A Flat-Shaped Consumable Article for an Aerosol Generating Device, Comprising a Support Structure

FIELD OF THE INVENTION

The present invention concerns a flat-shaped consumable article for an aerosol generating device, comprising a support structure.

Particularly, the flat-shaped consumable article according to the invention is configured to operate with an aerosol generating device, also known as a heat-not-burn device or HNB device. Such type of aerosol generating devices is adapted to heat, rather than burn, an aerosol generating substrate comprised in the article.

BACKGROUND OF THE INVENTION

The popularity and use of reduced-risk or modified-risk devices (also known as vaporisers or aerosol generating devices) has grown rapidly in the past few years as an aid to assist habitual smokers wishing to quit smoking traditional tobacco products such as cigarettes, cigars, cigarillos, and rolling tobacco. Various devices and systems are available that heat or warm vaporizable substances as opposed to burning tobacco in conventional tobacco products.

A commonly available reduced-risk or modified-risk device is the heated substrate aerosol generation device or heat-not-burn device, also known as HNB device. Devices of this type generate aerosol or vapour by heating an aerosol generating substrate that typically comprises moist leaf tobacco or other suitable vaporizable material to a temperature typically in the range 150° C. to 350° C. Heating an aerosol generating substrate, but not combusting or burning it, releases aerosol that comprises the components sought by the user but not the toxic and carcinogenic by-products of combustion and burning. Furthermore, the aerosol produced by heating the tobacco or other vaporizable material does not typically comprise the burnt or bitter taste resulting from combustion and burning that can be unpleasant for the user and so the substrate does not therefore require the sugars and other additives that are typically added to such materials to make the smoke and/or vapour more palatable for the user.

Some HNB devices can be adapted to operate with consumable articles having reduced dimensions. Such articles can have for example a flat shape and form a sensibly cuboid shape of 1 or 2 mm of thickness. Their transversal and longitudinal dimensions can be comprised between 10 and 30 mm. Due to such shape and dimensions, these consumable articles make the heat transfer for vapour generation more efficient compared to a rod-type format.

It is thus obvious that it may be difficult for the user to handle with consumable articles having reduced dimensions, without bending or breaking them. The handling can be particularly difficult while insertion or removal such articles in or from the HNB device. Additionally, accurate positioning of such articles inside the device can also be difficult.

SUMMARY OF THE INVENTION

One of the aims of the invention is to propose a flat-shaped consumable article for HNB devices which can be easily handled by the user, positioned inside the device to generate aerosol and extracted from it.

For this purpose, the invention relates to a flat-shaped consumable article for an aerosol generating device, the flat-shaped consumable article extending along an article axis and comprising:

- a tobacco substrate defining at least a first pair of opposite lateral surfaces extending along the article axis;
- a support structure comprising an outlet portion arranged successively with the tobacco substrate along the article axis and a substrate portion extending from the outlet portion along the article axis and configured to be engaged with said first pair of opposite lateral surfaces to maintain the tobacco substrate together with the support structure the outlet portion comprising an airflow passage extending from the tobacco substrate;
- the substrate portion comprising a pair of legs, each leg being configured to extend along at least a part of the corresponding lateral surface.

Thanks to these features, the tobacco substrate can be retained by the support structure. The support structure confers to the article an increased rigidity to facilitate handling and reduce its deformation. This retention is ensured notably by the legs extending according at least a part of the consumable article. Particularly, each leg can extend along the whole length of the tobacco substrate or according to a part of its length. This part can for example constitute at least ¼, advantageously at least ½ and more advantageously at least ¾, of the total length of the tobacco substrate. Thus, when the consumable article is inserted in the device or extracted from it, the user can simply handle it using the support structure which forms for example a solid element. It can be thus possible to avoid bending or breaking the tobacco substrate. Additionally, using the support structure, it is possible to position precisely the consumable article inside the device in order to generate aerosol. In particular, the consumable article can be more easily guided in the device, such as in a complementary heating chamber of it. Moreover, the height of the legs may be adapted so as to prevent excessive deformation/squishing of the tobacco substrate and blocking of flow channels. Thus, the user experience can be improved.

In some embodiments, the tobacco substrate can be assembled to the support structure during the article manufacturing. In some cases, the tobacco substrate can be fixed (for example glued) to the support structure and notably, to the legs retaining the tobacco substrate. In some other embodiments, the support structure can be provided separately from the tobacco substrate. In this case, the user can engage the tobacco substrate with the support structure before using the consumable article with the aerosol generating device. In both embodiments, the support structure can be recyclable.

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

Thanks to these features, the tobacco substrate forms a substantially cuboid shape. This shape is particularly suitable to be received at least partially inside an aerosol generating device.

According to some embodiments, each leg defines an internal surface configured to be engaged with the corresponding lateral surface of the tobacco substrate.

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

Advantageously, the cross-sectional shape of the internal surface of each leg has a concave rounded shape and the cross-sectional shape of the corresponding lateral surface having a convex rounded shape.

Thanks to these features, the tobacco substrate can be guided by the legs during its insertion in the support structure. For example, the legs can act as rails and the tobacco substrate can be simply slid between these rails while its insertion. Additionally, the complementary cross-sectional shapes of the legs and the corresponding lateral surfaces of the tobacco substrate can ensure a better contact between these elements as well as a more solid retention of the tobacco substrate between the legs.

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

Thanks to these features, the distance between the legs at the leg ends is greater than this distance in any other region of the legs. Thus, insertion of the tobacco substrate which is performed from the leg ends can be facilitated. Additionally, each leg can further define a straight portion which extends between the outlet portion of the support structure and the corresponding tapered portion. The distance between the legs along the straight portions can be constant. This distance is adapted to retain the tobacco substrate between the legs.

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

Thanks to these features, the support structure can be easily manufactured using for example injection moulding or any other available technique.

According to some embodiments, the support structure is made by injection moulding of a paper pulp material. In other words, the support structure is made of injection-moulded paper pulp material.

The paper pulp presents a particularly advantageous material since it is cheap and heat resistant. Additionally, it ensures a good stiffness and is compatible with this tobacco products.

According to some embodiments, the support structure comprises tobacco powder and/or a flavouring agent.

Particularly, the 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 moulding, the milled tobacco or powder or at least particles of milled tobacco can be added to the material, as the paper pulp, forming the support structure. The addition of tobacco in the support structure is used to increase sensory feeling for the user. For example, when the support structure is heated together with the tobacco substrate, the milled tobacco can release a tobacco taste increasing thus the user experience. Instead of or additionally to milled tobacco, any flavouring agent can be used. Such a flavouring agent can also be adapted to release a flavour upon heating. For example, flavouring agent with a polysaccharide carrier as described in EP2279677, EP2682007, EP2682008, EP2682009 or EP3533348 can be used.

According to some embodiments, comprising a wrapper wrapping the tobacco substrate with or without at least a part of the support structure.

Thanks to these features, the wrapper can ensure preserving of the tobacco and/or flavouring taste released while a vaping session. Additionally, the wrapper can prevent condensation leakage or vapour leakage and can efficiently conduct airflow along the whole area of the tobacco substrate until the outlet portion. The wrapper can be formed from any appropriate material as aluminium 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 whole support structure including the outlet portion. In this last case, the wrapper can be formed from a unique sheet or from different sheets covering separately 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 supporting structure. In this case, the tobacco substrate is wrapped before being inserted between the legs. The wrapper may comprise a tearable portion enabling at least part of the wrapper to be easily removed before insertion.

According to some embodiments, the outlet portion is hollow and preferably either empty or comprising supporting elements arranged inside the outlet portion.

A hollow structure can facilitate airflow inside the outlet portion. When the hollow structure is substantially empty, the airflow is unhindered, and so the pressure resistance is reduced. When the hollow structure comprises supporting elements, such as ribs, pillars or additional walls, can increase the stiffness of the hollow structure. Additionally, in some cases, the supporting elements can act as airflow guides and/or coolers. Thus, the airflow guided to the user can for example be mixed in a specific manner and/or cooled, to increase the user experience. Additionally, in some embodiments, the supporting elements can act as stoppers to prevent insertion of the tobacco substrate inside the outlet portion.

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

Thanks to these features, the surface of the tobacco substrate available for heat transfer is increased compared to a flat surface. The airflow can also be easily conducted through the tobacco substrate. The flow channels can be formed only on one of said lateral surfaces or on each of said lateral surfaces. In this last case, in each cross-section, the flow channels arranged on different lateral surfaces can be staggered between them.

According to some embodiments, the outlet portion comprises at least two edges extending perpendicularly to the article axis, at least a part of each edge being intended to be in contact with the tobacco substrate.

Particularly, the edges of the outlet portion can be in tight contact with the tobacco substrate so as the airflow conducted by the flow channels formed in the substrate can enter entirely inside the outlet portion. In particular, the edges are in contact with at least one protrusion, preferably a plurality of protrusions of the tobacco substrate between the flow channels.

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

In other words, the flow channels are aligned with the corresponding recess portions and each recess portion extends the corresponding flow channel. Thanks to these features, the recess portions can ensure aerosol cooling and good mouthfeel for the user. Additionally, their dimensions and/or alignment with the corresponding flow channel can be adjusted to adjust the cooling effect.

According to some embodiments, the support structure comprises at least one visual characteristic, such a colour, a symbol or an image, defining a flavour of the tobacco substrate.

Thanks to these features, the support structure makes it possible to distinguish a consumable article among other consumable articles having for example different tastes and/or flavourings.

According to some embodiments, said visual characteristic is a colour obtained by mixing the paper pulp material with one or several dyes during injection moulding.

Thus, the support structure can be at least partially or entirely coloured to designate different tastes and/or flavourings of the consumable article. The or each dye used to colour the paper pulp material is advantageously a food dye.

For example, one or any mixture of the following dyes can be used to colour the paper pulp: red, green, blue and yellow.

The red dye is for example Allura Red AC, also known as E129 dye. Its chemical formulation is C₁₈H₁₄N₂Na₂O₈S₂, and its full name is Disodium 6-hydroxy-5-[(2-methoxy-5-methyl-4-sulfonatophenyl)diazenyl]naphthalene-2-sulfonate.

The green dye is for example Fast Green FCF, also known as E143 dye. Its chemical formulation is C₃₇H₃₄N₂Na₂O₁₀S₃and its full 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.

The blue dye is for example Brillant Blue FCF, also known as E133 dye. Its chemical formulation is C₃₇H₃₄N₂Na₂O₉S₃and its full 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.

The yellow dye is for example Tartrazine, also known as E102 dye. Its chemical formulation is C₁₆H₉N₄Na₃O₉S₂and its full name is Trisodium 5-hydroxy-1-(4-sulfonatophenyl)-4-[(E)-(4-sulfonatophenyl)diazenyl]-1H-pyrazole-3-carboxylate.

The weight part of the or each dye in the paper pulp material may for example be comprised between 0.1% and 5%.

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

- a tobacco substrate defining at least a first pair of opposite lateral surfaces extending along the article axis;
- a support structure comprising an outlet portion arranged successively with the tobacco substrate along the article axis and a substrate portion extending from the outlet portion along the article axis and configured to be engaged with said first pair of opposite lateral surfaces to maintain the tobacco substrate together with the support structure, the outlet portion comprising an airflow passage extending from the tobacco substrate;
- wherein the support structure is made of injection-moulded paper pulp material.

Preferably, the support structure comprises tobacco powder and/or a flavouring agent. Preferably, the support structure may comprise at least one visual characteristic, such a colour, a symbol, or an image, defining a flavour of the tobacco substrate. Preferably, the visual characteristic is a colour obtained by mixing the paper pulp material with one or several dyes during injection moulding.

BRIEF DESCRIPTION OF THE DRAWINGS

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

FIG. 1 is a perspective view of an aerosol generating assembly comprising an aerosol generating device and a flat-shaped consumable article according the invention, the flat-shaped consumable article being usable with the aerosol generating device;

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

FIG. 3 is a perspective view of the flat-shaped consumable article of FIG. 1 according to an example of the first embodiment different from the example of FIG. 2;

FIG. 4 is a view similar to the view of FIG. 2, the consumable article being without the wrapper;

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

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

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

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

FIG. 9 is (A) a cross-sectional view according to plane VII-A of FIG. 8 and (B) a cross-sectional view according to plane VII-B of FIG. 8;

FIG. 10 is a perspective view of a flat-shaped consumable article according to a second embodiment of the invention; and

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

DETAILED DESCRIPTION OF THE INVENTION

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

As used herein, the term “aerosol generating device” or “device” may include a vaping device to deliver an aerosol to a user, including an aerosol for vaping, by means of a heater element explained in further detail below. The device may be portable. “Portable” may refer to the device being for use when held by a user. The device may be adapted to generate a variable amount of aerosol, e.g. by activating the heater element for a variable amount of time (as opposed to a metered dose of aerosol), which can be controlled by a trigger. The trigger may be user activated, such as a vaping button and/or inhalation sensor. The inhalation sensor may be sensitive to the strength of inhalation as well as the duration of inhalation to enable a variable amount of vapour to be provided (so as to mimic the effect of smoking a conventional combustible smoking article such as a cigarette, cigar or pipe, etc.). The device may include a temperature regulation control to drive the temperature of the heater and/or the heated aerosol generating substance (aerosol pre-cursor) to a specified target temperature and thereafter to maintain the temperature at the target temperature that enables efficient generation of aerosol.

As used herein, the term “aerosol” may include a suspension of vaporizable material as one or more of: solid particles; liquid droplets; gas. Said suspension may be in a gas including air. Aerosol herein may generally refer to/include a vapour. Aerosol may include one or more components of the vaporizable material.

As used herein, the term “vaporizable material” or “precursor” may refer to a smokable material which may for example comprise nicotine or tobacco and an aerosol former. Tobacco may take the form of various materials such as shredded tobacco, granulated tobacco, tobacco leaf and/or reconstituted tobacco. Suitable aerosol formers include: a polyol such as sorbitol, glycerol, and glycols like propylene glycol or triethylene glycol; a non-polyol such as 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 comprise at least one of a gelling agent, a binding agent, a stabilizing agent, and a humectant.

As used herein, the term “wider” applied in relation with two surfaces is used to compare dimensions of these surfaces in a transversal direction, i.e. direction perpendicular to the extension direction of these surfaces. When at least one of the surfaces has a non-plane shape, said dimension is measured according to a plane passing through at least two points limiting the surface according to the transversal direction.

First Embodiment of the Invention

FIG. 1 shows an aerosol generating assembly 10 comprising an aerosol generating device 11 and a flat-shaped consumable article 12 according to a first embodiment of the invention, called hereinafter consumable article 12. The aerosol generating device 11 is intended to operate with the consumable article 12 which is shown in more detail on FIGS. 2 to 9.

Referring to FIG. 1, the aerosol generating device 11 comprises a device body 15 extending along a device axis Y. The device body 15 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 different pieces. Particularly, according to this example, the mouthpiece 16 is designed to be fixed on or be 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 inside 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 piece. In this case, the consumable article 12 can be inserted inside the device 11 through for example a flow outlet. According to both examples, the mouthpiece 16 defines a through hole adapted to receive at least partially the consumable article 12. Particularly, the through hole can be adapted to receive at least an outlet portion of the consumable article 12, explained in further detail below. According to still another embodiment (not-shown), no mouthpiece 16 is provided with the aerosol generating device 11. In this case, the outlet portion of the consumable article 12 can form a mouth end designed to be in contact with the user's lips and/or mouth while a vaping session.

The housing 17 delimits an internal space of the device 11 receiving various elements designed to carry out different functionalities of the device 11. This internal space can for example receive 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. Particularly, the heating chamber is designed to receive at least a tobacco substrate of the consumable article 12 and to heat it using an appropriate heater. In the example of FIG. 1, the heating chamber may be for example arranged in the extension of the through hole of the mouthpiece 16, according to the device axis Y.

In reference to FIG. 2, the consumable article 12 is for example a flat-shaped cuboid extending along an article axis X between an inlet end 18 and an outlet end 19, and having external dimensions L×W×H. The consumable article 12 is adapted to conduct an airflow from the inlet end 18 to the outlet end 19 as it will be explained in further detail below. In a typical example, the length L of the article 12 according to the article axis X equals substantially to 25-35 mm, for example 33 mm while its width W is comprised between 8 and 15 mm, for example substantially equal to 12 mm and height H is comprised between 0.8 and 2 mm, for example is substantially equal to 1.2 mm. According to different examples, the values L, W and H can be selected within a range of +/−40%, for example.

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

FIG. 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 it is shown in FIG. 4. In reference to this FIG. 4, the consumable article 12 comprises a tobacco substrate 25 for generating aerosol and a support structure 26 for retaining the tobacco substrate 25. The support structure 26 may also serve to collect the aerosol flow from the tobacco substrate 25 and guide it to the user's mouth.

The tobacco substrate 25 is shown in more detail in FIG. 5. The tobacco substrate 25 defines the inlet end 18 of the consumable article 12 and contains a vaporizable or smokable material as defined above. The vaporizable material is for example compressed to form a solid structure which is able to release aerosol upon heating. Examples of tobacco substrates and their manufacturing methods are described in WO/2021/094365 and WO/2021/094366. Particularly, in reference to FIG. 5, the tobacco substrate 25 defines for example a substantially flat-shaped cuboid defining a first pair of opposite lateral surfaces 33A, 33B (represented as the right and left sides of the substrate in FIG. 5), and a second pair of opposite lateral surfaces 34A, 34B (represented as the top and bottom sides of the substrate in FIG. 5), each of said pairs of lateral surfaces extending along the article axis X. The second pair of opposite lateral surfaces 34A, 34B is for example at least 5 times, advantageously 10 times, wider than the first pair of lateral surfaces 33A, 33B. The first pair of opposite lateral surfaces 33A, 33B is designed to be in contact with the support structure 26 as it will be explained in further detail below. Each lateral surface 33A, 33B of the first pair can define a generally flat shape which can define rounded edges in each cross-section. Particularly, in each cross-section, each lateral surface 33A, 33B of the first pair can have a convex rounded shape. The second pair of lateral surfaces 34A, 34B is designed to be heated by the heating chamber of the device 11 by conduction and/or convection. According to another embodiment, the tobacco substrate 25 comprises susceptors and is designed to be heated by induction further to a magnetic interaction of the susceptors with a magnetic coil.

Each lateral surface 34A, 34B of the second pair defines a plurality of flow channels extending along the article axis X and designed to conduct an air flow along the tobacco substrate 25. In the example of FIG. 5, two flow channels 36A are formed on the lateral surface 34A and three flow channels 36B are formed on the lateral surface 34B. In each cross-section of the tobacco substrate 25, the flow channels arranged on different lateral surfaces 34A, 34B can be arranged in a staggered way, as it is shown in FIG. 5. Particularly, in this case, the tobacco substrate 25 can form in each cross-section a wave shape with valley portions between protrusions forming the flow channels 36A, 36B on each lateral surface 34A, 34B. This shape can for example be formed by stamping. In an alternative mode (not shown), the cross-section is not waved but has a widened thickness for a protrusion and a reduced thickness for a flow channel.

FIG. 6 shows in more detail the support structure 26 used to retain the tobacco substrate 25. In a preferred embodiment of the invention, the support structure 26 is formed from one single piece using for example an injection moulding process. The support structure 26 can be made of or comprise a paper pulp material. In some embodiments, the support structure 26 can comprise milled tobacco or a flavouring agent releasable upon heating. The support structure 26 can also be recyclable. The support structure 26 can also comprise at least one visual characteristic, such a colour, a symbol or an image, defining at a flavour of the tobacco substrate.

When said visual characteristic is a colour, it can be obtained by mixing the paper pulp material with one or several dyes during injection moulding. Thus, the support structure 26 can be at least partially or entirely coloured to designate different tastes and/or flavourings of the consumable article 12. The or each dye used to colour the paper pulp material is advantageously a food dye. For example, one or any mixture of the following dyes can be used to colour the paper pulp: red, green, blue and yellow.

In reference to FIG. 6, the support structure 26 comprises an outlet portion 41 designed to be arranged successively 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 be engaged with the first pair of opposite lateral surfaces 33A, 33B to maintain the tobacco substrate 25 together with the support structure 26.

The outlet portion 41 defines an airflow passage extending from the tobacco substrate 25 until the outlet end 19 of the consumable article 12 formed by this outlet portion 41. Thus, the outlet portion 41 is intended to extend the flow channels 36A, 36B of the tobacco substrate 25 and to conduct an airflow from each of these flow channels 36A, 36B until 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 inside or define supporting elements such as ribs, pillars or additional walls. In some embodiments, the outlet portion 41 can contain a filtering element. The filtering element can comprise paper or cellulose acetate tow. External walls delimiting the outlet portion 41 can have a thickness comprised between 0.01 mm and 0.5 mm, and preferably between 0.05 mm and 0.2 mm. At the end opposite to the outlet end 19, the outlet portion 41 comprises two edges 46A, 46B extending perpendicularly to the article axis X, at least a part of each edge 46A, 46B being intended to be in contact with the tobacco substrate 25 as it is shown in FIG. 4. Particularly, these edges 46A, 46B, or at least portions of them, are intended to be in a tight contact with the protrusions of the tobacco substrate 25 and according to the first embodiment of the invention, extend according to a substantially straight line. The thickness of the outlet portion 41 can be equal or less than the maximal height of the tobacco substrate 25. Preferably, the maximal height of the tobacco substrate 25 is between 0.05 mm and 0.2 mm greater compared to the outlet portion's thickness. Thus, in this case, the edges 46A, 46B can act as stoppers while insertion the tobacco substrate 25 in the substrate portion 42. The maximal height of the tobacco substrate 25 is preferably measured as a distance between two planes parallel to the article axis X and tangent to protrusions arranged on opposite lateral surfaces 34A, 34B. In other words, when the protrusions, the maximal height is measured as a distance between these protrusions. According to an alternative example of the support structure 26 shown in FIG. 7, the edges 46A, 46B can comprise stoppers 47 preventing the tobacco substrate 25 from sliding inside the outlet portion 41. These stoppers 47 can protrude from the edges 46A, 46B inside the outlet portion 41 as shown in FIG. 7.

The substrate portion 42 comprises a pair of legs 53A, 53B extending along the article axis X from the outlet portion 41 toward the inlet end 18 of the consumable article 12. Particularly, each leg 53A, 53B is configured to extend along at least a part of the corresponding lateral surface 33A, 33B of the first pair of lateral surfaces of the tobacco substrate 25. In the example of the Figures, the legs 53A, 53B extend according to the whole length of the tobacco substrate 25. According to other examples, the legs 53A, 53B extend according to at least ½, advantageously ¾ of the total length (in direction of axis X) of the tobacco substrate 25. The legs 53A, 53B are for example symmetric in respect with a central plane passing in the middle between the two legs 53A, 53B according to the article axis X. In the further description, only the leg 53B will be explained in detail in reference to FIGS. 8 and 9.

As it is shown in FIG. 8, the leg 53B comprises a straight portion 55 adjacent to the outlet portion 41 and a tapered portion 56 extending from the straight portion 55 until a leg end 57. The tapered portion 56 extends for example between 10 and 50% of the total length of the leg 53B and forms at the leg end 57 a taper angle comprised for example between 1° and 5°. The straight portion 55 defines for example a substantially constant cross-sectional shape shown in part A of FIG. 9. This shape is for example formed by two branches 61, 62 extending toward the central plane and a middle element 63 extending between the branches 61, 62. The tapered portion 56 defines for example a variable cross-sectional shape which gradually changes from the cross-sectional shape of the straight portion 55 until the cross-sectional shape of the leg end 57 shown in part B of FIG. 9. Particularly, as shown in FIG. 9, the extension of the branches 61, 62 gradually decreases from the straight portion 55 until the leg end 57. In some examples (not-shown), the leg end 57 can further define a blocking part blocking the tobacco substrate 25 once it is received between the legs 53A, 53B. The blocking part can protrude from the leg end 57 of each leg 53A, 53B toward the volume formed between the legs 53A, 53B.

The straight portion 55 and the tapered portion 56 form together an internal surface 64 which is configured to be contact with the lateral surface 33B of the tobacco substrate 25. Particularly, the internal surface 66 can define a cross-sectional shape complementary to the cross-sectional shape of the corresponding lateral surface 33B and can thus define a concave rounded shape. In some embodiments, each leg may also be divided in two separate elongated segments joining the outlet portion 41. The leg may also extend over a minor portion of the opposite lateral surfaces 34A, 34B, e.g., less than 5% of them.

Using of the consumable article 12 according to the invention will now be explained. 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 in the support structure 26 as explained above. When the user is intending to use the consumable article 12, he/she inserts the tobacco substrate 25 into the heating chamber and then, mounts the mouthpiece 16 on the outlet portion 41. Alternatively, when no mouthpiece 16 is needed, only the insertion step of tobacco substrate 25 into the heating chamber is performed by the user and the outlet portion 41 serves as a mouthpiece. Then, the user activates the operation of the aerosol generating device 11 that leads to heating of the tobacco substrate 25. Upon user puffs, an airflow is generated inside the consumable article 12 and flows from the inlet end 18 to the outlet end 19 passing first through the flow channels 36A, 36B and then, through the outlet portion 41.

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

Second Embodiment of the Invention

A flat-shaped consumable article 112 according to a second embodiment of the invention will now be explained in reference to FIGS. 10 and 11.

As in the previous case, the consumable article 112 comprises a tobacco substrate 125, a support structure 126 and in some examples, a wrapper (not shown in FIG. 10). The tobacco substrate 125 is similar to the tobacco substrate 25 explained in relation with the first embodiment of the invention. The support structure 126 is also similar to the support structure 26 explained above and notably, comprises an outlet portion 141 and a substrate portion 142 which is similar to the substrate portion 42 explained 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 by edges 146A, 146B intended to be in contact with tobacco substrate 125.

Particularly, as shown in FIG. 11, each edge 146A, 146B of the outlet portion 141 comprises a recess portion 136A, 136B for each flow channel arranged on the corresponding lateral surface of the tobacco substrate 125. Thus, a recess portion 136A, 136B is arranged to face and extend the corresponding flow channel. Each recess portion 136A, 136B can form a semi-circular shape and can extend from the tobacco substrate 125 to a maximal extension length comprised for example between 0.1 mm and 5 mm, preferably between 0.5 mm to 2.5 mm. The recess portions 136A, 136B can act as ventilation holes to cool the airflow inside the outlet portion 126. When a wrapper is provided and covers the outlet portion 141, it can also define holes facing the recess portions 136A, 136B.

A Flat-Shaped Consumable Article for an Aerosol Generating Device, Comprising a Support Structure

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