Flat-Shaped Consumable Article for an Aerosol Generating Device

Description

FIELD OF THE INVENTION

The present invention concerns a flat-shaped consumable article for an aerosol generating device. For example, said flat-shaped consumable article presents a solid substrate able to form aerosol when being heated.

The flat-shaped consumable article according to the invention is configured to operate with an aerosol generating device. Such type of aerosol generating device, also known as heat-not-burn device, is adapted to heat, rather than burn, the substrate by conduction, convection and/or radiation, to generate aerosol for inhalation.

BACKGROUND OF THE INVENTION

As opposed to tobacco burning devices, various devices that heat or warm vaporizable substances in conventional tobacco products are available.

For example, such devices are heated substrate aerosol generation devices or heat-not-burn devices. 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 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.

For instance, the aerosol substrate used is a flat-shaped consumable article comprising a tobacco portion and a mouthpiece portion. Said flat-shaped consumable article is intended to be received at least partially within a heating chamber of the aerosol generating device. The mouthpiece portion allows the vapour to cool down and to transfer from the tobacco portion to the outlet of the consumable article.

It is so important the flat-shaped consumable article does not collapse during handling, when inserted in the aerosol generating device or during use in the device. The collapsing of the flat-shaped consumable article may obstruct or hinder the flow of vapour.

SUMMARY OF THE INVENTION

One of the aims of the invention is to provide a flat-shaped consumable article that has greater resistance to deformation and that is easier to manufacture.

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 along an article plane parallel to the article axis, said flat-shaped consumable article comprising a tobacco portion and a mouthpiece portion arranged along the article axis,

• • the mouthpiece portion comprising a corrugated core and at least a planar support supporting the corrugated core, the corrugated core being attached to the at least one planar support.

Thanks to these features, the flat-shaped consumable article presents a greater resistance to deformation and is easier to manufacture. The corrugated core enhances the resistance to compression of the mouthpiece portion. In fact, the corrugations of the core increases the bending strength of the core in the direction perpendicular to the corrugations. The planar support further enhances the consumable article's resistance to deformation.

According to some embodiments, the corrugated core defines with the at least one planar support a plurality of flow channels extending substantially parallel to the article axis.

Thanks to these features, the corrugated core enables efficient and consistent vapour flow through the mouthpiece portion.

According to some embodiments, the corrugated core comprises a sheet, said sheet comprising two opposite non-planar surfaces, said non-planar surfaces being formed by generatrixes which are straight lines substantially parallel to the article axis, said generatrixes extending from a directrix that corresponds to a non-nil periodic function.

Thanks to these features, the corrugated core presents a shape that enhances at the same time the resistance to deformation of the consumable article and the flow of vapour through the mouthpiece portion.

According to some embodiments, each non-planar surface of the sheet comprises longitudinal edges extending longitudinally along the article axis, the at least one planar support being in contact with the longitudinal edges of the corresponding non-planar surface.

Thanks to these features, the planar support supports the corrugated core along regularly spaced lines. The resistance to deformation is enhanced homogeneously throughout the mouthpiece portion.

According to some embodiments, an orthogonal projection of the corrugated core onto the article plane is comprised within an orthogonal projection of the at least one planar support onto the article plane.

Thanks to these features, the corrugated core is entirely supported by the planar support. The resistance to deformation is enhanced throughout the entirety of the mouthpiece portion.

According to some embodiments, the corrugated core is glued or welded to the at least one planar support.

Thanks to these features, the resistance to deformation of the consumable article is further increased. In addition, manufacturing of the consumable article is further made easier since the corrugated core and the planar support are joined together. Movement of the corrugated core relatively to the planar support is prevented.

According to some embodiments, the at least one planar support is made up of paper, cardboard or film.

Thanks to these features, the planar support is made up of a material that is common, that has satisfying resistance to deformation features, and that presents no hazard for the user.

According to some embodiments, the flat-shaped consumable article further comprises a wrapper wrapping at least the mouthpiece portion.

Thanks to these features, the generation of condensation inside the aerosol generating device is prevented. Indeed, the wrapper prevents the generated vapour to escape from the article inside the device and to condensate within the heater. The corrugated core and planar support prevents the wrapper from collapsing. Conversely, the wrapper keeps the corrugated core and the support or board in position in the consumable article.

According to some embodiments, the at least one planar support is attached to the wrapper.

Thanks to these features, the resistance to deformation of the consumable article is further increased since the corrugated core, the planar support and the wrapper are mechanically joined together. The manufacturing of the consumable article is further made easier for the same reasons.

According to some embodiments, the flat-shaped consumable article comprises at least two planar supports configured for supporting the corrugated core.

Thanks to these features, the flat-shaped consumable article presents an even greater resistance to deformation.

According to some embodiments, each planar support is in contact with the longitudinal edges of the corresponding non-planar surface.

Thanks to these features, the corrugated core is supported by a planar support along regularly spaced lines on each side. The resistance to deformation is further enhanced homogeneously throughout the mouthpiece portion on both sides of the corrugated core.

The invention also relates to a method for manufacturing a flat-shaped consumable article as described above, said method comprising the steps of:

• • providing the tobacco portion;
  • producing the mouthpiece portion so that the corrugated core is attached to the at least one planar support;
  • arranging the tobacco portion and the mouthpiece portion along the article axis; and
  • attaching the tobacco portion and the mouthpiece portion together.

Thanks to these features, the planar support makes it easier for the consumable article to be manufactured, as the planar support can bear the corrugated core during the assembling process of the consumable article.

According to some embodiment, the step of producing the mouthpiece portion comprises attaching the corrugated core and the at least one planar support to form the mouthpiece portion.

Thanks to these features, the flat-shaped consumable article is easy to manufacture.

According to some embodiment, the step of producing the mouthpiece portion comprises forming the mouthpiece portion by simultaneous extrusion of the corrugated core and of the at least one planar support together.

Thanks to these features, the mouthpiece portion is produced in one step of extrusion. The manufacturing of the flat-shaped consumable article is made even easier. The manufacturing can also be carried out faster since the mouthpiece portion can be produced continuously by continuous extrusion.

According to some embodiment, the step of attaching the tobacco portion and the mouthpiece portion together comprises wrapping at least the mouthpiece portion with a wrapper.

Thanks to these features, the wrapping of the mouthpiece portion is made easier since during wrapping the planar support constitute a support for the corrugated core.

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 to the invention;
  • FIG. 2 is a simplified perspective view of the flat-shaped consumable article of FIG. 1;
  • FIG. 3 is a partial perspective view of the flat-shaped consumable article according to a first embodiment of the invention;
  • FIG. 4 is front view of the flat-shaped consumable article of FIG. 3;
  • FIG. 5 is a partial perspective view of the corrugated core of the flat-shaped consumable article of FIG. 3;
  • FIG. 6 is a partial perspective view of the flat-shaped consumable according to a second embodiment of the invention;
  • FIG. 7 is a partial perspective view of the flat-shaped consumable according to a third embodiment of the invention.

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.

First Embodiment of the Invention

FIG. 1 shows an aerosol generating assembly 1 according to the invention. The aerosol generating assembly 1 comprises an aerosol generating device 10 and an aerosol generating substrate 30, also called flat-shaped consumable article 30. The aerosol generating device 10 is intended to operate with the flat-shaped consumable article 30 according to a first embodiment of the invention, shown in more detail on FIGS. 2 to 5.

Referring again to FIG. 1, the aerosol generating device 10 comprises a device body 12. The device body 12 extends along a device axis X and comprises at least one side wall 14. The device body 12 further comprises a mouthpiece 16 and a housing 18 arranged successively along to the device axis X. For instance, the mouthpiece 16 and the housing 18 are two different parts.

For example, the mouthpiece 16 comprises a cavity 20 extending along the device axis X. In particular, the cavity 20 is designed to receive the flat-shaped consumable article 30 so that the device axis X coincides with an article axis Y which will be further detailed below. For instance, the cavity 20 has a cross-sectional shape substantially similar to the one of the flat-shaped consumable article 30. The cavity 20 is for instance a through-hole extending along the device axis X.

The housing 18 delimits an internal space of the device 10 receiving various elements designed to carry out different functionalities of the device 10. This internal space can for example receive a battery for powering the device 10, a control module for controlling the operation of the device 10, a heating chamber (not shown) for heating the flat-shaped consumable article 30 and at least one heating element (not shown) for heating the heating chamber.

In reference to FIG. 2, the flat-shaped consumable article 30 is for example a flat-shaped cuboid. The flat-shaped consumable article 30 substantially extends along the article axis Y and in an article plane A parallel to the article axis Y. The consumable article 30 presents a length L, a width W and a height H. The length L is measured according to the article axis Y between two opposite ends of the article 30. The width W is measured perpendicularly to the article axis Y in the article plane A between two opposite ends of the article 30. The height H is measured perpendicularly to the article axis Y and perpendicularly to the article plane A between two opposite ends of the article 30. For instance, by flat-shaped, it is meant that the height H is much less than both the length L and the width W. In particular, the height H is between 5 times and 50 times less than the length L or than the width W. In a typical example, the length L of the consumable article 30 is substantially equal to 33 mm while its width W and height H are substantially equal respectively to 12 mm and 1.2 mm. According to different examples, the values L, W and H can be selected within a range of +/−40% of the above-mentioned values, for example.

The flat-shaped consumable article 30 comprises a tobacco portion 32 and a mouthpiece portion 34 arranged along the article axis Y. In other terms, the tobacco portion 32 and the mouthpiece portion 34 are lined up along the article axis Y. The tobacco portion 32 and the mouthpiece portion 34 may be arranged consecutively along the article axis Y. Alternatively, an intermediate element (not shown on the drawings) may be arranged between the tobacco portion 32 and the mouthpiece portion 34. For example, the intermediate element is a filter plug. For instance, the consumable article 30 further comprises a wrapper 70. According to the article axis Y, the flat-shaped consumable article 30 comprises an abutting end 40 intended to be inserted in the cavity 20 of the mouthpiece 16 of the device 10, in particular in a heating chamber of the device 10, and a mouthpiece end 42 opposite the abutting end 40. For instance, the length L of the article 30 is measured between the abutting end 40 and the mouthpiece end 42.

The tobacco portion 32 comprises a tobacco substrate. The tobacco portion 32 is intended to be heated by a heater (using the heating chamber in the present example) and comprises vaporizable material as defined above. As shown on FIG. 2, the tobacco portion 32 comprises side walls 33 that extend substantially parallel to the article axis.

For instance, the mouthpiece portion 34 is intended to be received inside the mouthpiece 16 (as illustrated on FIG. 1). In some non-illustrated examples, the mouthpiece portion 34 forms itself a mouthpiece intended to be in contact with the user's mouth and/or lips. As shown on FIG. 2, the mouthpiece portion 34 comprises planar sides 35, said planar sides 35 being flush with the side walls 33 of the tobacco portion 32. As shown on FIGS. 3 to 5, the mouthpiece portion 34 comprises a corrugated core 50 and at least a planar support 60, advantageously at least two planar supports 60, configured for supporting the corrugated core 50. According to a non-illustrated example, the mouthpiece portion 34 comprises one planar support 60. According to the examples shown on FIGS. 3 and 4, the mouthpiece portion 34 comprises two planar supports 60, advantageously arranged on both sides of the corrugated core 50, relative to the article plane A.

The corrugated core 50 is attached to the at least one planar support 60. As illustrated on FIG. 4, the corrugated core 50 defines a first delimiting plane P1 and a second delimiting plane P2, both planes P1 and P2 extending substantially parallel to the article plane A. The corrugated core 50 extends between said first P1 and second P2 delimiting planes. As shown on FIG. 4, an orthogonal projection of the corrugated core 50 onto the article plane A is comprised within an orthogonal projection of the at least one planar support 60 onto the article plane A. The corrugated core 50 defines with the at least one planar support 60 a plurality of flow channels 51 extending substantially parallel to the article axis Y. According to the examples shown on FIGS. 3 to 5, the corrugated core 50 comprises a sheet 52. For example, the corrugated core 50 is made up of paper or cardboard. Advantageously, the corrugated core 50 is glued to the at least one planar support 60. According to a specific example, the corrugated core 50 is made up of paper or cardboard laminated with thermoplastic. In this specific example, the corrugated core 50 may be welded to the at least one planar support 60.

For example, the flow channels 51 are delimited by the corrugated core 50 and by a planar support 60 or are delimited by the corrugated core 50 and the wrapper 70. The flow channels 51 form passages for the vapour to flow in towards the user's mouth.

Advantageously, the sheet 52 of the corrugated core 50 extends between the two delimiting planes P1, P2. The sheet 52 comprises two opposite non-planar surfaces 54 (or corrugated surfaces). For instance, the non-planar surfaces 54 are each characterized by a directrix D (shown on FIGS. 4 and 5) that corresponds to a non-nil periodic function and generatrixes G (shown on FIG. 5) that are straight lines substantially parallel to the article axis Y. In particular, each non-planar surface 54 is formed by generatrixes G extending from a directrix D. For instance, the directrix D corresponds to a sine wave function, a square wave function, a triangular wave function or a sawtooth wave function. According to the example of FIGS. 3 to 5, the directrix D corresponds to a truncated triangular wave function. By “truncated triangular wave function”, it is meant that the directrix D corresponds to a triangular wave function, the ordinates of which being limited between a truncation maximum and a truncation minimum, the truncation maximum being less than the corresponding triangular wave function maximum and the truncation minimum being less than the corresponding triangular wave function minimum. In other terms, in this example, as shown on FIGS. 3 to 5, the directrix D corresponds to a trapezoid wave function. Advantageously, the period of the function of the directrix D is not constant. In particular, the directrix D may present a first portion of function with a first period and a second portion of function with a second period, said second period being different from the first period.

Each non-planar surface 54 of the sheet 52 comprises longitudinal edges 56 extending longitudinally along the article axis Y.

The longitudinal edges 56 of a non-planar surface 54 correspond to lines or sub-surfaces of said non-planar surface 54 that extend substantially parallel to the article axis Y. For example, as shown on FIG. 4, the longitudinal edges 56 of a first non-planar surface 54 of the sheet 52 extend within the first delimiting plane P1 and the longitudinal edges 56 of a second non-planar surface 54 of the sheet extend within the second delimiting plane P2. According to the example of FIGS. 3 to 5, the longitudinal edges 56 are planar surfaces substantially parallel to the article axis A. According to non-illustrated examples, the longitudinal edges 56 are straight lines substantially parallel to the article axis A, in particular when the directrix D corresponds to a sine wave function, a triangular wave function or a sawtooth wave function. Advantageously, the longitudinal edges 56 are glued or welded to the planar support 60 they face.

Advantageously, the at least one planar support 60 is in contact with the longitudinal edges 56 of the first non-planar surface 54. According to the examples shown in FIGS. 3 and 4, a first planar support 60 is in contact with the longitudinal edges 56 of the first non-planar surface 54 and a second planar support is in contact with the longitudinal edges of the second non-planar surface 54. For instance, the at least one planar support is attached to the wrapper 70, in particular is glued or welded to the wrapper 70. For example, the at least one planar support 60 is essentially made up of paper, cardboard or film such as an adhesive film, an anti-staining film or a moisture resistant film. According to a specific example, the at least one planar support 60 is made up of paper or cardboard, laminated with thermoplastic. In this specific example, the corrugated core 50, in particular the longitudinal edges 56 may be welded to the at least one planar support 60. As shown in the example of FIG. 3, the corrugated core 50 and the at least one planar support 60, here the two planar supports 60, are distinct parts. The at least one planar support 60 may present flat or ridged surfaces.

As shown in FIGS. 2, 3 and 4, the wrapper 70 wraps at least the mouthpiece portion 34. In particular, as shown in FIG. 2, the wrapper 70 wraps both the tobacco portion 32 and the mouthpiece portion 34. For example, the wrapper 70 attaches the tobacco portion 32 and the mouthpiece portion 34 together. In a non-illustrated example, the wrapper 70 comprises two separate parts, which are a first part wrapping the tobacco portion 32 and a second part wrapping the mouthpiece portion 34. The first part of the wrapper 70 is not integral with the second part of the wrapper 70. The tobacco portion 32 and the mouthpiece portion 34 are then fixed one to the other by other suitable mean.

The wrapper 70 can be made up of paper and/or non-woven fabric and/or aluminium. For instance, the wrapper 70 is made of a single layer. In a variant, the wrapper 70 is made of at least two layers. Preferably, the part of the wrapper 70 wrapping the tobacco portion 32 comprises an outer paper layer and an inner aluminium layer. The outer paper layer may extend to wrap the mouthpiece portion 34 and the inner aluminium layer may be shorter so as to wrap only the tobacco portion 32. Alternatively, the wrapper 70 comprises an inner paper layer and an outer aluminium layer. In this case, the inner paper layer may be longer than the outer aluminium layer. In a variant, the aluminium layer, whether it is an inner layer or an outer layer, wraps the whole mouthpiece portion.

The wrapper 70 may be porous or air impermeable. In an embodiment, at least a part of the wrapper 70 can be made of air impermeable material. The wrapper 70 can comprise a dedicated ventilation area. The ventilation area may be positioned in the part of the wrapper wrapping the mouthpiece portion 34. The ventilation area may be formed by air apertures provided through the wrapper 70. The air apertures may further be formed through the flat or planar support 60. For example, the air apertures can be formed as a series of perforations extending along a direction perpendicular to the article plane A of the consumable article 30 or in a direction parallel to the article plane A and perpendicular to the article axis Y. The air apertures (e.g., of diameter or longer dimension of 0.2 mm to 0.6 mm each) may be formed by laser cutting or any other suitable techniques. Since the planar sides 35 of the mouthpiece portion 34 are flush with the side walls 33 of the tobacco portion 32, when both the tobacco portion 32 and the mouthpiece portion 34 are wrapped by one wrapper 70, the article 30 seems to be in one piece to the touch. This makes the article 30 easier to produce and pleasant to the touch for the user.

A method for manufacturing the flat-shaped consumable article 30 will now be described. Initially, the method comprises a step of providing the tobacco portion 32. The method then comprises a step of producing the mouthpiece portion 34 so that the corrugated core is attached to the at least one planar support 60. For instance, the step of producing the mouthpiece portion 34 comprises a sub-step of attaching the corrugated core 50 and the at least one planar support 60. The corrugated core 50 is preferably glued or welded to the at least one planar support 60. Thanks to the rigidity conferred by the support 60, the mouthpiece portion 34 can be handled without risk of deformation. According to a specific example, for productivity reasons, the mouthpiece portion 34 can be formed by providing an elongated corrugated core element and an elongated support element attached together (e.g., gluing or welding) and then cut in segments corresponding to individual mouthpiece portions 34. By “elongated”, it is meant that the elongated corrugated core element and the elongated support element have a dimension greater than the dimension taken along the article axis Y of the mouthpiece portion 34 to be produced. In other terms, the elongated corrugated core element and the elongated support element both are formed from continuous elongated sheets and are then attached together to form an elongated ensemble. The elongated ensemble is then cut at the desired length into mouthpiece portions 34. According to another example, the corrugated core 50 and the at least one planar support 60 are produced by extrusion. For instance, the corrugated core 50 is formed by providing an elongated sheet 52 which for example is initially planar and then by corrugating said elongated sheet 52 to obtain a corrugated elongated sheet 52. According to another example, the corrugated core 50 is formed by providing an already corrugated elongated sheet 52, notably by extrusion. The method then comprises a step of arranging the tobacco portion 32 and the mouthpiece portion 34 consecutively along the article axis Y. Finally, the method comprises a step of attaching the tobacco portion 32 and the mouthpiece portion 34 together. For instance, the step of attaching the tobacco portion 32 and the mouthpiece portion 34 together comprises wrapping at least the mouthpiece portion 34 with the wrapper 70. In particular, both the tobacco portion 32 and the mouthpiece portion 34 are wrapped by the wrapper 70.

Second Embodiment of the Invention

FIG. 6 shows a flat-shaped consumable article 130 according to a second embodiment of the invention. The flat-shaped consumable article 130 of the second embodiment is similar to the flat-shaped consumable article 30 of the first embodiment except for the fact that the corrugated core 150 and the at least one planar support 160, here the two planar supports 160, are made in one piece. For instance, the corrugated core 150 and the at least one planar support 160 are formed by a single continuous sheet 152. In particular, the sheet 152 comprises at least an end part 152A corresponding to the at least one planar support 160 and a corrugated part 153 corresponding to the corrugated core 150. In the example of FIG. 6, said sheet 152 comprises a first end part 152A corresponding to a first planar support 160, a second end part 152B corresponding to a second planar support 160 and a corrugated part 153, arranged between the first and second end parts 152A, 152B, corresponding to the corrugated core 150. Advantageously, as illustrated on FIG. 6, opposite lateral ends of the corrugated core 150 are formed as an integral part of respectively the first and second planar support 160. As shown on FIG. 6, the first and second end parts 152A, 152B are folded relatively to the corrugated part 153 so that each planar support 160 is in contact with the longitudinal edges 156 of the corresponding non-planar surface 154. This further enhances the resistance to deformation of the flat-shaped consumable article 130. Furthermore, the wrapping of the corrugated core 150 and of the at least one planar support 160 with the wrapper 170 is made easier since the corrugated core 150 and the at least one planar support 160 are made in one piece.

The method for manufacturing the flat-shaped consumable article 130 according to the second embodiment of the invention is similar to the method described above. Advantageously, the step of producing the mouthpiece portion 34 also comprises, prior to the attachment sub-step, a sub-step of folding the single continuous sheet 152 so that the at least one planar support 160 is in contact with the longitudinal edges 156 of the corresponding non-planar surface 154. For instance, prior to the folding sub-step, the corrugated core 150 and the at least one planar support 160 are produced by extrusion. Advantageously, the corrugated core 150 and the at least one planar support 160 are extruded together simultaneously. According to a specific example, for productivity reasons, the mouthpiece portion 34 can be formed by providing an elongated continuous sheet 152, which after the folding and attachment sub-steps, is cut in segments corresponding to individual mouthpiece portions 34.

Third Embodiment of the Invention

FIG. 7 shows a flat-shaped consumable article 230 according to a third embodiment of the invention. The flat-shaped consumable article 230 of the third embodiment is similar to the flat-shaped consumable article 130 of the second embodiment except for the fact that the longitudinal edges 256 are formed as an integral part of the at least one planar support 260. In other terms, in the third embodiment, at least part of the non-planar surfaces 254 and the longitudinal edges 256 are virtual. In particular, there is no physical boundaries between the longitudinal edges 256 and the part of the non-planar surfaces 254 that extends opposite said longitudinal edges. Thus, the corrugated core 250 and the at least one planar support 260 are attached since they are made in one piece and since the longitudinal edges 256 are formed as an integral part of the at least one planar support 260. In the third embodiment, by “the corrugated core 250 comprises a sheet 252”, it is meant that the corrugated core 250 comprises a part similar to the sheet 52, 152 of the first and second embodiments, except for the fact that the sheet 252 is made integral with the at least one support 260 at the level of each longitudinal edge 256. This further enhances the resistance to deformation of the flat-shaped consumable article 230. Furthermore, the wrapping of the corrugated core 250 and of the at least one planar support 260 with the wrapper 270 is made easier since there are multiple continuous junctions between the corrugated core 250 and the at least one planar support 260.

The method for manufacturing the flat-shaped consumable article 130 according to the second embodiment of the invention is similar to the method first embodiment except for the fact that the step of producing the mouthpiece portion 34 comprises a sub-step of extrusion of the corrugated core 250 and of the at least one planar support 260 together simultaneously to form the mouthpiece portion 34. In other terms, the corrugated core 250 and the at least one planar support 260 are formed at the same time, in one piece, by extrusion. That is, the mouthpiece portion 34 is formed by simultaneous extrusion of the corrugated core 250 and of the at least one planar support 260 together. Advantageously, in this third embodiment, in comparison to the first and second embodiments, there is no need to attach the corrugated core 250 to the at least one planar support 260. According to a specific example, for productivity reasons, the mouthpiece portion 34 can be formed by extruding a continuous elongated single piece (which is in the third embodiment made up of the elongated core element and the elongated support element), which is then cut in segments corresponding to individual mouthpiece portions 34.