Consumable assembly for aerosol-generating system

Abstract

The present disclosure provides a consumable assembly 600 for an aerosol-generating device 60, and a method for manufacturing the consumable assembly, the consumable assembly 600 comprising a susceptor holder 540 housing a susceptor assembly 510, the susceptor assembly comprising a susceptor 520 on a strip 500 of wicking material, the susceptor holder 540 comprising: a first portion 540, the first portion 540 being configured to receive the susceptor 520 on the strip 500 of wicking material, the second portion 540 being configured to receive the susceptor 520 on the strip 500 of wicking material, and the second portion 540 being configured to receive the susceptor 520 on the strip 500 of wicking material; the first portion includes a hollow elongated portion housing a susceptor assembly 510, the hollow elongated portion having an opening at the connection end, the hollow elongated portion including two opposing slots 545 extending along the elongated portion from the opening at the connection end, wherein the wicking material 500 on either side of a susceptor 520 of the susceptor assembly 510 protrudes through a slot 545 in the first portion 540; and a second portion 550 attached to the connection end of the first portion 540 to retain the susceptor assembly 510 within the first portion 540.

Description

[0001] The present disclosure relates to a consumable component for an aerosol generating system; and a method for manufacturing a consumable component for an aerosol generating system.

[0002] Aerosol generating systems are generally known in the prior art which employ induction heating to heat an aerosol-forming substrate in order to generate an aerosol for inhalation by a user. The aerosol-forming substrate is heated and evaporated to form a vapour. The vapour 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 arranged in close proximity to an aerosol-forming substrate and arranged 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 assembly may form part of the cartridge.

[0004] The aerosol-forming substrate may be a liquid. In this case, the susceptor assembly may further comprise a wicking material configured to draw the liquid aerosol-forming substrate from the reservoir in the cartridge to the susceptor to be heated.

[0005] Typically, a cartridge comprising a susceptor assembly and a liquid aerosol-forming substrate reservoir is formed by inserting the susceptor assembly through a slot in the wall of a hollow elongated susceptor holder. The susceptor assembly must be fixed within the susceptor holder so that the wicking material of the susceptor assembly protrudes through the slot in the susceptor holder to maintain fluid communication with the liquid aerosol-forming substrate reservoir surrounding the susceptor holder. Manufacturing an aerosol-generating cartridge in this manner may be a cumbersome process and is not suitable for large-scale production.

[0006] It is desirable to provide a manufacturing process for efficiently forming a consumable assembly comprising a susceptor assembly within a susceptor holder for an inductive aerosol generating device cartridge. It is also desirable to provide a consumable assembly for an inductive aerosol generating device cartridge that is easier to manufacture.

[0007] According to a first aspect of the present disclosure, a consumable component for an aerosol generating device is provided. The consumable component may include a receptor holder that accommodates a receptor assembly that includes a receptor on a strip of wicking material. The receptor holder may include a first portion that includes a hollow elongated portion that accommodates the receptor assembly. The hollow elongated portion may have an opening at a connection end. The hollow elongated portion may include two opposing grooves extending from the opening at the connection end along the elongated portion. The wicking material on either side of the receptor of the receptor assembly may protrude through the groove in the first portion. The second portion may be attached to the connection end of the first portion to hold the receptor assembly within the first portion.

[0008] Advantageously, assembling the two parts of the susceptor holder around the wicking material strip including the susceptor assembly facilitates the rapid construction of the consumable assembly. Specifically, the susceptor assembly formed on the wicking material strip can be fed into the hollow elongated portion of the first susceptor holder part via the opening in the connecting end, and several parts of the wicking material strip are received in the groove in the first susceptor holder part, rather than awkwardly feeding the susceptor assembly through the groove in the wall of the susceptor holder and fixing the susceptor assembly in the appropriate position in the susceptor holder, while maintaining a part of the wicking material outside the susceptor holder. The susceptor assembly can then be retained in the first susceptor holder part by attaching the second susceptor holder part to the connecting end of the first susceptor holder part. Therefore, the proposed consumable assembly is easier to manufacture because the need for accurately positioning the susceptor assembly by the groove in the susceptor holder is avoided. On the contrary, the proposed consumable assembly can be reliably and efficiently manufactured by assembling the two parts of the susceptor holder around the susceptor assembly.

[0009] The wicking material may be configured to transport the liquid aerosol-forming substrate to the susceptor.The susceptor may be configured to heat and vaporize the liquid aerosol-forming substrate.

[0010] The slot in the first susceptor holder part may be sized to have a width greater than the wicking material but less than the width of the susceptor assembly. This advantageously prevents the susceptor assembly from sliding out of the first susceptor holder part through the slot.

[0011] The groove in the first susceptor holder part may have a length greater than the width of the strip of wicking material. Advantageously, this results in the strip of wicking material being completely contained within the groove.

[0012] The width of the slot in the first susceptor holder part may increase at the connection end. This may facilitate easier insertion of the strip of wicking material into the slot.

[0013] The second susceptor holder portion can hold the susceptor assembly in the first susceptor holder portion via one or more different mechanisms. The connection between the first susceptor holder portion and the second susceptor holder portion can apply a biasing force to the wicking material or the susceptor assembly. In one example, when connected to the first susceptor holder portion, the second susceptor holder portion can prevent the wicking material from sliding out of the groove at the connection end of the first susceptor holder portion. In one example, when connected to the first susceptor holder portion, the second susceptor holder portion can prevent the susceptor assembly from sliding out of the first susceptor holder portion via the opening at the connection end. In one example, when connected to the first susceptor holder portion, the second susceptor holder portion can apply a biasing force to the wicking material or the susceptor assembly against the first susceptor holder portion, thereby keeping the susceptor assembly in place. In another example, when connected to the first susceptor holder portion, the second susceptor holder portion can apply a biasing force on the first susceptor holder portion so that a portion of the first susceptor holder portion is deformed against the wicking material to keep the susceptor assembly in place. It should be appreciated that any known connection mechanism for providing the above-mentioned biasing force may be utilized.

[0014] The second susceptor holder part may form a snap fit connection with the first susceptor holder part via the connecting end.The snap fit connection may be irreversible to retain the susceptor assembly indefinitely within the first susceptor holder part after the second susceptor holder part is attached.

[0015] The surface of the first susceptor holder portion at the connection end may include threads, and the second susceptor holder portion may include corresponding threads for forming a threaded connection with the first susceptor holder portion. The threads on the first susceptor holder portion may be located on an outer surface of the first susceptor holder portion, and the threads on the second susceptor holder portion may be located on an inner surface of the second susceptor holder portion. Alternatively, the threads on the first susceptor holder portion may be located on an inner surface of the first susceptor holder portion, and the threads on the second susceptor holder portion may be located on an outer surface of the second susceptor holder portion.

[0016] The second susceptor holder portion may include a hollow portion and an opening at the connection end for connection with the connection end of the first susceptor holder portion. The connection end of the second susceptor holder portion may include two opposing slots extending from the opening. The slot in the second susceptor holder portion may be configured to receive at least a portion of the wicking material strip when the second susceptor holder portion is attached to the first susceptor holder portion. Advantageously, when the second susceptor holder portion is attached to the first susceptor holder portion, the slot in the second susceptor holder portion may engage and receive a portion of the wicking material strip. This may improve retention of the susceptor assembly within the first susceptor holder portion and limit rotation of the second susceptor holder portion when attached to the first susceptor holder portion.

[0017] The susceptor may comprise a first susceptor layer and a second susceptor layer. Thus, the strip of wicking material may comprise a first wicking layer and a second wicking 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 wicking material is 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.

[0018] The first susceptor layer and the second susceptor layer may be planar. In this case, a planar susceptor layer is a susceptor layer having a length and a width that are significantly greater than the thickness. The length and width directions 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 to flow over 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.

[0019] The first susceptor layer and the second susceptor layer may be separate components.

[0020] The first susceptor layer and the second susceptor layer may be integral with each other.

[0021] Advantageously, this may simplify the manufacture of the susceptor assembly.

[0022] The susceptor may include a connecting portion connecting the first susceptor layer to the second susceptor layer. The susceptor may include three parts. The first part of the susceptor may include the first susceptor layer. The second part of the susceptor may include the second susceptor layer. The third part of the susceptor may be a connecting portion connecting the first susceptor layer to the second susceptor layer.

[0023] The connecting portion may be U-shaped or V-shaped. Advantageously, a susceptor having a U-shaped or V-shaped connecting portion may keep the first and second wicking layers in contact with the first and second susceptor layers.

[0024] The susceptor 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 portion of the susceptor. Advantageously, a susceptor formed in this way may be relatively easy to manufacture.

[0025] 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.

[0026] 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.

[0027] 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 bending or folding in the wicking layer, which may compress the wicking layer and result in suboptimal liquid transport.

[0028] The susceptor assembly may be substantially planar.The susceptor assembly may have a rectangular cross-section taken across the first plane.

[0029] The susceptor assembly may include a heating region and at least one mounting region. The heating region is a region of the susceptor assembly configured to be heated to a temperature required to vaporize the aerosol-forming substrate when penetrated by a suitable alternating magnetic field. The heating region of the susceptor assembly may include at least a portion of the first susceptor layer. The heating region 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, and the second wicking layer may include a heating region.

[0030] Each of the first wicking layer and the second wicking layer may include a mounting area. At least one mounting area may be in contact with the susceptor holder. Preferably, when the susceptor assembly is inserted in the barrel, 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 substantially outside the liquid reservoir, and in particular arranging the heating area of ​​the first susceptor layer and the second susceptor layer outside the liquid reservoir, can ensure that the aerosol-forming substrate is fully heated to release volatile compounds only after the aerosol-forming substrate has been transported to the outside of the liquid reservoir. This can promote the release of volatile compounds from the aerosol generating system.

[0031] In a preferred embodiment, the cross-sectional area of ​​the wicking material taken across the first plane is greater than the cross-sectional area of ​​the susceptor taken across the first plane.The length of the first susceptor layer and the length of the second susceptor layer may be approximately equal to the length of the first wicking layer and the second wicking layer.

[0032] The width of the first susceptor layer and the second susceptor layer may be less than the width of the first wicking layer and the second wicking layer. The width of the first susceptor layer and the second wicking layer may be about 20% less than the width of the first wicking layer and the second wicking layer. The width of the first susceptor layer and the second susceptor layer may be approximately equal to the width of the heating area of ​​the first wicking layer and the second wicking layer. The first susceptor layer and the second susceptor layer may not include a mounting area.

[0033] The first susceptor layer and the second susceptor layer may include a mounting region.

[0034] The susceptor assembly may form a cross shape. The first susceptor layer, the second susceptor layer, the first wicking layer and the second wicking 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 substantially 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.

[0035] The wicking material strip may include a capillary material. The first wicking layer may include a capillary material. The second wicking layer may include a capillary material. Capillary material is a material that can transport liquid from one end of the material to the other end by 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-pored tubes. In certain embodiments, the capillary material may include a spongy or foamy material. The structure of the capillary material may form a plurality of pores or tubes, through which the liquid aerosol-forming substrate may be transported by capillary action.

[0036] The wicking material may include or consist of an electrically insulating material. The wicking material may include a non-metallic material. The wicking material may include a hydrophilic material or an oleophilic material. This may advantageously facilitate the transport of the aerosol-forming substrate through the wicking material. The wicking material may include or consist of a porous ceramic material.

[0037] The wicking material can include non-metallic materials. The example of suitable materials for wicking materials is a sponge or foam material, a ceramic or graphite-based material in the form of a fiber or sintered powder, a foamed metal or a plastic material, for example a fiber material made by spinning or extruding fibers, such as glass fiber, cellulose acetate, polyester or bonded polyolefin, polyethylene, terylene or polypropylene fibers, nylon fibers or ceramics. Suitable materials for wicking materials can include cellulosic materials, such as cotton or rayon.

[0038] The wicking material 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.

[0039] The first wicking layer may have a thickness between 0.1 and 0.5 millimeters. Preferably, the first wicking layer may have a thickness between 0.2 millimeters. The second wicking layer may have a thickness between 0.1 and 0.5 millimeters. Preferably, the second wicking layer may have a thickness between 0.2 millimeters.

[0040] The distance between the first wicking layer and the second wicking layer may be between 0.1 mm and 0.5 mm. Preferably, the distance between the first wicking layer and the second wicking layer may be between 0.2 mm and 0.4 mm.

[0041] The susceptor may be fluid permeable. The first susceptor layer may be fluid permeable. The second susceptor layer may be fluid permeable. A fluid permeable susceptor may advantageously allow evaporated aerosol-forming substrate to escape through the susceptor. Thus, aerosol-forming substrate vapor generated in the region of the wicking material immediately adjacent to the susceptor may escape through the susceptor without passing through the wicking material.

[0042] As used herein, "susceptor" means an element that can be heated by the penetration of an alternating magnetic field. The susceptor can generally be heated by at least one of Joule heating and hysteresis losses by inducing eddy currents in the susceptor. Possible materials for the susceptors include graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, and virtually any other conductive element. Advantageously, the first and second susceptors can be ferrite elements. The material and geometry of the susceptors can be selected to provide the desired resistance and heat generation. Preferably, the first and second susceptors comprise AISI 430 stainless steel.

[0043] Advantageously, in an aerosol generating system using induction heating, no electrical contact needs to be made between the susceptor assembly and the power source. This can eliminate the need for solder or other bonding elements. A cartridge comprising a susceptor assembly configured for induction heating can allow for the production of a simple, inexpensive and robust cartridge.

[0044] One or more susceptors may be printed or otherwise deposited on the wicking material strip as a film or multiple tracks. One or more susceptors may be fixed to the wicking material by folding the free edges of one or more susceptors around the wicking material strip. The free edges of the folded susceptors may be welded together to fix the susceptors around the wicking material strip. Preferably, one or more susceptors are arranged across the width of the wicking material strip. The susceptors may include or consist of a conductive material deposited directly on the wicking material. The conductive material of the susceptor may be deposited on the wicking material as multiple tracks. In operation, the vaporized aerosol-forming substrate may advantageously escape from the wicking material through the gaps or spaces between the tracks. The multiple tracks of each susceptor may advantageously be distributed on the surface of the wicking material to provide substantially uniform heating across the surface. For example, the width of each of the tracks and the spacing between the tracks may be substantially the same for each of the multiple tracks. The multiple tracks of each susceptor may include a first set of tracks parallel to each other. The multiple tracks may also include a second set of tracks perpendicular to the first set of tracks and overlapping the first set of tracks. The first set of tracks and the second set of tracks may form a mesh structure together.

[0045] The susceptor may comprise or consist of a perforated foil. In operation, the vaporized aerosol-forming substrate may advantageously escape from the wicking material through the perforations of the perforated foil. The perforations may be evenly distributed across the susceptor. The susceptor may be perforated to allow vapor to exit from the susceptor assembly or to allow liquid aerosol-forming substrate to enter.

[0046] The susceptor may comprise conductive filaments. The susceptor may comprise or consist of conductive filaments.

[0047] In a preferred embodiment, the susceptor may comprise a mesh. As used herein, the term "mesh" includes grids and arrays of filaments with spaces between them. The term mesh also includes woven and nonwoven fabrics.

[0048] The filaments may define spaces between the filaments, and the spaces may have a width 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 and the liquid. In operation, the vaporized aerosol-forming substrate may advantageously escape from the wicking material through the spaces between the filaments of the susceptor.

[0049] Each susceptor may have a thickness of no more than two millimeters. Preferably, each susceptor may have a thickness of less than one millimeter. Particularly preferably, the susceptor may have a thickness of between 0.1 millimeters and 0.2 millimeters. The thickness of each susceptor is advantageously of a similar order of magnitude to the skin depth of the material of the susceptor at the operating frequency of the system. Advantageously, the thickness of the susceptor assembly is no greater than ten times the skin depth of the material of the susceptor at the operating frequency. This may ensure that each susceptor has a suitably low mass and that the time taken for the susceptor to reach a temperature suitable for evaporating the aerosol-forming substrate is therefore less. When the susceptor is penetrated from the opposite side by the alternating magnetic field, the susceptor may advantageously have a thickness of at least twice the skin depth of the material of the susceptor at the operating frequency. This may minimize the interaction of the skin effect on the opposite sides of the susceptor.

[0050] 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 amount of liquid to evaporate quickly with minimal heat loss. Advantageously, the susceptor assembly or a heated region of the susceptor assembly may hold between 2 ml and 10 ml of liquid aerosol-forming substrate.

[0051] 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.

[0052] The susceptor assembly may include a spacer layer between the first wicking layer and the second wicking layer. It has been found that two layers of wicking material in contact with each other can lead to the formation of condensate, which is trapped between the two layers of wicking material. This can then cause the release of steam. The steam can cause deformation of the susceptor. The deformation of the susceptor may in turn lead to reduced contact between the susceptor and the wicking material, thereby resulting in a reduction in the liquid aerosol-forming substrate or inefficient aerosolization. Advantageously, the spacer layer can improve the liquid flow between the first wicking layer and the second wicking layer, and thus can prevent the accumulation of condensate between the two layers.

[0053] The first side of the spacer layer 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 layer 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 layer can be opposite to the second side of the spacer layer. In this arrangement, the first susceptor layer and the second susceptor layer can be sufficiently spaced 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.

[0054] The spacer layer may be fluid permeable.As used herein, a "fluid permeable" element means an element that allows liquids or gases to pass therethrough.

[0055] The spacer layer may be substantially planar, having a length and a width that are significantly greater than the thickness. The length and width directions are orthogonal to each other and define a first plane of the spacer layer. The first side of the spacer layer and the second side of the spacer layer may be opposite to each other and extend in a plane parallel to the first plane of the susceptor. The spacer layer may be configured to transport a liquid aerosol-forming substrate between the first side of the spacer layer and the second side of the spacer layer.

[0056] The spacer layer may be configured to transport the liquid aerosol-forming substrate between the first wicking layer and the second wicking layer. In particular, when the first wicking layer is in contact with a first side of the spacer layer and the second wicking layer is in contact with a second side of the spacer layer.

[0057] The first wicking layer can be in contact with a first side of the spacer layer, and the second wicking layer can be in contact with a second side of the spacer layer. The spacer layer can separate the first wicking layer from the second wicking layer. Advantageously, the spacer layer can prevent the first wicking layer from contacting the second wicking layer and thereby reduce the accumulation of undesirable condensate between the first wicking layer and the second wicking layer.

[0058] The spacer layer may include a porous material. The spacer layer may include more pores than the wicking material. The spacer layer may include larger pores than the wicking material. The spacer layer may be more porous than the wicking material.

[0059] The spacer layer may comprise a capillary material. The spacer layer may comprise more pores or tubes than the wicking material, through which the liquid aerosol-forming substrate may be transported by capillary action. The spacer layer may comprise larger pores or tubes than the wicking material, through which the liquid aerosol-forming substrate may be transported by capillary action. In this way, the liquid aerosol-forming substrate may be transported through the spacer layer more quickly than the wicking material.

[0060] The spacer layer may include a mesh. As used herein, the term "mesh" includes grids and arrays of filaments with spaces between them. The term mesh also includes woven and nonwoven fabrics.

[0061] The spacer layer may preferably comprise or consist of cotton. The spacer layer may comprise a plastic material. The spacer layer may comprise a polyetheretherketone (PEEK) film. The spacer layer may comprise a fiber sheet.

[0062] The spacer layer may comprise an orifice configured to convey the liquid aerosol-forming substrate between the first wicking layer and the second wicking layer. The spacer layer may comprise a plurality of orifices configured to convey the liquid aerosol-forming substrate between the first wicking layer and the second wicking layer.

[0063] One or more orifices may be defined by the spacer layer between the first side of the spacer layer and the second side of the spacer layer. In this way, the liquid aerosol-forming substrate may be transported through the one or more orifices between the first side of the spacer layer and the second side of the spacer layer.

[0064] The one or more orifices may have a circular cross-section.The one or more orifices may have a diameter of at least 0.1 mm.

[0065] The one or more orifices may have a rectangular cross-section. The one or more orifices may be defined at the ends of the spacer layer. The one or more orifices may be configured to enhance the transport of the liquid aerosol-forming substrate from the liquid reservoir to the center of the spacer layer.

[0066] The spacer layer may include one or more of a bend, an undulation, a fold, and a corrugation. The spacer layer may have a first end and a second end. The width of the spacer layer may extend from the first end to the second end. In the case where the spacer layer does not extend directly (i.e., extends in a straight line) from the first end to the second end, the spacer layer may be considered to include one or more of a bend, an undulation, a fold, and a corrugation.

[0067] The bend may refer to a gradual change in the direction of the spacer layer, for example, a gradual change in the direction of the spacer layer between the first end and the second end. Thus, the bend may form an arc or "C" shape. The bend in the spacer layer may enhance the transport of the liquid aerosol-forming substrate between the first wicking layer and the second wicking layer.

[0068] The spacer layer 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 keep the first wicking layer and the second wicking layer separated by a predetermined distance. The separation distance may be preset by adjusting the radius of the curved portion. Advantageously, the spacer layer 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 layer and the wicking material.

[0069] The fold may refer to a change in the direction of the spacer layer, for example, a step change in the direction of the spacer layer between the first end and the second end. Thus, the fold may form two sides of a polygon, or a "V" shape.

[0070] The undulations may include multiple curves. For example, the undulations may refer to a gradual change in the direction of the spacer layer in a first direction, followed by a gradual change in the direction of the spacer layer in another direction (e.g., the opposite direction). Thus, the undulations may form a sine wave or "S" shape. Multiple undulations may be referred to as corrugations. The spacer layer may include corrugations.

[0071] The corrugation may include multiple folds. For example, a corrugation may refer to a step change in the direction of the spacer layer, followed by another step change in the direction of the spacer layer. 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 layer may include triangular corrugations.

[0072] The corrugations may be formed by bending or folding the spacer material to form the spacer layer.The corrugations may be formed by molding the spacer material to form the spacer layer.

[0073] The undulations or corrugations of the spacer layer may enhance the flow of the liquid aerosol-forming substrate between the first layer of wicking material and the second layer of wicking material.

[0074] The thickness of the spacer layer may be between 0.1 mm and 0.5 mm. As used herein, the thickness of the spacer layer is defined as the distance between the first side of the spacer layer and the second side of the spacer layer. Preferably, the thickness of the spacer layer may be between 0.2 mm and 0.4 mm.

[0075] The depth of the spacer layer 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 layer may be defined as the sum of the maximum distance from the central axis to the first side of the spacer layer along a plane perpendicular to the first side and the maximum distance from the central axis to the second side of the spacer layer along a plane perpendicular to the second side.

[0076] According to a second aspect of the present disclosure, a cartridge for an aerosol generating system is provided. The cartridge may include a consumable component according to the first aspect of the present disclosure and a liquid reservoir for holding a liquid aerosol-forming substrate. The wicking material may be in fluid communication with the liquid reservoir and configured to transport the liquid aerosol-forming substrate between the liquid reservoir and a receptor.

[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 may be positioned in the airflow pathway.

[0079] The susceptor 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. An 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 portion 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 aspect of the present disclosure, an aerosol generating system is provided. The aerosol generating system may include a consumable component according to the first aspect of the present disclosure. The aerosol generating system may also include a liquid reservoir for holding a liquid aerosol-forming substrate, wherein the wicking material is in fluid communication with the liquid reservoir and is 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 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 may be positioned in the system airflow pathway.

[0088] The susceptor 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 out of 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 aerosol generating system may 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 may have a size comparable to a conventional cigar or cigarette. The aerosol generating system may have an overall length between about 30 mm and about 150 mm. The aerosol generating system may have an outer diameter between about 5 mm and about 30 mm. The aerosol generating system may be an electrically operated smoking device.

[0091] 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 power the inductor coil after the system is activated, or may be configured to power it intermittently, for example on a puff-by-puff basis. Electricity 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 system 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.

[0092] The control circuitry 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 drawn through the system airflow pathway. The sensor may allow the aerosol generating system to be powered on a puff-by-puff basis.

[0093] 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 spent smoking 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.

[0094] An aerosol generating system may comprise a cartridge according to the second aspect of the present disclosure and an aerosol generating device.The system air outlet may comprise a cartridge air outlet.

[0095] 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.

[0096] 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 so as to charge the power source of the aerosol generating device.

[0097] It should be understood that any features described herein with respect to one aspect of a consumable assembly may also apply to other aspects of cartridges and aerosol generating systems according to the present disclosure. Features described with respect to one aspect of the present disclosure may equally apply to another aspect of the present disclosure.

[0098] 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 may be released by heating or burning the aerosol-forming substrate.

[0099] 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.

[0100] 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.

[0101] As used herein, the term "liquid aerosol-forming substrate" is used to refer to an aerosol-forming substrate in a concentrated 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.

[0102] According to a fourth aspect of the present disclosure, a method for manufacturing a consumable component is provided. The method may include providing one or more susceptors across a strip of wicking material to form corresponding one or more susceptor assemblies. The method may also include sliding one or more first susceptor holder portions onto the wicking material strip to engage the corresponding one or more susceptor assemblies. The one or more first susceptor holder portions may each include a hollow elongated portion having an opening at a connection end. The hollow elongated portion may include two opposing grooves extending from the opening at the connection end along the elongated portion. The groove may be configured to receive and engage the wicking material strip on either side of the susceptor assembly when the susceptor assembly is received in the hollow elongated portion of the first susceptor holder portion. The method may then include attaching a second susceptor holder portion to the connection end of each of the one or more first susceptor holder portions to hold the wicking material strip including the one or more susceptor assemblies in the corresponding one or more first susceptor holder portions.

[0103] As mentioned above, forming two parts of the susceptor holder around a strip of wicking material including a susceptor assembly facilitates the rapid construction of a consumable assembly. The susceptor assembly formed on the wicking material strip is fed into the hollow elongated portion of the first susceptor holder portion via an opening in the connecting end, while several parts of the wicking material strip are received in the groove in the first susceptor holder portion, rather than awkwardly feeding the susceptor assembly through the groove in the wall of the susceptor holder and fixing the susceptor assembly in a suitable position in the susceptor holder while maintaining a portion of the wicking material outside the susceptor holder. The susceptor assembly is then retained in the first susceptor holder portion by attaching the second susceptor holder portion to the connecting end of the first susceptor holder portion. The proposed manufacturing method therefore eliminates the need to accurately locate the susceptor assembly through the groove in the susceptor holder, but instead proposes a technology for reliably assembling the susceptor holder around the susceptor assembly so as to improve the manufacturing efficiency of the consumable assembly.

[0104] The second susceptor holder part may retain the susceptor assembly within the first susceptor part via any of the mechanisms mentioned in relation to the first aspect.

[0105] The method may include securing one or more susceptors to the wicking material by folding a free edge of the one or more susceptors around a strip of wicking material.

[0106] The method may include providing one or more susceptors across the width of the strip of wicking material.

[0107] The method may include providing a plurality of susceptors on the strip of wicking material to form a corresponding plurality of susceptor assemblies.Where a plurality of susceptors are provided on the wicking material, each of the plurality of susceptors may be spaced apart along the length of the strip of wicking material.

[0108] The method may include transversely folding a strip of wicking material including one or more susceptors so that the one or more susceptors are arranged on the outer surface of each side of the folded strip of wicking material. Advantageously, by folding the strip of wicking material including one or more susceptors in this manner, one or more susceptor assemblies including two susceptor layers outside two inner wicking layers are efficiently formed. The free edges of the one or more folded susceptors can be welded together to prevent the wicking material strip from unfolding itself. Before folding the wicking material strip, a spacer layer can be arranged under the wicking material. This ensures that once the wicking material strip is folded, the spacer layer separates the two inner wicking layers, thereby producing a susceptor assembly including a spacer layer, as described with respect to the previous aspects.

[0109] The method may include cutting the wicking material strip outside of the first susceptor holder portions to separate each of the first susceptor holder portions from the remainder of the wicking material strip to form a plurality of consumable components while maintaining an exposed portion of the wicking material outside of the plurality of first susceptor holder portions. This advantageously facilitates efficient manufacture of a plurality of consumable components from a single wicking material strip.

[0110] The method may include inserting the consumable assembly into a cartridge housing, the cartridge housing and the consumable assembly forming a cartridge including a reservoir. When inserted into the cartridge housing, an exposed portion of the wicking material protruding from the groove in the first susceptor assembly portion may be in fluid communication with the reservoir.

[0111] The method may comprise inserting the cartridge into an aerosol generating device.

[0112] According to a fifth aspect of the present disclosure, a method for manufacturing a consumable component is provided. The method may include providing a plurality of susceptors spaced apart across a wicking material strip to form a corresponding plurality of susceptor assemblies. A plurality of first susceptor holder portions may be provided. The plurality of first susceptor holder portions may each include a hollow elongated portion. The hollow elongated portion may include two opposing grooves extending longitudinally along the elongated portion. The groove may be configured to receive a wicking material strip including a plurality of susceptor assemblies. The method may also include feeding a wicking material strip including a plurality of susceptor assemblies through the grooves of the plurality of first susceptor holder portions so that the plurality of susceptor holder portions are each aligned above the corresponding susceptor assemblies. The method may include cutting the wicking material strip outside the plurality of first susceptor holder portions to separate each of the plurality of first susceptor holder portions from the rest of the wicking material strip to form a plurality of consumable components, while maintaining an exposed portion of the wicking material outside the plurality of first susceptor holder portions.

[0113] Advantageously, the proposed method can improve the manufacturing efficiency of consumable components. The proposed method provides a plurality of susceptor assemblies on a strip of wicking material that is sequentially fed through slots in a plurality of susceptor holders so that each of the susceptor assemblies is aligned within a corresponding susceptor holder, rather than feeding a single susceptor assembly into a slot in a susceptor holder. The wicking material outside each susceptor holder is then cut to produce a plurality of susceptor assemblies.

[0114] The method may include attaching a second susceptor holder portion to each of the plurality of first susceptor holder portions to hold each of the plurality of susceptor assemblies within the respective first susceptor holder portion. The second susceptor holder portion may hold the susceptor assembly within the first susceptor portion via any of the mechanisms mentioned with respect to the first aspect.

[0115] The method may include securing one or more susceptors to the wicking material by folding a free edge of the one or more susceptors around a strip of wicking material.

[0116] The method may include providing one or more susceptors across the width of the strip of wicking material.

[0117] As described in relation to the fourth aspect, the method may include folding the strip of wicking material laterally so that one or more susceptors are disposed on the outer surface of each side of the folded strip of wicking material. Advantageously, by folding the strip of wicking material including one or more susceptors in this manner, one or more susceptor assemblies comprising two susceptor layers outside of two inner wicking layers are efficiently formed. Prior to folding the strip of wicking material, a spacer layer may be disposed beneath the wicking material. This ensures that once the strip of wicking material is folded, the spacer layer separates the two inner wicking layers, thereby producing a susceptor assembly comprising a spacer layer, as described in relation to the previous aspect.

[0118] The method may include inserting a consumable component into a cartridge housing, the cartridge housing and the consumable component forming a cartridge including a reservoir. When inserted into the cartridge housing, the exposed portion of the protruding wicking material may be in fluid communication with the reservoir.

[0119] The method may comprise inserting the cartridge into an aerosol generating device.

[0120] The present 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.

[0121] Ex1. A method for manufacturing one or more consumable components for an aerosol generating device, the method comprising:

[0122] providing one or more susceptors across the strip of wicking material to form corresponding one or more susceptor assemblies;

[0123] sliding one or more first susceptor holder portions onto the strip of wicking material to engage the corresponding one or more susceptor assemblies, the one or more first susceptor holder portions each comprising a hollow elongated portion having an opening at a connection end, the hollow elongated portion comprising two opposing slots extending along the elongated portion from the opening at the connection end, wherein the slots are configured to receive and engage the strip of wicking material on either side of the susceptor assembly when the susceptor assembly is received within the hollow elongated portion of the first susceptor holder portion; and

[0124] A second susceptor holder portion is attached to the connection end of each of the one or more first susceptor holder portions to retain the strip of wicking material including the one or more susceptor assemblies within the corresponding one or more first susceptor holder portions.

[0125] Ex2. The method according to Ex1, further comprising providing one or more spacer elements on a side of the wicking material strip opposite to the corresponding one or more susceptors, wherein the one or more spacer elements are at least partially aligned with the corresponding one or more susceptors.

[0126] Ex3. A method according to Ex2, wherein the one or more spacer elements comprise a porous material.

[0127] Ex4. A method according to any one of Ex2-Ex3, wherein the one or more spacer elements comprise a mesh.

[0128] Ex5. A method according to any one of Ex2-Ex4, wherein the one or more spacer elements include an orifice for allowing a liquid aerosol-forming substrate to be transported through the one or more spacer elements.

[0129] Ex6. A method according to Ex5, wherein the one or more spacer elements include a plurality of orifices for allowing a liquid aerosol-forming substrate to be transported through the one or more spacer elements.

[0130] Ex7. A method according to any one of Ex5-Ex6, wherein the one or more orifices have a circular cross-section.

[0131] Ex8. A method according to any one of Ex5-Ex7, wherein the one or more orifices comprise partial perforations in one or more spacer elements.

[0132] Ex9. A method according to any one of Ex2-Ex8, the method further comprising corrugating the one or more spacer elements to form a corrugated portion or a triangular corrugated portion.

[0133] Ex10. A method according to any one of Ex2-Ex9, wherein the one or more spacer elements comprise cotton.

[0134] Ex11. A method according to any one of Ex2-Ex10, wherein the one or more spacer elements comprise a plastic material.

[0135] Ex12. A method according to any one of Ex2-Ex11, wherein the one or more spacer elements comprise a PEEK film.

[0136] Ex13. A method according to any one of Ex2-Ex12, wherein the one or more spacer elements comprise a fiber sheet.

[0137] Ex14. A method according to any one of Ex2-Ex13, wherein the one or more spacer elements have a higher permeability than the permeability of the wicking material strip.

[0138] Ex15. A method according to any one of Ex1-Ex14, wherein the one or more receptors are fluid permeable.

[0139] Ex16. A method according to any one of Ex1-Ex15, wherein the one or more receptors comprise conductive filaments.

[0140] Ex17. A method according to any one of Ex1-Ex16, wherein the one or more receptors comprise a mesh.

[0141] Ex18. A method according to any one of Ex1-Ex17, wherein the strip of wicking material comprises cotton.

[0142] Ex19. A method according to any one of Ex1-Ex18, wherein the thickness of the one or more sensor components is greater than the width of the grooves in the one or more first sensor holder parts.

[0143] Ex20. A method according to any one of Ex1-Ex19, wherein the width of the groove increases at the connection end.

[0144] Ex21. A method according to any one of Ex1-Ex20, wherein the second susceptor holder part forms a snap-fit ​​connection with the connecting end when attached to the first susceptor holder part.

[0145] Ex22. A method according to any one of Ex1-Ex21, wherein the second susceptor holder part applies a biasing force on the susceptor assembly when attached to the first susceptor holder part.

[0146] Ex23. A method according to any one of Ex1-Ex22, wherein the second sensor holder portion includes a hollow portion and an opening at the connecting end for connecting to the connecting end of the first sensor holder portion, wherein the connecting end of the second sensor holder portion includes two opposing grooves extending from the opening, wherein the grooves in the second sensor holder portion are configured to receive at least a portion of the wicking material strip when the second sensor holder portion is attached to the first sensor holder portion.

[0147] Ex24. A method for manufacturing one or more consumable components for an aerosol generating device, the method comprising:

[0148] providing a plurality of susceptors spaced across the strip of wicking material to form a corresponding plurality of susceptor assemblies;

[0149] providing a plurality of first susceptor holder portions, each of the plurality of first susceptor holder portions comprising a hollow elongated portion including two opposing slots extending longitudinally along the elongated portion, wherein the slots are configured to receive the strip of wicking material including the plurality of susceptor assemblies;

[0150] feeding the strip of wicking material including the plurality of susceptor assemblies through the slots of the plurality of first susceptor holder portions such that each of the plurality of susceptor holder portions is aligned over a respective susceptor assembly; and

[0151] The strip of wicking material at the exterior of the plurality of first susceptor holder portions is cut to separate each of the plurality of first susceptor holder portions from the remainder of the strip of wicking material while maintaining an exposed portion of the wicking material exterior to the plurality of first susceptor holder portions.

[0152] Ex25. The method according to Ex24, further comprising securing the plurality of susceptors to the wicking material by folding free edges of the plurality of susceptors around the strip of wicking material.

[0153] Ex26. A method according to any one of Ex24-Ex25, wherein the plurality of susceptors are arranged across the width of the strip of wicking material.

[0154] Ex27. The method according to Ex26 further comprises transversely folding the strip of wicking material so that a plurality of susceptors are disposed on an outer surface on each side of the folded strip of wicking material.

[0155] Ex28. A method according to any one of Ex24-Ex27, the method further comprising providing a plurality of spacer elements on a side of the wicking material strip opposite to the corresponding plurality of susceptors, wherein each of the plurality of spacer elements is at least partially aligned with the corresponding susceptor.

[0156] Ex29. A method according to Ex28, wherein the plurality of spacer elements comprise a porous material.

[0157] Ex30. A method according to any one of Ex28-Ex29, wherein the plurality of spacer elements comprise a mesh.

[0158] Ex31. A method according to any one of Ex28-Ex30, wherein each of the plurality of spacer elements comprises an orifice for allowing a liquid aerosol-forming substrate to be transported through the corresponding spacer element.

[0159] Ex32. A method according to Ex31, wherein each of the plurality of spacer elements comprises a plurality of orifices for allowing a liquid aerosol-forming substrate to be transported through the corresponding spacer element.

[0160] Ex33. A method according to any one of Ex31-Ex32, wherein the one or more orifices have a circular cross-section.

[0161] Ex34. A method according to any one of Ex31-Ex33, wherein the one or more orifices comprise partial perforations in the spacer element.

[0162] Ex35. A method according to any one of Ex28-Ex34, the method further comprising corrugating the plurality of spacer elements to form a corrugated portion or a triangular corrugated portion.

[0163] Ex36. A method according to any one of Ex28-Ex35, wherein the plurality of spacer elements comprise cotton.

[0164] Ex37. A method according to any one of Ex28-Ex36, wherein the plurality of spacer elements comprise a plastic material.

[0165] Ex38. A method according to any one of Ex28-Ex37, wherein the plurality of spacer elements comprise a PEEK film.

[0166] Ex39. A method according to any one of Ex28-Ex38, wherein the plurality of spacer elements comprise fiber sheets.

[0167] Ex40. A method according to any one of Ex28-Ex39, wherein the plurality of spacer elements have a higher permeability than the permeability of the wicking material strips.

[0168] Ex41. A method according to any one of Ex24-Ex40, wherein the plurality of receptors are fluid permeable.

[0169] Ex42. A method according to any one of Ex24-Ex41, wherein the plurality of receptors comprises conductive filaments.

[0170] Ex43. A method according to any one of Ex24-Ex42, wherein the plurality of receptors comprises a mesh.

[0171] Ex44. A method according to any one of Ex24-Ex43, wherein the strip of wicking material comprises cotton.

[0172] Ex45. A method according to any one of Ex25-Ex44, wherein the second susceptor holder part forms a snap-fit ​​connection with the connecting end when attached to the first susceptor holder part.

[0173] Ex46. A method according to any one of Ex25-Ex45, wherein the second susceptor holder portion exerts a clamping pressure on the wicking material when attached to the first susceptor holder portion.

[0174] Ex47. A consumable component for an aerosol generating device, the consumable component comprising a susceptor holder, the susceptor holder accommodating a susceptor assembly, the susceptor assembly comprising a susceptor on a strip of wicking material, the susceptor holder comprising:

[0175] a first portion comprising a hollow elongated portion housing the susceptor assembly, the hollow elongated portion having an opening at a connection end, the hollow elongated portion comprising two opposing slots extending along the elongated portion from the opening at the connection end, wherein wicking material on either side of the susceptor of the susceptor assembly protrudes through the slots in the first portion; and

[0176] A second portion is attached to the connecting end of the first portion to retain the susceptor assembly within the first portion.

[0177] Ex48. A consumable component according to Ex47, wherein the sensor is fluid permeable.

[0178] Ex49. A consumable component according to any one of Ex47-Ex48, wherein the receptor comprises a conductive filament.

[0179] Ex50. A consumable component according to any one of Ex47-Ex49, wherein the receptor comprises a mesh.

[0180] Ex51. A consumable component according to any one of Ex47-Ex50, wherein the wicking material comprises cotton.

[0181] Ex52. A consumable component according to any one of Ex47-Ex51, wherein the width of the groove increases at the connection end.

[0182] Ex53. A consumable component according to any one of Ex47-Ex52, wherein the second part forms a snap-fit ​​connection with the connecting end of the first part.

[0183] Ex54. A consumable component according to any one of Ex47-Ex53, wherein the second part attached to the first part exerts a biasing force on the sensor assembly.

[0184] Ex55. A cartridge comprising a reservoir and a consumable component according to any one of Ex47-Ex54, wherein an exposed portion of the wicking material protruding through the groove in the first susceptor holder portion is in fluid communication with the reservoir.

[0185] Ex56. An aerosol generating device comprising a cartridge according to Ex55.

[0186] Examples will now be further described with reference to the accompanying drawings, in which:

[0187] Figure 1A a schematic diagram showing a cross-section of an aerosol generating system according to an embodiment of the present disclosure;

[0188] 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 configuration for use; and

[0189] Figure 2A Show Figure 1A and 1B A schematic diagram of a cross section of a cylinder;

[0190] Figure 2B The barrel is shown rotated 90 degrees about the central longitudinal axis of the barrel. Figure 2A A schematic diagram of a cross section of a cylinder;

[0191] Figure 3 Shows Figures 1A-2B A schematic diagram of a perspective view of a susceptor assembly shown in FIG.

[0192] Figure 4 shows a schematic side view of a susceptor assembly according to an embodiment of the present disclosure;

[0193] Figure 5 shows a schematic diagram of a strip of wicking material including a plurality of susceptor assemblies according to an embodiment of the present disclosure;

[0194] Figure 6 The horizontal folding of the embodiment according to the present disclosure is shown. Figure 5 Schematic diagram of an array of a strip of wicking material and a first susceptor holder portion and a second susceptor holder portion.

[0195] Fig. 7A Shows Figure 6 Schematic side view of a first susceptor holder portion.

[0196] Figure 7B Shows Fig. 7A A cross-sectional view of a first susceptor holder portion.

[0197] Fig. 8A Shows Figure 6 Schematic side view of a second susceptor holder portion.

[0198] Figure 8B Shows Fig. 8A A cross-sectional view of a second susceptor holder portion.

[0199] Fig. 9 A schematic diagram of a consumable assembly according to an embodiment of the present disclosure is shown.

[0200] Fig.10 A flow chart of a method for manufacturing a consumable component according to an embodiment of the present disclosure is shown.

[0201] Fig.11 A flow chart of a method for manufacturing a consumable component according to an embodiment of the present disclosure is shown.

[0202] 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.

[0203] Figure 1B Shows 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.

[0204] 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.

[0205] The susceptor assembly 12 is planar and thin, with a thickness dimension being significantly smaller than the length and width dimensions. The susceptor assembly 12 is shaped in the form of a rectangle.

[0206] The susceptor assembly includes a susceptor including a first susceptor layer 16 and a second susceptor layer 18. The susceptor assembly also includes a wicking material for transporting a liquid aerosol-forming substrate, the wicking material including a first wicking layer 20 and a second wicking layer 22. The susceptor assembly also includes Figure 1A4. The spacer layer 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 substantially formed in a rectangular shape, and each susceptor layer has the same length and width dimensions, and the width of the susceptors 16, 18 is less than the width of the first wicking layer 20 and the second wicking layer 22. Each of the first wicking layer 20 and the second wicking layer 22 thus includes an externally exposed portion of wicking material, each externally exposed portion protruding into one of the two channels 45. The first susceptor layer 16 and the second susceptor layer 18 are substantially identical and include a sintered mesh formed of ferritic stainless steel filaments and austenitic stainless steel filaments. The first wicking layer 20 and the second wicking layer 22 include a porous body of cotton filaments. The wicking material 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 16 and the second susceptor 18.

[0207] The first susceptor 16 and the second susceptor 18 are configured to be heated by the penetration of the alternating magnetic field for vaporizing the aerosol-forming substrate. The wicking material 20 contacts the susceptor holder 14 so that the susceptor holder 14 supports the susceptor assembly 12 in place in the cartridge 10 .

[0208] The susceptor assembly 12 is partially disposed within 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 16 and the second susceptor 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 wicking material extend through an opening in the side wall of the susceptor holder 14 into one of the two channels 45.

[0209] 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.

[0210] 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 contained.

[0211] 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.

[0212] 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.

[0213] 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 .

[0214] 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 .

[0215] 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 material 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 inner passage 26 of the susceptor holder 14.

[0216] 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.

[0217] 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.

[0218] The device 60 comprises a substantially 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 so that ambient air can be drawn into the cavity 64 at the base. The air inlet 65 of the device is a system air inlet.

[0219] The device 60 also includes an induction heating device disposed within the device outer housing 62. The induction heating device 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 is 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.

[0220] 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 size and shape of the inductor coil 90 matches the size and shape of the heating area of ​​the susceptor. 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.

[0221] 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 .

[0222] The induction heating device further comprises a flux concentrator element 91. The flux concentrator element 91 has a larger radius than the inductor coil 90 and thus partially surrounds the inductor coil 90. The flux concentrator element 91 is configured to reduce stray power losses of the generated magnetic field.

[0223] Figure 1B Shows Figure 1A An aerosol generating system is provided in which a cartridge 10 is coupled to a 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, through the air passageway, and through the susceptor assembly 12 and in particular through and across the first susceptor layer 16 and the second susceptor layer 18.

[0224] When the system is activated, the control circuit 70 controls the supply of power from the power source 72 to the inductor coil 90 .

[0225] 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. When a user draws on the cartridge 10 by the airflow sensor 63, the control circuit 72 supplies power to the inductor coil 90.

[0226] When the system is activated, an alternating current is generated in the inductor coil 90, and the alternating current generates an alternating magnetic field that penetrates the susceptor assembly 12 in the cavity 64, so that the susceptor including the first susceptor layer and the second susceptor layer becomes hot. The liquid aerosol-forming matrix in the channel 45 is sucked into the susceptor assembly 12 through the wicking material to reach the susceptor. 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 through the spacer layer. The liquid aerosol-forming matrix 42 at the susceptor 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.

[0227] Figure 2A A schematic diagram of the cartridge 10 is shown separated from the aerosol generating device.

[0228] Figure 2B The barrel is shown rotated 90 degrees about the central longitudinal axis of the barrel. Figure 2A Schematic diagram of the cylinder. Figure 2B The layered structure of the susceptor assembly 12 is shown. The susceptor assembly 12 is planar and thin, with a thickness dimension significantly smaller than the length and width dimensions. The susceptor assembly includes: a susceptor including a first susceptor layer 16 and a second susceptor layer 18; and a wicking material for transporting a liquid aerosol-forming substrate. The wicking material includes a first wicking layer 20 and a second wicking layer 22, wherein a spacer layer 24 is positioned between and in contact with the first wicking layer and the second wicking layer.

[0229] The spacer layer 24 is fluid permeable and is configured to allow the liquid aerosol-forming substrate to be transported between the first wicking layer 20 and the second wicking layer 22. The spacer layer 24 is substantially 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 layer 24 comprises a porous body of cotton.

[0230] Figure 3 Shows Figures 1A-2B Schematic diagram of a perspective view of a susceptor assembly shown in FIG. 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.

[0231] 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. Except for the differences in wicking materials and susceptors, the structures of the susceptor assembly of the first embodiment and the susceptor of the second embodiment are substantially the same, as described below.

[0232] Figure 4 The susceptor of WO 2009 / 051334 PCT / US2009 / 050063 comprises a first susceptor layer 116 and a second susceptor layer 118 that are substantially parallel. The susceptor further comprises a connecting portion 117 that connects the first susceptor layer 116 to the second susceptor layer 118. Figure 4 The connecting portion 117 shown in FIG. 1 is a U-shaped bend. The susceptor is formed by bending or folding a single piece of material to form a susceptor including a first susceptor layer 116, a second susceptor layer 118 and a connecting portion 117. The connecting portion 117 includes a sintered mesh formed of ferritic stainless steel filaments and austenitic stainless steel filaments.

[0233] In this example, the wicking material includes a first wicking layer 120 , a second wicking layer 122 , and a wicking connection portion 121 connecting the first wicking layer 120 to the second wicking layer 122 . Figure 4 The wicking connection portion 121 shown in the figure is a U-shaped bend. The wicking material is formed by bending or folding a single piece of material to form a wicking material including a first wicking layer 120, a second wicking layer 122 and a wicking connection portion 121. The wicking connection portion 121 includes a porous body of cotton filaments. In other examples not shown in the figures, alternative arrangements of wicking materials and susceptors may be possible. For example, the susceptor assembly may include a susceptor including a connection portion connecting a first susceptor layer to a second susceptor layer, wherein the wicking material includes a first wicking layer and a second wicking layer as separate components.

[0234] Figure 5 A schematic diagram of a wicking material strip 500 including a plurality of susceptor assemblies 510 is shown in accordance with an embodiment of the present disclosure. The susceptor assemblies 510 are formed by providing a plurality of susceptors 520 across the wicking material strip 500 with spaced gaps. To form a series of susceptor assemblies 510 having multiple layers of wicking material 500 and / or susceptors 520 or even spacer layers, additional susceptors, wicking layers, and / or spacer layers may be provided on the top and / or bottom of the wicking material strip 500. Additionally or alternatively, the wicking material strip 500 including the susceptor assemblies 510 may be folded transversely along a central axis 520 to create two inner wicking layers and two outer susceptor layers. Figure 4As shown in , providing a spacer layer beneath the strip of wicking material can create a central spacer layer separating the two wicking layers when the strip of wicking material is folded.

[0235] Figure 6 The horizontal folding of the embodiment according to the present disclosure is shown. Figure 5 FIG. 1 is a schematic diagram of a wicking material strip 500 and an array of first and second susceptor holder portions 540, 550. The first susceptor holder portions 540 are configured to engage with the wicking material strip 500 and each receive a susceptor assembly 510. The second susceptor holder portions 550 are configured to attach to the first susceptor holder portions 540 to hold the susceptor assembly 510 within the first susceptor holder portions 540.

[0236] Fig. 7A -B shows Figure 6 Schematic side and cross-sectional views of a first susceptor holder portion 540 of FIG. The first susceptor holder portion 540 includes a hollow elongated portion having an opening at a connection end. Extending from the opening are two opposing slots 545 along the elongated portion. The slots 545 are configured to receive the wicking material strip 500 via the opening in the connection end when the susceptor assembly 510 is received within the hollow portion of the first susceptor holder portion 540. The slots 545 include a wider or tapered portion 548 at the opening at the connection end. This facilitates easier insertion of the wicking material strip 500 within the slots 545.

[0237] Fig. 8A -B shows Figure 6 Schematic side and cross-sectional views of a second susceptor holder portion 550. The second susceptor holder portion 550 includes a hollow elongated portion having an opening at a connection end that is configured to connect with a connection end in the first susceptor holder portion 540. Extending from the opening are two opposing slots 555 along the elongated portion. The slots 555 are configured to engage and receive a portion of the wicking material strip 500 held within the slots 545 of the first susceptor holder portion 540 when the second susceptor holder portion 550 is connected to the first susceptor holder portion 540.

[0238] In other examples not shown in the figures, alternative arrangements of the first and second susceptor holder portions may be possible. For example, in some embodiments, the second susceptor holder portion 550 is received within the first susceptor holder portion 540 and holds the susceptor assembly 510 within the first susceptor holder portion 540 by blocking a portion of the opening at the connection end. In other embodiments, the second susceptor holder portion 550 may hold the susceptor assembly 510 within the first susceptor holder portion 540 by deforming the first susceptor holder portion 540 onto the susceptor assembly 510. In other embodiments, the second susceptor holder portion 550 may hold the susceptor assembly 510 within the first susceptor holder portion 540 by applying a biasing force to the susceptor assembly 510 or a portion of the wicking material strip 500 against the first susceptor holder portion 540.

[0239] Fig. 9 A schematic diagram of a consumable assembly 600 according to an embodiment of the present disclosure is shown. The consumable assembly 600 includes a wicking material strip 500 including a susceptor assembly 510 housed within a hollow portion of a first susceptor holder portion 540. The susceptor assembly 510 is held within the first susceptor holder portion 540 by a second susceptor holder portion 550 that receives a connection end of the first susceptor holder portion 540 and a portion of the wicking material strip 500.

[0240] Fig.10A flow chart of a method 700 for manufacturing a consumable assembly 600 according to an embodiment of the present disclosure is shown. Step 710 includes providing a plurality of susceptors 520 across a wicking material strip 500 to form a plurality of susceptor assemblies 510. The susceptors 520 are secured to the wicking material strip 500 by folding the free edges of the susceptors 520 around the wicking material 500. Step 720 includes folding the wicking material strip 500 laterally along a central axis 530 such that the susceptors 520 are disposed on an outer surface on each side of the folded wicking material strip 500. At step 730, the folded wicking material strip 500 is held under tension along its length. This is to facilitate easier insertion of the wicking material strip 500 into the slot 545 of the first susceptor holder portion 540. At step 740, a plurality of first susceptor holder portions 540 each receive a susceptor assembly 510 on the wicking material strip 500, while portions of the wicking material strip 500 on either side of the susceptor assembly 510 slide into the slots 545 of the first susceptor holder portion 540. Step 750 includes attaching a second susceptor holder portion 550 to the first susceptor holder portion 540 to hold the susceptor assembly 510 within the respective first susceptor holder portion 540. Step 760 includes cutting the wicking material strip outside of the first susceptor holder portion 540 to separate the first susceptor holder portion 540 from the wicking material strip 500 to form a plurality of consumable assemblies 600 while maintaining exposed portions of the wicking material 500 outside of the first susceptor holder portion 540. Step 770 includes inserting the consumable assembly 600 into the cartridge housing 36 to form the cartridge 10 such that the exposed portion of the wicking material 500 is in fluid communication with the reservoir 42 in the cartridge 10. The method 700 may also include inserting the cartridge 10 into the aerosol generating device 60 to form the aerosol generating system.

[0241] Fig.11A flow chart of a method 800 for manufacturing a consumable component 600 according to an embodiment of the present disclosure is shown. Steps 810 to 830 correspond to steps 710 to 730 described with respect to method 700. Step 840 includes feeding a wicking material strip 500 including a plurality of susceptor components 510 through a slot 545 in a first susceptor holder portion 540 such that each of the first susceptor holder portions 540 is aligned over a respective susceptor component 510. Step 850 includes attaching a second susceptor holder portion 550 to the first susceptor holder portion 540 so as to retain the susceptor components 510 within the respective first susceptor holder portion 540. Step 860 includes cutting the wicking material strip 500 outside the first susceptor holder portion 540 to separate the first susceptor holder portion 540 from the wicking material strip 500 to form a plurality of consumable components 600 while maintaining an exposed portion of the wicking material 500 outside the first susceptor holder portion 540. Step 870 includes inserting the consumable assembly 600 into the cartridge housing 36 to form the cartridge 10 such that the exposed portion of the wicking material 500 is in fluid communication with the reservoir 42 in the cartridge 10. The method 800 may also include inserting the cartridge 10 into the aerosol generating device 60 to form the aerosol generating system.

[0242] 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. Moreover, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein that 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 a 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 does not substantially affect the basic features and novel features of the invention claimed for protection. Moreover, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein that may or may not be specifically listed in this article.

Claims

1. A method for manufacturing one or more consumable components for an aerosol generating device, the method comprising: providing one or more susceptors across the width of the strip of wicking material to form corresponding one or more susceptor assemblies; folding the strip of wicking material laterally so that the one or more susceptors are disposed on an outer surface on each side of the folded strip of wicking material; sliding one or more first susceptor holder portions onto the strip of wicking material to engage the corresponding one or more susceptor assemblies, the one or more first susceptor holder portions each comprising a hollow elongated portion having an opening at a connection end, the hollow elongated portion comprising two opposing slots extending along the elongated portion from the opening at the connection end, wherein the slots are configured to receive and engage the strip of wicking material on either side of the susceptor assembly when the susceptor assembly is received within the hollow elongated portion of the first susceptor holder portion; and A second susceptor holder portion is attached to the connection end of each of the one or more first susceptor holder portions to retain the strip of wicking material including the one or more susceptor assemblies within the corresponding one or more first susceptor holder portions.

2. The method of claim 1, further comprising securing the one or more susceptors to the wicking material by folding a free edge of the one or more susceptors around the strip of wicking material.

3. The method of claim 1 , further comprising providing one or more spacer elements on a side of the strip of wicking material opposite the corresponding one or more susceptors, wherein the one or more spacer elements are at least partially aligned with the corresponding one or more susceptors.

4. The method of any one of claims 1-3, further comprising holding the strip of wicking material under tension while sliding the one or more first susceptor holder portions over the one or more susceptor assemblies.

5. A method according to any one of claims 1 to 4, wherein a plurality of susceptors are provided at spaced intervals along the length of the strip of wicking material to form a plurality of susceptor assemblies.

6. The method of claim 5, further comprising cutting the strip of wicking material at each side of the plurality of first susceptor holder portions to separate each of the plurality of first susceptor holder portions from the remainder of the strip of wicking material to form a corresponding plurality of consumable components while maintaining an exposed portion of the wicking material outside of the plurality of first susceptor holder portions.

7. The method of claim 6, further comprising inserting the consumable component into a cartridge housing, the cartridge housing and the consumable component forming a cartridge including a reservoir, wherein the exposed portion of the wicking material is in fluid communication with the reservoir.

8. The method of claim 7, further comprising inserting the cartridge into an aerosol generating device.

9. A method for manufacturing one or more consumable components for an aerosol generating device, the method comprising: providing a plurality of susceptors spaced across the strip of wicking material to form a corresponding plurality of susceptor assemblies; providing a plurality of first susceptor holder portions, each of the plurality of first susceptor holder portions comprising a hollow elongated portion including two opposing slots extending longitudinally along the elongated portion, wherein the slots are configured to receive the strip of wicking material including the plurality of susceptor assemblies; feeding the strip of wicking material including the plurality of susceptor assemblies through the slots of the plurality of first susceptor holder portions such that each of the plurality of susceptor holder portions is aligned over a respective susceptor assembly; as well as The strip of wicking material at the exterior of the plurality of first susceptor holder portions is cut to separate each of the plurality of first susceptor holder portions from the remainder of the strip of wicking material to form a corresponding plurality of consumable components while maintaining an exposed portion of the wicking material exterior to the plurality of first susceptor holder portions.

10. The method of claim 9, further comprising attaching a second susceptor holder portion to each of the plurality of first susceptor holder portions to retain the strip of wicking material comprising each of the plurality of susceptor assemblies within the corresponding first susceptor holder portion.

11. A consumable assembly for an aerosol generating device, the consumable assembly comprising a susceptor holder housing a susceptor assembly comprising a susceptor folded about an outer surface across the width of a folded strip of wicking material, the susceptor holder comprising: a first portion, the first portion comprising a hollow elongated portion housing the susceptor assembly, the hollow elongated portion having an opening at a connection end, the hollow elongated portion comprising two opposing slots extending along the elongated portion from the opening at the connection end, wherein wicking material on either side of the susceptor of the susceptor assembly protrudes through the slots in the first portion; as well as A second portion is attached to the connecting end of the first portion to retain the susceptor assembly within the first portion.

12. The consumable assembly of claim 11, wherein the second portion attached to the first portion exerts a biasing force on the susceptor assembly.

13. A cartridge comprising a reservoir and a consumable assembly according to any one of claims 11-12, wherein an exposed portion of wicking material protruding through the slot in the first portion is in fluid communication with the reservoir.

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