelepiped shape with a thickness of 1 or 2 mm. The short and long dimensions of the consumable articles can be 10-30 mm. Such shapes and dimensions make these consumable articles more efficient in heat transfer for steam generation compared to rod-type forms.

[0006] It is therefore apparent that it may be difficult for a user to handle a reduced-size consumable item without bending or breaking the consumable item. Handling of such items may be particularly difficult when inserting or removing them from an HNB device. Additionally, accurate positioning of such items within the device may also be difficult. Summary of the Invention [Problem to be solved by the invention]

[0007] One of the aims of the present invention is to propose a flat consumable item for an HNB device that can be easily handled by a user, positioned inside the device for generating an aerosol, and removed from the device. [Means for solving the problem]

[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 comprising: a tobacco substrate defining at least a first pair of opposing sides extending along an article axis; a support structure including an outlet portion disposed contiguous with the tobacco substrate along an article axis, and a substrate portion extending from the outlet portion along the article axis and configured to engage the first pair of opposing sides to hold the tobacco substrate together with the support structure, the outlet portion including an air flow passage extending from the tobacco substrate; Including, The substrate portion includes a pair of legs, each leg configured to extend along at least a portion of a corresponding side surface.

[0009] Due to these characteristics, the tobacco substrate can be held by the support structure. The support structure provides the article with an increased rigidity to facilitate handling and reduce deformation of the article. This holding is ensured by legs that extend in particular along at least a portion of the consumable article. In particular, each leg can extend along the entire length of the tobacco substrate or along a portion of its length. This portion can for example constitute at least ¼, advantageously at least ½, more advantageously at least ¾ of the entire length of the tobacco substrate. Thus, when the consumable article is inserted into or removed from the device, the user can simply handle the consumable article, for example using the support structure forming a solid element. It may therefore be possible to prevent bending or breaking the tobacco substrate. Additionally, using the support structure, it is possible to accurately position the consumable article inside the device for generating the aerosol. In particular, the consumable article can be more easily guided into the device, such as into the complementary heating chamber of the device. The height of the legs can also be adapted to prevent excessive deformation / crushing of the tobacco substrate and blocking of the flow path. Thus, the user experience can be improved.

[0010] In some embodiments, the tobacco substrate can be assembled to the support structure during manufacture of the article. In some cases, the tobacco substrate can be secured (e.g., glued) to the support structure, particularly to the legs that hold the tobacco substrate. In some other embodiments, the support structure can be provided separately from the tobacco substrate. In this case, a user can engage the tobacco substrate with the support structure prior to using the consumable article with the aerosol generating device. In both embodiments, the support structure can be reusable.

[0011] According to some embodiments, the tobacco substrate further defines a second pair of opposing sides extending along the article axis, the second pair of opposing sides being at least 5 times wider, advantageously 10 times wider, than the first pair of sides.

[0012] These characteristics result in the tobacco substrate forming a generally rectangular parallelepiped shape that is particularly well suited to be at least partially received within an aerosol generating device.

[0013] According to some embodiments, each leg defines an inner surface configured to be engaged with a corresponding side of the tobacco substrate.

[0014] According to some embodiments, the inner surface of each leg defines a cross-sectional shape that is complementary to the cross-sectional shape of the corresponding side of the tobacco substrate.

[0015] Advantageously, the cross-sectional shape of the inner surface of each leg has a concave rounded shape and the cross-sectional shape of the corresponding side surface has a convex rounded shape.

[0016] These features allow the tobacco substrate to be guided by the legs during insertion of the tobacco substrate into the support structure. For example, the legs can act as rails between which the tobacco substrate can easily slide during insertion. Additionally, the complementary cross-sectional shapes of the legs and the corresponding sides of the tobacco substrate can ensure good contact between these elements and greater solidity of the tobacco substrate between the legs.

[0017] According to some embodiments, each leg defines a tapered portion that extends to the leg end and defines a taper angle at the leg end.

[0018] These features allow the distance between the legs at the leg end to be greater than the distance at any other region of the leg, thus facilitating insertion of the tobacco substrate from the leg end. Additionally, each leg may further define a straight portion extending between the exit portion of the support structure and the corresponding tapered portion. The distance between the legs along the straight portion may be constant, the distance being adapted to retain the tobacco substrate between the legs.

[0019] According to some embodiments, the support structure is made in a single piece.

[0020] These features allow the support structure to be easily manufactured using, for example, injection molding or any other available technique.

[0021] According to some embodiments, the support structure may be made by injection molding of a paper pulp material, in other words, the support structure is made of an injection molded paper pulp material.

[0022] Paper pulp represents a particularly advantageous material since it is cheap and heat resistant, additionally it ensures good stiffness and compatibility with the tobacco product.

[0023] According to some embodiments, the support structure comprises tobacco powder and / or flavorings.

[0024] In particular, tobacco powder can be added as a filler during the manufacturing process of the support structure. For example, when the support structure is formed by injection molding, ground tobacco or tobacco powder or at least particles of ground tobacco can be added to the material, such as paper pulp, that forms the support structure. The addition of tobacco into the support structure is used to enhance the user's sensations. For example, when the support structure is heated together with the tobacco substrate, the ground tobacco can release a smoking taste and thus improve the user experience. Any flavoring can be used instead of or in addition to the ground tobacco. Also, such flavoring can be adapted to release a flavor when heated. For example, flavorings with polysaccharide carriers as described in EP-A-2279677, EP-A-2682007, EP-A-2682008, EP-A-2682009, or EP-A-3533348 can be used.

[0025] Some embodiments include a wrapper that encases the tobacco substrate with or without at least a portion of the support structure.

[0026] These features allow the wrapper to ensure the retention of the taste and / or flavor released during the vaping session. Additionally, the wrapper can prevent condensation or vapor leakage and can efficiently direct the air flow along the entire area of ​​the tobacco substrate to the outlet portion. The wrapper can be made of any suitable material, such as aluminum or paper. In some embodiments, the wrapper can cover only the tobacco substrate with the legs of the support structure. In some other embodiments, the wrapper can also cover the entire support structure including the outlet portion. In this last case, the wrapper can be made of a unique or different sheet that separately covers the tobacco substrate with the legs and the outlet portion. In some other cases, the wrapper can cover only the tobacco substrate separately from the legs of the support structure. In this case, the tobacco substrate is wrapped before being inserted between the legs. The wrapper can include a tearable portion that allows easy removal of at least a portion of the wrapper before insertion.

[0027] According to some embodiments, the outlet portion is hollow, preferably either empty or including a support element disposed within the outlet portion.

[0028] The hollow structure can promote airflow inside the outlet section. If the hollow structure is substantially empty, the airflow is not impeded, and the pressure resistance is reduced. If the hollow structure includes a support element, such as a rib, a strut, or an additional wall, the rigidity of the hollow structure can be increased. Additionally, in some cases, the support element can function as an airflow guide and / or cooler. Thus, the airflow guided to the user can be mixed and / or cooled in a specific manner, for example, to improve the user experience. Additionally, in some embodiments, the support element can function as a stopper to prevent the insertion of the tobacco substrate inside the outlet section.

[0029] According to some embodiments, the tobacco substrate includes at least one, and preferably a plurality of, channels extending along the article axis and formed in at least one of the second pair of opposing sides.

[0030] These features increase the surface of the tobacco substrate available for heat transfer compared to a flat surface, and also facilitate directing airflow through the tobacco substrate. Channels may be formed on only one of said sides or on each of said sides. In this last case, channels located on different sides may be staggered between each other in each cross section.

[0031] According to some embodiments, the outlet portion includes at least two edges extending perpendicular to the article axis, at least a portion of each edge intended to contact the tobacco substrate.

[0032] In particular, the edge of the outlet section can be intimately attached to the tobacco substrate such that airflow directed by the channels formed in the substrate can flow throughout the interior of the outlet section, and in particular, the edge contacts at least one protrusion, and preferably a plurality of protrusions, of the tobacco substrate between the channels.

[0033] According to some embodiments, each edge includes a recessed portion arranged to face a corresponding flow channel.

[0034] In other words, the flow paths are aligned with corresponding recessed portions, and each recessed portion extends a corresponding flow path. These features allow the recessed portions to ensure cooling of the aerosol and good mouthfeel for the user. Additionally, the dimensions of the recessed portions and / or their alignment with the corresponding flow paths can be adjusted to adjust the cooling effect.

[0035] According to some embodiments, the support structure can include at least one visual feature, such as a color, symbol, or image, that defines the flavor of the tobacco substrate.

[0036] These features allow the support structure to distinguish the consumable article from other consumable articles that have, for example, different tastes and / or flavors.

[0037] According to some embodiments, the visual characteristic is a color obtained by mixing the paper pulp material with one or more pigments during injection molding.

[0038] Thus, the support structure may be at least partially or entirely colored to impart different tastes and / or flavors to the consumable article. The or each dye used to color the paper pulp material is advantageously a food dye.

[0039] For example, one or any mixture of the following pigments can be used to color the paper pulp: red, green, blue, and yellow pigments.

[0040] The red dye is, for example, Allura Red AC, also known as E129 dye. Its chemical formula is 18 H 14 Its official name is disodium 6-hydroxy-5-[(2-methoxy-5-methyl-4-sulfonatophenyl)diazenyl]naphthalene-2-sulfonate.

[0041] The green dye is, for example, Fast Green FCF, also known as E143 dye. Its chemical formula is 37 H 34 N2Na2O 10 S3, whose official name is ethyl-[4-[[4-[ethyl-[(3-sulfophenyl)methyl]amino]phenyl]-(4-hydroxy-2-sulfophenyl)methylidene]-1-cyclohexa-2,5-dienylidene]-[(3-sulfophenyl)methyl]azanium.

[0042] An example of a blue dye is Brilliant Blue FCF, also known as E133 dye. Its chemical formula is 37 H 34Its official name is disodium 2-[[4-[ethyl-[(3-sulfonatophenyl)methyl]amino]phenyl]-[4-[ethyl-[(3-sulfonatophenyl)methyl]azaniumylidene]cyclohexa-2,5-dien-1-ylidene]methyl]benzenesulfonate.

[0043] An example of a yellow dye is tartrazine, also known as E102 dye. Its chemical formula is 16 Its official name is trisodium 5-hydroxy-1-(4-sulfonatophenyl)-4-[(E)-(4-sulfonatophenyl)diazenyl]-1H-pyrazole-3-carboxylate.

[0044] The part by weight of the or each pigment in the paper pulp material may be, for example, 0.1% to 5%.

[0045] 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: a tobacco substrate defining at least a first pair of opposing sides extending along an article axis; a support structure including an outlet portion disposed contiguous with the tobacco substrate along an article axis, and a substrate portion extending from the outlet portion along the article axis and configured to engage the first pair of opposing sides to hold the tobacco substrate together with the support structure, the outlet portion including an air flow passage extending from the tobacco substrate; Including, The support structure is made from an injection molded paper pulp material.

[0046] Preferably, the support structure comprises tobacco powder and / or flavorings. Preferably, the support structure may include at least one visual feature, such as a color, a symbol, or an image, that defines the flavor of the tobacco substrate. Preferably, the visual feature is a color obtained by mixing a paper pulp material with one or more pigments during injection molding.

[0047] The invention and its advantages will be better understood on reading the following description, given by way of non-limiting example only and with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0048] [Figure 1] FIG. 1 is a perspective view of an aerosol generating assembly including an aerosol generating device and a flat consumable article according to the present invention, the flat consumable article being usable with the aerosol generating device. [Diagram 2] 2 is a perspective view of the flat consumable article of FIG. 1 according to a first example embodiment of the present invention, in which the consumable article includes a wrapper. [Diagram 3] 3 is a perspective view of the flat consumable article of FIG. 1 according to a first embodiment example different from the example of FIG. 2. FIG. [Figure 4] FIG. 3 is a view similar to that of FIG. 2, but without the wrapper on the consumable item. [Diagram 5] FIG. 5 is a perspective view of the tobacco substrate of the consumable article of FIG. 4. [Figure 6] 5 is a perspective view of a support structure for the consumable article of FIG. 4. [Figure 7] 5 is a perspective view of an alternative support structure for the consumable article of FIG. 4. FIG. [Figure 8] FIG. 7 is a partial view of the support structure of FIG. 6. [Figure 9] 9A is a cross-sectional view taken along plane VII-A in FIG. 8, and FIG. 9B is a cross-sectional view taken along plane VII-B in FIG. [Figure 10] FIG. 2 is a perspective view of a flat consumable article according to a second embodiment of the present invention. [Figure 11] 11 is a perspective view of a support structure included in the consumable article of FIG. 10. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0049] Before the present invention is described, it should be understood that the invention is not limited to the details of construction set forth in the following description, as it will be apparent to one skilled in the art having the benefit of this disclosure that the invention is capable of other embodiments and of being practiced or carried out in various ways.

[0050] As used herein, the term "aerosol generating device" or "device" may include a vaping device for delivering aerosol, including aerosol for vaping, to a user using a heater element, which will be described in more detail below. The device may be portable. "Portable" may refer to a device that is held and used by a user. The device may be adapted to generate a variable amount of aerosol (as opposed to a fixed amount of aerosol), for example, by activating a heater element for a variable amount of time, the generation of which may be controlled by a trigger. The trigger may be user-activated, such as a vaping button and / or an inhalation sensor. The inhalation sensor may be sensitive to inhalation intensity and duration to allow for providing a variable amount of vapor (to mimic the smoking effect of a conventional combustible smoking article, such as a cigarette, cigar, or pipe). The device may include a temperature regulation control for driving the temperature of the heater and / or heated aerosol-generating material (aerosol precursor) to a specific target temperature and then maintaining the temperature at that target temperature that allows for efficient generation of aerosol.

[0051] As used herein, the term "aerosol" may encompass a suspension of vaporizable material that may be one or more of solid particles, liquid droplets, or gas. The suspension may be in a gaseous state, including air. Aerosol herein may generally refer to / include a vapor. Aerosol may include one or more components of a vaporizable material.

[0052] As used herein, the term "vaporizable material" or "precursor" may refer to smokable material, which may include, for example, nicotine or tobacco and an aerosol-forming agent. Tobacco may take the form of various materials, such as cut tobacco, granulated tobacco, tobacco leaf, and / or reconstituted tobacco. Suitable aerosol-forming agents include polyols (e.g., sorbitol, glycerol, and glycols, such as propylene glycol or triethylene glycol), non-polyols (e.g., monohydric alcohols, acids, such as lactic acid, glycerol derivatives, esters, such as triacetin, triethylene glycol diacetate, triethyl citrate, glycerin, or vegetable glycerin). In some embodiments, the aerosol-generating agent may be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. The substrate may also include at least one of a gelling agent, a binder, a stabilizer, and a humectant.

[0053] As used herein, the term "wider" applied in relation to two surfaces is used to compare the dimension of these surfaces in a short direction, i.e. in a direction perpendicular to the extension direction of these surfaces. If at least one of the surfaces has a non-planar shape, said dimension is measured along a plane passing through at least two points that define the surface along the short direction.

[0054] First embodiment of the present invention Figure 1 shows an aerosol generation assembly 10 including an aerosol generation device 11 and a flat consumable article 12 according to a first embodiment of the invention, hereinafter referred to as consumable article 12. The aerosol generation device 11 is intended to operate together with the consumable article 12, which is shown in more detail in Figures 2 to 9.

[0055] With reference to FIG. 1, the aerosol generating device 11 comprises a device body 15 extending along a device axis Y. The device body 15 comprises a mouthpiece 16 and a housing 17 arranged successively along the device axis Y. According to the example of FIG. 1, the mouthpiece 16 and the housing 17 form two distinct parts. In particular, according to this example, the mouthpiece 16 is designed to be fixed to or received in an insertion opening formed at one of the ends of the housing 17. In this case, the consumable article 12 can be inserted into the interior of the device 11 when the mouthpiece 16 is removed from the housing 17. According to another example (not shown), the mouthpiece 16 and the housing 17 form one unique part. In this case, the consumable article 12 can be inserted into the interior of the device 11, for example, through the outlet. According to both examples, the mouthpiece 16 defines a through hole adapted to at least partially receive the consumable article 12. In particular, the through hole can be adapted to receive at least an outlet portion of the consumable article 12, which will be explained in more detail below. According to yet another embodiment (not shown), the aerosol generating device 11 is not provided with a mouthpiece 16. In this case, the outlet portion of the consumable article 12 may form a mouth end designed to contact the user's lips and / or mouth during a vaping session.

[0056] The housing 17 defines an interior space of the device 11 that accommodates various elements designed to perform different functions of the device 11. This interior space may accommodate, for example, 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 article 12, etc. In particular, the heating chamber is designed to accommodate at least the tobacco substrate of the consumable article 12 and heat the consumable article 12 using a suitable heater. In the example of FIG. 1, the heating chamber may be located, for example, in the extension of the through hole of the mouthpiece 16 along the device axis Y.

[0057] 2, the consumable article 12 is, for example, a flat rectangular parallelepiped extending along an article axis X between an inlet end 18 and an outlet end 19 and having outer dimensions L×W×H. The consumable article 12 is adapted to direct an air flow from the inlet end 18 to the outlet end 19, as will be explained in more detail below. In a typical example, the length L of the article 12 along the article axis X is substantially equal to 25-35 mm, for example 33 mm, while the width W of the article 12 is substantially equal to 12 mm and the height H is substantially equal to 0.8-2 mm, for example 1.2 mm. According to different examples, the values ​​L, W and H can be selected, for example, within a range of ±40%.

[0058] In the example of FIG. 2, the consumable article 12 is wrapped by a common wrapper 21. In other words, in this example, the wrapper 21 is formed from a unique sheet that wraps substantially the entire length of the consumable article 12 around the article axis X. In other examples, the wrapper 21 extends along only a portion of the length of the consumable article 12. For example, the wrapper 21 can extend along only the tobacco substrate of the consumable article 12, advantageously wrapping only the tobacco substrate, as shown in the alternative embodiment of FIG. 3. According to another example, the wrapper 21 is formed from two different sheets that, for example, wrap the tobacco substrate and the support structure of the consumable article 12 separately. The wrapper 21 can be made of aluminum and / or paper. To prevent absorption of liquids, the paper can be coated with an impermeable coating, such as cooking paper or backing paper. In some embodiments, when the wrapper 21 is made of aluminum, the wrapper 21 can wrap only the tobacco substrate to prevent condensation leakage and / or steam leakage. Additionally, the aluminum allows for better heat transfer.

[0059] Figure 4 shows the consumable article 12 without the wrapper 21. In some embodiments, the consumable article 12 can be provided and used without the wrapper 21, as shown in Figure 4. With reference to this Figure 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 serve to collect the aerosol stream from the tobacco substrate 25 and guide the aerosol stream to the user's mouth.

[0060] In FIG. 5, the tobacco substrate 25 is shown in more detail. The tobacco substrate 25 defines the inlet end 18 of the consumable article 12 and includes a vaporizable or smokable material as defined above. The vaporizable material is, for example, compressed to form a solid structure capable of releasing an aerosol upon heating. Examples of tobacco substrates and methods of making the same are described in WO 2021 / 094365 and WO 2021 / 094366. In particular, referring to FIG. 5, the tobacco substrate 25 defines, for example, a generally flat rectangular parallelepiped defining a first pair of opposing sides 33A, 33B (represented in FIG. 5 as the right and left sides of the substrate) and a second pair of opposing sides 34A, 34B (represented in FIG. 5 as the top and bottom sides of the substrate), each of the pair of sides extending along the article axis X. The second pair of opposing sides 34A, 34B is, for example, at least 5 times, advantageously 10 times, wider than the first pair of sides 33A, 33B. The first pair of opposing sides 33A, 33B is designed to contact the support structure 26, as described in more detail below. Each side 33A, 33B of the first pair can define a generally flat plate shape that can define rounded edges in each cross section. In particular, each side 33A, 33B of the first pair can have a convex rounded shape in each cross section. The second pair of sides 34A, 34B is designed to be heated by conduction and / or convection using the heating chamber of the device 11. According to another embodiment, the tobacco substrate 25 includes a susceptor and is designed to be inductively heated following magnetic interaction between the susceptor and a magnetic coil.

[0061] Each of the second pair of sides 34A, 34B defines a plurality of flow channels extending along the article axis X and designed to direct air flow along the tobacco substrate 25. In the example of FIG. 5, two flow channels 36A are formed in the side 34A and three flow channels 36B are formed in the side 34B. The flow channels located on different sides 34A, 34B can be staggered in each cross-section of the tobacco substrate 25, as shown in FIG. 5. In particular, in this case, the tobacco substrate 25 can be formed in each cross-section with a corrugated shape with valleys between the protrusions that form the flow channels 36A, 36B in each side 34A, 34B. This shape can be formed, for example, by a stamping process. In an alternative embodiment (not shown), the cross-section is not corrugated but has an enlarged thickness of the protrusions and a reduced thickness of the flow channels.

[0062] 6 shows in more detail the support structure 26 used to hold the tobacco substrate 25. In a preferred embodiment of the present invention, the support structure 26 is formed from a single piece, for example using an injection molding process. The support structure 26 can be made of or can include a paper pulp material. In some embodiments, the support structure 26 can include ground tobacco or flavorings that can be released upon heating. The support structure 26 can also be reusable. The support structure 26 can also include at least one visual feature, such as a color, symbol, or image, that defines the flavor of the tobacco substrate.

[0063] When said visual characteristic is a color, the visual characteristic can be obtained by mixing the paper pulp material with one or more dyes during injection molding. Thus, the support structure 26 can be at least partially or entirely colored to indicate different tastes and / or flavors of the consumable article 12. The or each dye used to color the paper pulp material is advantageously an edible dye. For example, one or any mixture of the following dyes can be used to color the paper pulp: red, green, blue, and yellow dyes.

[0064] Referring to FIG. 6, the support structure 26 includes an outlet portion 41 designed to be positioned contiguous with the tobacco substrate 25 along the article axis X, and a substrate portion 42 extending from the outlet portion 41 along the article axis X and configured to engage the first pair of opposing sides 33A, 33B to hold the tobacco substrate 25 together with the support structure 26.

[0065] The outlet portion 41 defines an air flow passage extending from the tobacco substrate 25 to the outlet end 19 of the consumable article 12 formed by the outlet portion 41. The outlet portion 41 is therefore intended to extend the flow passages 36A, 36B of the tobacco substrate 25 and direct airflow from each of these flow passages 36A, 36B to the outlet end 19 of the consumable article 12. As shown in FIG. 6, the outlet portion 41 can have a rectangular cross section and can be hollow or define support elements such as ribs, struts, or additional walls. In some embodiments, the outlet portion 41 can accommodate a filter element. The filter element can include paper or cellulose acetate tow. The outer wall delimiting the outlet portion 41 can have a thickness of 0.01 mm to 0.5 mm, preferably 0.05 mm to 0.2 mm. The outlet portion 41 includes two edges 46A, 46B at the end opposite to the outlet end 19, which extend perpendicular to the article axis X, and at least a portion of each edge 46A, 46B is intended to contact the tobacco substrate 25 as shown in FIG. 4. In particular, these edges 46A, 46B, or at least a portion of the edges 46A, 46B, are intended to be in close contact with the protruding portion of the tobacco substrate 25 and extend along a substantially straight line according to the first embodiment of the present invention. The thickness of the outlet portion 41 can be equal to or less than the maximum height of the tobacco substrate 25. Preferably, the maximum height of the tobacco substrate 25 is 0.05 mm to 0.2 mm larger than the thickness of the outlet portion. Therefore, in this case, the edges 46A, 46B can function as a stopper when the tobacco substrate 25 is inserted 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 tangent to the protrusions located on the opposite sides 34A, 34B. In other words, in the case of protrusions, the maximum height is measured as the distance between these protrusions. According to an alternative embodiment of the support structure 26 shown in FIG. 7, the edges 46A, 46B can include stoppers 47 that prevent the tobacco substrate 25 from sliding inside the outlet portion 41. These stoppers 47 can protrude from the edges 46A, 46B into the outlet portion 41 as shown in FIG. 7.

[0066] The substrate portion 42 includes a pair of legs 53A, 53B extending from the outlet portion 41 toward the inlet end 18 of the consumable article 12 along the article axis X. In particular, each leg 53A, 53B is configured to extend along at least a portion of the corresponding side surface 33A, 33B of the first pair of sides of the tobacco substrate 25. In the illustrated example, the legs 53A, 53B extend along the entire length of the tobacco substrate 25. According to another example, the legs 53A, 53B extend along at least ½, advantageously ¾, of the entire length (in the direction of the axis X) of the tobacco substrate 25. The legs 53A, 53B are, for example, symmetrical about a central plane passing through the middle between the two legs 53A, 53B along the article axis X. In the further description, only the leg 53B will be described in detail with reference to Figures 8 and 9.

[0067] 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 the leg end 57. The tapered portion 56 extends, for example, over 10-50% of the total length of the leg 53B and forms a taper angle of, for example, 1°-5° at the leg end 57. The straight portion 55 defines, for example, a substantially constant cross-sectional shape as shown in part A of FIG. 9. This shape is formed, for example, by two branches 61, 62 extending toward the central plane and an intermediate element 63 extending between the branches 61, 62. The tapered portion 56 forms, for example, 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 shown in part B of FIG. 9. In detail, as shown in FIG. 9, the extension of the branches 61, 62 gradually decreases from the straight portion 55 to the leg end 57. In some examples (not shown), the leg ends 57 can further define blocking portions that block the tobacco substrate 25 when the tobacco substrate 25 is received between the legs 53A, 53B. The blocking portions can protrude from the leg ends 57 of each leg 53A, 53B into the volume formed between the legs 53A, 53B.

[0068] The straight portion 55 and the tapered portion 56 together form an inner surface 64 configured to contact the side 33B of the tobacco substrate 25. In particular, the inner surface 66 can define a cross-sectional shape that is complementary to the cross-sectional shape of the corresponding side 33B, and thus can define a concave rounded shape. In some embodiments, each leg can also be split into two separate elongated segments that join the outlet portion 41. The legs can also extend across only a small portion of the opposing sides 34A, 34B, for example, less than 5% of the opposing sides 34A, 34B.

[0069] The use of the consumable article 12 according to the present invention will now be described. In one embodiment, it is considered that the consumable article 12 is provided assembled. In other words, in this case, the tobacco substrate 25 is inserted into the support structure 26 as described above. When the user intends to use the consumable article 12, he inserts the tobacco substrate 25 into the heating chamber and then attaches the mouthpiece 16 to the outlet portion 41. Alternatively, if the mouthpiece 16 is not required, only the step of inserting the tobacco substrate 25 into the heating chamber is performed by the user, and the outlet portion 41 serves as the mouthpiece. The user then activates the operation of the aerosol generating device 11, which causes the tobacco substrate 25 to heat. During the user's puffing action, an air flow is generated inside the consumable article 12, flowing from the inlet end 18, first through the channels 36A, 36B, then through the outlet portion 41 to the outlet end 19.

[0070] According to another embodiment, the consumable article 12 is provided unassembled, in which case the user first inserts the tobacco substrate 25 between the legs 53A, 53B and then performs the steps described above.

[0071] Second embodiment of the present invention A flat consumable article 112 according to a second embodiment of the present invention will now be described with reference to FIGS.

[0072] As before, the consumable article 112 comprises a tobacco substrate 125, a support structure 126 and, in some instances, a wrapper (not shown in FIG. 10). The tobacco substrate 125 is similar to the tobacco substrate 25 described in connection with the first embodiment of the invention. The support structure 126 is also similar to the support structure 26 described above, in particular comprising an outlet portion 141 and a substrate portion 142 similar to the substrate 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 intended to contact the tobacco substrate 125.

[0073] In detail, as shown in FIG. 11, each edge 146A, 146B of the outlet portion 141 includes a recessed portion 136A, 136B for each flow passage disposed on the corresponding side of the tobacco substrate 125. Thus, the recessed portions 136A, 136B are disposed to extend facing the corresponding flow passage. Each recessed portion 136A, 136B can form a semicircular shape and can extend from the tobacco substrate 125 to a maximum extension length of, for example, 0.1 mm to 5 mm, preferably 0.5 mm to 2.5 mm. The recessed portions 136A, 136B can function as vents for cooling the air flow inside the outlet portion 126. If a wrapper is provided to cover the outlet portion 141, the wrapper can also define holes facing the recessed portions 136A, 136B.

Claims

1. A flat consumable article (12; 112) for an aerosol generating device (11), comprising: The flat consumable article (12; 112) extends along an article axis (X) and a tobacco substrate (25; 125) defining at least a first pair of opposing sides (33A, 33B) extending along the article axis (X); A support structure (26; 126) comprising: an outlet portion (41; 141) disposed contiguous with the tobacco substrate (25; 125) along the article axis (X); a substrate portion (42; 142) extending from said outlet portion (41; 141) along said article axis (X) and configured to engage said first pair of opposing side surfaces (33A, 33B) to hold said tobacco substrate (25; 125) together with said support structure (26; 126); a support structure (26; 126) including Including, said outlet portion (41; 141) comprising an air flow passage extending from said tobacco substrate (25; 125); The base portion (42; 142) includes a pair of legs (53A, 53B), Each leg (53A, 53B) is configured to extend along at least a portion of the corresponding side surface (33A, 33B). Flat consumable article (12; 112).

2. the tobacco substrate (25; 125) further defines a second pair of opposing sides (34A, 34B) extending along the article axis (X); the second pair of opposing sides (34A, 34B) are at least five times, preferably ten times, wider than the first pair of opposing sides (33A, 33B); A flat consumable article (12; 112) according to claim 1.

3. each leg (53A, 53B) defines an inner surface (64) configured to engage the corresponding side (33A; 33B) of the tobacco substrate (25; 125); A flat consumable article (12; 112) according to claim 1 or 2.

4. the inner surface (64) of each leg (53A, 53B) defines a cross-sectional shape complementary to the cross-sectional shape of the corresponding side (33A, 33B) of the tobacco substrate (25; 125); Advantageously, The cross-sectional shape of the inner surface (64) of each leg portion (53A, 53B) has a concave rounded shape; The cross-sectional shape of the corresponding side surfaces (33A, 33B) has a convex rounded shape. A flat consumable article (12; 112) according to claim 3.

5. Each leg (33A, 33B) defines a tapered portion (56) that extends to a leg end (57) and defines a taper angle at said leg end (57); A flat consumable article (12; 112) according to claim 1 or 2.

6. said support structure (26; 126) being made in a single piece; A flat consumable article (12; 112) according to claim 1 or 2.

7. said support structure (26; 126) being made of injection-molded paper pulp material; A flat consumable article (12; 112) according to claim 1.

8. the support structure (26; 126) contains tobacco powder or flavorings; A flat consumable article (12; 112) according to claim 1 or 2.

9. a wrapper (21) for encasing said tobacco substrate (25; 125) with or without at least a portion of said support structure (26; 126), A flat consumable article (12; 112) according to claim 1 or 2.

10. the outlet portion (41; 141) is hollow, preferably either empty or comprising a support element arranged inside the outlet portion (41; 141); A flat consumable article (12; 112) according to claim 1 or 2.

11. the tobacco substrate (25; 125) includes at least one, preferably a plurality of, channels (36A, 36B) extending along the article axis (X) and formed in at least one of the second pair of opposing sides (34A, 34B); A flat consumable article (12; 112) according to claim 2.

12. the outlet portion (41; 141) comprises at least two edges (46A, 46B; 146A, 146B) extending perpendicular to the article axis (X), At least a portion of each edge (46A, 46B; 146A, 146B) is intended to contact said tobacco substrate (25; 125); A flat consumable article (12; 112) according to claim 11.

13. Each edge (146A, 146B) includes a recessed portion (136A, 136B) disposed facing a corresponding flow channel (36A, 36B). A flat consumable article (12) according to claim 12.

14. the support structure (26; 126) includes at least one visual feature, such as a color, symbol, or image, that defines the flavor of the tobacco substrate; A flat consumable article (12; 112) according to claim 7.

15. the visual characteristic is a color obtained by mixing the paper pulp material with one or more pigments during injection molding; A flat consumable article (12; 112) according to claim 14.

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