Consumable assembly for aerosol generating systems

Abstract

The present disclosure provides a consumable assembly 600 for use in an aerosol generating device 60 and a method for manufacturing the same. The consumable assembly 600 includes a susceptor holder 540 that houses a susceptor assembly 510 including a susceptor 520 on a strip of wicking material 500, the susceptor holder 540 including a first portion 540 including a hollow elongated portion that houses the susceptor assembly 510, the hollow elongated portion having an opening at a connecting end, the hollow elongated portion including two opposing slots 545 extending along the elongated portion from the opening at the connecting end, the wicking material 500 on either side of the susceptor 520 of the susceptor assembly 510 protruding through the slots 545 in the first portion 540, and a second portion 550 attached to the connecting end of the first portion 540 to hold the susceptor assembly 510 within the first portion 540.

Description

[Technical Field]

[0001] The present disclosure relates to a consumable assembly for an aerosol generation system and a method of manufacturing a consumable assembly for an aerosol generation system. [Background technology]

[0002] Aerosol-generating systems that use inductive heating to heat an aerosol-forming substrate to produce an aerosol for user inhalation are generally known in the art. The aerosol-forming substrate is heated and vaporized to form a vapor. The vapor cools and condenses to form an aerosol, which is then inhaled by the user. Such electrically heated smoking systems are typically handheld and include a power source, a reservoir for holding a supply of aerosol-forming substrate, and an induction heating system.

[0003] Induction heating systems typically include at least one inductor coil connected to a power source. The induction heating system includes a susceptor assembly including a susceptor disposed in proximity to an aerosol-forming substrate within an alternating magnetic field. Some aerosol-generating systems include an aerosol-generating device and a cartridge configured for use with the device. When the aerosol-generating system includes 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 which case the susceptor assembly may further comprise a wicking material configured to draw the liquid aerosol-forming substrate from a reservoir in the cartridge to the heated susceptor.

[0005] Typically, a cartridge including 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 secured 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 aerosol-generating cartridges in this manner can be a cumbersome process that is unsuitable for large-scale manufacturing.

[0006] It is desirable to provide a manufacturing process for efficiently forming a consumable assembly that includes a susceptor assembly in a susceptor holder for an induction aerosol generator cartridge. It is also desirable to provide a consumable assembly for an induction aerosol generator cartridge that is easier to manufacture. Summary of the Invention

[0007] According to a first aspect of the present disclosure, a consumable assembly for use in an aerosol generating device is provided. The consumable assembly may include a susceptor holder that houses a susceptor assembly including a susceptor on a strip of wicking material. The susceptor holder may include a first portion having a hollow elongated portion that houses the susceptor assembly. The hollow elongated portion may have an opening at a connecting end. The hollow elongated portion may have two opposing slots extending along the elongated portion from the opening at the connecting end. Wicking material on either side of the susceptor of the susceptor assembly may protrude through the slots in the first portion. A second portion may be attached to the connecting end of the first portion to hold the susceptor assembly within the first portion.

[0008] Advantageously, assembling the two parts of the susceptor holder around the strip of wicking material comprising the susceptor assembly facilitates rapid construction of the consumable assembly. Specifically, rather than artificially threading the susceptor assembly through a slot in the wall of the susceptor holder to secure the susceptor assembly in place within the susceptor holder while maintaining a portion of the wicking material outside the susceptor holder, the susceptor assembly formed on the strip of wicking material may be fed into the hollow, elongated portion of the first susceptor holder part through an opening in the connecting end, while a portion of the strip of wicking material is received within the slot of the first susceptor holder part. The susceptor assembly may then be retained within the first susceptor holder part by connecting the second susceptor holder part to the connecting end of the first susceptor holder part. Thus, the proposed consumable assembly is easy to manufacture because the need for precise positioning of the susceptor assembly through a slot in the susceptor holder is avoided. Alternatively, the proposed consumable assembly may be manufactured reliably and efficiently by assembling two parts of a susceptor holder around a susceptor assembly.

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

[0010] The slot in the first susceptor holder portion may have a width greater than the wicking material but less than the width of the susceptor assembly, which advantageously prevents the susceptor assembly from sliding out of the first susceptor holder portion through the slot.

[0011] The slot in the first susceptor holder portion may have a length that is greater than a width of the strip of wicking material. Advantageously, this results in the strip of wicking material being fully contained within the slot.

[0012] The width of the slot in the first susceptor holder portion may increase at the connecting end, which may facilitate insertion of the strip of wicking material into the slot.

[0013] The second susceptor holder portion can hold the susceptor assembly within 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 against the wicking material or the susceptor assembly. In one embodiment, when connected to the first susceptor holder portion, the second susceptor holder portion can prevent the wicking material from sliding out of the slots at the connecting end of the first susceptor holder portion. In one embodiment, 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 through the openings at the connecting end. In one embodiment, when connected to the first susceptor holder portion, the second susceptor holder portion can apply a biasing force against the wicking material or the susceptor assembly against the first susceptor holder portion, thereby holding the susceptor assembly in place. In another embodiment, when connected to the first susceptor holder portion, the second susceptor holder portion may apply a biasing force to the first susceptor holder portion, which causes a portion of the first susceptor holder portion to deform against the wicking material to hold the susceptor assembly in place. It will be appreciated that any known connection mechanism for providing the above-mentioned biasing force may be utilized.

[0014] The second susceptor holder portion may form a snap-fit connection with the first susceptor holder portion via the connecting end, which may be irreversible to retain the susceptor assembly in the first susceptor holder portion indefinitely after attachment of the second susceptor holder portion.

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

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

[0017] The susceptor may comprise a first susceptor layer and a second susceptor layer. Accordingly, the strip of wicking material may comprise a first wicking layer and a second wicking layer. The first susceptor layer may contact at least a portion of the first wicking layer, and the second susceptor layer may contact at least a portion of the second wicking layer. This may advantageously mean that, during operation, the wicking material is heated from two sides. This may increase the amount of aerosol-forming substrate vaporized in a given time, compared to a susceptor assembly comprising only one susceptor layer.

[0018] The first and second susceptor layers may be planar. In this context, a planar susceptor layer is a susceptor layer having a length and width substantially greater than its thickness. The length and width directions are perpendicular 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 of the major surfaces may be advantageously flat. During use of the first and second susceptor layers in an aerosol-generating system, this allows air to flow across the surfaces of both the first and second susceptor layers, enhancing entrainment of the vaporized aerosol-forming substrate. The first and second susceptor layers may be substantially parallel to each other. The first and second susceptor layers may have a rectangular cross-section cut 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 section connecting the first susceptor layer to the second susceptor layer. The susceptor may include three sections. The first section of the susceptor may include the first susceptor layer. The second section of the susceptor may include the second susceptor layer. The third section of the susceptor may be a connecting section joining the first susceptor layer to the second susceptor layer.

[0023] The connecting section may be U-shaped or V-shaped. Advantageously, a susceptor having a U-shaped or V-shaped connecting section may hold 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 section of the susceptor. Advantageously, a susceptor formed in this manner may be relatively simple to manufacture.

[0025] The first and second wicking layers may be substantially planar. The first and second wicking layers of the susceptor assembly may be substantially parallel.

[0026] The first wicking layer and the second wicking layer may be integral with one another. The first wicking layer and the second wicking layer may be formed from a single piece of wicking material.

[0027] The first and second wicking layers may be separate components, which may advantageously prevent any bends or creases in the wicking layers that may compress the wicking layers 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 upon penetration by a suitable alternating magnetic field. The heating region of the susceptor assembly may comprise at least a portion of the first susceptor layer. The heating region of the susceptor assembly may comprise 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 and second wicking layers may include an attachment region. At least one attachment region may contact the susceptor holder. Preferably, a portion of at least one attachment region may extend into the liquid reservoir when the susceptor assembly is inserted into the cartridge. In a preferred embodiment, the heating region may be disposed outside the liquid reservoir. Advantageously, by disposing the susceptor substantially outside the liquid reservoir, and particularly by disposing the heating regions of the first and second susceptor layers outside the liquid reservoir, it may be ensured that the aerosol-forming substrate is heated sufficiently to release a volatile compound only after the aerosol-forming substrate is delivered outside the liquid reservoir. This may facilitate the release of the volatile compound from the aerosol generation 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 widths of the first and second susceptor layers may be smaller than the widths of the first and second wicking layers. The widths of the first and second susceptor layers may be approximately 20 percent smaller than the widths of the first and second wicking layers. The widths of the first and second susceptor layers may be approximately equal to the widths of the heating regions of the first and second wicking layers. The first and second susceptor layers may not include an attachment region.

[0033] The first susceptor layer and the second susceptor layer may include an attachment 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-sectional shape along a first plane. The susceptor assembly may include a pair of heating and mounting regions. The heating region may be substantially rectangular and located at the center of the susceptor assembly. The pair of mounting regions are substantially rectangular regions located on the periphery of the heating region. The mounting regions may be located on opposite sides of the heating region. The mounting regions may be disposed at the same central position along the length of the heating region. Each of the pair of mounting regions has a smaller surface area than the heating region.

[0035] The strip of wicking material may comprise a capillary material. The first wicking layer may comprise a capillary material. The second wicking layer may comprise a capillary material. A capillary material is a material that has the ability to transport liquid from one end of the material to another by capillary action. The capillary material may have a fibrous or spongy structure. Preferably, the capillary material comprises a bundle of capillaries. For example, the capillary material may comprise a plurality of fibers or threads, or other fine tubes. In some embodiments, the capillary material may comprise a spongy or foam-like material. The structure of the capillary material may form a plurality of small holes or tubes through which the liquid aerosol-forming substrate can be transported by capillary action.

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

[0037] The wicking material may include non-metallic materials. Examples of materials suitable for the wicking material include sponge or foam materials, ceramic or graphite-based materials in fiber or sintered powder form, expanded metal or plastic materials, fibrous materials made of spun or extruded fibers such as glass fiber, cellulose acetate, polyester, or bonded polyolefin, polyethylene, terylene, or polypropylene fibers, nylon fibers, or ceramics. Suitable materials for the wicking material may include cellulosic materials such as cotton or rayon.

[0038] The wicking material may preferably comprise cotton, rayon, or glass fiber. The first wicking layer may preferably consist of cotton. The second wicking layer may preferably comprise or consist of cotton.

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

[0040] The distance between the first wicking layer and the second wicking layer may be 0.1 to 0.5 mm. Preferably, the distance between the first wicking layer and the second wicking layer may be 0.2 to 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 vaporized aerosol-forming substrate to escape through the susceptor. Thus, vapor of the aerosol-forming substrate generated within a region of the wicking material immediately adjacent to the susceptor may escape through the susceptor element without having to pass through the wicking material.

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

[0043] Advantageously, in an aerosol generation system using induction heating, it is not necessary to form an electrical contact between the susceptor assembly and a power source. This may eliminate the need for solder or other joining elements. Cartridges incorporating susceptor assemblies configured to be inductively heated may allow for simple, inexpensive, and robust cartridge manufacturing.

[0044] The susceptor(s) may be printed or otherwise deposited on the strip of wicking material as a film or multiple tracks. The susceptor(s) may be secured to the wicking material by folding the free ends of the susceptor(s) around the strip of wicking material. The free ends of the folded susceptor(s) may be welded together to secure the susceptor(s) around the strip of wicking material. The susceptor(s) is preferably provided across the width of the strip of wicking material. The susceptor(s) may comprise 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. During operation, vaporized aerosol-forming substrate can advantageously escape from the wicking material through gaps or spaces between the tracks. Each of the multiple tracks of susceptors can advantageously be distributed over 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. Each of the plurality of tracks of the susceptor may include a first set of tracks that are parallel to one another. The plurality of tracks may further include a second set of tracks that are perpendicular to and overlap the first set of tracks. The first and second sets of tracks may together form a mesh-like structure.

[0045] The susceptor may comprise or consist of a perforated foil. During operation, vaporized aerosol-forming substrate can advantageously escape from the wicking material through the perforations in the perforated foil. The perforations may be uniformly distributed across the susceptor. The susceptor element may be perforated to allow the evacuation of vapor from the susceptor assembly or to allow the ingress of liquid aerosol-forming substrate.

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

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

[0048] The filaments may define gaps between the filaments, and the gaps may have a width of 10 micrometers to 100 micrometers. The filaments preferably create capillary action within the gaps so that, in use, the liquid aerosol-forming substrate is drawn into the gaps, increasing the contact area between the susceptor and the liquid. During operation, vaporized aerosol-forming substrate can advantageously escape from the wicking material through the gaps between the susceptor filaments.

[0049] Each susceptor may have a thickness of two millimeters or less. Preferably, each susceptor may have a thickness of less than one millimeter. Particularly preferably, the susceptors may have a thickness of 0.1 to 0.2 millimeters. Advantageously, the thickness of each susceptor is comparable to the skin depth of the susceptor material at the operating frequency of the system. Advantageously, the susceptor assembly has a thickness of ten times or less the skin depth of the susceptor material at the operating frequency. This ensures that each susceptor has a suitably low mass, thereby ensuring that the susceptor reaches a temperature suitable for volatilizing the aerosol-forming substrate in a short time. When the susceptor is penetrated by an alternating magnetic field from opposite sides, the susceptor may advantageously have a thickness of at least twice the skin depth of the susceptor material at the operating frequency. This minimizes skin effect interactions on opposite sides of the susceptor.

[0050] Advantageously, the susceptor assembly can be configured to hold only a small amount of liquid aerosol-forming substrate, sufficient for a single user puff. This is advantageous because it allows a small amount of liquid to be vaporized quickly with minimal heat loss. Advantageously, the susceptor assembly, or the heated region of the susceptor assembly, can hold between 2 milliliters and 10 milliliters of liquid aerosol-forming substrate.

[0051] The thickness of the susceptor assembly may be two millimeters or less, and preferably the susceptor assembly has a thickness of 0.8 to 1.2 millimeters.

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

[0053] The first side of the spacer layer may be in contact with the first side of the first wicking layer, the first susceptor layer may be in contact with the second side of the first wicking layer, and the first side of the first wicking layer faces the second side of the first wicking layer. The second side of the spacer layer may be in contact with the first side of the second wicking layer, and the second susceptor layer may be in contact with the second side of the second wicking layer, and the first side of the second wicking layer faces the second side of the second wicking layer. The first side of the spacer layer may face the second side of the spacer layer. In this arrangement, the first susceptor layer and the second susceptor layer may be sufficiently spaced apart from each other. The first wicking layer may be configured to transport the liquid aerosol-forming substrate to the first susceptor layer. The second wicking layer may be configured to transport the liquid aerosol-forming substrate to the second susceptor layer. This may allow for balancing the delivery of the liquid aerosol formulation between the first and second susceptor layers.

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

[0055] The spacer layer may be substantially planar, having a length and width substantially greater than a thickness. The length and width directions are perpendicular 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 face 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 can be configured to transport the liquid aerosol-forming substrate between the first wicking layer and the second wicking layer, particularly when the first wicking layer contacts a first side of the spacer layer and the second wicking layer contacts a second side of the spacer layer.

[0057] The first wicking layer may contact a first side of the spacer layer, and the second wicking layer may contact a second side of the spacer layer. The spacer layer may separate the first wicking layer from the second wicking layer. Advantageously, the spacer layer may prevent the first wicking layer from contacting the second wicking layer, thus reducing the buildup of undesired condensation between the first and second wicking layers.

[0058] The spacer layer may comprise a porous material. The spacer layer may comprise more pores than the wicking material. The spacer layer may comprise 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 have more small holes or tubes than the wicking material, through which the liquid aerosol-forming substrate can be transported by capillary action. The spacer layer may have larger holes or tubes than the wicking material, through which the liquid aerosol-forming substrate can be transported by capillary action. In this way, the liquid aerosol-forming substrate may be transported more quickly through the spacer layer compared to the wicking material.

[0060] The spacer layer may comprise a mesh. As used herein, the term "mesh" encompasses grids and arrays of filaments having spaces therebetween. The term mesh also includes woven and nonwoven fabrics.

[0061] Preferably, the spacer layer may 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 textile sheet.

[0062] The spacer layer may include an opening configured to transport the liquid aerosol-forming substrate between the first and second wicking layers. The spacer layer may include a plurality of openings configured to transport the liquid aerosol-forming substrate between the first and second wicking layers.

[0063] One or more apertures may be defined through the spacer layer between the first side of the spacer layer and the second side of the spacer layer, such that the liquid aerosol-forming substrate may be transported through the one or more apertures between the first side of the spacer layer and the second side of the spacer layer.

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

[0065] The one or more apertures may have a rectangular cross-section. The one or more apertures may be defined at an edge of the spacer layer. The one or more apertures may be configured to enhance 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 curve, an undulation, a fold, and a pleat. 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. If the spacer layer does not extend directly from the first end to the second end, i.e., is linear, the spacer layer may be considered to include one or more of a curve, an undulation, a fold, and a pleat.

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

[0068] The spacer layer may include a curve configured to act as a spring element between the first and second wicking layers. The spring may be resiliently biased to hold the first and second wicking layers at a predetermined separation distance. The separation distance may be preset by adjusting the radius of the curve. Advantageously, the spacer layer including a curve configured to act as a spring element may press against the first and second wicking layers, ensuring good contact between the spacer layer and the wicking material.

[0069] A fold may refer to a change in orientation of a spacer layer, for example, a gradual change in orientation of a spacer layer between a first end and a second end. Thus, a 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 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 known as corrugations. The spacer layer may include corrugations.

[0071] A corrugation may include multiple folds. For example, a pleat may refer to a step change in the orientation of a spacer layer followed by another step change in the orientation of the spacer layer. Thus, a corrugation may form three sides of a rectangle, or an "M" shape, or an "N" shape. Multiple pleats including "V" shaped folds may be known as triangular pleats. The spacer layer may include triangular pleats.

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

[0073] The undulations or corrugations in the spacer layer can 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 0.1 to 0.5 millimeters. 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 0.2 to 0.4 millimeters.

[0075] The depth of the spacer layer may be 0.1 to 0.5 millimeters, preferably 0.2 to 0.4 millimeters. 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] In a second aspect of the present disclosure, there is provided a cartridge for use in an aerosol generation system. The cartridge may include a consumable assembly 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 may be configured to transport the liquid aerosol-forming substrate between the liquid reservoir and the susceptor.

[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 within the airflow passage. A portion of the susceptor may be within the airflow passage.

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

[0080] The cartridge may have a mouth end and a connecting end, the connecting end configured to connect the cartridge to an aerosol generating device, and an air outlet may be provided in the mouth end.

[0081] The cartridge may include a mouthpiece, and the air outlet may be defined within 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 interior passage, and the air flow path may extend through the interior passage of the liquid reservoir.

[0083] The cartridge may include a susceptor holder. The susceptor holder may be a tubular susceptor holder. An internal passage of the tubular susceptor holder may form part of an enclosed air flow path. A sealed air flow path may extend from the air inlet, through the internal passage of the tubular susceptor holder, through the internal passage of the liquid reservoir, and to the air outlet.

[0084] The susceptor holder can support the susceptor assembly, can be in contact with at least one of the first wicking layer and the second wicking layer, and secures the susceptor assembly in place within the cartridge.

[0085] In a third aspect of the present disclosure, an aerosol generation system is provided. The aerosol generation system may include a consumable assembly according to the first embodiment of the present disclosure. The aerosol generation system may include a liquid reservoir for holding a liquid aerosol-forming substrate, and the wicking material is in fluid communication with the liquid reservoir and configured to transport the liquid aerosol-forming substrate. The aerosol generation system may further include an inductor coil and a power supply connected to the inductor coil, the power supply 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 generation system may include a system air inlet, a system air outlet, and an airflow passage extending between the system air inlet and the air intake and outlet.

[0087] At least a portion of the susceptor assembly may be within the system airflow passage.At least a portion of the susceptor may be within the system airflow passage.

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

[0089] The aerosol generation system may include a mouthpiece, with the system air outlet defined within the mouthpiece.

[0090] The aerosol generation system may be a handheld aerosol generation system configured to allow a user to draw on a mouthpiece to draw aerosol through the system air outlet. The aerosol generation system may have a size comparable to a conventional cigar or cigarette. The aerosol generation system may have an overall length of about 30 millimeters to about 150 millimeters. The aerosol generation system may have an outer diameter of about 5 millimeters to about 30 millimeters. The aerosol generation system may be an electrically powered smoking device.

[0091] The aerosol generation 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 system startup, or may be configured to provide power intermittently, such as after each puff. Power may be supplied to the induction heating assembly in the form of current pulses, for example, by pulse-width modulation (PWM). The control circuit may include a DC / AC inverter, which may include a class D or class E power amplifier. The control circuit may include additional electronic components. For example, in some embodiments, the control circuit may include a sensor element, a switch element, or a display element.

[0092] The control circuit may include a sensor for detecting when a user puffs on the aerosol generation system. The sensor may be configured to detect when air is drawn through the system airflow path. The sensor may enable the aerosol generation system to provide power for each puff.

[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 battery, a lithium iron phosphate battery, a lithium titanate battery, or a 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 numerous charge-discharge cycles. The power source may have a capacity that allows for storage of energy sufficient for one or more user experiences with the aerosol generation system; for example, the power source may have a capacity sufficient to allow continuous generation of aerosol for approximately six minutes, corresponding to the typical time it takes to smoke a conventional cigarette, or a multiple of six minutes. In another embodiment, the power source may have a capacity sufficient to allow for a predetermined number of puffs or discontinuous activation of the susceptor assembly.

[0094] The aerosol generation system may comprise a cartridge and an aerosol generator according to the second embodiment of the present disclosure. The system air outlet may comprise a cartridge air outlet.

[0095] The aerosol generating device includes an inductor coil and a power source connected to the inductor coil. The aerosol generating device may have a connecting end configured to connect the aerosol generating device to a cartridge. The connecting end may include a cavity for receiving the cartridge.

[0096] The aerosol generating device may have a distal end opposite the connecting end, which may include an electrical connector configured to connect the aerosol generating device to an electrical connector of an external power source for charging the power source of the aerosol generating device.

[0097] It will be understood that any feature described herein in relation to one embodiment of the consumable assembly may also be applied to other embodiments of the cartridge and aerosol generation system according to the present disclosure, and that a feature described in relation to one embodiment of the present disclosure may be equally applied to another embodiment according to the present disclosure.

[0098] As used herein, the term "aerosol-forming substrate" refers to a substrate capable of emitting a volatile compound that can form an aerosol. The volatile compound may be emitted 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, when used, facilitates the formation of an aerosol, for example, 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, polyhydric alcohols (such as triethylene glycol, 1,3-butanediol, glycerin), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of monocarboxylic, dicarboxylic, or polycarboxylic acids (such as dimethyl dodecanedioate, dimethyl tetradecanedioate, etc.).

[0100] The aerosol-forming substrate may comprise nicotine. The aerosol-forming substrate may comprise water. The aerosol-forming substrate may comprise glycerol, also known as glycerin, which has a higher boiling point than nicotine. The aerosol-forming substrate may comprise propylene glycol. The aerosol-forming substrate may comprise a plant-derived material. The aerosol-forming substrate may comprise a homogenized plant-derived material. The aerosol-forming substrate may comprise tobacco. The aerosol-forming substrate may comprise a tobacco-containing material. The tobacco-containing material may contain volatile tobacco flavor compounds. These compounds may be released from the aerosol-forming substrate upon heating. The aerosol-forming substrate may comprise a homogenized tobacco material. The aerosol-forming substrate may comprise other additives and ingredients such as flavorants.

[0101] As used herein, the term "liquid aerosol-forming substrate" refers to an aerosol-forming substrate in a condensed form. Thus, a "liquid aerosol-forming substrate" may be or include one or more of a liquid, a gel, or a paste. When the liquid aerosol-forming substrate is or includes a gel or 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] In a fourth aspect of the present disclosure, a method for manufacturing a consumable assembly is provided. The method may include providing one or more susceptors over a strip of wicking material to form one or more respective susceptor assemblies. The method may further include sliding one or more first susceptor holder portions over the strip of wicking material to engage the respective 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 connecting end. The hollow, elongated portion may include two opposing slots extending along the elongated portion from the opening at the connecting end. The slots may be 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. Next, the method may include attaching a second susceptor holder portion to the connecting end of each of the one or more first susceptor holder portions to retain a strip of wicking material containing one or more susceptor assemblies within each of the one or more first susceptor holder portions.

[0103] As described above, forming the two portions of the susceptor holder around a strip of wicking material containing a susceptor assembly facilitates rapid construction of the consumable assembly. Rather than threading the susceptor assembly artificially through a slot in the wall of the susceptor holder to secure the susceptor assembly in place within the susceptor holder while maintaining a portion of the wicking material outside the susceptor holder, the susceptor assembly formed on the strip of wicking material is fed into the hollow, elongated portion of the first susceptor holder portion through an opening in the connecting end, while a portion of the strip of wicking material is received within the slot in the first susceptor holder portion. The susceptor assembly is then retained within the first susceptor holder portion by attaching the second susceptor holder portion to the connecting end of the first susceptor holder portion. Thus, the proposed manufacturing method eliminates the need to precisely position the susceptor assembly through a slot in the susceptor holder, and instead presents a technique for reliable assembly of the susceptor holder around the susceptor assembly to improve manufacturing efficiency of consumable assemblies.

[0104] The second susceptor holder portion may hold the susceptor assembly within the first susceptor portion via any of the mechanisms mentioned in connection with the first embodiment.

[0105] The method may include securing one or more susceptors to the wicking material by folding free ends 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 respective multiple susceptor assemblies. When multiple susceptors are provided on the wicking material, each of the multiple susceptors may be spaced apart along the length of the strip of wicking material.

[0108] The method may include folding a strip of wicking material including one or more susceptor widths, so that one or more susceptors are provided on the outer surface of each side of the folded strip of wicking material. Advantageously, folding the strip of wicking material including one or more susceptors in this manner effectively forms one or more susceptor assemblies including two susceptor layers outside two inner wicking layers. The free ends of the one or more folded susceptors may be welded together to prevent the strip of wicking material from unfolding itself. Prior to folding the strip of wicking material, a spacer layer may be provided below the wicking material. This ensures that when the strip of wicking material is folded, the spacer layer separates the two inner wicking layers, thereby creating a susceptor assembly including a spacer layer as described in connection with the previous embodiment.

[0109] The method may include cutting the strip of wicking material outside of the first susceptor holder portions to separate each of the first susceptor holder portions from the remainder of the strip of wicking material to form a plurality of consumable assemblies, while maintaining exposed portions of the wicking material outside the plurality of first susceptor holder portions, which advantageously facilitates efficient production of a plurality of consumable assemblies from a single strip of wicking material.

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

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

[0112] In a fifth aspect of the present disclosure, a method for manufacturing a consumable assembly is provided. The method may include providing a plurality of susceptors spaced apart across a strip of wicking material to form a respective plurality of susceptor assemblies. A plurality of first susceptor holder portions may be provided. Each of the plurality of first susceptor holder portions may include a hollow elongated portion. The hollow elongated portion may include two opposing slots extending longitudinally along the elongated portion. The slots may be configured to receive the strip of wicking material comprising the plurality of susceptor assemblies. The method may further include feeding the strip of wicking material comprising the plurality of susceptor assemblies through the slots of the plurality of first susceptor holder portions such that the plurality of susceptor holder portions are each aligned over a respective susceptor assembly. The method may include cutting the strip of wicking material outside 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 plurality of consumable assemblies, while maintaining exposed portions of the wicking material outside the plurality of first susceptor holder portions.

[0113] Advantageously, the proposed method may improve the manufacturing efficiency of consumable assemblies. Rather than feeding individual susceptor assemblies into slots in a susceptor holder, the proposed method provides multiple susceptor assemblies on a strip of wicking material that is fed sequentially through slots in multiple susceptor holders so that each susceptor assembly is aligned within a respective susceptor holder. The wicking material on the outside of each susceptor holder is then cut to create multiple susceptor assemblies.

[0114] The method may include attaching a second susceptor holder portion to each of the plurality of first susceptor holder portions and holding 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 in connection with the first aspect.

[0115] The method may include securing one or more susceptors to the wicking material by folding free ends 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 connection with the fourth aspect, the method may include folding the strip of wicking material widthwise such that one or more susceptors are provided on the outer surface of each side of the folded strip of wicking material. Advantageously, folding the strip of wicking material containing one or more susceptors in this manner effectively forms one or more susceptor assemblies comprising two susceptor layers outside two inner wicking layers. Prior to folding the strip of wicking material, a spacer layer may be provided beneath the wicking material. This ensures that when the strip of wicking material is folded, the spacer layer separates the two inner wicking layers, thereby creating a susceptor assembly including a spacer layer as described in connection with the previous aspect.

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

[0119] The method may include inserting the cartridge into an aerosol generating device. [Brief explanation of the drawings]

[0120] [Figure 1A] FIG. 1A shows a schematic cross-sectional view of an aerosol generation system according to one embodiment of the present disclosure. [Figure 1B] FIG. 1B shows a cross-sectional schematic view of the aerosol generation system of FIG. 1A, with the system in an in-use configuration. [Figure 2A] FIG. 2A shows a schematic cross-sectional view of the cartridge of FIGS. 1A and 1B. [Figure 2B] FIG. 2B shows a schematic cross-sectional view of the cartridge of FIG. 2A rotated 90 degrees about the central longitudinal axis of the cartridge. [Figure 3] FIG. 3 shows a schematic diagram of a perspective view of the susceptor assembly shown in FIGS. 1A-2B. [Figure 4] FIG. 4 shows a schematic side view of a susceptor assembly according to one embodiment of the present disclosure. [Figure 5] FIG. 5 shows a schematic diagram of a strip of wicking material comprising multiple susceptor assemblies according to one embodiment of the present disclosure. [Figure 6] FIG. 6 shows a schematic diagram of the strip of wicking material of FIG. 5 folded widthwise and an array of first and second susceptor holder portions according to one embodiment of the present disclosure. [Figure 7A] FIG. 7A shows a schematic side view of the first susceptor holder portion of FIG. [Figure 7B] FIG. 7B shows a cross-sectional view of the first susceptor holder portion of FIG. 7A. [Figure 8A] FIG. 8A shows a schematic side view of the second susceptor holder portion of FIG. [Figure 8B] FIG. 8B shows a cross-sectional view of the second susceptor holder portion of FIG. 8A. [Figure 9] FIG. 9 shows a schematic diagram of a consumable assembly according to one embodiment of the present disclosure. [Figure 10] FIG. 10 illustrates a flow diagram of a method for manufacturing a consumable assembly according to one embodiment of the present disclosure. [Figure 11] FIG. 11 illustrates a flow diagram of a method for manufacturing a consumable assembly according to one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0121] The present invention is defined in the claims. However, below is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features described above, for example, with any one or more features of other examples, embodiments, or aspects described herein.

[0122] Example 1 1. A method of manufacturing one or more consumable assemblies for an aerosol generating device, the method comprising: providing one or more susceptors across the strip of wicking material to form respective one or more susceptor assemblies; sliding one or more first susceptor holder portions onto the strip of wicking material to engage a respective one or more susceptor assemblies, wherein the one or more first susceptor holder portions each include a hollow elongated portion having an opening at a connecting end, the hollow elongated portion including two opposing slots extending along the elongated portion from the opening at the connecting end, the slots 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 attaching a second susceptor holder portion to a connecting end of each of the one or more first susceptor holder portions to retain a strip of wicking material containing one or more susceptor assemblies within each of the one or more first susceptor holder portions.

[0123] Example 2. 2. The method of example 1, wherein the method further comprises providing, for each of the one or more susceptors, one or more spacer elements opposite the strip of wicking material, the one or more spacer elements being at least partially aligned with each of the one or more susceptors.

[0124] Example 3. The method of example 2, wherein one or more spacer elements comprise a porous material.

[0125] Example 4. The method of any one of Examples 2-3, wherein one or more spacer elements comprises a mesh.

[0126] Example 5. The method of any one of Examples 2 to 4, wherein one or more spacer elements comprise an opening to allow transport of the liquid aerosol-forming substrate through the one or more spacer elements.

[0127] Example 6 The method of example 5, wherein the one or more spacer elements comprise a plurality of openings to allow transport of the liquid aerosol-forming substrate through the one or more spacer elements.

[0128] Example 7 The method of any one of Examples 5-6, wherein the one or more openings have a circular cross-section.

[0129] Example 8 The method of any one of Examples 5-7, wherein the one or more openings comprise partial perforations of one or more spacer elements.

[0130] Example 9. The method of any one of Examples 2-8, wherein the method further comprises corrugating one or more spacer elements to form a wave shape or a triangular wave shape.

[0131] Example 10. The method of any one of Examples 2-9, wherein one or more spacer elements comprise cotton.

[0132] Example 11 The method of any one of Examples 2 to 10, wherein one or more spacer elements comprise a plastic material.

[0133] Example 12 The method of any one of Examples 2-11, wherein one or more spacer elements comprise a PEEK film.

[0134] Example 13 The method of any one of Examples 2 to 12, wherein one or more spacer elements comprises a fibrous sheet.

[0135] Example 14. The method of any one of Examples 2-13, wherein one or more spacer elements have a permeability higher than the permeability of the strip of wicking material.

[0136] Example 15. The method of any one of Examples 1 to 14, wherein one or more susceptors are fluid permeable.

[0137] Example 16. The method of any one of embodiments 1-15, wherein one or more susceptors comprise conductive filaments.

[0138] Example 17. The method of any one of Examples 1 to 16, wherein one or more susceptors comprise a mesh.

[0139] Example 18. The method of any one of Examples 1-17, wherein the strip of wicking material comprises cotton.

[0140] Example 19. The method of any of Examples 1-18, wherein the one or more susceptor assemblies have a thickness that is greater than a width of the slot in the one or more first susceptor holder portions.

[0141] Example 20. 20. The method of any of embodiments 1-19, wherein the width of the slot increases at the connecting end.

[0142] Example 21. 21. The method of any of embodiments 1-20, wherein the second susceptor holder part, when attached to the first susceptor holder part, forms a snap-fit connection with the connecting end.

[0143] Example 22. 22. The method of any of embodiments 1-21, wherein the second susceptor holder part exerts a biasing force on the susceptor assembly when attached to the first susceptor holder part.

[0144] Example 23. 23. The method of any of Examples 1-22, wherein the second susceptor holder part includes a hollow portion and an opening at a connecting end for connecting with the connecting end of the first susceptor holder part, the connecting end of the second susceptor holder part including two opposing slots extending from the openings, and the slots in the second susceptor holder part are configured to receive at least a portion of the strip of wicking material when the second susceptor holder part is attached to the first susceptor holder part.

[0145] Example 24. 1. A method of manufacturing one or more consumable assemblies for an aerosol generating device, the method comprising: providing a plurality of spaced apart susceptors across the strip of wicking material to form respective plurality of susceptor assemblies; providing a plurality of first susceptor holder portions, each of the plurality of first susceptor holder portions including a hollow elongated portion, the hollow elongated portion including two opposing slots extending longitudinally along the elongated portion, the slots configured to receive strips of wicking material comprising the plurality of susceptor assemblies; feeding strips of wicking material containing the plurality of susceptor assemblies through slots in the plurality of first susceptor holder portions such that the plurality of susceptor holder portions are each aligned over a respective susceptor assembly; and and cutting the strip of wicking material outside 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 while maintaining exposed portions of the wicking material outside the plurality of first susceptor holder portions.

[0146] Example 25. 25. The method of example 24, wherein the method further comprises securing the plurality of susceptors to the wicking material by folding free ends of the plurality of susceptors around the strip of wicking material.

[0147] Example 26. 26. The method of any of Examples 24-25, wherein a plurality of susceptors are provided across the width of the strip of wicking material.

[0148] Example 27. 27. The method of example 26, wherein the method further comprises folding the strip of wicking material widthwise such that a plurality of susceptors are provided on the outer surface of each side of the folded strip of wicking material.

[0149] Example 28. 28. The method of any one of Examples 24-27, wherein the method further comprises providing, for each of the plurality of susceptors, a plurality of spacer elements on opposite sides of the strip of wicking material, each of the plurality of spacer elements being at least partially aligned with a respective susceptor.

[0150] Example 29. 29. The method of example 28, wherein the plurality of spacer elements comprises a porous material.

[0151] Example 30. 30. The method of any one of Examples 28-29, wherein the plurality of spacer elements comprises a mesh.

[0152] Example 31. 31. The method of any one of Examples 28-30, wherein the plurality of spacer elements each comprise an opening to allow transport of the liquid aerosol-forming substrate through the respective spacer element.

[0153] Example 32. 32. The method of example 31, wherein the plurality of spacer elements each comprise a plurality of openings for permitting transport of the liquid aerosol-forming substrate through the respective spacer element.

[0154] Example 33. 33. The method of any one of Examples 31-32, wherein the one or more openings have a circular cross-section.

[0155] Example 34. 34. The method of any one of Examples 31-33, wherein the one or more openings comprise partial perforations in the spacer element.

[0156] Example 35. The method of any one of Examples 28-34, wherein the method further comprises corrugating the plurality of spacer elements to form a wave shape or a triangular wave shape.

[0157] Example 36. The method of any one of Examples 28-35, wherein the plurality of spacer elements comprises cotton.

[0158] Example 37. 37. The method of any one of Examples 28-36, wherein the plurality of spacer elements comprises a plastic material.

[0159] Example 38. The method of any one of Examples 28-37, wherein the plurality of spacer elements comprises a PEEK film.

[0160] Example 39. The method of any one of Examples 28-38, wherein the plurality of spacer elements comprises a fibrous sheet.

[0161] Example 40. 39. The method of any one of Examples 28-39, wherein the plurality of spacer elements have a permeability greater than the permeability of the strip of wicking material.

[0162] Example 41. The method of any one of Examples 24 to 40, wherein the plurality of susceptors are fluid permeable.

[0163] Example 42. 42. The method of any one of embodiments 24-41, wherein the plurality of susceptors comprises conductive filaments.

[0164] Example 43. The method of any one of Examples 24 to 42, wherein the plurality of susceptors comprises a mesh.

[0165] Example 44. The method of any one of Examples 24-43, wherein the strip of wicking material comprises cotton.

[0166] Example 45. The method of any of Examples 25-44, wherein the second susceptor holder part, when attached to the first susceptor holder part, forms a snap-fit connection with the connecting end.

[0167] Example 46. The method of any of Examples 25-45, wherein the second susceptor holder part applies clamping pressure to the wicking material when attached to the first susceptor holder part.

[0168] Example 47. 1. A consumable assembly for use in an aerosol generating device, the consumable assembly comprising: a susceptor holder that houses a susceptor assembly including a susceptor on a strip of wicking material, the susceptor holder comprising: a first portion including a hollow elongated portion for housing a susceptor assembly, the hollow elongated portion having an opening at a connecting end, the hollow elongated portion including two opposing slots extending along the elongated portion from the opening at the connecting end, with wicking material on either side of a susceptor of the susceptor assembly protruding through the slots in the first portion; and A consumable assembly including a second portion attached to a connecting end of the first portion for holding the susceptor assembly within the first portion.

[0169] Example 48. 48. The consumable assembly of Example 47, wherein the susceptor is fluid permeable.

[0170] Example 49. The consumable assembly of any one of Examples 47-48, wherein the susceptor comprises a conductive filament.

[0171] Example 50. 50. The consumable assembly of any of Examples 47-49, wherein the susceptor comprises a mesh.

[0172] Example 51. 51. The consumable assembly of any of Examples 47-50, wherein the wicking material comprises cotton.

[0173] Example 52. 52. The consumable assembly of any one of Examples 47-51, wherein the width of the slot increases at the connecting end.

[0174] Example 53. 53. The consumable assembly of any of Examples 47-52, wherein the second portion forms a snap-fit connection with the connecting end of the first portion.

[0175] Example 54. 54. The consumable assembly of any of Examples 47-53, wherein the second portion attached to the first portion exerts a biasing force on the susceptor assembly.

[0176] Example 55. A cartridge comprising the reservoir and consumable assembly of any of Examples 47-54, wherein an exposed portion of the wicking material protruding through the slot in the first susceptor holder portion is in fluid communication with the reservoir.

[0177] Example 56. An aerosol generating device comprising the cartridge described in Example 55.

[0178] The embodiments will now be further described with reference to the figures.

[0179] 1A shows a schematic diagram of an aerosol generation system according to one embodiment of the present disclosure. The system includes a cartridge 10 and a device 60, which can be coupled together to form the aerosol generation system. The aerosol generation system is portable and has a size comparable to that of a conventional cigar or cigarette.

[0180] FIG. 1B shows a schematic diagram of a cross-sectional view of the aerosol generation system of FIG. 1A, with cartridge 10 and device 60 coupled together to form the aerosol generation system.

[0181] Cartridge 10 includes a susceptor assembly 12 mounted in a susceptor holder 14. Cartridge 10 is shown separately from the aerosol generation system in Figures 2A and 2B. Figure 3 shows the susceptor assembly in more detail.

[0182] The susceptor assembly 12 is flat and thin, having a thickness dimension that is substantially smaller than its length and width dimensions, and is shaped in a rectangular configuration.

[0183] 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 further includes a spacer layer, not shown in FIG. 1A. The first susceptor layer 16, the second susceptor layer 18, and the first wicking layer 20 and the second wicking layer 22 each form a generally rectangular shape, each susceptor layer having the same length and width dimensions, with the width of the susceptors 16, 18 being smaller than the width of the first wicking layer 20 and the second wicking layer 22. Thus, the first wicking layer 20 and the second wicking layer 22 each include an outer, exposed portion of the wicking material, each protruding into one of the two channels 45. The first and second susceptor layers 16, 18 are substantially identical and comprise a sintered mesh formed from ferritic and austenitic stainless steel filaments. The first and second wicking layers 20, 22 comprise a porous body of cotton filaments. The wicking material 20 is configured to deliver liquid from the exposed outer surfaces of the first and second wicking layers 20, 22 to the first and second susceptors 16, 18.

[0184] The first and second susceptors 16, 18 are configured to be heatable by penetration by an alternating magnetic field to vaporize the aerosol-forming substrate. A wicking material 20 contacts the susceptor holder 14 such that the susceptor holder 14 supports the susceptor assembly 12 in place in the cartridge 10.

[0185] 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 and second susceptor elements 16, 18 are completely disposed 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 openings in the sidewall of the susceptor holder 14 into one of two channels 45.

[0186] The cartridge 10 has a mouth end and a connecting end opposite the mouth end. The outer housing 36 defines a mouth end opening 38 at the mouth end of the cartridge 10. The cartridge 10 may further include a mouthpiece at the mouth end. The connecting end is configured to connect the cartridge 10 to an aerosol generating device, as described in detail below. The susceptor assembly 12 and susceptor holder 14 are positioned toward the connecting end of the cartridge 10.

[0187] The outer housing 36 is formed from a moldable plastic material, such as polypropylene, and defines an interior space within which the susceptor assembly 12 and susceptor holder 14 are contained.

[0188] The outer width of the outer housing 36 is greater at the mouth end of the cartridge 10 than at the connecting end where it is joined by the shoulder 37. This allows the connecting end of the cartridge 10 to be received in the cavity of the aerosol generation device, with the shoulder 37 locating the cartridge in the correct position on the device. This also allows the mouth end of the cartridge 10 to remain outside the aerosol generation device, allowing the mouth end to conform to the external shape of the aerosol generation device.

[0189] The cartridge 10 further comprises a liquid reservoir 44. The liquid reservoir 44 is defined within the cartridge 10 for holding the liquid aerosol-forming substrate 42.

[0190] The liquid reservoir 44 extends from the mouth end of the outer housing 36 to the connecting end of the outer housing 36 and includes an annular space defined by the outer housing 36 .

[0191] The annular space has an interior passageway 48 extending between the mouth end opening 38 and the open end of the interior passageway 26 of the susceptor holder 14 .

[0192] The liquid reservoir 44 further includes two channels 45 defined between the inner surface of the outer housing 36 and the outer surface of the susceptor holder 14. The two channels 45 extend from the annular space defined by the outer housing 36 at the mouth end of the cartridge 10 to the connecting end of the cartridge 10, whereby the wicking material extends into the two channels 45 through openings in the sidewall of the susceptor holder 14. The two channels 45 extend from the annular space defined by the outer housing 36 at the mouth end of the cartridge 10 opposite the internal passage 26 of the susceptor holder 14.

[0193] The susceptor holder 14 includes a base 30 that partially closes one end of the internal passage 26. The base 30 includes a plurality of air inlets 32 that allow air to be drawn into the internal passage 26 through the partially closed end.

[0194] An air passageway is formed through the cartridge 10 by the internal passageway 26 of the susceptor holder 14 and the internal passageway 48 of the liquid reservoir 44. 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, through the internal passageway 48 of the liquid reservoir 44, to the mouth end air outlet 38. The air passageway allows air to be drawn through the cartridge 10 from the connection end to the mouth end.

[0195] Device 60 includes a generally cylindrical housing 62 having a connecting end and a distal end opposite the connecting end. A cavity 64 for receiving the connecting end of a cartridge is located at the connecting end of device 60. An air inlet 65 is provided through outer housing 62 at the base of cavity 64 to allow ambient air to be drawn into cavity 64 at the base. Device air inlet 65 is the system air inlet.

[0196] Device 60 further comprises an induction heating arrangement disposed within device outer housing 62. The induction heating arrangement includes an inductor coil 90, control circuitry 70, and a power source 72. Power source 72 comprises a rechargeable nickel-cadmium battery that is rechargeable via an electrical connector (not shown) at the distal end of the device. Control circuitry 70 is connected to power source 72 and inductor coil 90 such that control circuitry 70 controls the supply of power to inductor coil 90. Control circuitry 70 is configured to supply alternating current to inductor coil 90.

[0197] The inductor coil 90 is positioned around the susceptor assembly 12 when the cartridge 10 is received in the cavity 64, as shown in FIG. 1B. The inductor coil 90 has a size and shape that 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 disposed on a coil-forming element (not shown). The inductor coil 90 is a helical coil and has a circular cross section when viewed parallel to the longitudinal axis of the aerosol generating device.

[0198] 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 .

[0199] The induction heating arrangement further includes 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.

[0200] 1B shows the aerosol generation system of FIG. 1A with cartridge 10 coupled to apparatus 60 for operation. During operation, when a user draws on mouth-end opening 38 of cartridge 10, ambient air is drawn through system air inlet 65 into the base of cavity 64 and into cartridge 10 through air inlet 32 in base 30 of cartridge 10. Ambient air flows through cartridge 10 from base 30 to mouth-end air outlet 38, through air passageways, through susceptor assembly 12, and particularly through and across first susceptor layer 16 and second susceptor layer 18.

[0201] The control circuit 70 controls the supply of power from the power supply 72 to the inductor coil 90 when the system is powered up.

[0202] The control circuit 72 includes an 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 72 provides power to the inductor coil 90 when the airflow sensor 63 detects a puff by the user of the cartridge 10.

[0203] When the system is activated, an alternating current is established in the inductor coil 90, which generates an alternating magnetic field in the cavity 64 that penetrates the susceptor assembly 12, heating the susceptor, including the first and second susceptor layers. The liquid aerosol-forming substrate in the channel 45 is drawn into the susceptor assembly 12 and through the wicking material to the susceptor. In particular, the liquid is drawn through the first and second wicking layers 20 and 22 to the first and second susceptor layers 16 and 18, respectively. Liquid can also be transported between the first and second wicking layers 20 and 22 through the spacer layer. The liquid aerosol-forming substrate 42 in the susceptor is heated, and volatile compounds from the heated aerosol-forming substrate are released into the air passage of the cartridge 10, where they cool and form an aerosol. The aerosol is entrained in air drawn through the air passageway of the cartridge 10 and is drawn out of the cartridge 10 at the mouth-end air outlet 38 for inhalation by the user.

[0204] FIG. 2A shows a schematic diagram of the cartridge 10 separate from the aerosol generating device.

[0205] Figure 2B shows a schematic view of the cartridge of Figure 2A rotated 90 degrees about the central longitudinal axis of the cartridge. Figure 2B shows the layer structure of the susceptor assembly 12. The susceptor assembly 12 is planar and thin, having a thickness dimension substantially less than its 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 the liquid aerosol-forming substrate. The wicking material includes a first wicking layer 20 and a second wicking layer 22, with a spacer layer 24 positioned between and in contact with the first and second wicking layers.

[0206] The spacer layer 24 is fluid permeable and is configured to allow movement of the liquid aerosol forming substrate between the first wicking layer 20 and the second wicking layer 22. The spacer layer 24 generally forms a rectangular shape and has the same length dimension and width dimension as the first wicking layer and the second wicking layer. The spacer layer 24 includes a cotton porous body.

[0207] FIG. 3 shows a schematic view of a perspective view of the susceptor assembly shown in FIGS. 1A - 2B. The widths of the susceptor layers 16, 18 are smaller than the widths of the first wicking layer 20 and the second wicking layer 22. Thus, when mounted within the cartridge, the first susceptor layer 16 and the second susceptor layer 18 can be suspended so that they do not contact the susceptor holder. In this embodiment, the first susceptor layer 16 and the second susceptor layer 18 are separate, substantially identical components. The first wicking layer 20 and the second wicking layer 22 are separate, substantially parallel components.

[0208] FIG. 4 shows a schematic side view of a susceptor assembly according to a second embodiment of the present disclosure. The susceptor assembly of FIG. 4 is configured to operate in a manner similar to the susceptor assembly according to the first embodiment. The structures of the susceptor assembly of the first embodiment and the susceptor of the second embodiment are substantially the same except for differences in the wicking material and the susceptor, as described below.

[0209] The susceptor of FIG. 4 includes a first susceptor layer 116 and a second susceptor layer 118 that are substantially parallel. The susceptor further includes a connection section 117 that couples the first susceptor layer 116 to the second susceptor layer 118. The connection section 117 shown in FIG. 4 is a U-shaped curve. The susceptor is formed by bending or folding a single piece of material to form a susceptor that includes the first susceptor layer 116, the second susceptor layer 118, and the connection section 117. The connection section 117 comprises a sintered mesh formed from a ferritic stainless steel filament and an austenitic stainless steel filament.

[0210] In this embodiment, the wicking material includes a first wicking layer 120, a second wicking layer 122, and a wicking connecting section 121 that connects the first wicking layer 120 to the second wicking layer 122. The wicking connecting section 121 shown in FIG. 4 is a U-shaped curve. The wicking material is formed by bending or folding a single piece of material to form the wicking material including the first wicking layer 120, the second wicking layer 122, and the wicking connecting section 121. The wicking connecting section 121 comprises a porous body of cotton filaments. In other embodiments not shown in the figures, alternative arrangements of the wicking material and susceptor may be possible. For example, a susceptor assembly may include a susceptor including a connecting section that connects the first susceptor layer to the second susceptor layer, and the wicking material includes the first wicking layer and the second wicking layer that are separate components.

[0211] 5 shows a schematic diagram of a strip of wicking material 500 comprising multiple susceptor assemblies 510, according to one embodiment of the present disclosure. The susceptor assemblies 510 are formed by providing multiple susceptors 520 at spaced intervals across the strip of wicking material 500. Additional susceptors, wicking layers, and / or spacer layers may be provided on top and / or bottom of the strip of wicking material 500 to form a series of susceptor assemblies 510 having multiple wicking material layers 500 and / or susceptors 520, or even spacer layers. Additionally or alternatively, the strip of wicking material 500 comprising the susceptor assemblies 510 may be folded widthwise along a central axis 520 to form two inner wicking layers and two outer susceptor layers. Providing a spacer layer below the strip of wicking material can result in a central spacer layer separating the two wicking layers when the strip of wicking material is folded, as shown in FIG.

[0212] 6 shows a schematic diagram of the widthwise folded strip of wicking material 500 of FIG. 5 and an array of first and second susceptor holder portions 540, 550, according to one embodiment of the present disclosure. The first susceptor holder portions 540 are configured to engage the strip of wicking material 500, and each receive a susceptor assembly 510. The second susceptor holder portion 550 is configured to attach to the first susceptor holder portion 540 to hold the susceptor assembly 510 within the first susceptor holder portion 540.

[0213] 7A-B show schematic side and cross-sectional views of the first susceptor holder portion 540 of FIG. 6. The first susceptor holder portion 540 may include a hollow, elongated portion having an opening at a connecting end. Two opposing slots 545 extend from the opening along the elongated portion. The slots 545 are configured to receive the strips of wicking material 500 when the susceptor assembly 510 is received within the hollow portion of the first susceptor holder portion 540 through the opening at the connecting end. The slots 545 include a wider or tapered portion 548 at the opening at the connecting end, which facilitates insertion of the strips of wicking material 500 into the slots 545.

[0214] 8A-B show schematic side and cross-sectional views of the second susceptor holder portion 550 of FIG. 6. The second susceptor holder portion 550 includes a hollow elongated portion having an opening at a connecting end configured to connect with the connecting end of the first susceptor holder portion 540. Two opposing slots 555 extend from the opening along the elongated portion. The slots 555 are configured to engage and receive a portion of the strip house wicking material 500 held in the slot 545 of the first susceptor holder portion 540 when the second susceptor holder portion 550 is connected to the first susceptor holder portion 540.

[0215] In other examples not shown, 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 connecting 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 strip of wicking material 500 against the first susceptor holder portion 540.

[0216] 9 shows a schematic diagram of a consumable assembly 600 according to one embodiment of the present disclosure. The consumable assembly 600 includes a strip of wicking material 500, the strip of wicking material 500 comprising 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 connecting end of the first susceptor holder portion 540 and a portion of the strip of wicking material 500.

[0217] 10 shows a flow diagram of a method 700 for manufacturing a consumable assembly 600 according to one embodiment of the present disclosure. Step 710 includes providing a plurality of susceptors 520 over the strip of wicking material 500 to form a plurality of susceptor assemblies 510. The susceptors 520 are secured to the strip of wicking material 500 by folding the free ends of the susceptors 520 around the wicking material 500. Step 720 includes folding the strip of wicking material 500 widthwise along a central axis 530 so that a susceptor 520 is provided on the outer surface of each side of the folded strip of wicking material 500. In step 730, the folded strip of wicking material 500 is tensioned along its length to facilitate easier insertion of the strip of wicking material 500 into the slot 545 of the first susceptor holder portion 540. At Step 740, each of the plurality of first susceptor holder portions 540 receives a susceptor assembly 510 on the strip of wicking material 500, while a portion of the strip of wicking material 500 on either side of the susceptor assembly 510 slides within the slot 545 of the first susceptor holder portion 540. Step 750 includes attaching the second susceptor holder portion 550 to the first susceptor holder portion 540 to hold a susceptor assembly 510 within each first susceptor holder portion 540. Step 760 includes cutting the strip of wicking material outside the first susceptor holder portion 540 to separate the first susceptor holder portion 540 from the strip of wicking material 500 to form a plurality of consumable assemblies 600, while maintaining the exposed portion of the wicking material 500 outside 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 within the cartridge 10. The method 700 may further include inserting the cartridge 10 into the aerosol generation device 60 to form an aerosol generation system.

[0218] 11 shows a flow diagram of a method 800 for manufacturing a consumable assembly 600 according to one embodiment of the present disclosure. Steps 810-830 correspond to steps 710-730 described in connection with method 700. Step 840 includes feeding strips of wicking material 500 containing susceptor assemblies 510 through slots 545 in first susceptor holder portions 540 such that each first susceptor holder portion 540 is aligned over a respective susceptor assembly 510. Step 850 includes attaching second susceptor holder portions 550 to first susceptor holder portions 540 to retain the susceptor assemblies 510 within their respective first susceptor holder portions 540. Step 860 includes cutting the strip of wicking material 500 outside the side of the first susceptor holder portion 540 to separate the first susceptor holder portion 540 from the strip of wicking material 500 to form a plurality of consumable assemblies 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 further include inserting the cartridge 10 into the aerosol generation device 60 to form the aerosol generation system.

[0219] For purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, and the like are to be understood in all instances as modified by the term "about." Also, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein. Thus, in this context, the number A is to be understood as A ± 10 percent. Within this context, the number A may be considered to include a numerical value that is within the common standard error for measurement of the property that the number A modifies. In some instances, as used in the appended claims, the number A may deviate by the percentages recited above, provided that the amount by which A deviates does not materially affect the basic and novel characteristics of the claimed invention. Also, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein.

Claims

1. 1. A method of manufacturing a consumable assembly for one or more aerosol generating devices, the method comprising: providing one or more susceptors across the width of the strip of wicking material to form one or more respective susceptor assemblies; folding the strip of wicking material widthwise such that the one or more susceptors are provided on an outer surface of each side of the folded strip of wicking material; sliding one or more first susceptor holder portions over the strip of wicking material to engage the respective one or more susceptor assemblies, wherein the one or more first susceptor holder portions each include a hollow elongated portion having an opening at a connecting end, the hollow elongated portion including two opposing slots extending along the elongated portion from the opening at the connecting end, the slots 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 attaching a second susceptor holder portion to the connecting end of each of the one or more first susceptor holder portions to retain the strip of wicking material containing the one or more susceptor assemblies within each of the 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 free ends of the one or more susceptors around the strip of wicking material.

3. 2. The method of claim 1, further comprising providing one or more spacer elements opposite the strip of wicking material for each of the one or more susceptors, the one or more spacer elements being at least partially aligned with the respective one or more susceptors.

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

5. The method of any preceding claim, wherein a plurality of susceptors are provided at spaced intervals along the length of the strip of wicking material to form a multiple susceptor assembly.

6. 6. The method of claim 5, further comprising: cutting the strip of wicking material on 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 respective plurality of consumable assemblies, while maintaining exposed portions of the wicking material outside the plurality of first susceptor holder portions.

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

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

9. 1. A method of manufacturing a consumable assembly for one or more aerosol generating devices, the method comprising: providing a plurality of spaced apart susceptors across the strip of wicking material to form respective plurality of susceptor assemblies; providing a plurality of first susceptor holder portions, each of the plurality of first susceptor holder portions including a hollow elongated portion, the hollow elongated portion including two opposing slots extending longitudinally along the elongated portion, the slots configured to receive the strips of wicking material that comprise the plurality of susceptor assemblies; feeding the strips of wicking material containing the plurality of susceptor assemblies through the slots of the plurality of first susceptor holder portions such that the plurality of susceptor holder portions are each aligned over a respective susceptor assembly; and cutting the strip of wicking material outside 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 respective plurality of consumable assemblies, while maintaining an exposed portion of the wicking material outside of the plurality of first susceptor holder portions.

10. 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 respective first susceptor holder portion.

11. 1. A consumable assembly for use in an aerosol generating device, the consumable assembly comprising: a susceptor holder that houses a susceptor assembly including a susceptor folded about an outer surface across a width of a strip of folded wicking material, the susceptor holder comprising: a first portion including a hollow elongated portion for housing the susceptor assembly, the hollow elongated portion having an opening at a connecting end, the hollow elongated portion including two opposing slots extending along the elongated portion from the opening at the connecting end, and wicking material on either side of the susceptor of the susceptor assembly protruding through the slots in the first portion; and a second portion attached to the connecting end of the first portion for retaining 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 the consumable assembly of any one of claims 11 to 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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