Aerosol-generating device with tray for flat consumable

Abstract

The invention relates to an aerosol-generating device (10) comprising a housing (12) with a distal end and a proximal end. The housing defines a cavity (20). The aerosol-generating device further comprises a consumable tray (40) defining a receptacle (48) for a flat consumable (42). The consumable tray is configured to be inserted into the cavity of the housing. The invention relates to an aerosol-generating system comprising such aerosol-generating device and a consumable configured for insertion into a receptacle (48) of a consumable tray (40) of the aerosol-generating device (10).

Description

[0001] New PCT Patent Application September 1, 2025 Philip Morris Products S.A. 46070-PCT

[0002] -1-

[0003] AEROSOL-GENERATING DEVICE WITH TRAY FOR FLAT CONSUMABLE

[0004] The present invention relates to an aerosol-generating device comprising a tray for a flat consumable and to an aerosol-generating system comprising such aerosol-generating device.

[0005] It is known to provide an aerosol-generating device for generating an inhalable vapor. Such devices may heat aerosol-forming substrate to a temperature at which one or more components of the aerosol-forming substrate are volatilised without burning the aerosolforming substrate. Aerosol-forming substrate may be provided as part of an aerosolgenerating article. The aerosol-generating article may have a rod shape for insertion of the aerosol-generating article into a cavity, such as a heating chamber, of the aerosol-generating device. A heating element may be arranged in or around the heating chamber for heating the aerosol-forming substrate once the aerosol-generating article is inserted into the heating chamber of the aerosol-generating device.

[0006] Some aerosol-generating devices are configured to be used with flat, thin consumables, which are heated by planar heating elements. Such arrangements may achieve a more uniform heating of the aerosol-forming substrate contained in the aerosolgenerating articles, and higher overall performance in thermal transfer and related aerosolization performance. However, handling of the device, in particular inserting of fresh and replacing of spent consumables, may be cumbersome. Improper positioning within the heating chamber may lead to uneven heating, resulting in inconsistent aerosol quality.

[0007] It would be desirable to have an aerosol-generating device with simplified design that facilitates insertion and extraction of consumables. It would be desirable to have an aerosolgenerating device that reduces the risk of improper positioning of the consumable. It would be desirable to have an aerosol-generating device that reduces or avoids direct contact of the user with the consumable. It would be desirable to have an aerosol-generating device providing an optimized user experience. It would be desirable to have an aerosol-generating device providing an optimized user experience.

[0008] It would further be desirable to provide an aerosol-generating device allowing for a consistent aerosolization result in particular under varying ambient conditions. It would further be desirable to provide such aerosol-generating device, without significantly increasing the production costs of the aerosol-generating device. It would further be desirable to provide such aerosol-generating device, without significantly increasing complexity and dimensions of the aerosol-generating device.

[0009] According to an embodiment of the invention there is provided an aerosol-generating device. The aerosol-generating device may comprise a housing with a distal end and a New PCT Patent Application September 1, 2025 Philip Morris Products S.A. 46070-PCT

[0010] -2- proximal end, wherein the housing may define a cavity. The aerosol-generating device may further comprise a consumable tray defining a receptacle for a flat consumable. The consumable tray may be configured to be inserted into the cavity of the housing.

[0011] According to an embodiment of the invention there is provided an aerosol-generating device. The aerosol-generating device comprises a housing with a distal end and a proximal end, wherein the housing defines a cavity. The aerosol-generating device further comprises a consumable tray defining a receptacle for a flat consumable. The consumable tray is configured to be inserted into the cavity of the housing.

[0012] The implementation of a consumable tray facilitates insertion and removal of a thin flexible consumable into a cavity of an aerosol-generating device. The consumable tray can easily be completely extracted from the device to load the flat consumable. After loading the flat consumable, the consumable tray can be inserted back into the cavity of the aerosolgenerating device.

[0013] As used herein, the term “aerosol-generating device” refers to a device that interacts with an aerosol-forming substrate to generate an aerosol. An aerosol-generating device may interact with one or both of an aerosol-generating article comprising an aerosol-forming substrate, and a cartridge comprising an aerosol-forming substrate. In some examples, the aerosol-generating device may heat the aerosol-forming substrate to facilitate release of volatile compounds from the substrate. An electrically operated aerosol-generating device may comprise an atomiser, such as an electric heater, to heat the aerosol-forming substrate to form an aerosol.

[0014] The consumable to be received in the receptacle may be a flat consumable. The flat consumable may be a sheet-like consumable. The flat consumable may be a pouch-like consumable. The flat consumable may be formed as block. The flat consumable may comprise a solid aerosol-forming substrate.

[0015] As used herein, the term ‘flat’ relates to an element having a substantially greater length and width than thickness. The length and width directions are orthogonal to one another and define a first plane. The thickness extends orthogonal to the first plane. A flat element may have two opposing major surfaces extending in plane parallel to the first plane. One or both major surfaces are advantageously planar.

[0016] The consumable may have a length of between 5 and 50 millimetres. The consumable may have a length of between 10 and 40 millimetres. The consumable may have a length of between 10 and 30 millimetres.

[0017] The consumable may have a width of between 5 and 50 millimetres. The consumable may have a width of between 10 and 40 millimetres. The consumable may have a width of between 10 and 30 millimetres. New PCT Patent Application September 1, 2025 Philip Morris Products S.A. 46070-PCT

[0018] -3-

[0019] The consumable may have a thickness of between 0.1 and 10 millimetres. The consumable may have a thickness of between 0.2 and 6 millimetres. The consumable may have a thickness of between 0.5 and 4 millimetres.

[0020] The receptacle may have a generally rectangular cross section. The rectangular cross section of the receptacle may correspond to the dimensions of the flat consumable to be received therein. The receptacle may have width that corresponds to the width of the flat consumable. The receptacle may have height that corresponds to the thickness of the flat consumable. The receptacle may have depth that corresponds to the length of the flat consumable.

[0021] The consumable tray may be shaped to be able to securely and reliably receive the flat consumable. The consumable tray may comprise a frame. The frame may be configured to have a bottom plate with an elevated edge contour to form the receptacle. By providing the consumable tray with a frame forming the receptacle, the flat consumable may suitably be accommodated within the consumable tray. The frame structure helps to maintain the flat consumable in position, in particular during insertion and extraction of the consumable tray from the cavity of the aerosol-generating device.

[0022] The consumable tray and the flat consumable to be inserted therein may have an asymmetric shape. Preferably the consumable tray and the flat consumable have a corresponding asymmetric shape. The consumable tray may comprise an alignment edge that matches a cut-off portion of the flat consumable. Such alignment edge may facilitate correct placement of the consumable within the receptacle. In general, by providing the consumable tray and the flat consumable with a unique asymmetric shape, it can be ensured that the flat consumable is inserted with the correct orientation. This facilitates handling of the device and may enhance the user experience.

[0023] The housing of the aerosol-generating device may be configured to form a mouthpiece. The mouthpiece may be formed at the proximal end of the housing of the aerosol-generating device. The mouthpiece may be configured to be detachable.

[0024] The housing of the aerosol-generating device may comprise a cavity at its distal end. The cavity may be configured for receiving the consumable tray. The cavity may have a cross-section and a depth that correspond to the size of the consumable tray to be received within the cavity.

[0025] The cavity may be configured to extend from an access opening at the distal end of the housing. The cavity of the aerosol-generating device may be configured for sliding insertion of the consumable tray. The consumable tray may be slidingly inserted into the cavity along a length axis of the consumable tray. In this case the access opening of the cavity may have a shape that corresponds to the cross-sectional shape of the consumable New PCT Patent Application September 1, 2025 Philip Morris Products S.A. 46070-PCT

[0026] -4- tray. The access opening of the cavity can be provided as a slit with height and width dimensions corresponding to the height and the width of the loaded consumable tray.

[0027] The housing may be made from plastics, such as acrylonitrile butadiene styrene (ABS), polycarbonate, polypropylene, polyethylene terephthalate (PET), polyvinyl chloride (PVC), Polyurethane, polyethylene (PE), polypropylene (PP), polyester, polyether ether ketone (PEEK), polyphenylsulfone, nylon, and compounds thereof. The housing may also be made from metals such as aluminum or stainless steel, metal alloys, composite materials, or a combination of these materials.

[0028] The housing and the mouthpiece may also be made from polymeric and / or elastomeric materials which may incorporate polyethylene (PE), Ultra-high-molecular-weight polyethylene (UHMWPE), polyethylene terephthalate (PET), silicone rubber, polyurethane, Polymethyl methacrylate (PMMA), polysulfones, hydrogels and polyphosphazenes, thermoplastic elastomers, polydimethylsiloxane, and compounds of those.

[0029] The consumable tray may comprise a gripping element. A gripping element may serve as the primary interface for the user to push or pull the consumable tray out of or into the cavity. Thus, the gripping element may enable insertion and removal of the consumable tray into and from the cavity of the aerosol-generating device.

[0030] The gripping element may be provided at one edge of the consumable tray. The gripping element may be provided at a distal edge of the consumable tray. The gripping element may be stem-shaped to allow being securely gripped by a user’s hand.

[0031] The consumable tray and the gripping element may be formed from FDA (Food and Drug Administration) grade polymeric materials, which may include polyetheretherketone (PEEK), liquid crystal polymers (LCP), polysulfones (PSU), polyethersulfones (PES), polyetherimide (PEI), polyphenylsulfone (PPS), and compounds of those.

[0032] The gripping element may have a shape that corresponds to the shape of the access opening of the cavity of the aerosol-generating device. When the consumable tray is fully inserted into the cavity, the gripping element may completely cover the access opening of the cavity.

[0033] The gripping element and the access opening of the cavity may be formed to have corresponding shapes. The gripping element and the access opening may be formed to form a releasable connection, such as a form fitting or friction fitting connection.

[0034] The access opening of the cavity may be provided with a notch that engages with a corresponding rounded tab of the gripping element upon full insertion of the consumable tray into the cavity. By forming a releasable and tight connection, the consumable is reliably retained in the cavity of the housing of the aerosol-generating device. New PCT Patent Application September 1, 2025 Philip Morris Products S.A. 46070-PCT

[0035] -5-

[0036] Further, sealing elements may be provided between the gripping element and the access opening of the cavity. The sealing elements may assist in ensuring a hermetic sealing between matching surfaces of the gripping element and the access opening of the cavity.

[0037] The sealing elements may be formed from rubberized materials. The sealing elements may be formed from one or more of silicone rubber, polytetrafluoroethylene (PTFE), EPDM (ethylene propylene diene monomer), neoprene, and butyl rubber.

[0038] The sealing elements may be formed as gaskets. The sealing elements may be provided as part of the consumable tray. The sealing elements may be provided as part of the access opening. The sealing elements may ensure an air tight connection between the gripping element and the access opening of the housing. In addition, the sealing elements may increase compressive retention between matching surfaces of the gripping element and the access opening of the cavity.

[0039] The aerosol-generating device may comprise a heating arrangement for heating the consumable. The heating arrangement may be an inductive heating arrangement. The inductive heating arrangement may comprise one or more induction coils. The heating arrangement may also comprise one or more susceptor elements. The susceptor elements may be provided as part of the aerosol-generating device. The susceptor elements may be provided as part of the consumable to be received in the cavity of the aerosol-generating device.

[0040] The one or more induction coils may be provided adjacent the cavity of the housing. The one or more induction coils may be provided to surround the cavity of the housing.

[0041] The heating arrangement may comprise one or more flat induction coils. The heating arrangement may comprise a flat induction coil provided on either side of the cavity. The heating arrangement may comprise a flat induction coil provided on either of the major sides of the cavity. Flat heating coils can be provided directly adjacent to surfaces forming the cavity of the mouthpiece. Thus, flat heating coils allow a compact design and allow an efficient heating configuration.

[0042] The one or more induction coils may even be arranged within one or more side walls of the cavity of the housing of the aerosol-generating device. By incorporating the induction coils within the side walls of the cavity, a particularly compact design may be obtained. Further, the side walls may protect the induction coils from inadvertent damage during assembly and use of the aerosol-generating device.

[0043] In use of the aerosol-generating device, the cavity may be subjected to increased temperatures. It may therefore be advantageous to arrange a thermal insulation to surround the cavity. The thermal insulation may be provided as one or more layers of material that are configured to surround the cavity. The cavity wall may also be completely formed from a New PCT Patent Application September 1, 2025 Philip Morris Products S.A. 46070-PCT

[0044] -6- thermally insulating material. In such configuration it may be particularly advantageous to arrange the one or more induction coils to be embedded in the cavity walls. By use of the thermal insulation, heat generated within the receptacle may be more efficiently preserved and heat losses through heat conduction may be limited. At the same time the thermal insulation may help to prevent overheating of any outer surfaces of the main body or the mouthpiece of the aerosol-generating device.

[0045] The sidewalls of the cavity may comprise electromagnetic shields. Electromagnetic shields may protect internal parts and the exterior of the aerosol-generating device from electromagnetic radiation caused by the induction coils.

[0046] As used herein, a ‘susceptor’ or ‘susceptor element’ means an element that heats up when subjected to an alternating magnetic field. This may be the result of eddy currents induced in the susceptor element, hysteresis losses, or both eddy currents and hysteresis losses. During use, the susceptor element is located in thermal contact or close thermal proximity with an aerosol-forming substrate received in the aerosol-generating device. In this manner, the aerosol-forming substrate is heated by the susceptor such that an aerosol is formed.

[0047] Susceptor elements may be provided to surround the cavity. Susceptor elements may be embedded into one of the cavity sidewalls, in particular embedded into an upper cavity side wall and a lower cavity side wall. Providing the susceptor elements embedded in the cavity wall may ensure good thermal contact with the cavity walls. At the same time sufficient heat transfer into the cavity may be ensured such that in use the consumable can be efficiently heated.

[0048] The aerosol-generating device may comprise a power supply for powering the heating arrangement. The power supply may comprise a battery. The power supply may be a lithium-ion battery. Alternatively, the power supply may be a nickel-metal hydride battery, a nickel cadmium battery, or a lithium-based battery, for example a lithium-cobalt, a lithium- iron-phosphate, lithium titanate or a lithium-polymer battery. The power supply may require recharging and may have a capacity that enables to store enough energy for one or more usage experiences; for example, the power supply may have sufficient capacity to continuously generate aerosol for a period of around six minutes or for a period of a multiple of six minutes. In another example, the power supply may have sufficient capacity to provide a predetermined number of puffs or discrete activations of the heating arrangement.

[0049] The power supply may be a direct current (DC) power supply. In one embodiment, the power supply is a DC power supply having a DC supply voltage in the range of 2.5 Volts to 4.5 Volts and a DC supply current in the range of 1 Amp to 10 Amps (corresponding to a DC power supply in the range of 2.5 Watts to 45 Watts). The aerosol-generating device may New PCT Patent Application September 1, 2025 Philip Morris Products S.A. 46070-PCT

[0050] -7- advantageously comprise a direct current to alternating current (DC / AC) inverter for converting a DC current supplied by the DC power supply to an alternating current. The DC / AC converter may comprise a Class-D, Class-C or Class-E power amplifier. The AC power output of the DC / AC converter is supplied to the induction coil.

[0051] The power supply may be adapted to power an inductor coil and may be configured to operate at high frequency. A Class-E power amplifier is preferable for operating at high frequency. As used herein, the term ‘high frequency oscillating current’ means an oscillating current having a frequency of between 500 kilohertz and 30 megahertz. The high frequency oscillating current may have a frequency of from 1 megahertz to 30 megahertz, preferably from 1 megahertz to 10 megahertz, and more preferably from 5 megahertz to 8 megahertz.

[0052] In another embodiment the switching frequency of the power amplifier may be in the lower kilohertz range, e.g. between 100 kilohertz and 400 kilohertz. In the embodiments, where a Class-D or Class-C power amplifier is used, switching frequencies in the lower kilohertz range are particularly advantageous.

[0053] The aerosol-generating device may comprise electric circuitry. The electric circuitry may comprise a microprocessor, which may be a programmable microprocessor. The microprocessor may be part of a controller. The electric circuitry may comprise further electronic components. The electric circuitry may be configured to regulate a supply of power to the heating element. Power may be supplied to the heating arrangement continuously following activation of the aerosol-generating device or may be supplied intermittently, such as on a puff-by-puff basis. The power may be supplied to the heating arrangement in the form of pulses of electrical current.

[0054] The controller may be electrically connected to the one or more inductor coils. The controller may be configured to control the electrical current supplied to the induction coil(s), and thus the magnetic field strength generated by the induction coil(s).

[0055] The power supply and the control unit may be connected to the inductor coil(s).

[0056] The controller may be configured to be able to chop the current supply on the input side of the DC / AC converter. This way the power supplied to the inductor coil(s) may be controlled by conventional methods of duty-cycle management.

[0057] The aerosol-generating device may comprise a charging port for re-charging the power supply. The charging port may allow the power supply to be recharged by connecting the charging port via a cable to an external electrical source such as an electrical wall socket.

[0058] The aerosol-generating device may comprise a display. The display may be configured as user interface. The user interface may be configured to allow switching on and off the aerosol-generating device and switching between operating modes of the aerosolgenerating device. New PCT Patent Application September 1, 2025 Philip Morris Products S.A. 46070-PCT

[0059] -8-

[0060] The display may be configured to comprise various display portions for indicating various information to the user.

[0061] The display may be configured to comprise a display portion for indicating status information to the user. The display may be configured for indicating information regarding device status, state of charge of the power supply and power supply life.

[0062] The display may be configured to comprise a display portion acting as a consumption tracking display. A consumption tracking display may act as a visual indicator of the consumption level of a consumable. Prior to the insertion of a freshly loaded consumable tray, the display may be configured to remain unlit.

[0063] After insertion of a consumable tray loaded with an unused consumable the consumption tracking display may indicate a full or nearly full consumable. For this purpose, any self-explanatory signals may be used. As an example, one or more green lights may be used to signal a full consumable to the user. It is of course possible to use similar easy to understand optical or non-optical signals to convey consumption tracking information to a user.

[0064] As the consumable is gradually depleted during use, the optical signals may be varied to indicate the gradual depletion of the consumable to the user. As an example, the one or more green lights may be controlled to gradually turn red. Thereby, it may be indicated to the user that the consumable is being depleted. Such easy to understand visual indication helps users to understand how much of the consumable is left. In addition, the user may receive early information as to when the consumable might need replacing or refilling. Using such consumption tracking display gives the user additional consumption information and thereby enhances the overall user experience.

[0065] The display may also comprise additional visual indicators, relating to parameters such as the current operation mode of the aerosol-generating device or the type of consumable being used. The display may also indicate whether a specific flavorized consumable and which type of flavorized consumable is currently inserted into the aerosolgenerating device.

[0066] The aerosol-generating device may define an airflow path from an air inlet via the cavity towards the mouthpiece. When the aerosol-generating device is operated for generating an aerosol, fresh ambient air may be guided from the air inlet to the towards cavity and past the heated consumable. Vaporized compounds of the aerosol-forming substrate are entrained and mixed with the fresh ambient air, generating an inhalable aerosol. The aerosol is then guided towards the mouthpiece. New PCT Patent Application September 1, 2025 Philip Morris Products S.A. 46070-PCT

[0067] -9-

[0068] A cooling chamber may be provided between the cavity and the mouthpiece. The cooling chamber may be used to cool down the heated aerosol before inhalation. Cooling down the aerosol may enhance the aerosolization process.

[0069] The air inlet may be provided at a distal end of the housing. The air inlet may be provided in the gripping element. For this purpose, the gripping element may define an airflow channel for introduction of ambient air into the cavity. The airflow channel of the gripping element may comprise an air inlet at the outer surface of the gripping element and an air outlet towards the cavity.

[0070] Providing the air inlet at a distal portion or at the distal end of the housing of the aerosol-generating device is advantageous in that thereby an essentially unidirectional airflow path from the air inlet at the distal end to the mouthpiece at the proximal end of the aerosol-generating device is obtained.

[0071] The air outlet of the gripping element may be formed as a slit. The slit may be oriented parallel to the width dimension of the consumable tray. By providing the air outlet of the gripping element in the form of a slit, may allow to spread up the air flow upon entering into the cavity. In this way a uniform airflow across the consumable may be obtained.

[0072] The consumable tray may be configured to define an air duct. The air duct may extend longitudinally along the length of the consumable tray. When the consumable tray is inserted into the cavity, the air duct is in fluid connection with an air inlet in the housing of the aerosol-generating device.

[0073] The air inlet of the aerosol-generating device may be provided in the housing adjacent a proximal end of the consumable tray. The air duct may be configured to guide fresh ambient air from the proximal end of the consumable tray towards the distal end of the consumable tray. At the distal end of the consumable tray the air flow is redirected onto the aerosol-forming substrate provided in an inserted consumable for aerosol generation. By guiding the fresh air from the air inlet via the air duct towards the distal end of the consumable tray, the fresh ambient air may be preheated. Preheating the ambient air may allow to maintain the temperature during the volatilization reaction on a sufficiently high level. This allows to perform aerosolization at optimal conditions resulting in reliable and more uniform aerosolization product. Thereby an optimum aerosol quality is obtained which leads to an enhanced consumer experience.

[0074] The consumable tray may comprise one or more susceptor elements. Susceptor elements comprised in the consumable tray may be referred to as tray susceptors. When the consumable tray is inserted into the cavity, the one or more induction coils of the aerosolgenerating device may cooperate with the susceptor elements of the consumable tray to heat a consumable deposited on the consumable tray. New PCT Patent Application September 1, 2025 Philip Morris Products S.A. 46070-PCT

[0075] -10-

[0076] The susceptor elements of the consumable tray may further be configured to heat an airflow guided through the air duct of the consumable tray. Thus, the susceptor elements of the consumable tray may be used to heat both, the aerosol-forming substrate and the airflow guided through the air duct of the consumable tray. Accordingly, the aerosol-generating device may be configured to pre-heat fresh ambient air guided through the air duct of the consumable tray and to subsequently guide the heated airflow across the consumable in order to generate an aerosol.

[0077] The consumable tray may comprise a laminated structure. The laminated structure of the consumable tray may comprise a plurality of layers.

[0078] The consumable tray may comprise a base layer, a porous middle layer and dielectric top layer.

[0079] The base layer and the dielectric top layer may be configured to be not air permeable. The base layer may be made from one or more of stainless steel foil, aluminum foil and copper foil.

[0080] The top layer may be made from one or more of polyimide films, high-temperature polyester, and ceramic coatings.

[0081] The porous middle layer may be configured to be air-permeable. The porous middle layer may be made of porous ceramics, sintered metals, and porous polymers like polytetrafluoroethylene (PTFE). The porous middle layer may be configured to form the air duct of the consumable tray that is used to preheat fresh ambient air.

[0082] The consumable tray may comprise a frame structure. The frame structure may encase the laminated structure of the consumable tray. A frame inlet may be provided to allow fresh air from the air inlet to enter into the porous middle layer of the consumable tray. The frame inlet may be provided in the frame structure at the proximal end of the consumable tray.

[0083] With the above described construction the porous middle layer is surrounded at each side with an air impermeable layer such that the porous middle layer forms an air duct extending along the length of the consumable tray from the proximal end to the distal end of the consumable tray.

[0084] The distal end of the laminated structure of the consumable tray may be retained within the gripping element. The consumable tray may be configured to form a reverse duct for guiding the heated airflow from the air duct towards the consumable. In more detail, the reverse duct may be formed between the gripping element and the laminated structure of the consumable tray.

[0085] One or more susceptor elements may be provided at the top dielectric layer of the laminated structure of the consumable tray. The one or more susceptor elements are New PCT Patent Application September 1, 2025 Philip Morris Products S.A. 46070-PCT

[0086] -11- provided in vicinity and of the one or more induction coils. The varying magnetic field may inductively heat the one or more susceptor elements.

[0087] A consumable may be positioned on the consumable tray and directly on the susceptor elements formed on the dielectric top layer. The susceptor elements transfer heat to the consumable and may be used to vaporize volatile compounds of the aerosol-forming substrate. The preheated air is guided across the consumable and mixes with and entrails these vaporized compounds to form an aerosol.

[0088] The present invention also relates to an aerosol-generating system comprising an aerosol-generating device as described above and a consumable to be inserted into the consumable tray.

[0089] As used herein, the term "aerosol-generating system" refers to the combination of an aerosol-generating device with an aerosol-forming substrate. When the aerosol-forming substrate forms part of an aerosol-generating article, the aerosol-generating system refers to the combination of the aerosol-generating device with the aerosol-generating article. In the aerosol-generating system, the aerosol-forming substrate and the aerosol-generating device cooperate to generate an aerosol.

[0090] The aerosol-generating substrate may be provided in the form of a consumable. The consumable may be configured for insertion into the receptacle of the consumable tray. The consumable may be formed to have a flat and generally rectangular shape.

[0091] As discussed above, when the receptacle of the consumable tray is formed with an alignment edge, the consumable may be provided with a matching cut-off portion. Such alignment edge and corresponding cut-off portion may facilitate correct placement of the consumable within the receptacle.

[0092] The consumable may be formed as a laminated sheet. The consumable may be formed as a layered structure, preferably comprising a plurality of layers.

[0093] The consumable may comprise a layer of aerosol-forming substrate. The aerosol forming substrate may comprise tobacco material.

[0094] The consumable may comprise a susceptor element. Susceptor elements comprised in the consumable may also be referred to as consumable susceptors. The susceptor element may be in direct contact with the aerosol-forming substrate. Positioning the susceptor element close to the aerosol-forming substrate ensures optimal heat transfer from the susceptor element to the aerosol-forming substrate.

[0095] The consumable may further comprise a bottom layer. The bottom layer may be made of thermally conductive material. Manufacturing the bottom layer from thermally conductive material may help to achieve a uniform heat distribution within the consumable. New PCT Patent Application September 1, 2025 Philip Morris Products S.A. 46070-PCT

[0096] -12-

[0097] The consumable may comprise a frame structure circumscribing the layer of aerosolforming substrate.

[0098] A consumable may comprise a bottom layer, a thin paper-based frame, a layer of aerosol-forming substrate and a susceptor element. The layers may be attached to each other by means of lamination or gluing. A removable foil may be used to envelope and thereby protect the consumable during storage and transport. The removable foil may be provided as a peelable layer. The removable foil is to be removed before inserting the consumable in the consumable tray.

[0099] In embodiments in which the susceptor is comprised in the consumable tray, the consumable does not require an additional susceptor element. Such consumables may be provided in a very simple form as a single layer of aerosol-forming substrate.

[0100] The consumable may be provided in the form of a blister pack. The blister pack may be configured to encase an aerosol-forming substrate. The blister pack may be designed with end apertures at both ends of the blister pack. The end apertures of the blister pack may be configured to open when the blister pack is inserted into the aerosol generating device. In order to facilitate opening of the end apertures, the end apertures of the blister pack may comprise scoring lines configured to rupture upon insertion of the consumable tray into the cavity of the aerosol generating device. The scoring lines can also be configured to be opened manually by the user. Using a blister pack may reduce the likelihood that a user’s hand comes into physical contact with the aerosol-forming substrate. Thus, using a blister pack may enhance the overall user experience.

[0101] Below, there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0102] Example 1 : An aerosol-generating device comprising: a housing with a distal end and a proximal end, the housing defining a cavity, and a consumable tray defining a receptacle for a flat consumable, wherein the consumable tray is configured to be inserted into the cavity of the housing.

[0103] Example 2: The aerosol-generating device according to example 1 , wherein the proximal end of the housing is configured to form a mouthpiece.

[0104] Example 3: The aerosol-generating device according to any one of the preceding examples, wherein the consumable tray comprises a frame. New PCT Patent Application September 1, 2025 Philip Morris Products S.A. 46070-PCT

[0105] -13-

[0106] Example 4: The aerosol-generating device according to any one of the preceding examples, wherein the frame is configured to have a bottom plate with an elevated edge contour to form the receptacle.

[0107] Example 5: The aerosol-generating device according to any one of the preceding examples, wherein the consumable tray comprises an alignment edge for correct placement of the consumable.

[0108] Example 6: The aerosol-generating device according to any one of the preceding examples, wherein the cavity is configured for sliding insertion of the consumable tray.

[0109] Example 7: The aerosol-generating device according to any one of the preceding examples, wherein the consumable tray comprises a gripping element.

[0110] Example 8: The aerosol-generating device according to any one of the preceding examples, wherein, when the consumable tray is fully inserted into the cavity, the gripping element completely covers an access opening of the cavity.

[0111] Example 9: The aerosol-generating device according to any one of the preceding examples, wherein sealing elements are provided between the gripping element and the access opening of the cavity.

[0112] Example 10: The aerosol-generating device according to any one of the preceding examples, wherein the sealing elements are provided as gaskets, or wherein the sealing elements are provided as part of the consumable tray or as part of the access opening.

[0113] Example 11: The aerosol-generating device according to any one of the preceding examples, wherein the gripping element comprises a tab, preferably a rounded tab, configured to interlock with a corresponding notched portion at the access opening of the cavity.

[0114] Example 12: The aerosol-generating device according to any one of the preceding examples, wherein the cavity is configured to extend from an access opening at the distal end of the housing.

[0115] Example 13: The aerosol-generating device according to any one of the preceding examples, further comprising a heating arrangement for heating the consumable.

[0116] Example 14: The aerosol-generating device according to any one of the preceding examples, wherein the heating arrangement is configured to inductively heat the consumable. New PCT Patent Application September 1, 2025 Philip Morris Products S.A. 46070-PCT

[0117] -14-

[0118] Example 15: The aerosol-generating device according to any one of the preceding examples, wherein the heating arrangement comprises an induction coil located adjacent to the cavity.

[0119] Example 16: The aerosol-generating device according to any one of the preceding examples, wherein a thermal insulation layer is arranged to surround the cavity.

[0120] Example 17: The aerosol-generating device according to any one of the preceding examples, wherein the aerosol-generating device comprises a power supply and electronic circuitry.

[0121] Example 18: The aerosol-generating device according to any one of the preceding examples, wherein the aerosol-generating device comprises a charging port for re-charging the power supply.

[0122] Example 19: The aerosol-generating device according to any one of the preceding examples, wherein the aerosol-generating device comprises a display, preferably configured as user interface.

[0123] Example 20: The aerosol-generating device according to any one of the preceding examples, wherein the user interface allows switching on and off the aerosol-generating device and switching between operating modes of the aerosol-generating device.

[0124] Example 21: The aerosol-generating device according to any one of the preceding examples, wherein the display is configured for indicating devices status and power supply life.

[0125] Example 22: The aerosol-generating device according to any one of the preceding examples, wherein the display comprises consumption tracking display.

[0126] Example 23: The aerosol-generating device according to any one of the preceding examples, wherein a cooling chamber is provided between the mouthpiece and the cavity of the aerosol-generating device.

[0127] Example 24: The aerosol-generating device according to any one of the preceding examples, wherein the gripping element defines an air flow channel for introduction of ambient air into the cavity.

[0128] Example 25: The aerosol-generating device according to any one of the preceding examples, wherein the air flow channel of the gripping element comprises an air inlet at the outer surface of the gripping element and an air outlet towards the cavity. New PCT Patent Application September 1, 2025 Philip Morris Products S.A. 46070-PCT

[0129] -15-

[0130] Example 26: The aerosol-generating device according to any one of the preceding examples, wherein the air outlet of the gripping element is formed as a slit, so as to spread up the airflow and so as to create a uniform air flow across the consumable.

[0131] Example 27: The aerosol-generating device according to any one of the preceding examples, wherein the consumable tray is configured to define an air duct, preferably an air duct that extends longitudinally along the length of the consumable tray.

[0132] Example 28: The aerosol-generating device according to any one of the preceding examples, wherein, when the consumable tray is inserted into the cavity, the air duct is in fluid connection with an air inlet in the housing of the aerosol-generating device.

[0133] Example 29: The aerosol-generating device according to any one of the preceding examples, wherein the consumable tray comprises one or more susceptor elements and wherein, when the consumable tray is inserted into the cavity, the induction coil of the aerosol-generating device cooperates with the susceptor elements of the consumable tray to heat a consumable inserted in the consumable tray

[0134] Example 30: The aerosol-generating device according to any one of the preceding examples, wherein the susceptor elements of the consumable tray are further configured to heat an airflow guided through the air duct of the consumable tray.

[0135] Example 31: The aerosol-generating device according to any one of the preceding examples, wherein the aerosol-generating device is configured such that the heated airflow guided through the air duct of the consumable tray is subsequently guided across the consumable in order to generate an aerosol.

[0136] Example 32: The aerosol-generating device according to any one of the preceding examples, wherein the consumable tray comprises a laminated structure, comprising a top dielectric layer, a porous middle layer and a base layer.

[0137] Example 33: The aerosol-generating device according to any one of the preceding examples, wherein the top dielectric layer and the base layer are not air permeable and wherein the porous middle layer is air-permeable.

[0138] Example 34: The aerosol-generating device according to any one of the preceding examples, wherein the air duct of the consumable tray is formed in the porous middle layer.

[0139] Example 35: The aerosol-generating device according to any one of the preceding examples, wherein the consumable tray is configured to form a reverse duct for guiding the heated airflow from the air duct towards the consumable. New PCT Patent Application September 1, 2025 Philip Morris Products S.A. 46070-PCT

[0140] Example 36: The aerosol-generating device according to any one of the preceding examples, wherein the laminated structure of the consumable tray is retained within the gripping element.

[0141] Example 37: The aerosol-generating device according to any one of the preceding examples, wherein the reverse duct is formed between the gripping element and the laminated structure of the consumable tray.

[0142] Example 38: The aerosol-generating device according to any one of the preceding examples, wherein the one or more susceptor elements are provided at the top dielectric layer of the laminated structure of the consumable tray.

[0143] Example 39: An aerosol-generating system comprising an aerosol-generating device according to any one of the preceding examples and a consumable configured for insertion into the receptacle of the consumable tray.

[0144] Example 40: The aerosol-generating system according to the preceding example, wherein the consumable is formed to have a flat rectangular shape.

[0145] Example 41: The aerosol-generating system according to the preceding example, wherein the consumable is formed as a laminated sheet.

[0146] Example 42: The aerosol-generating system according to the preceding example, wherein the consumable is formed as a layered structure.

[0147] Example 43: The aerosol-generating system according to the preceding example, wherein the consumable comprises a layer of aerosol-forming substrate, preferably comprising tobacco material.

[0148] Example 44: The aerosol-generating system according to the preceding example, wherein the consumable comprises a susceptor material preferably in direct contact with the aerosol-forming substrate.

[0149] Example 45: The aerosol-generating system according to the preceding example, wherein the consumable comprises a bottom layer made from thermally conductive material.

[0150] Example 46: The aerosol-generating system according to the preceding example, wherein the consumable comprises a frame made from paper-based material.

[0151] Example 47: The aerosol-generating system according to the preceding example, wherein the consumable comprises a protective layer at the top, wherein the protective layer is preferably provided in the form of a thin peelable layer. New PCT Patent Application September 1, 2025 Philip Morris Products S.A. 46070-PCT

[0152] -17-

[0153] Example 48: The aerosol-generating system according to the preceding example, wherein the consumable is provided in the form of a blister pack.

[0154] Example 49: The aerosol-generating system according to the preceding example, wherein the consumable provided in the form of a blister pack is designed with end apertures at both ends of the blister pack.

[0155] Example 50: The aerosol-generating system according to the preceding example, wherein the end apertures of the blister pack are configured to open when the blister pack is inserted into an aerosol generating device.

[0156] Example 51: The aerosol-generating system according to the preceding example, wherein the end apertures of the blister pack comprise scoring lines configured to rupture upon insertion of the consumable tray into the cavity of an aerosol generating device.

[0157] Features described in relation to one embodiment may equally be applied to other embodiments of the invention.

[0158] The invention will be further described, by way of example only, with reference to the accompanying drawings in which:

[0159] Fig. 1 shows an aerosol-generating device with removable consumable tray;

[0160] Fig. 2 shows details of the removable consumable tray;

[0161] Fig. 3 shows a consumable for use with the aerosol-generating device of Fig. 1;

[0162] Fig. 4 shows details of the distal portion of the aerosol-generating device of Fig. 1 ;

[0163] Fig. 5 shows operation of a display the aerosol-generating device;

[0164] Fig. 6 shows a modified aerosol generating device;

[0165] Fig. 7 shows details of the removable consumable tray of Fig. 6;

[0166] Fig. 8 shows details of the distal portion of the aerosol-generating device of Fig. 6;

[0167] Fig. 9 shows a consumable for use with the aerosol-generating device of Fig. 6.

[0168] Fig. 1 schematically depicts an aerosol-generating device 10 comprising a housing 12 with a distal end 14 and a proximal end 16. At the proximal end 16 of the housing 12 a mouthpiece 18 is formed.

[0169] The housing 12 defines a cavity 20 with an access opening 21 at the distal end 14 of the housing 12. The cavity 20 is configured to receive a consumable tray 40. The consumable tray 40 defines a receptacle 48 for a flat consumable 42. New PCT Patent Application September 1, 2025 Philip Morris Products S.A. 46070-PCT

[0170] -18-

[0171] The housing further comprises a power source 22, electronic circuitry 24, a display 26, a charging port 28 and a heating arrangement 30 comprising a plurality of flat induction coils 32.

[0172] The aerosol-generating device 10 defines an airflow passage from an air inlet 34, via airflow channel 35, through the cavity 20 towards an aerosol outlet 36 at the mouthpiece 18. Between the cavity 20 and the mouthpiece 18 there is provided a cooling chamber 38.

[0173] The consumable tray 40 is depicted in more detail in Fig. 2. The consumable tray 40 comprises a rectangular plate 44 designed with an elevated edge contour 46 to form a framed receptacle 48. The receptacle 48 is configured for receiving a sheet-like, flat consumable 42. In the embodiment depicted in Fig. 2 the consumable has a cut-off portion 43 and the receptacle 48 is formed with a correspondingly formed alignment edge 50. Cut-off portion 43 and alignment edge 50 facilitate correct placement of the consumable 42.

[0174] At the distal end of the consumable tray 40 there is provided a stem-shaped gripping element 52. The gripping element 52 serves as a handle for the user and is formed to be gripped by the user’s hand for inserting or removing the consumable tray 40 into or from the cavity 20.

[0175] The air inlet 34 (not visible in Fig. 2) is formed at the distal end of the gripping element 52. The gripping element defines an airflow channel 35 (not visible in Fig. 2) which extends from the air inlet 34 and which is configured for introduction of ambient air into the cavity 20. The airflow channel 35 of the gripping element comprises an air outlet 59 for releasing fresh ambient air into the cavity 20. As indicated in Fig. 2, the air outlet 59 of the gripping element 52 is formed as a slit. The slit spreads up the airflow upon entering into the cavity 20. In this way a uniform airflow across the consumable 42 may be obtained.

[0176] The gripping element 52 is formed such as to completely cover the access opening 21 , when the consumable tray 40 is fully inserted into the cavity 20 of the aerosol-generating device 10. As depicted in Fig. 2, the access opening 21 of the cavity 20 is provided with a notched portion 54. The gripping element 52 has a correspondingly shaped rounded tab 56. These features allow a user to securely handle the consumable tray 40 upon insertion and removal. In addition, the notched portion 54 of the access opening 21 and the rounded tab 56 form an interlock to retain the consumable tray 40 in the cavity 20. For enhanced sealing effectiveness, the gripping element 52 includes a sealing element 58 (see Fig. 4). The sealing element 58 may assist in creating a hermetic seal between the mating surfaces of the gripping element 52 and the access opening 21 of the cavity 20. In addition, the sealing element 58 may ensure compressive retention between the gripping element 52 and the access opening 21 of the cavity 20. New PCT Patent Application September 1, 2025 Philip Morris Products S.A. 46070-PCT

[0177] -19-

[0178] In Fig. 3 details of a consumable 42 suitable to be used with the aerosol-generating device 10 of Fig. 1 is depicted. The consumable 42 is formed as a laminated sheet comprising a plurality of layers. The consumable 42 comprises a bottom layer 62 of thermally conductive material. On top of the bottom layer 62 there is provided a layer of aerosolforming substrate 64. The layer of aerosol-forming substrate 64 comprises tobacco-based material and susceptor elements 66. The aerosol-forming substrate 64 is surrounded by a thin paper-based frame 68. A thin peelable foil 70 is provided as protective layer on top of the layered structure of the consumable 42. Each layer is attached to the neighboring layers by means of lamination. As indicated by the arrow in Fig. 3, the peelable foil 70 can be detached once the consumable 42 is placed in the receptacle 48 and just before the consumable tray 40 is inserted into the cavity 20 of the aerosol-generating device 10.

[0179] The susceptor elements 66 are in intimate contact with the layer of aerosol-forming substrate 64 that is to be heated in use. Varying magnetic fields generated by the induction coils 32 heat up the susceptor elements 66, which in turn heat up the aerosol-forming substrate 64.

[0180] In Fig. 4 an enlarged view of the distal portion of the aerosol-generating device 10 is depicted. Identical components are denoted with identical reference numerals. In Fig. 4 when a consumable tray 40 is fully inserted into the cavity 20 of the aerosol-generating device 10, a pair of sealing elements 58 is positioned at the access opening 21. The pair of sealing elements 58 assists in retaining the consumable tray 40 within the housing 12, while hermetically sealing the cavity 20.

[0181] The bottom layer 62 of the consumable tray 40 rests against a lower sidewall of the cavity 20. A consumable 42 is positioned on the tray 40 and is located beneath the plurality of induction coils 32. The induction coils are embedded in an upper sidewall of the cavity 20. A gap is formed between the consumable 42 and the upper sidewall of the cavity 20. Ambient air entering the cavity 20 through the air inlet 34 and the airflow channel 35 of the gripping element 52 is guided along the gap between the consumable 42 and the upper sidewall of the cavity 20.

[0182] The induction coils 32 are supplied by the controller 24 with electrical power from the power source 22. The induction coils 32 are operated to generate a varying magnetic field for inductively heating the susceptor elements 66 of the consumable 42. By heating the susceptor elements 66 and in turn the aerosol-generating substrate 64, volatile compounds of the aerosol-generating substrate 64 are vaporized. The airflow through the cavity 20 mixes with and entrains the vaporized compounds forming an inhalable aerosol. This aerosol is then guided into the cooling chamber 38 and may be inhaled by a user taking a puff at the mouthpiece 18. New PCT Patent Application September 1, 2025 Philip Morris Products S.A. 46070-PCT

[0183] -20-

[0184] Fig. 5 illustrates an operation cycle of the aerosol-generating device 10 comprising a large display 26 acting as a user interface. The display 26 comprises various sections 26a, 26b configured to convey specific operation related information to the user. Most prominently the display 26 comprises a consumption tracking display 26a which visually indicates the consumption level of the inserted consumable 42. As shown in the top view of Fig. 5, prior to the insertion of the consumable tray 40, the consumption tracking display 26a remains unlit. Upon insertion of the consumable tray 40 loaded with a fresh consumable 42 green lights signify a full or nearly full consumable 42, as depicted in the second view of Fig. 5. The green lights suggest that the consumable 42 is essentially unused. Upon use of the aerosolgenerating device 10 and as the consumable 42 depletes, the indicator lights of the consumption tracking display 26a gradually turn red, as indicated in the third view of Fig. 5. By turning red, the consumption tracking display 26a indicates to the user that the consumable 42 is being depleted. This visual indication helps users to understand how much of the consumable 42 is left and gives an early alert as to when the consumable 42 might need replacing or refilling. Once the consumable 42 is fully depleted, the user may decide to remove the depleted consumable 42 as indicated in the lowermost view of Fig. 5.

[0185] Apart from the consumption tracking display 26a the display 26 also integrates an additional display portion 26b with further visual indicators. In the depicted case the display portion 26b includes indicators relating to the current operation mode of the aerosolgenerating device 10. The display portion 26b also comprises indicators providing information as to the type of consumable 42 being used such as information regarding a specific flavor of the consumable 42.

[0186] Fig. 6 shows a further embodiment of an aerosol-generating device 10 comprising a consumable tray 40. Similar to the embodiment depicted in Fig. 1 , the aerosol-generating device 10 of Fig. 6 comprises a housing 12 with a distal end 14 and a proximal end 16. At the proximal end 16 of the housing 12 a mouthpiece 18 is formed. Also in this case the consumable tray 40 is to be inserted into a cavity 20 extending from an access opening 21 formed at a distal end 14 of the aerosol-generating device 10.

[0187] The housing 12 defines a cavity 20 with an access opening 21 at the distal end 14 of the housing 12. The cavity 20 is configured to receive a consumable tray 40. The consumable tray 40 defines a receptacle 48 for a flat consumable 42. The housing 12 comprises a power source 22, electronic circuitry 24, a display 26, a charging port 28 and a heating arrangement 30 comprising a plurality of flat induction coil 32. The aerosolgenerating device 10 defines an air flow channel from an air inlet 34 through the cavity 20 towards an aerosol outlet 36 at the mouthpiece 18. Between the cavity 20 and the mouthpiece 18 there is provided a cooling chamber 38. New PCT Patent Application September 1, 2025 Philip Morris Products S.A. 46070-PCT

[0188] -21-

[0189] In this embodiment the air inlet 34 is not formed in the gripping element 52 of the consumable tray 40. Instead, the air inlet 34 is formed in the housing 12 of the aerosol generating device 10 adjacent to the proximal end of the fully inserted consumable tray 40. Fresh ambient air is guided from the air inlet 34 towards the distal end 14 of the aerosolgenerating device 10. Subsequently the airflow is redirected and guided across the consumable 42 to generate an aerosol. The aerosol is then guided via the cooling chamber 38 towards the mouthpiece 18 of the aerosol-generating device 10.

[0190] Details of the consumable tray 40 are depicted in Fig. 7. The consumable tray 40 has a layered structure comprising a base layer 70, a middle layer 72 and a top layer 74. The base layer 70 is impermeable for air and is formed from a thin foil of stainless steel. The top layer 74 is formed from a dielectric material. In this case the top layer 74 is formed as a polyimide film.

[0191] Between the air impermeable base and top layers 70, 74, there is provided a middle layer 72. The middle layer 72 is designed as a thin block of porous ceramic material. The middle layer 72 is air permeable and sandwiched between the two air impermeable layers 70, 74. The middle layer 72 forms a generally flat airduct 75 for ambient air from the air inlet 34. Frame elements 76a, b, 78 formed from air impermeable material are provided to circumscribe the lateral side edges and the proximal end edge of the layers 70, 72, 74 of the consumable tray 40. The proximal frame element 78 comprises a frame inlet 80 that is configured to communicate in the assembled state with the air inlet 34 of the aerosolgenerating device 10. The frame elements 76a, 76b, 78 have an increased height as compared to the layered structure of the consumable tray 40 such that the upper portions of the frame elements 76a, 76b, 78 form the receptacle 48 for receiving a consumable 42.

[0192] As depicted in Fig. 7 the base layer 70 and the middle layer 72 are designed with a greater length than the top layer 74. Thereby an extension 82 is created which engages with the gripping element 52. In more detail, an overlapping edge 84 of the gripping element 52 is formed with a widened nozzle 86 designed to extend over the extension 82. This arrangement positions the widened nozzle 86 directly above the extension 82 thereby establishing a reverse duct 88. Fresh ambient air introduced into the aerosol-generating device 10 via air inlet 34 is guided towards the frame inlet 80 and further guided through the airduct 75 towards the distal end of the consumable tray 40. At the reverse duct 88 the airflow is redirected by 180 degrees and is guided by the widened nozzle 86 towards a consumable 42 positioned on the consumable tray 40.

[0193] The top dielectric layer 74 supports a group of susceptor elements, further referred to as tray susceptors 90. The tray susceptors 90 are evenly distributed on the top layer 74 and are designed such that their upper surfaces are exposed and capable of contacting a New PCT Patent Application September 1, 2025 Philip Morris Products S.A. 46070-PCT

[0194] -22- consumable 42 positioned thereon. The bottom surfaces of the tray susceptors 90 are in good thermal contact with the dielectric top layer 74 and in particular with the airduct 75 formed in the porous middle layer 72 below. This arrangement enables the tray susceptors 90 to simultaneously heat a consumable 42 positioned on the consumable tray 40 and an airflow guided within the airduct 75 formed in the middle layer 72 of the consumable tray 40. Since the base layer 70 is formed from stainless steel, the base layer 70 acts as a protective barrier against heat and electromagnetic interference, effectively shielding nearby electronic components from any electromagnetic fields generated by the induction coils 32 of the aerosol-generating device 10.

[0195] As described above, the consumable tray 40 can be produced using lamination processes such as heat sealing, to bond together the different layers. The layered structure may be cut to the required dimensions, and subsequently be encased with the frame elements 76a, 76b, 78. Finally, the layered structure of the consumable tray 40 is combined with the gripping element 52 using a friction fit engagement.

[0196] An enlarged view of the distal portion of the aerosol-generating device 10 with inserted consumable tray 40 is depicted in Fig. 8. Identical components are denoted with identical reference numerals. In Fig. 8 when the consumable tray 40 is fully inserted into the cavity 20 of the aerosol-generating device 10 a pair of sealing elements 58 is positioned at the access opening 21. The pair of sealing elements 58 assists in retaining the consumable tray 40 within the housing 12, while hermetically sealing the cavity 20.

[0197] The base layer 70 of the consumable tray 40 rests against a lower sidewall of the cavity 20. A consumable 42 is positioned on the tray 40 and is located beneath the plurality of induction coils 32. The induction coils 32 are embedded in an upper sidewall of the cavity 20. In register with the induction coils 32 there are provided susceptor elements that are referred in the following as cavity susceptors 37. The cavity susceptors 37 are inductively heated by varying magnetic fields generated by the induction coils 32.

[0198] Adjacent to the induction coils 32 an electromagnetic shield 39 is provided that surrounds the cavity 20 and primarily provides heat and electromagnetic protection to nearby electronic components, in particular the electric circuitry 24 and the display 26.

[0199] Ambient air entering the cavity 20 through the air inlet 34 is guided through the airduct 75 in the middle layer 72 of the consumable tray 40. During this passage the fresh ambient air is preheated by the heat generated by the tray susceptors 90. At the distal end of the consumable tray 40 the preheated airflow is redirected by the reverse duct 88 and is spread via the widened nozzle 86 onto the consumable 42 positioned on the consumable tray 40. New PCT Patent Application September 1, 2025 Philip Morris Products S.A. 46070-PCT

[0200] -23-

[0201] The preheated air through the cavity 20 mixes with and entrains the vaporized compounds of the heated aerosol-forming substrate of the consumable 40 forming an inhalable aerosol. This aerosol is then guided into the cooling chamber 38 and may be inhaled by a user taking a puff at the mouthpiece 18. In this embodiment heating of the consumable is performed by the tray susceptors 90 and by the cavity susceptors 37.

[0202] Fig. 9 shows a consumable that is particularly suitable to be used with the aerosolgenerating device of Figs. 6 to 8. The flat consumable 42 is designed as a blister pack 92 that encases a sheet-like aerosol-forming substrate. The aerosol-forming substrate is formed from tobacco material. The blister pack 92 comprises a top sheet 94 and a bottom sheet 96 that are welded together to form the sealed blister pack 92. The blister pack 92 is designed with end apertures 98, 99 at the distal and the proximal end of the blister pack 92. These apertures 98, 99 allow an airflow throughout the interior of the blister pack 92 for aerosol generation. Since the aerosol-forming substrate is completely enveloped by the blister pack 92 a user does not come into direct physical contact with the aerosol-forming substrate.

[0203] The end apertures 98, 99 are designed to be opened manually when the blister pack 92 is inserted into an aerosol generating device by rupturing scoring lines 97.

Claims

New PCT Patent Application September 1, 2025 Philip Morris Products S.A. 46070-PCT-24-CLAIMS1. An aerosol-generating device comprising: a housing with a distal end and a proximal end, the housing defining a cavity, and a consumable tray defining a receptacle for a flat consumable, wherein the consumable tray is configured to be inserted into the cavity of the housing.

2. The aerosol-generating device according to claim 1 , wherein the consumable tray comprises a frame.

3. The aerosol-generating device according to any one of the preceding claims, wherein the frame is configured to have a bottom plate with an elevated edge contour to form the receptacle.

4. The aerosol-generating device according to any one of the preceding claims, wherein the consumable tray comprises a gripping element.

5. The aerosol-generating device according to any one of the preceding claims, wherein, when the consumable tray is fully inserted into the cavity, the gripping element completely covers an access opening of the cavity.

6. The aerosol-generating device according to any one of the preceding claims, wherein the cavity is configured to extend from an access opening at the distal end of the housing.

7. The aerosol-generating device according to any one of the preceding claims, wherein the gripping element defines an air flow channel for introduction of ambient air into the cavity.

8. The aerosol-generating device according to any one of the preceding claims, wherein the air flow channel of the gripping element comprises an air inlet at the outer surface of the gripping element and an air outlet towards the cavity.New PCT Patent Application September 1, 2025 Philip Morris Products S.A. 46070-PCT-25-9. The aerosol-generating device according to any one of the preceding claims, wherein the air outlet of the gripping element is formed as a slit, so as to spread up the airflow and so as to create a uniform air flow across the consumable.

10. The aerosol-generating device according to any one of the preceding claims, wherein the consumable tray is configured to define an air duct, preferably an air duct that extends longitudinally along the length of the consumable tray.

11. The aerosol-generating device according to claim 10, wherein, when the consumable tray is inserted into the cavity, the air duct is in fluid connection with an air inlet in the housing of the aerosol-generating device.

12. The aerosol-generating device according to any one of the preceding claims, wherein the consumable tray comprises one or more susceptor elements and wherein, when the consumable tray is inserted into the cavity, the induction coil of the aerosol-generating device cooperates with the susceptor elements of the consumable tray to heat a consumable inserted in the consumable tray.

13. An aerosol-generating system comprising an aerosol-generating device according to any one of the preceding claims and a consumable configured for insertion into the receptacle of the consumable tray of the aerosol-generating device.

14. The aerosol-generating system according to the preceding claim, wherein the consumable is formed as a layered structure.

15. The aerosol-generating system according to the preceding claim, wherein the consumable is provided in the form of a blister pack.

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