Receptor assembly for an aerosol-generating system and method

Abstract

A susceptor assembly (312) for an aerosol-generating system is provided. The susceptor assembly includes a susceptor element (16) and a wicking element (318) in the form of a sheet. The wicking element includes one or more wicking layers (321, 322) in fluid communication with the liquid reservoir. The one or more wicking layers deliver a liquid aerosol-forming substrate across a surface of the susceptor element, wherein the wicking element forms an outer surface of the susceptor assembly. A cartridge for an aerosol-generating system, an aerosol-generating system, an aerosol-generating device, and a method of manufacturing a susceptor assembly are also provided.

Description

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

[0002] Aerosol-generating systems that use induction heating to generate an inhalable aerosol from a liquid aerosol-forming substrate are known in the art. Such electrically heated smoking systems are typically handheld and include a power source, a reservoir for holding the aerosol-forming substrate, and an induction heating system. The induction heating system typically includes a coil arranged around a susceptor element to which the liquid aerosol-forming substrate is supplied. An alternating current flows through the coil, inducing eddy currents in the susceptor element, thereby heating the susceptor element. The liquid aerosol-forming substrate in contact with or near the susceptor element is thereby heated and vaporized. The aerosol-generating system typically also includes a wicking element configured to draw the aerosol-forming substrate from the liquid reservoir to the susceptor element for heating. The airflow passing through the susceptor element entrains the generated vapor. The entrained vapor cools and condenses to form an aerosol. The aerosol can then be inhaled by the user.

[0003] Typically, the susceptor assembly of an inductive aerosol generating system may comprise a single wicking element comprising a single wicking layer.

[0004] A susceptor assembly comprising a susceptor element wrapped around a central wicking element to overlie an outwardly facing surface of the wicking element, wherein the susceptor element comprises a mesh. In use, when a mesh configuration is employed for the susceptor element, vaporized aerosol-forming substrate can advantageously escape from the wicking element through the gaps present.

[0005] Susceptors known in the art are woven meshes made of ferritic stainless steel wires that are heated when an alternating magnetic field is applied.A disadvantage of woven susceptors is that they are fragile and therefore can be difficult to manufacture.

[0006] It would be desirable to use components in the susceptor assembly that have simpler designs to reduce manufacturing complexity and cost.

[0007] According to a first embodiment of the present disclosure, there is provided a susceptor assembly for an aerosol generating system, a susceptor element in the form of a sheet material, and a wicking element comprising at least one wicking layer for transporting a liquid aerosol-forming substrate across a surface of the sheet material, wherein the wicking element forms an outer surface of the susceptor assembly.

[0008] Preferably, the wicking element will include a plurality of apertures exposing portions of the susceptor element.The wicking layer has apertures to allow the generated vapor to mix with the air flow.

[0009] The orifice may have a diameter between 0.05 mm and 1.0 mm. Preferably, the orifice has a diameter between 0.1 mm and 0.5 mm.

[0010] The at least one wicking layer of the wicking element may include a top wicking layer and a bottom wicking layer, each forming an outer surface of the susceptor assembly. The top wicking layer and the bottom wicking layer may be separate components. Advantageously, this may simplify the manufacture of the susceptor assembly.

[0011] The susceptor element may comprise a blank sheet. The susceptor element may be a blank sheet. As used herein, "blank sheet" means a sheet formed from a single piece of material and having no perforations or apertures. The susceptor element may not have perforations. This means that complex machining does not need to be performed. Advantageously, this design significantly reduces manufacturing complexity compared to a mesh susceptor element because fewer steps are required to produce the susceptor element. The susceptor element may be configured to heat and vaporize the liquid aerosol-forming substrate. The susceptor element may be fluid-impermeable.

[0012] Advantageously, susceptor elements in the form of blank sheets have mechanical properties superior to those of woven susceptors. This makes it easier to handle the susceptor elements during the manufacturing process. The susceptor sheet allows for greater freedom in parts procurement and reduces the overall manufacturing difficulty. Another benefit of the susceptor sheet over a woven susceptor is that there is no risk of loose parts from the susceptor element being lost into the main flow of the system during use. Non-woven susceptors allow for the possibility of more complex shapes (e.g., S-shapes) than a simple flat rectangle.

[0013] The susceptor element may be sandwiched between a top wicking layer and a bottom wicking layer, wherein the top wicking layer and the bottom wicking layer substantially cover opposing surfaces of the susceptor element. The wicking element provides wetting of the susceptor element during use of the susceptor assembly. This may advantageously mean that, in operation, the susceptor element is wetted on both sides. This may increase the amount of aerosol-forming substrate evaporated in a given time compared to a susceptor assembly comprising only one wicking layer.

[0014] The susceptor element can have a variety of shapes. The susceptor element can be substantially planar. In this context, a planar susceptor element is one whose length and width are substantially greater than its thickness. The length and width directions are orthogonal to each other and define a first plane. The planar susceptor element can have two opposing major surfaces extending in a plane parallel to the first plane. One or both major surfaces are advantageously planar.

[0015] The susceptor element may have an S-shape. Advantageously, this allows the liquid aerosol-forming substrate to reach all areas of the susceptor more easily than with a rectangular shape.

[0016] As used herein, the term "aerosol-generating device" is used to describe a device that interacts with an aerosol-forming substrate to generate an aerosol. Preferably, the aerosol-generating device is a smoking device that interacts with an aerosol-forming substrate to generate an aerosol that can be inhaled directly into the user's lungs through the user's mouth.

[0017] As used herein, "aerosol generating system" means a system that generates an aerosol from one or more aerosol-forming substrates.

[0018] As used herein, the term "aerosol-forming substrate" refers to a substrate consisting of or comprising an aerosol-forming material that is capable of releasing volatile compounds upon heating to generate an aerosol.

[0019] As used herein, the term "liquid" refers to a substance provided in liquid form and encompasses substances provided in gel form.

[0020] As used herein, a "susceptor element" means an element that can be heated by the penetration of an alternating magnetic field. The susceptor element can typically be heated by at least one of Joule heating and hysteresis losses, which are generated by inducing eddy currents in the susceptor element. Suitable materials for the susceptor element include graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, and other conductive materials. Advantageously, the susceptor element can be formed of a ferromagnetic material.

[0021] The wicking element may comprise a porous material. The wicking element may comprise a capillary material. A 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 comprises a capillary bundle. For example, the capillary material may comprise a plurality of fibers or threads or other fine-pored tubes. In some embodiments, the capillary material may comprise a spongy or foamy material.

[0022] The wicking element may comprise or consist of an electrically insulating material. The wicking element may comprise a non-metallic material. The wicking element may comprise a hydrophilic material or a lipophilic material. This may advantageously facilitate transport of the aerosol-forming substrate through the wicking element.

[0023] As used herein, "wicking layer" means a single layer of wicking material that may partially or completely cover one or more exterior surfaces of a susceptor element.

[0024] The wicking element may comprise or consist of cotton, rayon, or fiberglass. The top wicking layer may preferably comprise or consist of cotton. The bottom wicking layer may comprise or consist of cotton.

[0025] The wicking element may comprise a mesh. The interstices present in the mesh allow the liquid aerosol-forming substrate to pass through the mesh towards the susceptor element to be evaporated.

[0026] The wicking element may comprise orifices. The orifices may be arranged in a uniform pattern. Advantageously, a uniform arrangement allows for a simpler manufacturing process and also allows for a more equal distribution of the liquid aerosol-forming substrate.

[0027] The wicking element may comprise a plurality of fibers.The diameter of the orifice may be greater than the diameter of the fibers.

[0028] The distance between the edge of the orifice and the edge of the adjacent orifice can be between 0.05 mm and 0.5 mm. Preferably, the distance between the edge of the orifice and the edge of the adjacent orifice can be between 0.1 and 0.4 mm. The orifice can be a hole, a cutout or a channel. The orifice can be defined as passing through the wicking layer.

[0029] The orifice may have a circular cross-section.The orifice may have a diameter of at least 0.1 mm.

[0030] The orifice may have a rectangular cross-section. The orifice may have a triangular cross-section. The orifice may have any suitable cross-section. The orifice may have a cross-sectional area of ​​at least 0.005 square millimeters. The orifice may have a cross-sectional area of ​​at least 0.01 square millimeters.

[0031] The top wicking layer may have a thickness between 0.1 and 0.5 mm. Preferably, the top wicking layer has a thickness between 0.2 and 0.4 mm. The bottom wicking layer may have a thickness between 0.1 and 0.5 mm. Preferably, the bottom wicking layer has a thickness between 0.2 and 0.4 mm. Preferably, the top and bottom wicking layers have substantially the same thickness. An advantage of wicking layers having substantially the same thickness is that they are substantially uniform, so aerosolization can be uniform on both sides of the susceptor element.

[0032] The wicking element may be folded around the susceptor element, thereby covering its outwardly facing surface. Advantageously, this increases the surface area of ​​the susceptor element in contact with the wicking element, thereby promoting increased heat transfer between the susceptor element and the wicking element. In use, the increased heat transfer from the susceptor element to the wicking element may enhance the generation of vapor from the liquid aerosol-forming substrate entrained in the wicking element.

[0033] From a manufacturing standpoint, a wicking layer having orifices evenly distributed across its entire surface is easier to produce.

[0034] The susceptor assembly may comprise a heated region and a non-heated region. The heated region is a region of the susceptor assembly that is configured to be heated to a temperature required to vaporize the aerosol-forming substrate when penetrated by a suitable alternating magnetic field. The heated region of the susceptor assembly may comprise at least a portion of the susceptor element.

[0035] In a preferred embodiment of the planar susceptor element, the cross-sectional area of ​​the top wicking layer and the bottom wicking layer are the same.The cross-sectional area of ​​the top wicking layer and the bottom wicking layer is preferably larger than the cross-sectional area of ​​the susceptor element.

[0036] The susceptor element and the wicking element may be the same length.The wicking element may be wider than the susceptor element.

[0037] There are embodiments in which the wicking element comprises a first region overlying the susceptor element and at least a second region not overlying the susceptor element, wherein the orifice is positioned above the first region and each of the second regions does not include an orifice. The first region may be positioned between two second regions. Advantageously, this configuration allows for increased liquid flow to the center of the susceptor element, thereby reducing the risk of overheating.

[0038] Preferably, the susceptor assembly has an upstream end and a downstream end, the upstream end and the downstream end being arranged such that, during use, air flows within the aerosol generating system from the upstream end across the susceptor assembly to the downstream end. The airflow path may be parallel to the length of the susceptor assembly and perpendicular to the width of the susceptor assembly. The thickness of the susceptor assembly may be substantially uniform.

[0039] The susceptor element may be a metal blank.The susceptor element may comprise a ferrous material.

[0040] The susceptor element may comprise annealed steel. Advantageously, annealed steel has increased ductility, allowing it to be more easily formed than hardened steel or steel that has not undergone heat treatment. Annealed steel also has increased toughness, allowing it to withstand greater forces before permanent deformation occurs.

[0041] The susceptor element may comprise ferritic stainless steel. Due to its chemical composition, ferritic stainless steel is relatively inexpensive compared to other types of stainless steel. Another advantage of stainless steel is its corrosion resistance, which is a desirable property for a susceptor element material.

[0042] The susceptor element may include at least one of graphite, molybdenum, silicon carbide, stainless steel, niobium, and aluminum.

[0043] The susceptor assembly may comprise one or more ferromagnetic materials.Where ferromagnetic materials are used to heat the susceptor element, it is advantageous to use ferromagnetic materials because of their magnetic properties.

[0044] Preferably, the susceptor element comprises AISI 430 stainless steel.

[0045] When measured at an appropriate frequency and temperature, for example, when measured at a frequency of up to 10 kHz at a temperature of 20 degrees Celsius, the susceptor element can have a relative permeability between 1 and 40,000. When it is desired that most of the heating be dependent on eddy currents, a lower permeability material can be used, and when a hysteresis effect is desired, a higher permeability material can be used. Preferably, the material has a relative permeability between 500 and 40,000. This provides for efficient heating of the susceptor element.

[0046] The susceptor element may be heated by at least one of Joule heating and hysteresis losses generated by inducing eddy currents in the susceptor element.

[0047] As used herein, the terms "air inlet" and "air outlet" are used to describe one or more orifices through which air can be drawn into and exhausted from, respectively, a cartridge, an aerosol generating system or a component or part of an aerosol generating device.

[0048] As used herein, the term "cartridge" also refers to an article comprising an aerosol-forming substrate capable of releasing volatile compounds that can form an aerosol. The cartridge may also be disposable.

[0049] According to a second aspect of the present disclosure, there is provided a cartridge. The cartridge may comprise a susceptor assembly according to the first aspect of the present disclosure, and a liquid reservoir holding a liquid aerosol-forming substrate, wherein the wicking element of the susceptor assembly is in fluid communication with the liquid aerosol-forming substrate in the liquid reservoir.

[0050] The tube may include a liquid reservoir housing. The tube may include a holding material contained within the reservoir, the holding material being used to hold the liquid aerosol to form a matrix. The holding material may be a foam, sponge, or a collection of fibers. The holding material may be formed from a polymer or copolymer. The holding material may be a spinning polymer.

[0051] The susceptor element may be continuously wetted by the liquid aerosol-forming substrate contained in the reservoir by means of a wicking element in direct contact with both the liquid reservoir and the susceptor element.

[0052] The cartridge may further comprise an air inlet, an air outlet and an air flow path extending from the air inlet through the susceptor assembly to the air outlet. Advantageously, this arrangement allows airflow over the susceptor assembly when the susceptor assembly is in use, so that aerosolized liquid aerosol-forming substrate can continuously travel to the air outlet and to the user during puffing.

[0053] As used herein, the term "puff" is used to describe the action of a user drawing air through an aerosol generating system by inhaling.

[0054] The cartridge may further comprise a susceptor holder for holding the susceptor assembly, wherein at least a portion of the airflow path is defined by the susceptor holder. The susceptor holder may have an elongated shape. The susceptor holder may be a tubular susceptor holder. The susceptor holder may be coupled to the susceptor assembly.

[0055] The susceptor holder may be positioned within the reservoir housing. The susceptor holder may support the susceptor assembly. The susceptor holder may be in contact with the wicking element. The susceptor element may be in contact with one or more wicking layers.

[0056] The susceptor holder can hold the susceptor assembly so that the at least one wicking layer is in direct fluid communication with the liquid aerosol-forming substrate in the liquid reservoir. The susceptor holder can define an air channel internally. The susceptor holder is configured to hold the susceptor element internally to intercept the airflow generated by the user during inhalation.

[0057] The susceptor holder may provide a liquid seal around the susceptor assembly to prevent the liquid aerosol-forming substrate from escaping from the liquid reservoir except through the at least one wicking layer.

[0058] The susceptor holder may comprise a thermally insulating material. The susceptor holder may comprise an electrically insulating material. The susceptor holder may comprise at least one polymer. The susceptor holder may comprise polyetheretherketone (PEEK). The susceptor holder may be formed by injection molding. Advantageously, injection molding can simplify the manufacture of the cartridge.

[0059] The liquid reservoir may be in fluid communication with the second portion of the wicking element.The liquid reservoir may be in fluid communication with the side portion of the wicking element.

[0060] The liquid aerosol-forming substrate may include volatile compounds that can form an aerosol. The volatile compounds may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may include both a liquid component and a solid component. The liquid aerosol-forming substrate may contain nicotine. The nicotine-containing liquid aerosol-forming substrate may be a nicotine salt substrate. The liquid aerosol-forming substrate may include a plant-based material. The liquid aerosol-forming substrate may include tobacco. The liquid aerosol-forming substrate may include a tobacco-containing material containing volatile tobacco flavor compounds, which are released from the aerosol-forming substrate upon heating. The liquid aerosol-forming substrate may include a homogenized tobacco material. The liquid aerosol-forming substrate may include a tobacco-free material. The liquid aerosol-forming substrate may include a homogenized plant-based material.

[0061] The liquid aerosol-forming substrate may include one or more aerosol formers. An aerosol former is any suitable known compound or mixture of compounds that promotes the formation of a dense and stable aerosol in use and is substantially resistant to thermal degradation at the operating temperature of the system. Examples of suitable aerosol formers include glycerol and propylene glycol. 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 triacetate of glycerol; and aliphatic esters of mono-, di- or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. The liquid aerosol-forming substrate may comprise water, solvents, ethanol, plant extracts and natural or artificial flavors.

[0062] The liquid aerosol-forming substrate may comprise nicotine and at least one aerosol former. The aerosol former may be glycerol or propylene glycol. The aerosol former may comprise both glycerol and propylene glycol. The liquid aerosol-forming substrate may have a nicotine concentration of between about 0.5% and about 10%, for example, about 2%.

[0063] The at least one wicking layer of the susceptor assembly may extend in a direction transverse to the direction of airflow in the airflow channel past the susceptor assembly.The direction of liquid feed from the liquid reservoir may be perpendicular to the direction of airflow in the airflow channel past the susceptor assembly.

[0064] Preferably, the cartridge comprises a mouthpiece, wherein the mouthpiece comprises the air outlet.

[0065] During use, air can enter the cartridge through the cartridge air inlet, flow through the airflow channel, across the susceptor assembly, and exit the cartridge through the air outlet defined by the mouthpiece. The vaporized liquid aerosol-forming substrate generated by the susceptor assembly can be entrained in the airflow in the airflow channel. When the aerosol exits the cartridge through the air outlet defined by the mouthpiece, the entrained vapor condenses to form an aerosol for inhalation by the user.

[0066] The cartridge may include at least one seal extending across a portion of the airflow channel. The cartridge may include an upstream seal extending across the cartridge air inlet. The upstream seal may be sealed to a retainer. The upstream seal may be sealed to the cartridge outer housing. The upstream seal may be sealed to both the retainer and the cartridge outer housing. The upstream seal may be frangible or removable. The upstream seal may be arranged to automatically rupture when the cartridge is inserted into the aerosol generating device.

[0067] The cartridge may include a downstream seal. The downstream seal may extend across an air outlet defined by the mouthpiece. The downstream seal may seal to the mouthpiece. The downstream seal may be frangible or removable.

[0068] In the embodiment where the cartridge comprises a cartridge outer shell, the mouthpiece may be integrally formed with the cartridge outer shell. The mouthpiece may be formed separately from the cartridge outer shell and connected to the cartridge outer shell. The mouthpiece may be connected to the cartridge outer shell by an interference fit.

[0069] In the embodiment in which the tube includes a mouthpiece, a tube outer shell, or both a mouthpiece and a tube outer shell, each of the mouthpiece and the tube outer shell can be formed by any suitable material or combination of materials. Preferably, the mouthpiece and the tube outer shell are formed by plastics or thermoplastics suitable for food or pharmaceutical applications. For example, each of the mouthpiece and the tube outer shell can include at least one of polypropylene, polyetheretherketone (PEEK), and polyethylene. Preferably, the material is lightweight and non-brittle.

[0070] According to a third aspect of the present disclosure, an aerosol-generating system is provided. The aerosol-generating system may include a cartridge according to the second aspect of the present disclosure and an aerosol-generating device. The aerosol-generating device may include an inductor coil and a power supply connected to the inductor coil and configured to provide current to the inductor coil to generate an alternating field; wherein the cartridge and the aerosol-generating device are connectable to each other such that a susceptor assembly is positioned within the magnetic field. Advantageously, less power is required to heat the susceptor element in this arrangement compared to a susceptor placed elsewhere in the system.

[0071] The cartridge of the aerosol generating system may comprise a mouth end and a connecting end, wherein the connecting end is configured to connect the cartridge to an aerosol generating device.

[0072] The aerosol generating system may include control circuitry. The control circuitry may include a sensor for detecting when a user puffs on the aerosol generating system. The sensor may be configured to be in fluid communication with an airflow pathway of the device when the cartridge is coupled to the aerosol generating device. The control circuitry may be configured to detect when a user puffs on the system based on a signal from the sensor. The sensor may be an airflow sensor. The sensor may be a pressure sensor. The sensor may allow the aerosol generating system to be powered on a puff-by-puff basis.

[0073] The control circuit system can be configured to continuously supply power to the inductor coil after system activation, or can be configured to supply power intermittently, such as on a puff-by-puff basis. Power can be supplied to the induction heating assembly in the form of current pulses, for example, using pulse width modulation (PWM). The control circuit system 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 system may include any of a sensor, a switch, and a display element.

[0074] The inductor coil may be a helical coil, wherein when the aerosol generating device and the cartridge are connected to each other, at least a portion of the helical coil defines the susceptor assembly. The helical coil may have a circular cross-section when viewed parallel to the longitudinal axis of the aerosol generating system. The inductor coil may comprise one or more coils.

[0075] The aerosol generating system can be a handheld aerosol generating system configured to allow a user to draw on a mouthpiece to inhale an aerosol through the system air outlet. The aerosol generating system can be of a size comparable to a conventional cigar or cigarette. The aerosol generating system can have an overall length between about 30 mm and about 150 mm. The aerosol generating system can have an outer diameter between about 5 mm and about 30 mm. The aerosol generating system can be an electrically operated smoking system.

[0076] 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 to allow storage of energy sufficient for one or more user experiences with the aerosol generating system; for example, the power source may have sufficient capacity to allow continuous aerosol generation for a period of about six minutes (corresponding to the typical time spent smoking a conventional cigarette), or for a period 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.

[0077] According to a fourth aspect of the present disclosure, an aerosol-generating device is provided. The aerosol-generating device may include a susceptor assembly according to the first aspect of the present disclosure. The device may include an inductor coil and a power supply. The power supply is connected to the inductor coil and configured to provide current to the inductor coil to generate an alternating field such that the susceptor assembly is positioned within the magnetic field. Advantageously, less power is required to heat the susceptor element in this arrangement compared to a susceptor placed elsewhere in the system.

[0078] The aerosol-generating device may include control circuitry. 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 be in fluid communication with the device's airflow pathway when the cartridge is coupled to the aerosol-generating device. The control circuitry may be configured to detect when a user takes a puff on the system based on a signal from the sensor. The sensor may be an airflow sensor. The sensor may be a pressure sensor. The sensor may allow the aerosol-generating system to be powered on a puff-by-puff basis.

[0079] The control circuitry can be configured to continuously supply power to the inductor coil after the device is activated, or can be configured to supply power intermittently, such as on a puff-by-puff basis. Power can be supplied to the induction heating assembly in the form of current pulses, for example, using pulse width modulation (PWM). The control circuitry can include a DC / AC inverter, which can include a Class D or Class E power amplifier. The control circuitry can include other electronic components. For example, in some embodiments, the control circuitry can include any of a sensor, a switch, and a display element.

[0080] The inductor coil may be a helical coil, wherein at least a portion of the helical coil defines the susceptor assembly.The helical coil may have a circular cross-section when viewed parallel to the longitudinal axis of the aerosol generating device.

[0081] The aerosol generating device may further comprise an air inlet, an air outlet and an air flow path extending from the air inlet through the susceptor assembly.The air flow path may be perpendicular to the direction of liquid feed from the liquid reservoir.

[0082] The aerosol generating device may comprise a susceptor holder holding the susceptor assembly, wherein at least a portion of the airflow path is defined by the susceptor holder. This is advantageous because vaporized aerosol-forming substrate exiting the susceptor assembly immediately mixes with air in the airflow path for inhalation by the user.

[0083] The susceptor holder may provide a liquid seal around the susceptor assembly to prevent the liquid aerosol-forming substrate from escaping from the liquid reservoir except through the at least one wicking layer.

[0084] The aerosol generating device may include a mouthpiece. The aerosol generating device may be a handheld aerosol generating device configured to allow a user to draw on the mouthpiece to inhale the aerosol through the device air outlet. The aerosol generating system may be of a size comparable to a conventional cigar or cigarette. The aerosol generating device may have an overall length between about 30 mm and about 150 mm. The aerosol generating device may have an outer diameter between about 5 mm and about 30 mm.

[0085] According to another aspect of the present disclosure, there is provided a method of manufacturing a susceptor assembly, the method comprising the steps of:

[0086] providing a first sheet of material capable of being heated by induced eddy currents and hysteresis losses to vaporize an aerosol-forming substrate;

[0087] providing at least one layer of wicking material for transporting the aerosol-forming substrate across the surface of the sheet;

[0088] The first sheet of material and the at least one layer of wicking material are assembled, wherein the at least one layer of wicking material at least partially covers an outer surface of the first sheet of material, and wherein the wicking element forms an outer surface of the susceptor assembly.

[0089] The invention is defined in the claims. However, a non-exhaustive list of non-limiting examples is provided below. Any one or more features of these examples may be combined with any one or more features of another example, embodiment or aspect described herein.

[0090] Example Ex1: A susceptor assembly for an aerosol generating system, the susceptor assembly comprising:

[0091] a susceptor element in the form of a sheet; and

[0092] a wicking element comprising at least one wicking layer for transporting a liquid aerosol-forming substrate across a surface of the sheet material, wherein the wicking element forms an outer surface of the susceptor assembly.

[0093] Example Ex2: The susceptor assembly of example Ex1, wherein the wicking element comprises a plurality of apertures exposing portions of the susceptor element.

[0094] Example Ex3: A susceptor assembly according to example Ex1 or Ex2, wherein the wicking element consists of a top wicking layer and a bottom wicking layer.

[0095] Example Ex4: A susceptor assembly according to example Ex3, wherein the top wicking layer and the bottom wicking layer are separate components.

[0096] Example Ex5: The susceptor assembly according to any of the preceding examples, wherein the susceptor element is a blank sheet.

[0097] Example Ex6: The susceptor assembly according to examples Ex3 to Ex5, wherein the susceptor element, the top wicking layer and the bottom wicking layer are substantially parallel.

[0098] Example Ex7: The susceptor assembly according to Examples Ex3 to Ex6, wherein the susceptor element is sandwiched between the top wicking layer and the bottom wicking layer, wherein the top wicking layer and the bottom wicking layer substantially cover the surface of the susceptor element.

[0099] Example Ex8: The susceptor assembly according to any of the preceding examples, wherein the susceptor assembly is substantially planar.

[0100] Example Ex9: The susceptor assembly according to any of the preceding examples, wherein the susceptor element has an S-shape.

[0101] Example Ex10: The susceptor assembly according to any of the preceding examples, wherein the wicking element comprises a porous material.

[0102] Example Ex11: The susceptor assembly according to any of the preceding examples, wherein the wicking element comprises cotton.

[0103] Example Ex 12: The susceptor assembly according to any of the preceding examples, wherein the wicking element comprises a mesh.

[0104] Example Ex 13: The susceptor assembly according to any of the preceding examples, wherein the apertures are arranged in a uniform pattern.

[0105] Example Ex 14: The susceptor assembly according to any of the preceding examples, wherein the wicking element comprises a plurality of fibers, and wherein the diameter of each of the orifices is greater than the diameter of each of the fibers.

[0106] Example Ex 15: The susceptor assembly according to any of the preceding examples, wherein the distance between the edge of an orifice and the adjacent orifice is between 0.05 mm and 0.5 mm.

[0107] Example Ex 16: The susceptor assembly according to any of the preceding examples, wherein the width of the wicking element is greater than the width of the susceptor element.

[0108] Example Ex 17: The susceptor assembly according to any of the preceding examples, wherein the susceptor element comprises a central opening.

[0109] Example Ex18: The susceptor assembly according to any of the preceding examples, wherein the wicking element comprises a first region overlying the susceptor element and at least one second region not overlying the susceptor element, wherein the orifice is positioned in the first region, and wherein each of the second regions does not include an orifice.

[0110] Example Ex19: The susceptor assembly according to example Ex18, wherein the first region is positioned between two second regions.

[0111] Example Ex20: The susceptor assembly according to any of the preceding examples, wherein the susceptor element comprises a ferrous material.

[0112] Example Ex21: The susceptor assembly according to any of the preceding examples, wherein the susceptor element comprises annealed steel.

[0113] Example Ex22: The susceptor assembly according to any of the preceding examples, wherein the susceptor element comprises ferritic stainless steel.

[0114] Example Ex23: The susceptor assembly according to any of the preceding examples, wherein the susceptor element comprises at least one of graphite, molybdenum, silicon carbide, stainless steel, niobium, and aluminum.

[0115] Example Ex24: The susceptor assembly according to any of the preceding examples, wherein the susceptor element comprises at least one ferromagnetic material.

[0116] Example Ex25: The susceptor assembly according to any of the preceding examples, wherein the susceptor element comprises AISI 430 stainless steel.

[0117] Example Ex26: The susceptor assembly according to any of the preceding examples, wherein the susceptor element has a relative permeability between 1 and 40,000 when measured at a frequency up to 10 kHz at a temperature of 20 degrees Celsius.

[0118] Example Ex27: The susceptor assembly according to any of the preceding examples, wherein the susceptor element has a relative permeability between 500 and 40,000 when measured at a frequency of up to 10 kHz at a temperature of 20 degrees Celsius.

[0119] Example Ex28: The susceptor assembly according to any of the preceding examples, wherein the wicking element is folded around the susceptor element.

[0120] Example Ex29: The susceptor assembly according to any of the preceding examples, wherein the susceptor element is heatable by at least one of Joule heating and hysteresis losses generated by inducing eddy currents in the susceptor element.

[0121] Example Ex30: A cartridge for an aerosol generating system, the cartridge comprising:

[0122] The sensor assembly according to any preceding example;

[0123] a liquid reservoir holding a liquid aerosol-forming substrate therein,

[0124] wherein the wicking element of the susceptor assembly is arranged in fluid communication with the liquid aerosol-forming substrate in the liquid reservoir.

[0125] Example Ex31: The cartridge according to Example Ex30, further comprising an air inlet, an air outlet, and an air flow path extending from the air inlet through the susceptor assembly to the air outlet.

[0126] Example Ex32: The cartridge of Example Ex31, further comprising a susceptor holder that holds the susceptor assembly, wherein at least a portion of the airflow path is defined by the susceptor holder.

[0127] Example Ex33: A cartridge according to example Ex32, wherein the susceptor holder holds the susceptor assembly such that at least a portion of the susceptor assembly is positioned in the airflow path and such that the at least one wicking layer is in direct fluid communication with the liquid aerosol-forming substrate in the liquid reservoir.

[0128] Example Ex34: The cartridge according to example Ex33, wherein the susceptor holder provides a liquid seal around the susceptor assembly to prevent the liquid aerosol-forming substrate from escaping from the liquid reservoir except through at least one wicking layer.

[0129] Example Ex35: The cartridge according to example Ex30 or Ex34, wherein at least one wicking layer extends transversely to the direction of airflow through the susceptor assembly.

[0130] Example Ex36: The cartridge according to any one of Examples Ex30 to Ex35, wherein an opposite end of the at least one wicking layer is in fluid communication with the liquid reservoir.

[0131] Example Ex37: The cartridge according to any one of Examples Ex30 to Ex36, further comprising a mouthpiece, wherein the mouthpiece comprises an air outlet.

[0132] Example Ex38: An aerosol generating system, comprising:

[0133] A cartridge according to any one of Examples Ex30 to Ex37; and

[0134] An aerosol generating device, comprising:

[0135] Inductor coil;

[0136] a power source connected to the inductor coil and configured to provide current to the inductor coil to generate an alternating magnetic field; wherein the cartridge and the aerosol generating device are connectable to each other such that the susceptor assembly is positioned within the alternating magnetic field.

[0137] Example Ex39: An aerosol generating system according to Ex38, further comprising a control circuit system, wherein the control circuit system is connected to the inductor coil and is configured to control power delivery to the inductor coil.

[0138] Example Ex40: An aerosol generating system according to example Ex39 or Ex40, wherein the inductor coil is a helical coil positioned around the susceptor assembly when the aerosol generating device and the cartridge are connected to each other.

[0139] Example Ex41: An aerosol generating device comprising:

[0140] The susceptor assembly according to any one of Examples Ex1 to Ex30;

[0141] a liquid reservoir holding a liquid aerosol-forming substrate therein,

[0142] wherein the wicking element of the susceptor assembly is in fluid communication with the liquid aerosol-forming substrate in the liquid reservoir;

[0143] an inductor coil; and

[0144] A power source is connected to the inductor coil and configured to provide an alternating current to the inductor coil to generate an alternating magnetic field; wherein the susceptor assembly is positioned within the alternating magnetic field.

[0145] Example Ex42: The aerosol generating device of Example Ex41, further comprising control circuitry, wherein the control circuitry is connected to the inductor coil and configured to control power delivery to the inductor coil.

[0146] Example Ex43: An aerosol-generating device according to Example Ex42, wherein the control circuitry includes a sensor and is configured such that when a puff is detected by the sensor, the control circuitry delivers power from the power source to the coil.

[0147] Example Ex44: An aerosol-generating device according to any one of Examples Ex41 to Ex43, wherein the inductor coil is a helical coil positioned around the susceptor element.

[0148] Example Ex45: An aerosol generating device according to any one of Examples Ex41 to Ex44, further comprising an air inlet, an air outlet, and an air flow path extending from the air inlet through the susceptor assembly to the air outlet.

[0149] Example Ex46: An aerosol-generating device according to any one of Examples Ex41 to Ex45, further comprising a susceptor holder that holds the susceptor assembly, wherein at least a portion of the airflow path is defined by the susceptor holder.

[0150] Example Ex47: An aerosol-generating device according to example Ex46, wherein the susceptor holder holds the susceptor assembly so that at least a portion of the susceptor element is positioned in the airflow path and so that at least the wicking layer is in fluid communication with the liquid aerosol-forming substrate in the liquid reservoir.

[0151] Example Ex48: An aerosol-generating device according to example Ex47, wherein the susceptor holder provides a liquid seal around the susceptor assembly to prevent the liquid aerosol-forming substrate from escaping from the liquid reservoir except through the at least one wicking layer.

[0152] Example Ex49: A method of manufacturing a susceptor assembly for an aerosol-generating device, the method comprising:

[0153] providing a first sheet of material capable of being heated by induced eddy currents and hysteresis losses to vaporize an aerosol-forming substrate;

[0154] providing at least one layer of wicking material for transporting the aerosol-forming substrate across the surface of the sheet; and

[0155] The first sheet of material and the at least one layer of wicking material are assembled, wherein the at least one layer of wicking material at least partially covers an outer surface of the first sheet of material, and wherein the wicking element forms an outer surface of the susceptor assembly.

[0156] Examples will now be further described with reference to the accompanying drawings, in which:

[0157] Figure 1A a schematic diagram showing a cross section of a cartridge for an aerosol generating system, the cartridge including a susceptor assembly;

[0158] Figure 1B Shown Figure 1A Schematic diagram of an alternative cross section of a cylinder;

[0159] Figure 2 Show Figure 1A and 1B A schematic diagram of another alternative cross section of the barrel;

[0160] Figure 3A a schematic diagram showing a cross section of an aerosol generating system formed by a cartridge and an aerosol generating device, wherein the cartridge is separated from the aerosol generating device;

[0161] Figure 3B Show Figure 3A Schematic diagram of a cross-section of an aerosol-generating system in which a cartridge is coupled to an aerosol-generating device.

[0162] Figure 4 a schematic diagram showing a cross section of an aerosol generating device including a susceptor assembly;

[0163] Figure 5A shows a schematic diagram of an embodiment of a susceptor assembly according to the present disclosure, wherein the wicking element substantially covers the top and bottom surfaces of the susceptor element;

[0164] Figure 5B Shown Figure 5A Exploded view of the receptor assembly in;

[0165] Figure 6 A schematic diagram of an embodiment of a susceptor assembly according to the present disclosure is shown, wherein the wicking element substantially covers the top and bottom surfaces of the susceptor element, and wherein side portions of the wicking layer are free of perforations.

[0166] Figure 7 A schematic diagram showing an embodiment of a susceptor element having an S-shape.

[0167] Figure 1A and 1B Schematic diagram of two cross sections of a cartridge 10 for an aerosol generating system, the cartridge comprising a susceptor assembly according to a first embodiment of the present disclosure is shown. The two cross sections are taken in two planes perpendicular to each other.

[0168] FIG1 shows a cartridge 10 comprising a susceptor holder 14 and a susceptor assembly 12 mounted in the susceptor holder 14. The susceptor assembly 12 in this embodiment is planar and thin, with a thickness dimension significantly smaller than the length and width dimensions. The susceptor assembly 12 is shaped into a rectangular form and comprises a susceptor element 16 sandwiched between wicking elements. The width w of the susceptor element 16 is SE Less than the width w of the wicking element 18 WE , wherein the susceptor element 16 is sandwiched between the central region of the wicking element 18 to define an externally exposed portion 20 of the wicking element 18 that is not in contact with the susceptor element 16. The externally exposed portion 20 of the wicking element 18 protrudes into one of the two channels 45 through a pair of openings 28 disposed on opposite sides of the interior sidewall 27 of the susceptor holder 14. The interior sidewall 27 defines the interior passageway 26 of the susceptor holder 14. The susceptor element 16 comprises a blank sheet formed of ferritic stainless steel. The wicking element 18 comprises a porous body of rayon. The wicking element 18 is configured to deliver liquid to the susceptor element 16 via the externally exposed portion 20 of the wicking element 18.

[0169] The susceptor element 16 is configured to be heated by the penetration of the alternating magnetic field for vaporizing the aerosol-forming substrate. An externally exposed portion 20 of the wicking element 18 protrudes through a pair of openings 28 in the susceptor holder 14 so that the susceptor holder 14 supports the susceptor assembly 12 in place in the cartridge 10.

[0170] The susceptor assembly 12 is partially disposed within the interior passageway 26 of the tubular susceptor holder 14 and extends in a plane parallel to the central longitudinal axis of the susceptor holder 14. The susceptor element 16 is disposed entirely within the interior passageway 26 of the susceptor holder 14, and the externally exposed portion 20 of the wicking element 18 extends into the two channels 45 through a pair of openings 28 in the interior sidewall 27 of the susceptor holder 14. The externally exposed portion 20 of the wicking element 18 defines a mounting area of ​​the susceptor assembly 12 for mounting the susceptor assembly in the susceptor holder 14.

[0171] The cartridge 10 has an orifice and a connection end opposite the orifice. An outer housing 36 defines an orifice opening 38 at the orifice of the cartridge 10. As described in detail below, the connection end is configured to connect the cartridge 10 to an aerosol generating device 60. The susceptor assembly 12 and the susceptor holder 14 are positioned toward the connection end of the cartridge 10.

[0172] The outer housing 36 is formed of a moldable plastic material such as polypropylene. The outer housing 36 defines an interior space in which the susceptor assembly 12 and the susceptor holder 14 are housed.

[0173] The outer width of the outer housing 36 is greater at the mouth end of the cartridge 10 than at the connecting end, with the mouth end and the connecting end being joined by a shoulder 37. This enables the connecting end of the cartridge 10 to be received in the cavity of the aerosol generating device 60, with the shoulder 37 positioning the cartridge in the correct position in the aerosol generating device 60. It also enables the mouth end of the cartridge 10 to remain outside the aerosol generating device 60, with the mouth end conforming to the external shape of the aerosol generating device 60.

[0174] 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.

[0175] The liquid reservoir 44 extends from the mouth end of the outer housing 36 to the connection end of the outer housing 36 and includes an annular space defined by the outer housing 36 and the inner sidewall of the cartridge 10 .

[0176] The interior sidewall of the cartridge 10 defines an interior passageway 48 that extends between the mouth end opening 38 and the open end of the interior passageway 26 of the susceptor holder 14 .

[0177] The liquid reservoir 44 also includes two channels 45 defined between the outer shell 36 at the connection end and the inner sidewall 27 defining the interior passageway 26 of the susceptor holder 14. The two channels 45 extend from the annular space defined by the outer shell 36 and the inner sidewall of the cartridge 10 at the mouth end of the cartridge 10 to the connection end of the cartridge 10. The outer exposed portion 20 of the wicking element 18 extends through the opening 28 in the inner sidewall 27 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 and the inner sidewall of the cartridge 10 at the mouth end of the cartridge 10 on opposite sides of the interior passageway 26 of the susceptor holder 14.

[0178] 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.

[0179] An air passageway is formed through the cartridge 10 by the internal passageway 26 and the internal passageway 48 of the susceptor holder 14. The air passageway extends from the air inlet 32 ​​in the base 30 of the susceptor holder 14, through the internal passageway 26 of the susceptor holder 14, and through the internal passageway 48 to the mouth end opening 38. The air passageway enables air to be drawn through the cartridge 10 from the connection end to the mouth end.

[0180] Figure 2 Show Figure 1A and 1B Schematic diagram of another alternative cross section of the barrel 10. Figure 1A and 1B The view shown in the viewing tube 10 makes Figure 1A The cross section shown in is indicated by the dotted line AB, and Figure 1B The cross section shown in is indicated by the dashed line CD.

[0181] The cartridge 10 includes a susceptor holder 14. The susceptor holder 14 includes a tubular body formed from a moldable plastic material, such as polypropylene. The tubular body of the susceptor holder 14 includes an interior sidewall 27 defining an interior passageway 26 having an open end. A pair of openings 28 extend through the interior sidewall 27 at opposite sides of the tubular susceptor holder 14. The openings 28 are centrally located along the length of the susceptor holder 14.

[0182] A pair of openings 28 in the sidewalls 27 of the susceptor holder 14 are sized to receive the susceptor assembly 12 with a friction fit such that the susceptor assembly is secured within the susceptor holder 14. The friction fit between the susceptor assembly 12 and the susceptor holder 14 causes the mounting area to directly contact the susceptor holder 14 at the openings 28. The susceptor assembly 12 and the susceptor holder 14 are secured together such that movement of the susceptor holder 14 also moves the susceptor assembly 12.

[0183] It should be appreciated that the susceptor assembly 12 and the susceptor holder 14 may be secured together by other means. For example, in some embodiments, the susceptor assembly 12 is secured to the susceptor holder 14 at the mounting region of the susceptor assembly 12 by an adhesive, such that the mounting region indirectly contacts the susceptor holder 14.

[0184] The two channels 45 are located on opposite sides of the internal passageway 26 and, in use, supply the liquid aerosol-forming substrate to the susceptor assembly 12. The externally exposed portion of the wicking element 18, which forms the mounting area of ​​the susceptor assembly 12, extends from the internal passageway 26 into the channels 45 via the opening 28. The channels 45 are located on opposite sides of the internal passageway 26. Figure 2 The aerosol-forming substrate is shown empty but is understood to be filled with a liquid aerosol-forming substrate prior to use.

[0185] exist Figure 2 The tube 10 is viewed from the mouth end toward the connection end. Figure 2 A plurality of air inlets 32 in the base 30 can be seen.

[0186] Figure 3A A schematic diagram showing a cross-section of an aerosol generating system 100 according to the present disclosure is shown, with the cartridge 10 separated from the aerosol generating device 60 .

[0187] Cylinder 10 and Figure 1A 、 1B The same as the barrel presented in 2 and its corresponding description.

[0188] The aerosol generating device 60 comprises a generally cylindrical outer 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 10 is located at the connection end of the device 60, and an air inlet 65 is provided through the outer housing 62 at the base of the cavity 64 to allow ambient air to be drawn into the cavity 64.

[0189] The aerosol generating device 60 further comprises an induction heating device disposed within the device outer housing 62. The induction heating device comprises an inductor coil 90, a control circuit system 70, and a power source 72. The power source 72 comprises a rechargeable nickel-cadmium battery or a lithium-ion battery that is rechargeable via an electrical connector (not shown) at the distal end of the device. The control circuit system 70 is connected to the power source 72 and to the inductor coil 90 so that the control circuit system 70 controls the supply of power to the inductor coil 90. The control circuit system 70 is configured to supply an alternating current to the inductor coil 90.

[0190] When the cartridge 10 is received in the cavity 64, a single inductor coil 90 is positioned around the susceptor assembly 12. The size and shape of the inductor coil 90 match the size and shape of the susceptor element 16. The inductor coil 90 is made of copper wire having a circular cross-section and is arranged on a coil former element (not shown). The inductor coil 90 is both tubular and helical and defines a circular cross-section when viewed along the longitudinal axis of the aerosol generating device 60.

[0191] The inductor coil 90 is configured such that when the cartridge 10 is received in the cavity 64 , the inductor coil generates an alternating magnetic field in the region of the susceptor assembly 12 when an alternating current is supplied to the inductor coil.

[0192] 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 therefore partially surrounds the inductor coil 90. The flux concentrator element 91 is configured to reduce stray power losses from the generated magnetic field.

[0193] Figure 3B Show Figure 3A Schematic diagram of a cross-section of an aerosol generating system 100 , but with the cartridge 10 coupled to an aerosol generating device 60 .

[0194] 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 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 opening 38, through the air passage defined by the internal passageway 26, and through the susceptor assembly 12.

[0195] When the system is activated, control circuitry 70 controls the supply of power from power source 72 to inductor coil 90 .

[0196] The control circuit system 72 is coupled to the airflow sensor 63. The airflow sensor 63 is in fluid communication with the path of ambient air drawn through the system by the user. The control circuit system 72 supplies power to the inductor coil 90 when the airflow sensor 63 detects the user applying suction on the cartridge 10.

[0197] When the system 100 is activated, an alternating current is generated in the inductor coil 90, which generates an alternating magnetic field in the cavity 64 (where the susceptor assembly 12 is located), thereby heating the susceptor element 16. The liquid aerosol-forming substrate in the channel 45 is drawn into the susceptor assembly 12 through the wicking element 18 toward the susceptor element 16. The liquid aerosol-forming substrate 42 at the susceptor element 16 is heated, and volatile compounds from the heated aerosol-forming substrate are released into the air passage defined by the internal passage 48 of the cartridge 10 and cool to form an aerosol. The aerosol is entrained in the air drawn through the internal passage 48 of the cartridge 10 and is drawn out of the cartridge 10 at the mouth end opening 38 for inhalation by the user.

[0198] Figure 4 A schematic diagram of a cross-section of an aerosol-generating device 200 is shown, the device 200 including a susceptor assembly 112. As used herein, the terms aerosol-generating device and device are used interchangeably.

[0199] In operation, when a user draws on the mouth end opening 138 of the device, ambient air is drawn into the device 200 through the air inlet 165. Ambient air flows from the air inlet 165 through the device 200 to the mouth end opening 138, through the air passage defined by the internal passageway 126 and across the susceptor assembly 112.

[0200] When the system is activated, control circuitry 170 controls the supply of power from power source 172 to inductor coil 190 .

[0201] The control circuitry 172 is coupled to the airflow sensor 163. The airflow sensor 163 is in fluid communication with the path of ambient air drawn through the system by the user. The control circuitry 172 supplies power to the inductor coil 190 when the airflow sensor 163 detects a puff applied by the user on the aerosol generating device 200.

[0202] When the aerosol generating device 200 is activated, an alternating current is generated in the inductor coil 190, which generates an alternating magnetic field in the cavity 64 (in which the susceptor assembly 112 is located), thereby heating the susceptor element 116. The liquid aerosol-forming substrate in the channel 145 is drawn into the susceptor assembly 112 through the wicking element 118 toward the susceptor element 116. The liquid aerosol-forming substrate 142 at the susceptor element 116 is heated, and volatile compounds from the heated aerosol-forming substrate are released into the air passage defined by the internal passage 148 of the aerosol generating device 200 and cool to form an aerosol. The aerosol is entrained in the air drawn through the internal passage 148 of the aerosol generating device 200 and is drawn out of the internal passage 148 at the mouth end opening 138 for inhalation by the user.

[0203] The aerosol generating device 200 comprises a generally cylindrical device outer housing 162 having a connection end and a distal end opposite the connection end. An air inlet 65 is provided through the device outer housing 62 at the base of the cavity 64 to enable ambient air to be drawn into the cavity 64.

[0204] The aerosol generating device 200 further comprises an induction heating device disposed within the device outer housing 162. The induction heating device comprises an inductor coil 190, a control circuit system 170, and a power source 172. The power source 172 comprises a rechargeable nickel-cadmium battery or a lithium-ion battery that is rechargeable via an electrical connector (not shown) at the distal end of the device. The control circuit system 170 is connected to the power source 172 and to the inductor coil 190 so that the control circuit system 170 controls the supply of power to the inductor coil 190. The control circuit system 170 is configured to supply an alternating current to the inductor coil 190.

[0205] A single inductor coil 190 is positioned around the susceptor assembly 112 in the aerosol generating device 200. The size and shape of the inductor coil 90 match the size and shape of the susceptor element 116. The inductor coil 190 is made of copper wire having a circular cross-section and is arranged on a coil former element (not shown). The inductor coil 190 is both tubular and helical and defines a circular cross-section when viewed along the longitudinal axis of the aerosol generating device 200.

[0206] The inductor coil 190 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 112 .

[0207] The induction heating device further comprises a flux concentrator element 191. The flux concentrator element 191 has a larger radius than the inductor coil 190 and therefore partially surrounds the inductor coil 190. The flux concentrator element 191 is configured to reduce stray power losses from the generated magnetic field.

[0208] Figure 5A A schematic diagram of an embodiment of a susceptor assembly 212 according to the present disclosure is shown, wherein the wicking element substantially covers the top and bottom surfaces of the susceptor element 16. A top wicking layer 221 covers the top surface of the susceptor and a bottom wicking layer 222 covers the bottom surface of the susceptor.

[0209] Figure 5B Shown Figure 5A Exploded view of the susceptor assembly in FIG. Each wicking layer is independent of the others. The susceptor element 16 has a smaller surface area than the wicking element.

[0210] The orifices 280 cover substantially the entire surface of the wicking element 18. The orifices 280 are distributed across the surface of the wicking element in a uniform pattern. The orifices 280 extend from one surface of the wicking layers 221, 222 through to the opposite surface of the wicking layers 221, 222, wherein the area of ​​the orifices 280 exposes portions of the susceptor element 16. In this embodiment, the cross-section of the orifices 280 is circular.

[0211] The width of the wicking element 218 is greater than the susceptor element 16, and the length of the wicking element 218 is substantially equal to the length of the susceptor element.

[0212] The susceptor element 16 is a blank sheet. In this embodiment, the susceptor element 16 is a flat rectangular shape. The susceptor element 16 is located in the middle of the wicking element 218 so that the side portions 20 of the wicking element have equal widths. The side portions 20 of the wicking element 218 are in fluid communication with the liquid reservoir 44. The liquid aerosol-forming substrate travels from the liquid reservoir 44 across the wicking element 16 to the susceptor element 16 to be aerosolized. The top wicking layer 221 and the bottom wicking layer 222 allow the susceptor element 16 to be wetted on both surfaces.

[0213] Figure 6 A schematic diagram of an embodiment of a susceptor assembly according to the present disclosure is shown in which a wicking element 318 substantially covers the top and bottom surfaces of the susceptor element 16. In this embodiment, orifices 380 are present only in the areas of the wicking element 318 that cover the surface of the susceptor element 16. Areas of the wicking element 318 that do not cover the surface of the susceptor element 16 do not have orifices 380. The wicking element 318 includes a top layer 321 and a bottom layer 322.

[0214] The airflow path 330 is parallel to the length of the susceptor assembly 312 and perpendicular to the width of the susceptor assembly 312. Liquid is fed to the susceptor assembly 312 parallel to the width of the susceptor assembly 312. The thickness of the susceptor assembly is substantially the same throughout any section.

[0215] The apertures 380 are distributed in a uniform pattern across the area of ​​the wicking element 318 that covers the susceptor element 16. The apertures 380 extend from one surface of the wicking layer through to the opposite surface of the wicking layer such that the apertures 380 expose portions of the susceptor element 16. In this embodiment, the apertures 380 are circular in cross-section.

[0216] Although the previous figures show the susceptor assembly as a rectangle, the susceptor assembly may take any other suitable shape or form. For example, the susceptor may take an S-shaped form. An example of this arrangement is shown in FIG. Figure 7 Shown in.

[0217] Figure 7 FIG2 shows a schematic diagram of another embodiment of a susceptor assembly 612. The susceptor assembly 612 includes a planar S-shaped susceptor element 616. Figure 6 616. In this embodiment, the wicking element 618 substantially covers the top and bottom surfaces of the S-shaped susceptor element 616. In this embodiment, the wicking element 616 is rectangular. Other embodiments may exist in which the wicking element has a different planar polygonal shape. In this embodiment, the orifice 680 covers the rectangular area in which the S-shaped susceptor element 616 is present. Other embodiments may exist in which the orifice covers only the surface of the wicking element that covers the S-shaped susceptor element 616. In this embodiment, the wicking element 618 includes a top layer 621 and a bottom layer 622.

Claims

1. A susceptor assembly for an aerosol generating system, the susceptor assembly comprising: a susceptor element in the form of a sheet; as well as a wicking element comprising at least one wicking layer for transporting a liquid aerosol-forming substrate across a surface of the sheet material, wherein the wicking element forms an outer surface of the susceptor assembly; wherein the width of the wicking element is greater than the width of the susceptor element.

2. The susceptor assembly of claim 1 , wherein the wicking element comprises a plurality of apertures exposing portions of the susceptor element.

3. The susceptor assembly of claim 1 or 2, wherein the wicking element consists of a top wicking layer and a bottom wicking layer.

4. The susceptor assembly of claim 3, wherein the susceptor element is sandwiched between the top wicking layer and the bottom wicking layer, wherein the top wicking layer and the bottom wicking layer substantially cover a surface of the susceptor element.

5. A susceptor assembly according to any preceding claim, wherein the susceptor element is a blank sheet.

6. A susceptor assembly according to any preceding claim, wherein the susceptor assembly is substantially planar.

7. A susceptor assembly according to any preceding claim, wherein the susceptor element has an S-shape.

8. A susceptor assembly according to any preceding claim, wherein the susceptor element comprises a central opening.

9. The susceptor assembly of any one of claims 2 to 8, wherein the wicking element comprises a first region overlying the susceptor element and at least one second region not overlying the susceptor element, wherein a plurality of orifices are positioned in the first region, and wherein each of the second regions does not include an orifice.

10. The susceptor assembly of claim 9, wherein the first region is positioned between two second regions.

11. A susceptor assembly according to any preceding claim, wherein the wicking element is folded around the susceptor element.

12. A cartridge for an aerosol generating system, the cartridge comprising: A susceptor assembly according to any preceding claim; A liquid reservoir holds a liquid aerosol-forming substrate therein, wherein the wicking element of the susceptor assembly is arranged in fluid communication with the liquid aerosol-forming substrate in the liquid reservoir.

13. An aerosol generating system, comprising: The cartridge according to claim 12; as well as An aerosol generating device, comprising: Inductor coil; a power source connected to the inductor coil and configured to provide current to the inductor coil to generate an alternating magnetic field; wherein the cartridge and the aerosol-generating device are connectable to each other such that when the cartridge and the aerosol-generating device are connected to each other, at least a portion of the susceptor assembly is positioned within the alternating magnetic field.

14. An aerosol generating device comprising: The susceptor assembly according to any one of claims 1 to 11; a liquid reservoir holding a liquid aerosol-forming substrate therein, wherein the wicking element of the susceptor assembly is in fluid communication with the liquid aerosol-forming substrate in the liquid reservoir; Inductor coil; as well as A power source is connected to the inductor coil and configured to provide an alternating current to the inductor coil to generate an alternating magnetic field; wherein at least a portion of the susceptor assembly is positioned within the alternating magnetic field.

15. A method of manufacturing a susceptor assembly for an aerosol-generating device, the method comprising: providing a first sheet of material capable of being heated by induced eddy currents and hysteresis losses to vaporize an aerosol-forming substrate; providing at least one layer of wicking material for transporting the aerosol-forming substrate across the surface of the sheet; as well as assembling the first sheet of material and the at least one layer of wicking material, wherein the at least one layer of wicking material at least partially covers an outer surface of the first sheet of material, and wherein the wicking element forms an outer surface of the susceptor assembly, wherein the width of the wicking element is greater than the width of the susceptor material.

Images