FIELD OF THE INVENTION

The present invention concerns a flat-shaped tobacco article comprising a gap. The present invention also concerns an aerosol generating device and an aerosol generating assembly associated to such an article.

Particularly, the aerosol generating device according to the invention is configured to operate with the flat-shaped tobacco article according to the invention which comprises for example a solid substrate able to form aerosol when being heated. Thus, such type of aerosol generating devices, also known as heat-not-burn devices, is adapted to heat, rather than burn, the substrate by conduction, convection and/or radiation, to generate aerosol for inhalation.

BACKGROUND OF THE INVENTION

The popularity and use of reduced-risk or modified-risk devices (also known as vaporisers) 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. Devices of this type generate aerosol or vapour by heating an aerosol 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 substrate, but not combusting or burning it, releases aerosol that comprises the components sought by the user but not the toxic and carcinogenic byproducts 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. Tobacco articles, usable with such type of aerosol generating devices can take various forms. Some of them can present an elongated stick or any other suitable shape, like for example a flat shape. However, design of a tobacco article is often a trade-off between its aesthetics and efficiency in heating.

Particularly, in the case of a flat-shaped tobacco article, it is generally necessary to wrap its tobacco portion in paper to make the sample more attractive to the consumer. However, the paper acts as a thermal barrier when heated externally reducing thus the potential efficiency of the device. Additionally, since such a tobacco article is very thin (for example 1 mm), internal heating as it used for example for tobacco sticks, is also challenging.

SUMMARY OF THE INVENTION

One of the aims of the invention is to provide a flat-shaped tobacco article with increased heating efficiency.

For this purpose, the invention relates to a flat-shaped tobacco article configured to operate with an aerosol generating device and extending along an article axis between a mouth end and an abutting end, the tobacco article comprising a mouthpiece portion adjacent to the mouth end and a tobacco portion adjacent to the abutting end; the tobacco portion comprising:

- a substrate layer extending along the article axis and forming two opposite sides;

- a wrapper forming an internal surface and arranged around the substrate layer so as its internal surface is in contact with one side of the substrate layer and forms a gap with the other side of the substrate layer; the gap being adapted to receive a heating blade of the aerosol generating device.

Thanks to these features, the heating blade can be close to the substrate layer increasing thus heating efficiency. Particularly, in this case, no intermediate layer (like a paper wrapper) is interposed between the heating blade and the substrate layer. Additionally, the wrapper preserves the external shape and attractive appearance of the tobacco article for the user. According to some embodiments, the gap is adapted to receive the heating blade of the aerosol generating device so as the heating blade is in contact with the corresponding side of the substrate layer.

Thanks to these features, the heating efficiency can be further increased as substantially all heat generated by the heating blade is transmitted from the heating blade to the substrate layer.

According to some embodiments, the substrate layer is thicker than the gap.

In this case, the substrate layer can contain a greater quantity of vaporizable material. Thus, the time of using of the tobacco article can be prolonged.

According to some embodiments, the mouthpiece portion is adjacent to the tobacco portion.

According to some embodiments, the mouthpiece portion comprises a core and a wrapper forming an internal surface and arranged around the core so as its entire internal surface is in contact with the core.

Thanks to these features, the core can act as a filtering member and/or as a cooling member. Additionally, no gap is formed in the mouthpiece portion. Thus, when the mouthpiece portion forms a filter and/or a cooler, the flow formed in the tobacco portion can be fully filtered and/or at least slightly cooled before achieving the user’s mouth/lips.

According to some embodiments, the internal surface of the wrapper is defined by a single wrapping sheet. For example, the single wrapping sheet may be bended so that the internal surface comprises four parts. In particular, one part of the internal surface may be in contact with one side of the substrate layer, and another part of the internal surface may form the gap with the other side of the substrate layer.

According to some embodiments, the side of the substrate layer forming the gap with the internal surface of the wrapper defines a substrate surface. The substrate surface extends for example in one single plane. According to some embodiments, the substrate surface extends substantially along the whole length of the tobacco portion along the article axis and/or extends transversally to the article axis along a whole width delimited by the internal surface of the wrapper.

According to some embodiments, the substrate surface has the same area size as a part of the internal surface of the wrapper defining the gap with said substrate surface.

According to embodiments, the substrate surface extends in a first plane, and the part of the internal surface of the wrapper defining the gap with said substrate surface extends in a second plane, the first and second plane being substantially parallel one to the other.

According to some embodiments, the flat-shaped tobacco article defines only one gap, which is adapted to receive the heating blade of the aerosol generating device.

According to some embodiments, the wrapper of the mouthpiece portion and the wrapper of the tobacco portion are formed by a same wrapping sheet.

Thanks to these features, the tobacco and the mouthpiece portions can be assembled together.

According to some embodiments, the core comprises corrugated paper.

Thanks to these features, a filter effect and/or cooler effect of the mouthpiece portion can be achieved.

According to some embodiments, the wrapper is made from paper.

Thanks to these features, the cost of the tobacco article can be decreased while preserving a desired design.

The present invention also concerns an aerosol generating device configured to receive the flat-shaped tobacco article as defined above, the aerosol generating device comprising a heating blade configured to be received in the gap of the flat-shaped tobacco article. The present invention also concerns an aerosol generating device comprising a heating chamber extending along a device axis between a closed end and an opening; the heating chamber being configured to receive through its open end a flat-shaped tobacco article as defined above, and comprising a heating blade extending from its closed end and configured to be received in the gap of the flat-shaped tobacco article.

Thanks to these features, the heating blade can be received in the gap formed in the article.

According to some embodiments, the heating blade forms two opposite sides, one of these sides being designed to be in contact with the substrate layer of the tobacco portion of the flat-shaped tobacco article and the other side being designed to be in contact with the internal surface of the wrapper of the tobacco portion of the flat-shaped tobacco article.

According to some embodiments, the heating blade comprises a heating element arranged on the side of the heating blade designed to be in contact with the internal surface of the wrapper of the tobacco portion of the flat-shaped tobacco article.

Thanks to these features, the heating efficiency can be further increased as the heating element is arranged only on the side of the heating blade which faces the substrate layer.

According to some embodiments, the heating chamber comprises two parallel opposite walls extending along the device axis, the heating blade extending parallel to said opposite walls with uneven distances until these walls.

According to some embodiments, the heating blade extends between one of said opposite walls and a plane arranged at mid-distance between these opposite walls.

Thanks to these features, the heating blade can be received in the gap without additional adjustment while insertion. Particularly, the wall of the heating chamber can act as guiding means for the heating blade.

The invention also relates to an aerosol generating assembly, comprising:

- a flat-shaped tobacco article as defined above;

- an aerosol generating device as defined above. 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:

- Figure 1 is a perspective view of an aerosol generating assembly according to the invention, the aerosol generating assembly comprising an aerosol generating device according to the invention and a flat-shaped tobacco article according the invention, the flatshaped tobacco article being usable with the aerosol generating device;

- Figure 2 is a perspective view of the flat-shaped tobacco article of Figure 1 ;

- Figure 3 is different views (A: top, B: front, C: bottom) of the flat-shaped tobacco article of Figure 2;

- Figure 4 is different views (A: front, B: side) of a heating chamber integrated in the aerosol generating device of Figure 1 ; and

- Figure 5 is a side view of the flat-shaped tobacco article of Figure 2 inserted in the heating chamber of Figure 4.

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.

Figure 1 shows an aerosol generating assembly 10 comprising an aerosol generating device 11 and a flat-shaped tobacco article 12, called hereinafter tobacco article 12. The aerosol generating device 1 1 is intended to operate with the flat-shaped tobacco article 12 which is shown in more detail on Figures 2 and 3.

In reference to Figure 2, the tobacco article 12 is for example a flat-shaped cuboid extending along an article axis X and having external dimensions LxWxD. In a typical example, the length L of the article 12 according to the article axis X equals substantially to 33 mm while its width W and depth D are substantially equal respectively to 12 mm and 1 ,2 mm. According to different examples, the values L, W and D can be selected within a range of +/- 40%, for example. The depth D of the tobacco article 12 is formed by a pair of parallel walls 13A, 13B, called hereinafter narrow walls 13A, 13B, and the width W of the substrate is formed by a pair of parallel walls 14A, 14B, called hereinafter wide walls 14A, 14B. In some embodiments, the edges between the wide and narrow walls 13A, 13B, 14A, 14B can be rounded. According to other embodiments of the invention, the tobacco article 12 can have any other suitable flat shape and/or external dimensions.

The tobacco article 12 comprises a tobacco portion 15 and a mouthpiece portion 16 arranged along the article axis X. The tobacco portion 15 may for example be slightly longer than the mouthpiece portion 16. For example, the length L2 of the tobacco portion 15 according to the article axis X may be substantially equal to 18 mm and the length L1 of the mouthpiece portion 16 according to the article axis X may be substantially equal to 15 mm. The tobacco portion 15 defines an abutting end 18 of the article 12 and the mouthpiece portion 16 defines a mouth end 20 of the article 12. The tobacco portion 15 and the mouthpiece portion 16 may be fixed one to the other by a wrapper 21 extending around the substrate axis X. The wrapper 21 forms the narrow and wide walls 13A, 13B, 14A, 14B of the tobacco article 12. In some embodiments, the wrapper 21 is formed from a same wrapping sheet. For example, the narrow and wide walls 13A, 13B, 14A, 14B are formed by a same wrapping sheet, in particular bended so as to form these walls. In some other embodiments, the wrapper 21 is formed by separate wrapping sheets wrapping separately the portions 15, 16 and fixed one to the other by any other suitable mean. The wrapper 21 may, for example, comprise paper and/or non-woven fabric and/or aluminium foil. The wrapper 21 may be porous or air impermeable and forms a plurality of airflow channels extending inside the article 12 between the abutting end 18 and the mouth end 20.

The mouthpiece portion 16 comprises a core 27 also shown on part A of Figure 3 corresponding to a top view of the tobacco article 12. The core 27 is intended to act for example as a cooler to cool slightly the vapour before it is inhaled by the user and may comprise for this purpose for example corrugated paper. The core 27 may be formed through an extrusion and/or rolling process into a stable shape. Advantageously, the core 27 is arranged inside the mouthpiece portion 16 to be entirely in contact with the internal surface of the wrapper 21 delimiting this mouthpiece portion 16, as it is shown on part A of Figure 3. In other words, no gap is formed in the mouthpiece portion 16 between the internal surface of the wrapper 21 and the core 27. In a particular embodiment of the invention (not shown), the mouthpiece portions 16 defines a plurality of venting holes arranged for example according to the whole perimeter of the mouthpiece portion 16 along two axis perpendicular to the article axis X. In other words, according to this particular embodiment, the venting holes are arranged on each wall of the substrate among the narrow walls 13A, 13B and the wide walls 14A, 14B. According to another example, the venting holes are arranged only on the wide walls 14A, 14B or preferably, only on one of the wide walls 14A, 14B. In both examples, the venting holes may be aligned perpendicularly to the article axis X on the or each corresponding wall of the article 12, and can be spaced by a same distance. The venting holes allow fresh air entering inside the article 12 to achieve particular vaping/tasting effects. In a preferred embodiment of the invention, no venting hole is provided.

The tobacco portion 15 is intended to be heated by a heating blade as it will be explained in further detail below. As it is shown on part C of Figure 3 corresponding to a bottom view of the tobacco article 12, the tobacco portion 15 comprises a substrate layer 30 comprising a vaporizable material as defined above. The substrate layer 30 extends inside the tobacco portion 15 along the article axis X and forms two opposite sides. Particularly, the substrate layer 30 is arranged so as one of its side is in contact with the wrapper 21 and the other side forms a gap 32 with the wrapper 21 . For example, one of the sides of the substrate layer 30 can be in contact with the wide wall 14A and the other side can form the gap 32 with the wide wall 14B. In other words, the gap 32 is formed between the internal surface of the wrapper 21 and the corresponding side of the substrate layer 30.

The gap 32 is configured to receive the heating blade parallel to the substrate layer 30 as it will be explained in further detail below. Additionally, as it shown on part C of Figure 3, the substrate layer 30 can be thicker than the gap 32. Particularly, the thickness of the substrate layer 30 can be 1 ,5 or 2 or 3 times greater than the thickness of the gap 32. For example, the thickness of the substrate layer 30 can be comprised between 0,7 and 1 ,1 mm whereas the thickness of the gap 32 can be comprised between 0,1 and 0,5 mm. According to another embodiment, the substrate layer 30 and the gap 32 have the same thicknesses.

Referring again to Figure 1 , the aerosol generating device 1 1 comprises a device body 40 extending along a device axis Y. The device body 40 comprises a mouthpiece 42 and a housing 44 arranged successively along the device axis Y. According to the example of Figure 1 , the mouthpiece 42 and the housing 44 form two different pieces. Particularly, according to this example, the mouthpiece 42 is designed to be fixed on or be received in an insertion opening formed at one of the ends of the housing 44. In this case, the tobacco article can be inserted inside the device 1 1 when the mouthpiece 42 is removed from the housing 44. According to another example (not-shown), the mouthpiece 42 and the housing 44 form one unique piece. In this case, the tobacco article 12 can be inserted inside the device 11 through for example a flow outlet. According to both examples, the mouthpiece 42 defines a through hole adapted to receive at least partially the tobacco article 12. Particularly, the through hole can be adapted to receive at least a part of the mouthpiece portion 16 of the tobacco article 12 as it is shown on Figure 1 .

The housing 44 delimits an internal space of the device 11 receiving various elements designed to carry out different functionalities of the device 1 1. 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 50 for heating the tobacco portion 15 of the tobacco article 12, etc. Among these elements, only the heating chamber 50 will be explained in further detail in reference to Figures 4 and 5.

Particularly, as it is shown on these Figures, the heating chamber 50 can form a cup shape adapted to receive at least the tobacco portion 15 of the tobacco article 12 and in some cases, at least a part of the mouthpiece portion 16, as it is shown in the example of Figure 5. As the tobacco article 12, the heating chamber 50 may also form a cuboid shape extending along the device axis Y and comprising a pair of parallel narrow walls 53A, 53B extending along the device axis Y, a pair of parallel wide walls 54A, 54B extending also along the device axis Y and a bottom wall 58 adjacent to each of said walls and extending perpendicularly to the device axis Y. The bottom wall 58 forms thus a closed end of the chamber 50. Opposite to the bottom wall 58, the heating chamber 50 defines an opening 60 configured to receive the tobacco article 12 so as the corresponding wide walls 14A, 14B of the tobacco article 12 face the corresponding wide walls 54A, 54B of the heating chamber 50, the corresponding narrow walls 13A, 13B of the tobacco article 12 face the corresponding narrow walls 53A, 53B of the heating chamber 50 and the abutting end 18 of the tobacco article 12 abuts against the bottom wall 58 or at least a rib extending from this bottom wall 58. Particularly, the heating chamber 50 is configured to receive the tobacco article 12 so as the narrow wall 13A (respectfully 13B) of the tobacco article 12 faces the narrow wall 53B (respectfully 53A) of the heating chamber 50, and the wide wall 14A (respectfully 14B) of the tobacco article 12 faces the wide wall 54B (respectfully 54A) of the heating chamber 50. The facing wide walls 14A, 14B, 54A, 54B and the facing narrow walls 13A, 13B, 53A, 53B can be in contact one with the other or spaced one from the other.

The heating chamber 50 further comprises a heating blade 62 extending from the bottom wall 58 along the device axis Y. For example, the heating blade 62 can extend along at least a half, advantageously %, of the total length of the heating chamber 50 according to the device axis Y. As shown on part B of Figure 4, the heating blade 62 can be arranged with uneven distances until the wide walls 54A, 54B of the heating chamber 50. For example, the heating blade 62 can extend between the wide wall 54A of the heating chamber and a plane arranged at mid-distance between the wide walls 54A, 54B. In other words, the heating blade 62 can be arranged closer to the wide wall 54A than to the wide wall 54B. This arrangement allows the heating blade 62 to be received in the gap 32 of the tobacco article 12. This respective position of the heating blade 62 and the tobacco article 12 is shown on Figure 5.

The heating blade 62 forms two opposite sides and comprises a heating element 64 arranged on one of the sides. Particularly, as it is shown on part B of Figure 4, the heating element 64 is arranged to face the wide wall 54B of the heating chamber 50. In other words, the heating element 64 is arranged to face a greater volume formed between the heating blade 62 and the corresponding wide wall of the heating chamber 50 in comparison with the volume formed between the heating blade 62 and the other wide wall of the heating chamber 50. Thus, as shown on Figure 5, the heating element 64 is configured to be in contact with the substrate layer 30 to heat this substrate layer 30 by conduction. The heating element 64 may form a heating track or a polyimide film heater extending along substantially the total area of the corresponding side of the heating blade 62 or only for example a centre part of this side. The heating blade 62 may be made of ceramic or metal. Its thickness can for example be comprised between 0,1 mm and 0,5 mm, and can be advantageously equal to 0,3 mm.