Receptor assembly

Abstract

A susceptor assembly (12) for an aerosol-generating system is provided. The susceptor assembly (12) comprises one or more wicking elements for delivering a liquid aerosol-forming substrate. The one or more wicking elements comprise a first wicking layer (20) and a second wicking layer (22). The susceptor assembly (12) further includes a spacer element (24) positioned between the first wicking layer (20) and the second wicking layer (22) and in contact with the first wicking layer and the second wicking layer; and a susceptor element in contact with at least a portion of the one or more wicking elements. A cartridge for an aerosol-generating system, an aerosol-generating system, and a method for manufacturing a susceptor assembly are also provided.

Description

[0001] The present disclosure relates to a susceptor assembly for an aerosol generating system; a cartridge for an aerosol generating system; an aerosol generating system; and a method for manufacturing a susceptor assembly.

[0002] Aerosol generating systems that employ induction heating to heat an aerosol-forming substrate in order to generate an aerosol for inhalation by a user are well known in the prior art. The aerosol-forming substrate is heated and evaporated to form a vapor. The vapor cools and condenses to form an aerosol, which is then inhaled by the user. Such electrically heated smoking systems are typically handheld and comprise a power source, a reservoir for holding a supply of the aerosol-forming substrate, and an induction heating system.

[0003] The induction heating system typically comprises at least one inductor coil connected to a power source. The induction heating system comprises a susceptor assembly comprising a susceptor element arranged in close proximity to the aerosol-forming substrate and within an alternating magnetic field. Some aerosol generating systems comprise an aerosol generating device and a cartridge configured for use with the device. When the aerosol generating system comprises an aerosol generating device and a cartridge, the susceptor element may form part of the cartridge.

[0004] The aerosol-forming substrate may be a liquid. In such cases, the aerosol generating system may further comprise a wicking element configured to draw the liquid aerosol-forming substrate from the storage portion to the susceptor element for heating.

[0005] Typically, the susceptor assembly of an inductive aerosol generating system may comprise a single wicking element comprising a single wicking layer.

[0006] It is desirable to provide a susceptor assembly and an aerosol generating system having more than one wicking layer to improve the delivery of a liquid aerosol-forming substrate to the susceptor element and thereby enhance evaporation of the liquid aerosol-forming substrate.

[0007] According to a first embodiment of the present disclosure, a susceptor assembly for an aerosol generating system is provided. The susceptor assembly may include one or more wicking elements for conveying a liquid aerosol-forming substrate. The one or more wicking elements may include a first wicking layer and a second wicking layer. The susceptor assembly may also include a spacer element positioned between the first wicking layer and the second wicking layer and in contact with the first wicking layer and the second wicking layer. The susceptor assembly may also include a susceptor element in contact with at least a portion of the one or more wicking elements.

[0008] Advantageously, providing a first wicking layer and a second wicking layer can improve the ease of manufacturing a susceptor assembly for an aerosol generating system, while delivering enough liquid aerosol-forming substrates for aerosolization. However, it has been found that two wicking layers in contact with each other may cause condensate to be trapped between the two wicking layers. This may then cause the release of vapor. The vapor may cause the deformation of the susceptor assembly. The deformation of the susceptor assembly may then cause the contact between the susceptor element and one or more wicking elements to be reduced, thereby causing the aerosolization of the liquid aerosol-forming substrate to be reduced or inefficient. The present invention provides a spacer element positioned between the first wicking layer and the second wicking layer and in contact with the first wicking layer and the second wicking layer. Advantageously, the spacer element can improve the liquid flow between the first wicking layer and the second wicking layer. In addition, the spacer element can provide a space for accumulating vapor before the vapor escapes the susceptor assembly, thereby minimizing the deformation of the susceptor assembly.

[0009] The one or more wicking elements may be configured to transport the liquid aerosol-forming substrate to the susceptor element.The susceptor element may be configured to heat the liquid aerosol-forming substrate and vaporize the liquid aerosol-forming substrate.

[0010] The susceptor element may comprise a first susceptor layer and a second susceptor layer. The first susceptor layer may be in contact with at least a portion of the first wicking layer, and the second susceptor layer may be in contact with at least a portion of the second wicking layer. This may advantageously mean that in operation, the one or more wicking elements are heated from both sides. This may increase the amount of aerosol-forming substrate evaporated in a given time compared to a susceptor assembly comprising only one susceptor layer.

[0011] The first side of the spacer element can be in contact with the first side of the first wicking layer, and the first susceptor layer can be in contact with the second side of the first wicking layer, wherein the first side of the first wicking layer is opposite to the second side of the first wicking layer. The second side of the spacer element can be in contact with the first side of the second wicking layer, and the second susceptor layer can be in contact with the second side of the second wicking layer, wherein the first side of the second wicking layer is opposite to the second side of the second wicking layer. The first side of the spacer element can be opposite to the second side of the spacer element. In this arrangement, the first susceptor layer and the second susceptor layer can be spaced apart from each other. The first wicking layer can be configured to deliver the liquid aerosol-forming substrate to the first susceptor layer. The second wicking layer can be configured to deliver the liquid aerosol-forming substrate to the second susceptor layer. This can allow the delivery of the liquid aerosol-forming substrate to be balanced between the first susceptor layer and the second susceptor layer.

[0012] The first susceptor layer and the second susceptor layer may be planar. In this context, a planar susceptor layer is a susceptor layer having a length and a width that are significantly greater than the thickness. The length direction and the width direction are orthogonal to each other and define a first plane. The planar susceptor layer may have two opposing major surfaces extending in a plane parallel to the first plane. One or both major surfaces are advantageously flat. During use of the first susceptor layer and the second susceptor layer in an aerosol generating system, this may allow air flow to cross the surfaces of both the first susceptor layer and the second susceptor layer, thereby enhancing the entrainment of the evaporated aerosol-forming substrate. The first susceptor layer and the second susceptor layer may be substantially parallel to each other. The first susceptor layer and the second susceptor layer may have a rectangular cross-section taken across the first plane.

[0013] The first susceptor layer and the second susceptor layer may be separate components.

[0014] The first susceptor layer and the second susceptor layer may be integral with each other. Advantageously, this may simplify the manufacture of the susceptor assembly.

[0015] The susceptor element may include a connecting section that connects the first susceptor layer to the second susceptor layer. The susceptor element may include three sections. The first section of the susceptor element may include the first susceptor layer. The second section of the susceptor element may include the second susceptor layer. The third section of the susceptor element may be a connecting section that links the first susceptor layer to the second susceptor layer.

[0016] The connecting section may be "U" shaped or "V" shaped. Advantageously, a susceptor element having a "U" shaped or "V" shaped connecting section may hold one or more wicking elements and a spacer element together, in contact with each other, and the first and second wicking layers in contact with the first and second susceptor layers.

[0017] The susceptor element may be formed by bending or folding a single piece of susceptor material to form the first susceptor layer, the second susceptor layer and the connecting sections of the susceptor element. Advantageously, a susceptor element formed in this way may be easy to manufacture.

[0018] The first wicking layer and the second wicking layer may be substantially planar.The first wicking layer and the second wicking layer of the susceptor assembly may be substantially parallel.

[0019] The first wicking layer and the second wicking layer may be integral with each other.The first wicking layer and the second wicking layer may be formed from a single piece of wicking material.

[0020] The first wicking layer and the second wicking layer may be separate components. Advantageously, the first wicking layer and the second wicking layer being separate components may prevent any bends or folds in the wicking layer which may compress the wicking layer and result in suboptimal liquid transport.

[0021] The susceptor assembly may be substantially planar.The susceptor assembly may have a rectangular cross-section taken across a first plane.

[0022] The susceptor assembly may include a heating zone and at least one mounting zone. The heating zone is a zone of the susceptor assembly that is configured to be heated to a temperature required to evaporate the aerosol-forming substrate when penetrated by a suitable alternating magnetic field. The heating zone of the susceptor assembly may include at least a portion of the first susceptor layer. The heating zone of the susceptor assembly may include at least a portion of the second susceptor layer. Each of the first susceptor layer, the second susceptor layer, the first wicking layer, the second wicking layer, and the spacer element may include a heating zone.

[0023] Each of the first wicking layer, the second wicking layer and the spacer element may include a mounting area. At least one mounting area may be in contact with the susceptor holder. Preferably, a portion of at least one mounting area may extend into the liquid reservoir. In a preferred embodiment, the heating area may be arranged outside the liquid reservoir. Advantageously, arranging the susceptor element substantially outside the liquid reservoir, in particular arranging the heating area of ​​the susceptor assembly outside the liquid reservoir, can ensure that the aerosol-forming substrate is sufficiently heated to release the volatile compounds only after the aerosol-forming substrate has been transported to the outside of the liquid reservoir. This can facilitate the release of volatile compounds from the aerosol generating system.

[0024] In a preferred embodiment, the cross-sectional area of ​​the one or more wicking elements and the cross-sectional area of ​​the spacer element taken across the first plane is greater than the cross-sectional area of ​​the susceptor element taken across the first plane. The length of the first susceptor layer and the length of the second susceptor layer can be approximately equal to the length of the first wicking layer, the second wicking layer, and the spacer element.

[0025] The width of the first susceptor layer and the second susceptor layer may be less than the width of the first wicking layer, the second wicking layer, and the spacer element. The width of the first susceptor layer and the second susceptor layer may be about 20% less than the width of the first wicking layer, the second wicking layer, and the spacer element. The width of the first susceptor layer and the second susceptor layer may be about equal to the width of the heating zone of the first wicking layer, the second wicking layer, and the spacer element. The first susceptor layer and the second susceptor layer may not include a mounting area.

[0026] The first susceptor layer and the second susceptor layer may include a mounting region.

[0027] The susceptor assembly may form a cross shape. The first susceptor layer, the second susceptor layer, the first wicking layer, the second wicking layer, and the spacer layer may have a cross-shaped cross-section along the first plane. The susceptor assembly may include a pair of mounting areas and a heating area. The heating area may be substantially rectangular and centrally located on the susceptor assembly. The pair of mounting areas may be approximately rectangular areas located at the periphery of the heating area. The mounting areas may be located at opposite sides of the heating area. The mounting areas may be arranged at the same central position along the length of the heating area. Each of the pair of mounting areas may have a smaller surface area than the heating area.

[0028] The spacer element may be fluid permeable.As used herein, a "fluid permeable" element means an element that allows liquids or gases to pass through it.

[0029] The spacer element may be substantially planar, having a length and width substantially greater than the thickness. The length direction and the width direction are orthogonal to each other and define a first plane of the spacer element. The first side of the spacer element and the second side of the spacer element may be opposite to each other and extend in a plane parallel to the first plane of the susceptor element. The spacer element may be configured to allow a liquid aerosol-forming substrate to move between the first side of the spacer element and the second side of the spacer element. The spacer element may be configured to transport a liquid aerosol-forming substrate between the first side of the spacer element and the second side of the spacer element.

[0030] In the thickness direction, the spacer element is preferably at least partially uncovered. For example, the spacer element may have at least one area in the thickness direction that is not covered by another component. Thus, at least one area of ​​the spacer element in the thickness direction may open to an airflow path in which the susceptor assembly is placed during use. During use of the susceptor assembly, vapor may accumulate within the spacer element. Advantageously, the vapor may escape from the at least partially uncovered area of ​​the spacer element in the thickness direction before the vapor reaches a pressure that may cause deformation of the susceptor assembly.

[0031] The spacer element may be configured to allow the liquid aerosol-forming substrate to move between the first wicking layer and the second wicking layer. In particular, when the first wicking layer is in contact with the first side of the spacer element and the second wicking layer is in contact with the second side of the spacer element, the liquid aerosol-forming substrate may move between the first wicking layer and the second wicking layer.

[0032] The first wicking layer may be in contact with the first side of the spacer element, and the second wicking layer may be in contact with the second side of the spacer element. The spacer element may separate the first wicking layer from the second wicking layer. Advantageously, the spacer element may prevent the first wicking layer from contacting the second wicking layer, and thus provide space for vapor. One or more wicking elements may include a capillary material. The first wicking layer may include a capillary material. The second wicking layer may include a capillary material. The capillary material is a material that can transport liquid from one end of the material to the other end by means of capillary action. The capillary material may have a fibrous or spongy structure. The capillary material preferably includes a capillary bundle. For example, the capillary material may include a plurality of fibers or threads or other fine-pore tubes. In some embodiments, the capillary material may include a spongy or foamy material. The structure of the capillary material may form a plurality of small openings or tubes, and the liquid aerosol-forming substrate may be transported through the plurality of small openings or tubes by capillary action.

[0033] One or more wicking elements may include or be composed of an electrically insulating material. One or more wicking elements may include a non-metallic material. Preferably, one or more wicking elements may not heat up in a magnetic field. One or more wicking elements may include a hydrophilic material or a lipophilic material. This may advantageously facilitate the transport of an aerosol-forming substrate through one or more wicking elements. One or more wicking elements may include or be composed of a porous ceramic material.

[0034] One or more wicking elements can include non-metallic materials. Examples of suitable materials for one or more wicking elements are sponges or foams, ceramic-based or graphite-based materials in the form of fibers or sintered powders, foamed metals or plastic materials, for example, fibrous materials made of spun or extruded fibers, such as glass fibers, cellulose acetate, polyester or bonded polyolefins, polyethylene, polyester or polypropylene fibers, nylon fibers or ceramics. Suitable materials for one or more wicking elements can include cellulosic materials, such as cotton or rayon.

[0035] The one or more wicking elements may preferably comprise cotton, rayon or fiberglass.The first wicking layer may preferably comprise or consist of cotton.The second wicking layer may preferably comprise or consist of cotton.

[0036] The first wicking layer may have a thickness between 0.1 mm and 0.5 mm. Preferably, the first wicking layer may have a thickness between 0.2 mm. The second wicking layer may have a thickness between 0.1 mm and 0.5 mm. Preferably, the second wicking layer may have a thickness between 0.2 mm.

[0037] The spacer element may comprise a porous material. The spacer element may comprise more pores than one or more wicking elements. The spacer element may comprise larger pores than one or more wicking elements. The spacer element may be more porous than one or more wicking elements.

[0038] The spacer element may include a capillary material. The spacer element may include more small openings or tubes than one or more wicking elements, through which the liquid aerosol-forming substrate may be transported by capillary action. The spacer element may include larger openings or tubes than one or more wicking elements, through which the liquid aerosol-forming substrate may be transported by capillary action. In this way, the delivery rate of the liquid aerosol-forming substrate through the spacer element may be higher than the delivery rate of the liquid aerosol-forming substrate through the first wicking layer or the second wicking layer.

[0039] The spacer element may not include capillary material.

[0040] The spacer element may comprise a mesh. As used herein, the term "mesh" includes grids and arrays of wires with spaces therebetween. The term mesh also includes woven and nonwoven fabrics.

[0041] The spacer element may comprise or consist of an electrically insulating material.The spacer element may comprise a non-metallic material.Preferably, the spacer element may not heat up in a magnetic field.

[0042] The spacer element may preferably comprise or consist of cotton. The spacer element may comprise a plastic material. The spacer element may comprise a polyetheretherketone (PEEK) film. The spacer element may comprise a fiber sheet.

[0043] The spacer element may have a higher fluid permeability than the fluid permeability of the one or more wicking elements.

[0044] The spacer element may comprise an aperture configured to allow liquid aerosol-forming substrate to move between the first wicking layer and the second wicking layer. The spacer element may comprise a plurality of apertures configured to allow liquid aerosol-forming substrate to move between the first wicking layer and the second wicking layer.

[0045] The aperture or apertures may also be holes, cutouts or channels.

[0046] The aperture or apertures may be defined through the spacer element between the first side of the spacer element and the second side of the spacer element. In this way, the liquid aerosol-forming substrate may pass through the aperture or apertures between the first side of the spacer element and the second side of the spacer element.

[0047] The orifice or orifices may have a circular cross-section.The orifice or orifices may have a diameter of at least 0.1 mm.

[0048] The orifice or orifices may have a rectangular cross-section. The orifice or orifices may have a triangular cross-section. The orifice or orifices may have any suitable cross-section.

[0049] The aperture or apertures may be defined at an end of the spacer element.The aperture or apertures may be a finger-like aperture, which means that the aperture may be defined by three sides.

[0050] The orifice or each of the plurality of orifices may have a cross-sectional area of ​​at least 0.005 square millimeters. The orifice or each of the plurality of orifices may have a cross-sectional area of ​​at least 0.01 square millimeters.

[0051] The aperture or apertures may be configured to enhance transport of the liquid aerosol-forming substrate from the liquid reservoir to the centre of the spacer element.

[0052] One or more wicking elements can include small openings, tubes or holes, and liquid aerosol formation substrate can be maintained in the small openings, tubes or holes, and alternatively or additionally can be transported through the small openings, tubes or holes by capillary action. Each in the small openings, tubes or holes can have a volume for maintaining or conveying liquid aerosol formation substrate. The volume of each of the orifices in the orifice in the spacer element or a plurality of orifices can be greater than the volume of each of the small openings, tubes or holes in one or more wicking elements. The total volume of the orifice in the spacer element or a plurality of orifices can be greater than the total volume of the small openings, tubes and holes in one or more wicking elements.

[0053] The spacer element may include one or more of a bend, an undulation, a fold, and a corrugation. The spacer element may have a first end and a second end. The width of the spacer element may extend from the first end to the second end. In the case where the spacer element does not extend directly from the first end to the second end (i.e., extends in a straight line), the spacer element may be considered to include one or more of a bend, an undulation, a fold, and a corrugation.

[0054] The bend may refer to a gradual change in the direction of the spacer element, for example, a gradual change in the direction of the spacer element between the first end and the second end. Thus, the bend may form an arc or "C" shape. The bend in the spacer element may enhance the transport of the liquid aerosol-forming substrate between the first wicking layer and the second wicking layer.

[0055] The spacer element may include a curved portion configured to act as a spring element between the first wicking layer and the second wicking layer. The spring may be elastically biased to maintain the first wicking layer and the second wicking layer at a predetermined spacing distance. The spacing distance may be preset by adjusting the radius of the curved portion. Advantageously, the spacer element including the curved portion configured to act as a spring element may be pressed against the first wicking layer and the second wicking layer, thereby ensuring good contact between the spacer element and one or more wicking elements.

[0056] A fold may refer to a change in direction of a spacer element, for example a step-like change in direction of the spacer element between a first end and a second end. Thus, the fold may form two sides of a polygon, or a "V" shape.

[0057] The undulations may include multiple curves. For example, the undulations may refer to a gradual change in the direction of the spacer element in a first direction, followed by a gradual change in the direction of the spacer element in another direction (e.g., in the opposite direction). Thus, the undulations may form a sine wave or "S" shape. Multiple undulations may be referred to as wavy corrugations. The spacer element may include wavy corrugations.

[0058] The corrugation may include multiple folds. For example, a corrugation may refer to a step-like change in the direction of the spacer element, followed by another step-like change in the direction of the spacer element. Thus, the corrugation may form three sides of a rectangle, or an "M" shape, or an "N" shape. Multiple corrugations including a "V" shaped fold may be referred to as triangular corrugations. The spacer element may include a triangular corrugation.

[0059] The corrugations may be formed by bending or folding the spacer material to form the spacer elements.The corrugations may be formed by moulding the spacer material to form the spacer elements.

[0060] The undulations or corrugations of the spacer element may enhance the flow of the liquid aerosol-forming substrate between the first layer of the one or more wicking elements and the second layer of the one or more wicking elements.

[0061] The spacer element can provide a pore or multiple pores between the first wicking layer and the second wicking layer. The pore or multiple pores may include an orifice or multiple orifices. The pore or multiple pores may be limited between the spacer element and the first wicking layer or the second wicking layer by a bend, fold, undulation or corrugation in the spacer layer. The pore or multiple pores may provide a certain volume of space for holding a liquid or gas aerosol-forming substrate and alternatively or additionally transporting the liquid or gas aerosol-forming substrate through the space. Advantageously, the pore or multiple pores may prevent the vapor formed between the first wicking layer and the second wicking layer from deforming the susceptor assembly.

[0062] The thickness of the spacer element may be between 0.1 mm and 0.5 mm. As used herein, the thickness of the spacer element is defined as the distance between the first side of the spacer element and the second side of the spacer element. Preferably, the thickness of the spacer element may be between 0.2 mm and 0.4 mm.

[0063] The depth of the spacer element may be between 0.1 mm and 0.5 mm, preferably between 0.2 mm and 0.4 mm. As used herein, the depth of the spacer element may be defined as the sum of the maximum distance from the central axis of the plane to the first side of the spacer element in a plane perpendicular to the first side and the maximum distance from the central axis of the plane to the second side of the spacer element in a plane perpendicular to the second side. For example, in a spacer element comprising a corrugated portion, the depth of the spacer element is the peak-to-peak amplitude of the corrugated portion.

[0064] The separation distance between the first wicking layer and the second wicking layer may be between 0.1 mm and 0.5 mm. Preferably, the separation distance between the first wicking layer and the second wicking layer may be between 0.2 mm and 0.4 mm. The depth of the spacer element may be the maximum separation distance between the first wicking layer and the second wicking layer.

[0065] The susceptor element may be fluid permeable. The first susceptor layer may be fluid permeable. The second susceptor layer may be fluid permeable. A fluid permeable susceptor element may advantageously allow evaporated aerosol-forming substrate to escape through the susceptor element. Thus, aerosol-forming substrate vapor generated in a region of the one or more wicking elements that is immediately adjacent to the susceptor element may escape through the susceptor element without passing through the one or more wicking elements.

[0066] As used herein, "susceptor element" means an element that can be heated by the penetration of an alternating magnetic field. The susceptor element can typically be heated by at least one of Joule heating and hysteresis losses through eddy currents induced in the susceptor element. Possible materials for the susceptor element include graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, and virtually any other conductive element. Advantageously, the first susceptor element and the second susceptor element can be ferrite elements. The material and geometry of the susceptor elements can be selected to provide the desired resistance and heat generation. Preferably, the first susceptor element and the second susceptor element comprise AISI 430 stainless steel.

[0067] Advantageously, in an aerosol generating system using inductive heating, no electrical contacts need to be formed between the susceptor assembly and the power source. This may eliminate the need for welds or other bonding elements. A cartridge comprising a susceptor assembly configured to be inductively heated may allow for the production of a simple, inexpensive and robust cartridge.

[0068] The susceptor element or multiple susceptor elements can be printed or otherwise deposited on one or more wicking elements as a film or multiple tracks. The susceptor element can include or be composed of a conductive material directly deposited on one or more wicking elements. The conductive material of the susceptor element can be deposited on one or more wicking elements as multiple tracks. In operation, the vaporized aerosol-forming substrate can advantageously escape from the one or more wicking elements through the gaps or intervals between the tracks. The multiple tracks of each of the susceptor elements can advantageously be distributed on the surface of one or more wicking elements to provide substantially uniform heating across the surface. For example, the width of each track in the track and the spacing between the tracks can be substantially the same for each track in the multiple tracks. The multiple tracks of each susceptor element in the susceptor element can include a first group of tracks parallel to each other. The multiple tracks can also include a second group of tracks perpendicular to the first group of tracks and overlapping with the first group of tracks. The first group of tracks and the second group of tracks can form a mesh structure together.

[0069] The susceptor element may comprise or consist of a perforated foil. In operation, the vaporized aerosol-forming substrate may advantageously escape from the one or more wicking elements through the perforations of the perforated foil. The perforations may be evenly distributed across the susceptor element. The susceptor element may be perforated to allow vapor to escape from the susceptor assembly or to allow entry of a liquid aerosol-forming substrate.

[0070] The susceptor element may include conductive filaments. The first susceptor layer may include or consist of conductive filaments. The second susceptor layer may include or consist of conductive filaments.

[0071] In a preferred embodiment, the susceptor element may comprise a mesh. The first susceptor layer may comprise or consist of a mesh. The second susceptor layer may comprise or consist of a mesh. As used herein, the term "mesh" includes grids and arrays of wires with spaces therebetween. The term mesh also includes woven and nonwoven fabrics.

[0072] The filaments may define spaces between the filaments, and the spaces may have a width of between 10 microns and 100 microns. Preferably, the filaments create capillary action in the spaces so that, in use, the liquid aerosol-forming substrate is drawn into the spaces, thereby increasing the contact area between the susceptor element and the liquid. In operation, the vaporized aerosol-forming substrate may advantageously escape from the one or more wicking elements through the spaces between the filaments of the susceptor element.

[0073] Each susceptor layer may have a thickness of no more than two millimeters. Preferably, each susceptor layer may have a thickness of less than one millimeter. Particularly preferably, the first susceptor layer may have a thickness of between 0.1 millimeters and 0.2 millimeters. Particularly preferably, the second susceptor layer may have a thickness of between 0.1 millimeters and 0.2 millimeters. The thickness of each of the susceptor layers is advantageously of a similar order of magnitude to the skin depth of the material of the susceptor layer at the operating frequency of the system. Advantageously, the susceptor assembly has a thickness of no more than ten times the skin depth of the material of the susceptor layer at the operating frequency. This may ensure that each of the susceptor layers has a suitably low mass and therefore that the time taken for the susceptor layer to reach a temperature suitable for evaporating the aerosol-forming substrate is less. Each susceptor layer may advantageously have a thickness of at least twice the skin depth of the material of the susceptor layer at the operating frequency when the susceptor element is penetrated from opposite sides by the alternating magnetic field. This may minimize the interaction of skin effects on opposite sides of the susceptor layers.

[0074] Advantageously, the susceptor assembly may be configured to hold only a small volume of liquid aerosol-forming substrate sufficient for a single user puff. This is advantageous because it allows a small volume of liquid to evaporate quickly with minimal heat loss. Advantageously, the susceptor assembly or the heated zone of the susceptor assembly may hold between 2 milliliters and 10 milliliters of liquid aerosol-forming substrate.

[0075] The thickness of the susceptor assembly may not exceed two millimeters.Preferably, the susceptor assembly has a thickness between 0.8 millimeters and 1.2 millimeters.

[0076] According to a second embodiment of the present disclosure, a cartridge for an aerosol generating system is provided. The cartridge may include a susceptor assembly according to the first embodiment of the present disclosure and a liquid reservoir for holding a liquid aerosol-forming substrate. One or more wicking elements may be in fluid communication with the liquid reservoir and configured to transport the liquid aerosol-forming substrate between the liquid reservoir and the susceptor element.

[0077] The cartridge may include an air inlet and an air outlet. The cartridge may include an air flow passage extending between the air inlet and the air outlet.

[0078] At least a portion of the susceptor assembly may be positioned in the airflow pathway.A portion of the susceptor element may be positioned in the airflow pathway.

[0079] The susceptor element may be in fluid communication with the air flow passage. The aerosol-forming substrate evaporated by the susceptor assembly may escape into the air flow passage. The vapor may condense within the air flow passage to form an aerosol. The aerosol may be drawn from the aerosol generating system through an air outlet.

[0080] The cartridge may comprise a mouth end and a connection end, wherein the connection end is configured to connect the cartridge to an aerosol generating device.An air outlet may be provided in the mouth end.

[0081] The cartridge may include a mouthpiece. The air outlet may be defined in the mouthpiece.

[0082] The airflow passage may pass through the liquid reservoir. For example, the liquid reservoir may have an annular cross-section defining an internal passage, and the airflow passage may extend through the internal passage of the liquid reservoir.

[0083] The cartridge may include a susceptor holder. The susceptor holder may be a tubular susceptor holder. The internal passage of the tubular susceptor holder may form a part of a closed airflow passage. The closed airflow passage may extend from an air inlet through the internal passage of the tubular susceptor holder, through the internal passage of the liquid reservoir to an air outlet.

[0084] The susceptor holder may support the susceptor assembly.The susceptor holder may contact at least one of the first wicking layer and the second wicking layer.The susceptor holder may secure the susceptor assembly in place in the cartridge.

[0085] According to a third embodiment of the present disclosure, an aerosol generating system is provided. The aerosol generating system may include a susceptor assembly according to the first embodiment of the present disclosure. The aerosol generating system may also include a liquid reservoir for holding a liquid aerosol-forming substrate, wherein one or more wicking elements are in fluid communication with the liquid reservoir and are configured to transport the liquid aerosol-forming substrate. The aerosol generating system may also include an inductor coil and a power supply connected to the inductor coil, the power supply being configured to provide an alternating current to the inductor coil to generate an alternating magnetic field. The susceptor element may be configured to be heated by the alternating magnetic field.

[0086] The aerosol generating system may comprise a system air inlet, a system air outlet, and a system air flow passage extending between the system air inlet and the system air outlet.

[0087] At least a portion of the susceptor assembly may be positioned in the system airflow pathway.At least a portion of the susceptor element may be positioned in the system airflow pathway.

[0088] The susceptor element may be in fluid communication with the system airflow pathway. The aerosol-forming substrate evaporated by the susceptor assembly may escape into the airflow pathway. The vapor may condense within the system airflow pathway to form an aerosol. The aerosol may be drawn from the aerosol generating system through the system air outlet.

[0089] The aerosol generating system may comprise a mouthpiece, wherein the system air outlet is defined in the mouthpiece.

[0090] The inductor coil may define a susceptor assembly. The inductor coil may be a tubular spiral coil. Preferably, the inductor coil is a spiral coil. The inductor coil may be a spiral coil defining a susceptor assembly, wherein at least a portion of the spiral coil defines the susceptor assembly. The spiral coil may have a circular cross-section when viewed parallel to the longitudinal axis of the aerosol generating system.

[0091] The aerosol generating system can be a handheld aerosol generating system configured to allow a user to draw on a mouthpiece to draw an aerosol through the system air outlet. The aerosol generating system can have a size comparable to a conventional cigar or cigarette. The aerosol generating system can have a total length between about 30 mm and about 150 mm. The aerosol generating system can have an outer diameter between about 5 mm and about 30 mm. The aerosol generating system can be an electrically operated smoking system.

[0092] The aerosol generating system may include a control circuit. The control circuit may include a microprocessor. The microprocessor may be a programmable microprocessor, a microcontroller or an application specific integrated chip (ASIC) or other electronic circuit capable of providing control. The control circuit may be configured to continuously supply power to the inductor coil after the system is activated, or may be configured to supply power intermittently, such as on a puff-by-puff basis. Power may be supplied to the induction heating assembly in the form of current pulses, for example, by means of pulse width modulation (PWM). The control circuit may include a DC / AC inverter, which may include a class D or class E power amplifier. The control circuit may include other electronic components. For example, in some embodiments, the control circuit may include any one of a sensor, a switch, and a display element.

[0093] The control circuit may include a sensor for detecting when a user takes a puff on the aerosol generating system. The sensor may be configured to detect when air is puffed through the system airflow pathway. The sensor may allow the aerosol generating system to be supplied with power on a puff-by-puff basis.

[0094] The power source may be a DC power source. The power source may be a battery. The battery may be a lithium-based battery, such as a lithium cobalt, lithium iron phosphate, lithium titanate, or lithium polymer battery. The battery may be a nickel metal hydride battery or a nickel cadmium battery. The power source may be another form of charge storage device, such as a capacitor. The power source may be rechargeable and configured for many charge and discharge cycles. The power source may have a capacity that allows storage of energy sufficient for one or more user experiences of the aerosol generating system; for example, the power source may have sufficient capacity to allow continuous generation of aerosol for a period of about six minutes (corresponding to the typical time taken to smoke a conventional cigarette), or for a period of time that is a multiple of six minutes. In another example, the power source may have sufficient capacity to allow a predetermined number of puffs or discontinuous activation of the receptor assembly.

[0095] An aerosol generating system may comprise a cartridge and an aerosol generating device according to the second embodiment of the present disclosure.The system air outlet may comprise a cartridge air outlet.

[0096] The aerosol generating device may include an inductor coil, and a power source connected to the inductor coil. The aerosol generating device may have a connection end configured to connect the aerosol generating device to the cartridge. The connection end may include a cavity for receiving the cartridge.

[0097] The aerosol generating device may have a distal end opposite the connection end.The distal end may include an electrical connector configured to connect the aerosol generating device to an electrical connector of an external power source for charging the power source of the aerosol generating device.

[0098] It should be understood that any features described herein with respect to one embodiment of a susceptor assembly may also be applicable to other embodiments of cartridges and aerosol generating systems according to the present disclosure. Features described with respect to one embodiment of the present disclosure may also be applicable to another embodiment according to the present disclosure.

[0099] According to a fourth embodiment of the present disclosure, a method for manufacturing a susceptor assembly is provided. The method may include providing a susceptor element; placing one or more wicking elements including a first wicking layer and a second wicking layer on the susceptor element. The method may also include placing a spacer element on the first wicking layer and folding the susceptor element so that the spacer element is positioned between and in contact with the first wicking layer and the second wicking layer, and the susceptor element forms the first susceptor layer and the second susceptor layer.

[0100] As used herein, the term "aerosol-forming substrate" refers to a substrate capable of releasing volatile compounds that can form an aerosol. The volatile compounds can be released by heating or burning the aerosol-forming substrate.

[0101] The aerosol-forming substrate may include an aerosol former. As used herein, the term "aerosol former" refers to any suitable compound or mixture of compounds that promotes the formation of an aerosol in use, such as a stable aerosol that is substantially resistant to thermal degradation at the operating temperature of the system. Suitable aerosol formers are well known in the art and include, but are not limited to: polyols such as triethylene glycol, 1,3-butanediol and glycerol; esters of polyols such as mono-, di- or triacetates of glycerol; and aliphatic esters of mono-, di- or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0102] The aerosol-forming substrate may include nicotine. The aerosol-forming substrate may include water. The aerosol-forming substrate may include glycerine, also known as glycerol, which has a higher boiling point than nicotine. The aerosol-forming substrate may include propylene glycol. The aerosol-forming substrate may include plant-based materials. The aerosol-forming substrate may include homogenized plant-based materials. The aerosol-forming substrate may include tobacco. The aerosol-forming substrate may include tobacco-containing materials. The tobacco-containing materials may contain volatile tobacco flavor compounds. These compounds may be released from the aerosol-forming substrate when heated. The aerosol-forming substrate may include homogenized tobacco materials. The aerosol-forming substrate may include other additives and ingredients, such as spices.

[0103] As used herein, the term "liquid aerosol-forming substrate" is used to refer to an aerosol-forming substrate in a condensed form. Thus, a "liquid aerosol-forming substrate" may be or may include one or more of a liquid, a gel, or a paste. If the liquid aerosol-forming substrate is or includes a gel or a paste, the gel or paste may liquefy upon heating. For example, the gel or paste may liquefy upon heating to a temperature of less than 50, 75, 100, 150, or 200 degrees Celsius.

[0104] The invention is defined in the claims. However, a non-exhaustive list of non-limiting examples is provided below. Any one or more features of these examples may be combined with any one or more features of another example, embodiment or aspect described herein.

[0105] Example Ex1: A sensor component for an aerosol generating system, the sensor component comprising: one or more wicking elements for transporting a liquid aerosol-forming matrix, the one or more wicking elements comprising a first wicking layer and a second wicking layer; a spacer element, the spacer element being positioned between the first wicking layer and the second wicking layer and in contact with the first wicking layer and the second wicking layer; and a sensor element, the sensor element being in contact with at least a portion of the one or more wicking elements.

[0106] Example Ex2: The susceptor assembly of example Ex1, wherein the susceptor element comprises a first susceptor layer and a second susceptor layer.

[0107] Example Ex3: The susceptor assembly of example Ex2, wherein the first susceptor layer contacts at least a portion of the first wicking layer, and the second susceptor layer contacts at least a portion of the second wicking layer.

[0108] Example Ex4: A susceptor assembly according to Example Ex2 or Ex3, wherein the first side of the spacer element contacts the first side of the first wicking layer, and the first susceptor layer contacts the second side of the first wicking layer, wherein the first side of the first wicking layer is opposite to the second side of the first wicking layer.

[0109] Example Ex5: A susceptor assembly according to Example Ex2, Ex3 or Ex4, wherein the second side of the spacer element contacts the first side of the second wicking layer, and the second susceptor layer contacts the second side of the second wicking layer, wherein the first side of the second wicking layer is opposite to the second side of the second wicking layer.

[0110] Example Ex6: The susceptor assembly of any of Examples Ex2 to Ex5, wherein the first susceptor layer and the second susceptor layer are substantially parallel.

[0111] Example Ex7: The susceptor assembly of examples Ex2 to Ex6, wherein the first susceptor layer and the second susceptor layer are separate components.

[0112] Example Ex8: The susceptor assembly of any of Examples Ex2 to Ex6, wherein the susceptor element comprises a connecting section joining the first susceptor layer to the second susceptor layer.

[0113] Example Ex9: The susceptor assembly according to example Ex8, wherein the connecting section is U-shaped or V-shaped.

[0114] Example Ex10: The susceptor assembly of any one of Examples Ex1 to Ex9, wherein the first and second wicking layers are substantially planar.

[0115] Example Ex11: The susceptor assembly of any one of Examples Ex1 to Ex10, wherein the first wicking layer and the second wicking layer are substantially parallel.

[0116] Example Ex12: The susceptor assembly of any one of Examples Ex1 to Ex11, wherein the first wicking layer and the second wicking layer are formed from a single piece of wicking material.

[0117] Example Ex13: The susceptor assembly according to any one of Examples Ex1 to Ex11, wherein the first wicking layer and the second wicking layer are separate components.

[0118] Example Ex14: The susceptor assembly of any one of Examples Ex1 to Ex13, wherein the susceptor assembly is substantially planar.

[0119] Example Ex15: The susceptor assembly according to any one of examples Ex1 to Ex14, wherein the spacer element is fluid permeable.

[0120] Example Ex16: The susceptor assembly according to any one of examples Ex1 to Ex15, wherein the spacer element is substantially planar.

[0121] Example Ex17: The susceptor assembly of any one of Examples Ex1 to Ex16, wherein the first wicking layer is in contact with a first side of the spacer element, and the second wicking layer is in contact with a second side of the spacer element.

[0122] Example Ex18: The susceptor assembly of any one of Examples Ex1 to Ex17, wherein the spacer element separates the first wicking layer from the second wicking layer.

[0123] Example Ex19: The susceptor assembly of any one of Examples Ex1 to Ex18, wherein the one or more wicking elements comprise a capillary material.

[0124] Example Ex20: The susceptor assembly of any one of Examples Ex1 to Ex19, wherein the one or more wicking elements comprise cotton.

[0125] Example Ex21: The susceptor assembly of any one of Examples Ex1 to Ex20, wherein the spacer element comprises a porous material.

[0126] Example Ex22: The susceptor assembly of any one of Examples Ex1 to Ex21, wherein the spacer element comprises a mesh.

[0127] Example Ex23: The susceptor assembly of any one of Examples Ex1 to Ex22, wherein the spacer element comprises cotton.

[0128] Example Ex24: The susceptor assembly of any one of Examples Ex1 to Ex23, wherein the spacer element comprises a plastic material.

[0129] Example Ex25: The susceptor assembly of any one of Examples Ex1 to Ex24, wherein the spacer element comprises a PEEK film.

[0130] Example Ex26: The susceptor assembly of any one of Examples Ex1 to Ex25, wherein the spacer element comprises a fiber sheet.

[0131] Example Ex27: The susceptor assembly according to any one of Examples Ex1 to Ex26, wherein the spacer element comprises an orifice configured to allow a liquid aerosol-forming substrate to move between the first wicking layer and the second wicking layer.

[0132] Example Ex28: The susceptor assembly of Example Ex27, wherein the spacer element comprises a plurality of apertures configured to allow a liquid aerosol-forming substrate to move between the first wicking layer and the second wicking layer.

[0133] Example Ex29: The susceptor assembly of Example Ex27 or Ex28, wherein the orifice or orifices have a circular cross-section.

[0134] Example Ex30: The susceptor assembly of Example Ex29, wherein the orifice or orifices have a diameter of about 0.1 mm.

[0135] Example Ex31: The susceptor assembly of Example Ex27 or Ex28, wherein the orifice or orifices have a rectangular cross-section.

[0136] Example Ex32: The susceptor assembly of any one of Examples Ex1 to Ex31, wherein the spacer element comprises a bend or a fold.

[0137] Example Ex33: The susceptor assembly of any one of Examples Ex1 to Ex32, wherein the spacer element comprises a corrugation or a plurality of corrugations.

[0138] Example Ex34: The susceptor assembly of Example Ex33, wherein the spacer element comprises a wavy corrugation or a triangular corrugation.

[0139] Example Ex35: The susceptor assembly according to any one of examples Ex1 to Ex34, wherein the thickness of the spacer element is between 0.1 mm and 0.5 mm, preferably between 0.2 mm and 0.4 mm.

[0140] Example Ex36: The susceptor assembly according to any one of examples Ex1 to Ex35, wherein the depth of the spacer element is between 0.1 mm and 0.5 mm, preferably between 0.2 mm and 0.4 mm.

[0141] Example Ex37: The susceptor assembly of any one of Examples Ex1 to Ex36, wherein the distance between the first wicking layer and the second wicking layer is between 0.1 mm and 0.5 mm.

[0142] Example Ex38: The susceptor assembly of Example Ex37, wherein the distance between the first wicking layer and the second wicking layer is between 0.2 mm and 0.4 mm.

[0143] Example Ex39: The susceptor assembly of any one of Examples Ex1 to Ex38, wherein the susceptor element is fluid permeable.

[0144] Example Ex40: The susceptor assembly of any one of Examples Ex1 to Ex39, wherein the susceptor element comprises a conductive filament.

[0145] Example Ex41: The susceptor assembly of Example Ex40, wherein the susceptor element comprises a mesh.

[0146] Example Ex42: A cartridge for an aerosol generating system, the cartridge comprising:

[0147] A susceptor assembly according to any one of Examples Ex1 to Ex41; and

[0148] A liquid reservoir for holding a liquid aerosol-forming substrate, wherein the one or more wicking elements are in fluid communication with the liquid reservoir and are configured to transport the liquid aerosol-forming substrate from the liquid reservoir to the susceptor element.

[0149] Example Ex43: The cartridge according to Example Ex42 further includes an air inlet, an air outlet, and an air flow passage extending between the air inlet and the air outlet.

[0150] Example Ex44: A cartridge according to Example Ex43, wherein the susceptor assembly is positioned in the airflow pathway.

[0151] Example Ex45: The cartridge of Example Ex44, wherein the susceptor element is in contact with air in the airflow pathway.

[0152] Example Ex46: The cartridge according to any one of Examples Ex42 to Ex45, comprising a mouth end and a connection end, wherein the connection end is configured to connect the cartridge to an aerosol generating device.

[0153] Example Ex47: A cartridge according to Example Ex46, wherein the air outlet is provided in the mouth end.

[0154] Example Ex48: The cartridge of any one of Examples Ex43 to Ex47, further comprising a mouthpiece, wherein the air outlet is defined in the mouthpiece.

[0155] Example Ex49: An aerosol generating system, comprising:

[0156] A susceptor assembly according to any one of Examples Ex1 to Ex41;

[0157] a liquid reservoir for holding a liquid aerosol-forming substrate, wherein the one or more wicking elements are in fluid communication with the liquid reservoir and are configured to transport the liquid aerosol-forming substrate;

[0158] an inductor coil; and

[0159] A power source is connected to the inductor coil and is configured to provide an alternating current to the inductor coil to generate an alternating magnetic field, wherein the susceptor element is configured to be heated by the alternating magnetic field.

[0160] Example Ex50: An aerosol generating system according to Ex49, further comprising a system air inlet, a system air outlet, and a system air flow passage extending between the system air inlet and the system air outlet.

[0161] Example Ex51: An aerosol generating system according to Ex50, wherein the sensor assembly is positioned in the system airflow pathway.

[0162] Example Ex52: An aerosol generating system according to Ex50 or Ex51, further comprising a mouthpiece, wherein the air outlet is defined in the mouthpiece.

[0163] Example Ex53: An aerosol generating system according to any one of Ex49 to Ex52, wherein the inductor coil defines the susceptor assembly.

[0164] Example Ex54: An aerosol generating system according to any one of Ex49 to Ex53, wherein the inductor coil is a spiral coil.

[0165] Example Ex55: A method for manufacturing a sensor assembly, the method comprising: providing a sensor element; placing one or more wicking elements including a first wicking layer and a second wicking layer on the sensor element; placing a spacer element on the first wicking layer; and folding the sensor element so that the spacer element is positioned between the first wicking layer and the second wicking layer and in contact with the first wicking layer and the second wicking layer, and the sensor element forms the first sensor layer and the second sensor layer.

[0166] Several examples will now be further described with reference to the accompanying drawings, in which:

[0167] Figure 1A a schematic diagram showing a cross section of an aerosol generating system according to a first embodiment of the present disclosure;

[0168] Figure 1B Show Figure 1A a schematic diagram of a cross-section of an aerosol generating system of claim 1, wherein the system is in a use configuration; and

[0169] Figure 2A Show Figure 1A and 1B A schematic diagram of a cross section of a cylinder;

[0170] Figure 2B Show Figure 2A A schematic diagram of a cross section of a cylinder rotated 90 degrees around the central longitudinal axis of the cylinder;

[0171] Figure 3 Show Figures 1A-2B A schematic diagram of a perspective view of a susceptor assembly shown in;

[0172] Figure 4 shows a schematic side view of a susceptor assembly according to a second embodiment of the present disclosure;

[0173] Figure 5 A schematic cross-sectional view showing a susceptor assembly according to a third embodiment of the present disclosure;

[0174] Figure 6 A schematic cross-sectional view showing a susceptor assembly according to a fourth embodiment of the present disclosure;

[0175] Figure 7 A schematic cross-sectional view showing a susceptor assembly according to a fifth embodiment of the present disclosure;

[0176] Figure 8 A schematic cross-sectional view showing a susceptor assembly according to a sixth embodiment of the present disclosure;

[0177] Fig. 9 shows a schematic cross-sectional view of a spacer element according to a seventh embodiment of the present disclosure;

[0178] FIG10A shows a perspective view of a susceptor assembly according to an eighth embodiment of the present disclosure;

[0179] FIG10B shows a plan view of a spacer element of the susceptor assembly of FIG10A;

[0180] Figure 11-14 showing a plan view of an exemplary spacer element according to the present disclosure;

[0181] FIG. 15A shows a perspective view of a spacer element according to a thirteenth embodiment of the present disclosure;

[0182] FIG. 15B shows a plan view of the spacer element of FIG. 15A ;

[0183] FIG. 16A shows a perspective view of a spacer element according to a fourteenth embodiment of the present disclosure; and

[0184] FIG. 16B shows a plan view of the spacer element of FIG. 16A .

[0185] Figure 1A A schematic diagram of an aerosol generating system according to an example of the present disclosure is shown. The system comprises a cartridge 10 and a device 60 which can be coupled together to form an aerosol generating system. The aerosol generating system is portable and has a size comparable to a conventional cigar or cigarette.

[0186] Figure 1B Show Figure 1A Schematic diagram of an aerosol generating system of , in which a cartridge 10 and a device 60 are coupled together to form an aerosol generating system.

[0187] The cartridge 10 includes a susceptor assembly 12 mounted in a susceptor holder 14. Figure 2A and 2B is shown separated from the aerosol generating system. Figure 3 The susceptor assembly is shown in more detail.

[0188] The susceptor assembly 12 is planar and thin, having a thickness dimension that is substantially smaller than the length and width dimensions. The susceptor assembly 12 is shaped in the form of a rectangle.

[0189] The susceptor assembly comprises a susceptor element comprising a first susceptor layer 16 and a second susceptor layer 18. The susceptor assembly further comprises a wicking element for transporting a liquid aerosol-forming substrate, the wicking element comprising a first wicking layer 20 and a second wicking layer 22. The susceptor assembly further comprises Figure 1A 4. The spacer element not shown in the figure. Each of the first susceptor layer 16, the second susceptor layer 18, and the first wicking layer 20 and the second wicking layer 22 is generally formed in a rectangular shape, and each susceptor layer has the same length and width dimensions, and the width of the susceptor elements 16, 18 is less than the width of the first wicking layer 20 and the second wicking layer 22. Therefore, each of the first wicking layer 20 and the second wicking layer 22 includes an externally exposed portion of the wicking element, each of which protrudes into one of the two channels 45. The first susceptor layer 16 and the second susceptor layer 18 are substantially the same and include a sintered mesh formed of ferritic stainless steel wire and austenitic stainless steel wire. The first wicking layer 20 and the second wicking layer 22 include a porous body of cotton yarn. The wicking element 20 is configured to deliver liquid from the externally exposed surfaces of the first wicking layer 20 and the second wicking layer 22 to the first susceptor element 16 and the second susceptor element 18.

[0190] The first and second susceptor elements 16 and 18 are configured to be heatable by penetration of the alternating magnetic field for vaporizing the aerosol-forming substrate. The wicking element 20 contacts the susceptor holder 14 such that the susceptor holder 14 supports the susceptor assembly 12 in place in the cartridge 10 .

[0191] The susceptor assembly 12 is partially disposed inside the interior passage 26 of the tubular susceptor holder 14 and extends in a plane parallel to the central longitudinal axis of the susceptor holder 14. The first susceptor element 16 and the second susceptor element 18 are disposed entirely within the interior passage 26 of the susceptor holder 14. The first wicking layer 20 and the second wicking layer 22 of the wicking element extend through an opening in the side wall of the susceptor holder 14 into one of the two channels 45.

[0192] The tube 10 has an oral end and a connection end opposite to the oral end. An outer shell 36 defines an oral end opening 38 at the oral end of the tube 10. The tube 10 may also include a mouthpiece at the oral end. As described in detail below, the connection end is configured to connect the tube 10 to an aerosol generating device. The receptor assembly 12 and the receptor holder 14 are positioned toward the connection end of the tube 10.

[0193] The outer housing 36 is formed of a moldable plastic material such as polypropylene. The outer housing 36 defines an interior space in which the susceptor assembly 12 and the susceptor holder 14 are housed.

[0194] The outer width of the outer housing 36 is greater at the mouth end of the cartridge 10 than at the connection end, the mouth end and the connection end being joined by a shoulder 37. This enables the connection end of the cartridge 10 to be received in the cavity of the aerosol generating device, wherein the shoulder 37 locates the cartridge in the correct position in the device. This also enables the mouth end of the cartridge 10 to be retained outside the aerosol generating device, wherein the mouth end conforms to the external shape of the aerosol generating device.

[0195] The cartridge 10 further comprises a liquid reservoir 44. The liquid reservoir 44 is defined in the cartridge 10 for holding the liquid aerosol-forming substrate 42.

[0196] The liquid reservoir 44 extends from the mouth end of the outer casing 36 to the connection end of the outer casing 36 , and includes an annular space defined by the outer casing 36 .

[0197] The annular space has an internal passage 48 extending between the mouth end opening 38 and the open end of the internal passage 26 of the susceptor holder 14 .

[0198] The liquid reservoir 44 also includes two channels 45 defined between the inner surface of the outer shell 36 and the outer surface of the susceptor holder 14. The two channels 45 extend from the annular space defined by the outer shell 36 at the mouth end of the barrel 10 to the connection end of the barrel 10 so that the wicking element extends through the opening in the side wall of the susceptor holder 14 into the two channels 45. The two channels 45 extend from the annular space defined by the outer shell 36 at the mouth end of the barrel 10 on opposite sides of the internal passage 26 of the susceptor holder 14.

[0199] The susceptor holder 14 includes a base 30 that partially closes one end of the internal passageway 26. The base 30 includes a plurality of air inlets 32 that enable air to be drawn into the internal passageway 26 through the partially closed end.

[0200] An air passage is formed through the cartridge 10 by the internal passage 26 of the susceptor holder 14 and the internal passage 48 of the liquid reservoir 44. The air passage extends from the air inlet 32 ​​in the base 30 of the susceptor holder 14, through the internal passage 26 of the susceptor holder 14, and through the internal passage 48 of the liquid reservoir 44 to the mouth end air outlet 38. The air passage enables air to be drawn from the connection end through the cartridge 10 to the mouth end.

[0201] The device 60 includes a generally cylindrical housing 62 having a connection end and a distal end opposite the connection end. A cavity 64 for receiving the connection end of the cartridge is located at the connection end of the device 60. An air inlet 65 is provided through the outer housing 62 at the base of the cavity 64 to allow ambient air to be drawn into the cavity 64 at the base. The air inlet 65 of the device is a system air inlet.

[0202] The device 60 also includes an induction heating arrangement arranged within the device outer housing 62. The induction heating arrangement includes an inductor coil 90, a control circuit 70, and a power source 72. The power source 72 includes a rechargeable nickel-cadmium battery that can be recharged via an electrical connector (not shown) at the distal end of the device. The control circuit 70 is connected to the power source 72 and to the inductor coil 90 so that the control circuit 70 controls the power supply to the inductor coil 90. The control circuit 70 is configured to supply an alternating current to the inductor coil 90.

[0203] When the cartridge 10 is received in the cavity 64, the inductor coil 90 is positioned around the susceptor assembly 12, as shown in FIG. Figure 1B The inductor coil 90 has a size and shape that matches the size and shape of the heating area of ​​the susceptor element. The inductor coil 90 is made of copper wire with a circular cross-section and is arranged on a coil former element (not shown). The inductor coil 90 is a spiral coil and has a circular cross-section when viewed parallel to the longitudinal axis of the aerosol generating device.

[0204] The inductor coil 90 is configured such that when an alternating current is supplied to the inductor coil, the inductor coil generates an alternating magnetic field in the region of the susceptor assembly 12 when the cartridge 10 is received in the cavity 64 .

[0205] The induction heating arrangement further comprises a flux concentrator element 91. The flux concentrator element 91 has a larger radius than the inductor coil 90 and therefore partially surrounds the inductor coil 90. The flux concentrator element 91 is configured to reduce stray power losses from the generated magnetic field.

[0206] Figure 1B Show Figure 1A An aerosol generating system is provided in which the cartridge 10 is coupled to the device 60 for operation. In operation, when a user draws on the mouth end opening 38 of the cartridge 10, ambient air is drawn into the base of the cavity 64 through the system air inlet 65 and into the cartridge 10 through the air inlet 32 ​​in the base 30 of the cartridge 10. Ambient air flows from the base 30 through the cartridge 10 to the mouth end air outlet 38, flows through the air passageway, and flows through the susceptor assembly 12 and in particular flows through and across the first susceptor layer 16 and the second susceptor layer 18.

[0207] When the system is activated, the control circuit 70 controls the supply of power from the power source 72 to the inductor coil 90 .

[0208] The control circuit 72 includes an airflow sensor 63. The airflow sensor 63 is in fluid communication with the passage of ambient air drawn through the system by the user. The control circuit 72 supplies power to the inductor coil 90 when the airflow sensor 63 detects that the user is drawing on the cartridge 10.

[0209] When the system is activated, an alternating current is generated in the inductor coil 90, which generates an alternating magnetic field in the cavity 64, and the alternating magnetic field penetrates the susceptor assembly 12, heating the susceptor element including the first susceptor layer and the second susceptor layer. The liquid aerosol-forming matrix in the channel 45 is sucked into the susceptor assembly 12 to reach the susceptor element through the wicking element. In particular, the liquid is sucked into the first susceptor layer 16 and the second susceptor layer 18 through the first wicking layer 20 and the second wicking layer 22, respectively. The liquid can also be transferred between the first wicking layer 20 and the second wicking layer 22 by the spacer element. The liquid aerosol-forming matrix 42 at the susceptor element is heated, and the volatile compounds from the heated aerosol-forming matrix are released into the air passage of the tube 10, and the volatile compounds are cooled to form an aerosol. The aerosol is entrained in the air sucked through the air passage of the tube 10, and is sucked out of the tube 10 at the mouth end air outlet 38 for the user to inhale.

[0210] Figure 2AA schematic diagram of the cartridge 10 is shown separated from the aerosol generating device.

[0211] Figure 2B Show Figure 2A Schematic diagram of a barrel rotated 90 degrees about the central longitudinal axis of the barrel. Figure 2B The layered structure of the susceptor assembly 12 is illustrated. The susceptor assembly 12 is planar and thin, having a thickness dimension that is substantially smaller than the length dimension and the width dimension. The susceptor assembly includes a susceptor element, which includes a first susceptor layer 16 and a second susceptor layer 18, and a wicking element for transporting a liquid aerosol-forming substrate. The wicking element includes a first wicking layer 20 and a second wicking layer 22, wherein a spacer element 24 is positioned between and in contact with the first wicking layer and the second wicking layer.

[0212] The spacer element 24 is fluid permeable and is configured to allow the liquid aerosol-forming substrate to move between the first wicking layer 20 and the second wicking layer 22. The spacer element 24 is generally formed in a rectangular shape and has the same length and width dimensions as the first wicking layer and the second wicking layer. The spacer element 24 comprises a porous body of cotton.

[0213] Figure 3 Show Figures 1A-2B Schematic diagram of a perspective view of a susceptor assembly shown in . The width of the susceptor layers 16, 18 is less than the width of the first wicking layer 20 and the second wicking layer 22. Therefore, when installed in the cartridge, the first susceptor layer 16 and the second susceptor layer 18 can be suspended so that they are not in contact with the susceptor holder. In this embodiment, the first susceptor layer 16 and the second susceptor layer 18 are substantially identical separate components. The first wicking layer 20 and the second wicking layer 22 are substantially parallel separate components.

[0214] Figure 4 A schematic side view of a susceptor assembly according to a second embodiment of the present disclosure is shown. Figure 4 The susceptor assembly of is configured to operate in a similar manner to the susceptor assembly according to the first embodiment. The structure of the susceptor assembly of the first embodiment and the structure of the susceptor of the second embodiment are largely the same, except for the differences in the wicking element and the susceptor element, as described below.

[0215] Figure 4 The susceptor element of EMBODIMENT 1 comprises a first susceptor layer 116 and a second susceptor layer 118 which are substantially parallel. The susceptor element further comprises a connecting section 117 which joins the first susceptor layer 116 to the second susceptor layer 118. Figure 4The connecting section 117 is shown as a U-shaped bend. The susceptor element is formed by bending or folding a single piece of material to form a susceptor element including a first susceptor layer 116, a second susceptor layer 118, and a connecting section 117. The connecting section 117 comprises a sintered mesh formed of ferritic stainless steel wires and austenitic stainless steel wires.

[0216] In this example, the wicking element includes a first wicking layer 120 , a second wicking layer 122 , and a wicking connection section 121 that joins the first wicking layer 120 to the second wicking layer 122 . Figure 4 The wicking connection section 121 shown in the figure is a U-shaped bend. The wicking element is formed by bending or folding a single piece of material to form a wicking element including a first wicking layer 120, a second wicking layer 122, and a wicking connection section 121. The wicking connection section 121 includes a porous body of cotton yarn. In other examples not shown in the drawings, alternative arrangements of the wicking element and the susceptor element are possible. For example, the susceptor assembly may include a susceptor element including a connection section connecting the first susceptor layer to the second susceptor layer, wherein the wicking element includes a first wicking layer and a second wicking layer that are separate components.

[0217] Figure 5 A schematic cross section of a susceptor assembly according to a third embodiment of the present disclosure is shown. The wicking element and the susceptor element may be connected to Figure 3 Or 4 the wicking element and the sensor element are the same. Figure 5 The spacer element 224 shown in is substantially planar and includes a first side of the spacer element in contact with the first wicking layer 20, 120 and a second side of the spacer element 224 in contact with the second wicking layer 22, 122, wherein the first side of the spacer element 224 is opposite to the second side of the spacer element 224. Figure 5 The spacer element 224 includes a plurality of apertures 226 defined through the spacer element. The apertures extend between a first side of the spacer element 224 and a second side of the spacer element 224.

[0218] In use, the orifices 226 allow or enhance the movement of the liquid aerosol-forming substrate between the first wicking layer 20, 120 and the second wicking layer 22, 122. In this example, the spacer element 224 may comprise a fluid permeable material comprising a woven mesh of cotton filaments, wherein the liquid aerosol-forming substrate may move through the spacer element via the spaces between the filaments of the spacer element and through the orifices 224. Alternatively, the spacer material may comprise a plastic material, such as a PEEK film, wherein the liquid aerosol-forming substrate is able to move through the spacer element 224 only via the orifices 226.

[0219] Figure 6A schematic cross-section of a susceptor assembly according to a fourth embodiment of the present disclosure is shown. Figure 6 The spacer element 234 shown in FIG. 2 comprises a triangular corrugation 234. The triangular corrugation 234 is formed by a fold in the spacer element 234, wherein the fold is a "V" shaped step-like change in direction.

[0220] Figure 7 A schematic cross-section of a susceptor assembly according to a fifth embodiment of the present disclosure is shown. Figure 7 The spacer element 244 shown in FIG. 2 includes an undulating corrugation. The undulating corrugation is formed by a plurality of bends in the spacer element. The bends are arcuate or "C" shaped gradual changes in the direction of the spacer element 244.

[0221] Figure 8 A schematic cross-section of a susceptor assembly according to a sixth embodiment of the present disclosure is shown. Figure 8 The spacer element 254 shown in FIG. 2 includes a curved portion configured to act as a spring element between the first wicking layer 20, 120 and the second wicking layer 22, 122. The spring is resiliently biased to maintain the first wicking layer 20, 120 and the second wicking layer 22, 122 at a predetermined separation distance.

[0222] Fig. 9 A schematic plan view of a spacer element 264 according to a seventh embodiment of the present disclosure is shown. The spacer element 264 includes a finger-like aperture 266 passing through the spacer element. The aperture 266 has a rectangular cross-section and is defined to pass through the spacer element 264 between the first side and the second side of the spacer element to enhance the transport of the liquid aerosol-forming substrate between the first wicking layer and the second wicking layer.

[0223] Fig.10a A perspective view of a susceptor assembly according to an eighth embodiment of the present disclosure is shown, wherein the susceptor assembly is shaped as a cross. Each of the first susceptor layer 216, the second susceptor layer 218, the first wicking layer 220, the second wicking layer 222, and the spacer element 334 is shaped as a cross.

[0224] Fig.10b Show Fig.10a 334. The spacer element 334 includes a pair of mounting areas 330 and a heating area 332. The heating area 332 is substantially rectangular and centrally located on the spacer element. The pair of mounting areas 330 are also generally rectangular areas located at the periphery of the heating area 332 at opposite sides of the heating area 332. In this embodiment, the mounting areas 330 are arranged at the same central location along the length of the heating area 332. Each of the pair of mounting areas 330 has a smaller surface area than the heating area 332.

[0225] In this embodiment, the cross-section of the spacer element 334 is the same as the cross-section of each of the first susceptor layer 216, the second susceptor layer 218, the first wicking layer 220, and the second wicking layer 222. The first susceptor layer 216, the second susceptor layer 218, the first wicking layer 220, and the second wicking layer 222 each have a respective mounting area and heating area that correspond to the mounting area and heating area of ​​the spacer element 334.

[0226] The heating regions of the first susceptor layer 216 and the second susceptor layer 218 are configured to be heated by the penetration of the alternating magnetic field for vaporizing the aerosol-forming substrate. A pair of mounting regions of the first susceptor layer 216 and the second susceptor layer 218 are configured to contact the susceptor holder so that the susceptor holder can support the susceptor assembly in a suitable position in the cartridge. The pair of mounting regions are configured to minimize heat transfer from the susceptor assembly to the susceptor holder.

[0227] Fig.11 -16B shows a cross-shaped spacer element with various numbers and shapes of apertures defined through the spacer element.

[0228] Figure 11-14 Shown is a plan view of an exemplary spacer element according to the present disclosure.

[0229] Fig.11 A cross-shaped spacer element 344 according to a ninth embodiment of the present disclosure is shown. The cross-shaped spacer element 344 includes a finger-shaped orifice 346 defined through the spacer element 344. The orifice 346 is defined as passing through the spacer element 344 between the first side and the second side of the spacer element to enhance the movement of the liquid aerosol-forming substrate between the first wicking layer and the second wicking layer. The cross-shaped spacer element 344 includes six finger-shaped orifices with a rectangular cross section. The finger-shaped orifice 346 is mainly included in the mounting area 340 of the spacer element 344. At least a portion of the finger-shaped orifice 346 extends into the heating area 342 of the spacer element 344. The finger-shaped orifice 346 is orthogonal to the plane of the longitudinal direction of the susceptor assembly. The finger-shaped orifice 346 extends from the opposite end of the spacer element 344 toward the center of the spacer element 344. The opposite end is located in the mounting area 340 and is configured as the end of the spacer element extending into the liquid reservoir. In this way, the finger-shaped orifices enhance the transport of the liquid aerosol-forming substrate from the liquid reservoir to the central heating zone 342 of the spacer element 344 and hence to the centre of the susceptor assembly, which should be the hottest part of the susceptor assembly during operation.

[0230] Fig.12A plan view of a cross-shaped spacer element 354 according to a tenth embodiment of the present disclosure is shown. The cross-shaped spacer element 354 includes two finger-shaped apertures 356 defined through the spacer element 354 and four "L"-shaped apertures 358 defined through the spacer element 354. The apertures 354, 356 are defined through the spacer element 354 between the first side and the second side of the spacer element 354. The finger-shaped apertures 356 are primarily included in the mounting area 350 of the spacer element 354. At least a portion of the finger-shaped apertures 356 extends into the heating area 352 of the spacer element 354. The finger-shaped apertures 356 are orthogonal to a plane of the longitudinal direction of the susceptor assembly. The finger-shaped apertures 356 extend from opposite ends of the spacer element 354 toward the center of the spacer element 354. The opposite ends are located in the mounting area 350 of the spacer element 354 and are configured as the ends of the spacer element 354 extending into the liquid reservoir. The first section of the "L" shaped orifice 358 extends from the opposite end of the spacer element 354 towards the center of the spacer element 354. The opposite end is located in the mounting area 350 of the spacer element 354 and is configured as the end of the spacer element 354 extending into the liquid reservoir. At least a portion of the first section of the finger-shaped orifice 358 extends into the heating zone 352 of the spacer element 354. The first section of the "L" shaped orifice is parallel to the finger-shaped orifice 356. The second section of the "L" shaped orifice 358 is perpendicular to the finger-shaped orifice 356. The second section of the "L" shaped orifice 358 extends in a plane parallel to the longitudinal direction of the susceptor assembly. The second section of the "L" shaped orifice is included in the heating zone 352. In this configuration, the "L" shaped orifice is configured to draw liquid from the liquid reservoir and through the spacer element in use to provide a more uniform distribution of the liquid aerosol-forming substrate across the susceptor assembly.

[0231] Fig.13 A plan view of a cross-shaped spacer element 364 according to an eleventh embodiment of the present disclosure is shown. The cross-shaped spacer element 364 includes two finger-shaped apertures 366 defined through the spacer element 364 and four "L"-shaped apertures 368 defined through the spacer element 364. The finger-shaped apertures 366 and the "L"-shaped apertures 368 are substantially the same as those of the tenth embodiment, except as listed below.

[0232] The difference between the orifice of the eleventh embodiment and the orifice of the tenth embodiment is that the finger-shaped orifice 366 and the "L"-shaped orifice 368 of the eleventh embodiment further include an orifice 367 having a circular cross-section.

[0233] Fig.14 A plan view of a cross-shaped spacer element 384 is shown in accordance with a twelfth embodiment of the present disclosure. In this embodiment, the cross-sectional area of ​​the aperture 376 is relatively large compared to the overall cross-section of the spacer element 374.

[0234] 15A shows a perspective view of a spacer element according to a thirteenth embodiment of the present disclosure. In this embodiment, the spacer element 384 comprises six apertures 386. The apertures 386 are configured to allow the liquid aerosol-forming substrate to move from a first side of the spacer element to a second side of the spacer element, and to allow the liquid aerosol-forming substrate to move from a first end or a second end of the spacer element 384 to a central portion of the spacer element 384.

[0235] FIG. 15B shows a plan view of the spacer element 384 of FIG. 15A. An aperture 386 is defined through the spacer element at both the mounting area 380 and the heating area 382. The aperture 386 is similar to Fig.12 shaped aperture shown in , however, aperture 386 includes a bend between a first section of the "L" shaped aperture and a second section of the "L" shaped aperture.

[0236] FIG. 16A shows a perspective view of a spacer element 394 according to a fourteenth embodiment of the present disclosure. The spacer element 394 includes three apertures 396 defined therethrough. The apertures 396 have a gradually changing cross-section. The cross-section of the apertures 396 gradually decreases from the outer portion of the spacer element 394 to the central portion of the spacer element 394.

[0237] FIG. 16B shows a plan view of the spacer element of FIG. 16A .

[0238] For the purpose of this specification and the appended claims, unless otherwise indicated, all numbers representing amounts, quantities, percentages, etc. should be understood to be modified by the term "about" in all cases. In addition, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically listed in this article. Therefore, in this context, the number A is understood to be A±10% A. In this context, the number A can be regarded as including the numerical value within the general standard error for the measurement of the attribute modified by the number A. In certain cases used in the appended claims, the number A may deviate from the percentages listed above, provided that the amount of A deviation will not substantially affect the basic features and novel features of the invention claimed for protection. In addition, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically listed in this article.

Claims

1. A susceptor assembly for an aerosol generating system, the susceptor assembly comprising: one or more wicking elements for transporting a liquid aerosol-forming substrate, the one or more wicking elements comprising a first wicking layer and a second wicking layer; a spacer element positioned between and in contact with the first wicking layer and the second wicking layer, wherein the spacer element is configured to permit movement of the liquid aerosol-forming substrate between the first wicking layer and the second wicking layer; as well as A susceptor element is in contact with at least a portion of the one or more wicking elements.

2. The susceptor assembly according to claim 1, wherein: The spacer element separates the first wicking layer from the second wicking layer.

3. The susceptor assembly according to claim 1 or 2, wherein: The first wicking layer is in contact with a first side of the spacer element, and the second wicking layer is in contact with a second side of the spacer element.

4. The susceptor assembly according to claim 3, wherein: The spacer element comprises an orifice or multiple orifices defined through the spacer element between a first side of the spacer element and a second side of the spacer element, wherein the orifice or multiple orifices are configured to allow a liquid aerosol-forming substrate to move between the first wicking layer and the second wicking layer.

5. The susceptor assembly according to any one of claims 1 to 4, wherein: The spacer element comprises a bend or a fold.

6. The susceptor assembly according to claim 5, wherein: The spacer element comprises a corrugation.

7. The susceptor assembly according to any one of claims 1 to 6, wherein: The spacer element is fluid permeable.

8. The susceptor assembly according to any one of claims 1 to 7, wherein: The spacer element comprises cotton.

9. The susceptor assembly according to any one of claims 1 to 8, wherein: The thickness of the spacer element is between 0.1 mm and 0.5 mm, preferably between 0.2 mm and 0.4 mm.

10. The susceptor assembly according to any one of claims 1 to 9, wherein: The susceptor element includes a first susceptor layer and a second susceptor layer.

11. The susceptor assembly according to claim 10, wherein: The susceptor element includes a connecting section that joins the first susceptor layer to the second susceptor layer.

12. A cartridge for an aerosol generating system, the cartridge comprising: A susceptor assembly according to any one of claims 1 to 11; as well as A liquid reservoir for holding a liquid aerosol-forming substrate, wherein the one or more wicking elements are in fluid communication with the liquid reservoir and are configured to transport the liquid aerosol-forming substrate from the liquid reservoir to the susceptor element.

13. The cartridge of claim 12, further comprising an air inlet, an air outlet, and an air flow passage extending between the air inlet and the air outlet, wherein the susceptor assembly is positioned in the air flow passage.

14. An aerosol generating system comprising: A susceptor assembly according to any one of claims 1 to 13; a liquid reservoir for holding a liquid aerosol-forming substrate, wherein the one or more wicking elements are in fluid communication with the liquid reservoir and are configured to transport the liquid aerosol-forming substrate; Inductor coil; as well as A power source is connected to the inductor coil and is configured to provide an alternating current to the inductor coil to generate an alternating magnetic field, wherein the susceptor element is configured to be heated by the alternating magnetic field.

15. An aerosol generating system according to claim 14, further comprising a system air inlet, a system air outlet and a system air flow pathway extending between the system air inlet and the system air outlet, wherein the susceptor assembly is positioned in the system air flow pathway.

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