Susceptor Assembly

Abstract

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

Description

[Technical Field]

[0001] The present disclosure relates to a susceptor assembly for an aerosol generation system, a cartridge for an aerosol generation system, an aerosol generation system, and a method for manufacturing the susceptor assembly. [Background technology]

[0002] Aerosol-generating systems that use inductive heating to heat an aerosol-forming substrate to generate an aerosol for user inhalation are generally known in the prior 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 element 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 element may form part of the cartridge.

[0004] The aerosol-forming substrate may be a liquid, in which case the aerosol-generating system may further comprise a wicking element configured to draw the liquid aerosol-forming substrate from the storage portion to the susceptor element to be heated.

[0005] Typically, a susceptor assembly of an induction aerosol generation system may include a single wicking element that includes a single wicking layer.

[0006] It is desirable to provide an aerosol-generating system that includes a susceptor assembly and two or more wicking layers to improve delivery of the liquid aerosol-forming substrate to the susceptor element and thus enhance vaporization of the liquid aerosol-forming substrate. Summary of the Invention

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

[0008] Advantageously, providing a first wicking layer and a second wicking layer improves ease of manufacturing of a susceptor assembly for an aerosol generating system while conveying sufficient liquid aerosol-forming substrate for aerosolization. However, it has been found that two wicking layers in contact with each other can lead to condensate being trapped between the two wicking layers. This can then cause vapor release. The vapor can cause deformation of the susceptor assembly. Deformation of the susceptor assembly can then lead to reduced contact between the susceptor element and one or more wicking elements, resulting in reduced or inefficient aerosolization of the liquid aerosol-forming substrate. The present invention provides a spacer element positioned between and in contact with the first and second wicking layers. Advantageously, the spacer element can improve liquid flow between the first and second wicking layers. Additionally, the spacer elements may provide space for the vapor to accumulate before it escapes from the susceptor assembly, thus minimizing deformation of the susceptor assembly.

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

[0010] The susceptor element may include a first susceptor layer and a second susceptor layer. The first susceptor layer may be in contact with at least a portion of the first wicking layer, and the second susceptor layer may be in contact with at least a portion of the second wicking layer. This may advantageously mean that during operation, the one or more wicking elements are 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.

[0011] The first side of the spacer element 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 element 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 element may face the second side of the spacer element. In this arrangement, the first susceptor layer and the second susceptor layer may be 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 a balanced delivery of the liquid aerosol formulation between the first and second susceptor layers.

[0012] 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 a 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 taken across the first plane.

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

[0014] The first susceptor layer and the second susceptor layer may be integral with one another, which may advantageously simplify the manufacture of the susceptor assembly.

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

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

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

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

[0019] 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.

[0020] The first and second wicking layers may be separate components, which may advantageously prevent any bends or creases in the wicking layers from compressing them and resulting in suboptimal liquid transport.

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

[0022] 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 include at least a portion of the first susceptor layer. The heating region of the susceptor assembly may include at least a portion of the second susceptor layer. Each of the first susceptor layer, the second susceptor layer, the first wicking layer, the second wicking layer, and the spacer element may include a heating region.

[0023] Each of the first wicking layer, the second wicking layer, and the spacer element 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. In a preferred embodiment, the heating region may be disposed outside the liquid reservoir. Advantageously, by disposing the susceptor element substantially outside the liquid reservoir, and in particular by disposing the heating region of the susceptor assembly outside the liquid reservoir, it may be ensured that the aerosol-forming substrate is heated sufficiently to release the volatile compound only after the aerosol-forming substrate is transported outside the liquid reservoir. This may facilitate the release of the volatile compound from the aerosol-generating system.

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

[0025] The widths of the first and second susceptor layers may be smaller than the widths of the first and second wicking layers and the spacer elements. 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 and the spacer elements. 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 and the spacer elements. The first and second susceptor layers may not include an attachment region.

[0026] The first susceptor layer and the second susceptor layer may include an attachment region.

[0027] The susceptor assembly may form a cross shape. The first susceptor layer, the second susceptor layer, the first wicking layer, the second wicking layer, and the spacer layer may have a cross-shaped cross-section along the first plane. The susceptor assembly may include a pair of mounting regions and a heating region. The heating region may be substantially rectangular and located at the center of the susceptor assembly. The pair of mounting regions may be substantially rectangular regions located on the periphery of the heating region. The mounting regions may be located on either side 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 may have a smaller surface area than the heating region.

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

[0029] The spacer element 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 element. The first side of the spacer element and the second side of the spacer element may face each other and extend in a plane parallel to the first plane of the susceptor element. The spacer element may be configured to allow a liquid aerosol formation to move between the first side of the spacer element and the second side of the spacer element. The spacer element may be configured to transport a liquid aerosol-forming substrate between the first side of the spacer element and the second side of the spacer element.

[0030] In the thickness direction, the spacer elements are preferably at least partially uncovered. For example, the spacer elements in the thickness direction may have at least one region that is not covered by another component. Thus, at least one region of the spacer elements in the thickness direction may be open to an airflow passage in which the susceptor assembly is placed during use. During use of the susceptor assembly, steam may accumulate within the spacer elements. Advantageously, the steam can escape from the at least partially uncovered region of the spacer elements in the thickness direction before reaching a pressure that could lead to deformation of the susceptor assembly.

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

[0032] The first wicking layer may contact a first side of the spacer element, and the second wicking layer may contact a second side of the spacer element. The spacer element may separate the first wicking layer from the second wicking layer. Advantageously, the spacer element may prevent the first wicking layer from contacting the second wicking layer, thus providing a space for vapor. One or more wicking elements may include a capillary material. The first wicking layer may include a capillary material. The second wicking layer may include a capillary material. 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 includes a bundle of capillaries. For example, the capillary material may include a plurality of fibers or threads or other fine tubes. In some embodiments, the capillary material may include 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.

[0033] The one or more wicking elements may comprise or consist of a layer of an electrically insulating material. The one or more wicking elements may comprise a non-metallic material. Preferably, the one or more wicking elements may not be heated in a magnetic field. The one or more wicking elements may comprise a hydrophilic or oleophilic material. This may advantageously facilitate transport of the aerosol-forming substrate through the one or more wicking elements. The one or more wicking elements may comprise or consist of a porous ceramic material.

[0034] The one or more wicking elements may comprise a non-metallic material. Examples of suitable materials for the one or more wicking elements include sponge or foam materials, ceramic or graphite-based materials in the form of fibers or sintered powders, expanded metal or plastic materials, fibrous materials, such as fibrous materials made of spun or extruded fibers, such as glass fibers, cellulose acetate, polyester, or bonded polyolefin, polyethylene, terylene, or polypropylene fibers, nylon fibers, or ceramics. Suitable materials for the one or more wicking elements may include cellulosic materials, such as cotton or rayon.

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

[0036] 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 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 0.2 millimeters.

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

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

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

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

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

[0042] The spacer elements may comprise, and may preferably consist of, cotton. The spacer elements may comprise a plastic material. The spacer elements may comprise a polyetheretherketone (PEEK) film. The spacer elements may comprise a textile sheet.

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

[0044] The spacer element can include an opening configured to allow the liquid aerosol-forming substrate to move between the first and second wicking layers. The spacer element may include a plurality of openings configured to allow the liquid aerosol-forming substrate to move between the first and second wicking layers.

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

[0046] An aperture or apertures may be defined through the spacer element between the first side of the spacer element and the second side of the spacer element, such that the liquid aerosol-forming substrate can pass through the aperture or apertures between the first side of the spacer element and the second side of the spacer element.

[0047] The aperture or apertures may have a circular cross-section. The aperture or apertures may have a diameter of at least 0.1 millimeters.

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

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

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

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

[0052] The one or more wicking elements may include small holes, tubes, or pores within which the liquid aerosol-forming substrate may be held or, alternatively, or additionally, transported by capillary action. Each one of the small holes, tubes, or pores may have a volume for holding or transporting the liquid aerosol-forming substrate. The volume of the or each opening within the plurality of openings within the spacer element may be greater than the volume of each of the small holes, tubes, or pores within the one or more wicking elements. The total volume of the opening or openings within the spacer element may be greater than the total volume of the small holes, tubes, and pores within the one or more wicking elements.

[0053] The spacer element may include one or more of a curve, an undulation, a fold, and a wave. The spacer element may have a first end and a second end. The width of the spacer element may extend from the first end to the second end. If the spacer element does not extend directly, i.e., in a straight line, from the first end to the second end, the spacer element may be considered to include one or more of a curve, an undulation, a fold, and a wave.

[0054] The curve may refer to a gradual change in the orientation of the spacer element, such as a gradual change in the orientation of the spacer element between a first end and a second end. Thus, the curve may form an arc, or a "C" shape. The curve in the spacer element may enhance the transport of the liquid aerosol-forming substrate between the first and second wicking layers.

[0055] The spacer element 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 a predetermined distance apart. The distance may be preset by adjusting the radius of the curve. Advantageously, the spacer element including a curve configured to act as a spring element may compress the first and second wicking layers to ensure good contact between the spacer element and one or more wicking elements.

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

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

[0058] A corrugation may include multiple folds. For example, a corrugation may refer to a gradual change in the orientation of a spacer element followed by another gradual change in the orientation of a spacer element. Thus, a corrugation may form three sides of a rectangle, or an "M" shape, or an "N" shape. A multiple corrugation including "V" shaped folds may be known as a triangular corrugation. A spacer element may include a triangular corrugation.

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

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

[0061] The spacer element may provide a void or voids between the first and second wicking layers. The void or voids may include an opening or openings. The void or voids may be defined between the spacer element and the first or second wicking layer by curves, folds, undulations, or corrugations in the spacer layer. The void or voids may provide a volume of space for the liquid or gas aerosol-forming substrate to be held and, alternatively or additionally, transported therethrough. Advantageously, the void or voids may prevent vapor formed between the first and second wicking layers from deforming the susceptor assembly.

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

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

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

[0065] The susceptor element may be fluid-permeable. The first susceptor layer may be fluid-permeable. The second susceptor layer may be fluid-permeable. A fluid-permeable susceptor element may advantageously allow vaporized aerosol-forming substrate to escape through the susceptor element. Thus, vapor of the aerosol-forming substrate generated within the region of one or more wicking elements immediately adjacent to the susceptor element may escape through the susceptor element without having to pass through one or more wicking elements.

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

[0067] 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.

[0068] The susceptor element or elements may be printed or otherwise deposited as a film or tracks on one or more wicking elements. The susceptor element may comprise or consist of a conductive material deposited directly on the one or more wicking elements. The conductive material of the susceptor element may be deposited as multiple tracks on the one or more wicking elements. During operation, vaporized aerosol-forming substrate may advantageously escape from the one or more wicking elements through gaps or spaces between the tracks. The multiple tracks of each of the susceptor elements may advantageously be distributed over the surface of the one or more wicking elements to provide substantially uniform heating across the surface. For example, the width of each of the tracks and the spacing between the tracks may be substantially the same for each of the multiple tracks. The multiple tracks of each of the susceptor elements may include a first set of tracks parallel to one another. The multiple tracks may further include a second set of tracks perpendicular to and overlapping the first set of tracks. The first and second sets of tracks may together form a mesh-like structure.

[0069] The susceptor element may comprise or consist of a perforated foil. During operation, vaporized aerosol-forming substrate can advantageously escape from one or more wicking elements through the perforations in the perforated foil. The perforations may be uniformly distributed across the susceptor element. 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.

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

[0071] In a preferred embodiment, the susceptor element may include a mesh. The first susceptor layer may include or consist of a mesh. The second susceptor layer may include or consist of 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.

[0072] The filaments may define inter-filament gaps, and the gaps may have a width of 10 micrometers to 100 micrometers. Preferably, the filaments create capillary action within the gaps such that, in use, the liquid aerosol-forming substrate is drawn into the gaps, increasing the contact area between the susceptor element and the liquid. During operation, vaporized aerosol-forming substrate may advantageously escape from one or more wicking elements through the gaps between the filaments of the susceptor element.

[0073] Each susceptor layer may have a thickness of 2 millimeters or less. Preferably, each susceptor layer may have a thickness of less than 1 millimeter. Particularly preferably, the first susceptor layer may have a thickness of 0.1 to 0.2 millimeters. Particularly preferably, the second susceptor layer may have a thickness of 0.1 to 0.2 millimeters. Advantageously, the thickness of each susceptor layer is on the same order of magnitude as the skin depth of the material of the susceptor layer at the operating frequency of the system. Advantageously, the susceptor assembly has a thickness of 10 times or less the skin depth of the material of the susceptor layer at the operating frequency. This ensures that each susceptor layer has a suitably low mass, thereby ensuring that the susceptor layer reaches a temperature suitable for volatilizing the aerosol-forming substrate in a short time. When the susceptor element is penetrated by alternating magnetic fields from opposite sides, each susceptor layer may advantageously have a thickness of at least twice the skin depth of the material of the susceptor layer at the operating frequency. This may minimize skin effect interactions on opposite sides of the susceptor layer.

[0074] 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.

[0075] The thickness of the susceptor assembly may be 2 millimeters or less, and preferably the susceptor assembly has a thickness of 0.8 to 1.2 millimeters.

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

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

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

[0079] The susceptor element 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 airflow passage 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 a portion of the sealed airflow passage. The sealed airflow passage 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 contact at least one of the first wicking layer and the second wicking layer, and can secure the susceptor assembly in place within the cartridge.

[0085] According to a third embodiment of the present disclosure, there is provided an aerosol generation system. The aerosol generation system may include the susceptor assembly according to the first embodiment of the present disclosure. The aerosol generation system may further include a liquid reservoir for holding a liquid aerosol-forming substrate, and the one or more wicking elements are 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 element 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 a system airflow passageway extending between the system air inlet and the system air outlet.

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

[0088] The susceptor element 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 a system air outlet.

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

[0090] The inductor coil may surround the susceptor assembly. The inductor coil may be a tubular spiral coil. The inductor coil is preferably a helical coil. The inductor coil may be a surrounding helical coil, at least a portion of which surrounds the susceptor assembly. The helical coil may have a circular cross section when viewed parallel to the longitudinal axis of the aerosol generation system.

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

[0092] 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 advantageously 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.

[0093] The control circuit may include a sensor for detecting when a user takes a puff 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 with each puff.

[0094] The power source may be a DC power source. The power source may be a battery. The battery may be a lithium-based battery, such as a lithium cobalt 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.

[0095] An 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.

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

[0097] 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.

[0098] It will be understood that any feature described herein with respect to one embodiment of a susceptor assembly may also be applied to other aspects of the cartridge and aerosol generation system according to the present disclosure, and that a feature described with respect to one embodiment of the disclosure may be equally applied to another embodiment according to the present disclosure.

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

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

[0101] The aerosol-forming substrate may include an aerosol former. As used herein, the term "aerosol former" refers to any suitable compound or mixture of compounds that, 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.).

[0102] 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.

[0103] 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. [Brief explanation of the drawings]

[0104] [Figure 1A] FIG. 1A shows a schematic cross-sectional view of an aerosol generation system according to a first 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 a second embodiment of the present disclosure. [Figure 5] FIG. 5 shows a schematic cross-section of a susceptor assembly according to a third embodiment of the present disclosure. [Figure 6] FIG. 6 shows a schematic cross section of a susceptor assembly according to a fourth embodiment of the present disclosure. [Figure 7] FIG. 7 shows a schematic cross section of a susceptor assembly according to a fifth embodiment of the present disclosure. [Figure 8] FIG. 8 shows a schematic cross section of a susceptor assembly according to a sixth embodiment of the present disclosure. [Figure 9] FIG. 9 shows a schematic cross section of a spacer element according to a seventh embodiment of the present disclosure. [Figure 10A] FIG. 10A shows a perspective view of a susceptor assembly according to an eighth embodiment of the present disclosure. [Figure 10B] FIG. 10B shows a top view of the spacer element of the susceptor assembly of FIG. 10A. [Figure 11] FIG. 11 shows a plan view of an exemplary spacer element according to the present disclosure. [Figure 12] FIG. 12 shows a plan view of an exemplary spacer element according to the present disclosure. [Figure 13] FIG. 13 shows a plan view of an exemplary spacer element according to the present disclosure. [Figure 14] FIG. 14 shows a plan view of an exemplary spacer element according to the present disclosure. [Figure 15A] FIG. 15A shows a perspective view of a spacer element according to a thirteenth embodiment of the present disclosure. [Figure 15B] FIG. 15B shows a plan view of the spacer element of FIG. 15A. [Figure 16A] FIG. 16A shows a perspective view of a spacer element according to a fourteenth embodiment of the present disclosure. [Figure 16B] FIG. 16B shows a plan view of the spacer element of FIG. 16A. DETAILED DESCRIPTION OF THE INVENTION

[0105] [Example] 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 of any other example, embodiment, or aspect described herein.

[0106] Example 1: A susceptor assembly for an aerosol generation system, the susceptor assembly comprising: one or more wicking elements for transporting a liquid aerosol-forming substrate, the one or more wicking elements including a first wicking layer and a second wicking layer; a spacer element positioned in contact with the first wicking layer and the second wicking layer; and a susceptor element in contact with at least a portion of the one or more wicking elements.

[0107] Example 2: The susceptor assembly of example 1, wherein the susceptor element comprises a first susceptor layer and a second susceptor layer.

[0108] Example 3: The susceptor assembly of example 2, wherein the first susceptor layer contacts at least a portion of the first wicking layer and the second susceptor layer contacts at least a portion of the second wicking layer.

[0109] Example 4: A susceptor assembly as described in Example 2 or 3, wherein the first side of the spacer element contacts the first side of the first wicking layer, the first susceptor layer contacts 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.

[0110] Example 5: A susceptor assembly as described in Examples 2, 3, or 4, wherein the second side of the spacer element contacts the first side of the second wicking layer, the second susceptor layer contacts 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.

[0111] Example 6: The susceptor assembly of any one of Examples 2-5, wherein the first susceptor layer and the second susceptor layer are substantially parallel.

[0112] Example 7: The susceptor assembly of any one of Examples 2-6, wherein the first susceptor layer and the second susceptor layer are separate components.

[0113] Example 8: The susceptor assembly of any one of Examples 2-6, wherein the susceptor element includes a connection section that couples the first susceptor layer to the second susceptor layer.

[0114] Example 9: The susceptor assembly of example 8, wherein the connecting section is U-shaped or V-shaped.

[0115] Example 10: The susceptor assembly of any one of Examples 1-9, wherein the first wicking layer and the second wicking layer are substantially planar.

[0116] Example 11: The susceptor assembly of any one of Examples 1-10, wherein the first wicking layer and the second wicking layer are substantially parallel.

[0117] Example 12: The susceptor assembly of any one of Examples 1-11, wherein the first wicking layer and the second wicking layer are formed from a single piece of wicking material.

[0118] Example 13: The susceptor assembly of any one of Examples 1-11, wherein the first wicking layer and the second wicking layer are separate components.

[0119] Example 14: The susceptor assembly of any one of Examples 1-13, wherein the susceptor assembly is substantially planar.

[0120] Example 15: The susceptor assembly of any one of Examples 1-14, wherein the spacer element is fluid permeable.

[0121] Example 16: The susceptor assembly of any one of Examples 1-15, wherein the spacer element is substantially planar.

[0122] Example 17: 17. The susceptor assembly of any one of Examples 1-16, wherein the first wicking layer contacts a first side of the spacer element and the second wicking layer contacts a second side of the spacer element.

[0123] Example 18: The susceptor assembly of any one of Examples 1-17, wherein a spacer element separates the first wicking layer from the second wicking layer.

[0124] Example 19: 19. The susceptor assembly of any of Examples 1-18, wherein the one or more wicking elements comprise a capillary material.

[0125] Example 20: 20. The susceptor assembly of any of Examples 1-19, wherein the one or more wicking elements comprise cotton.

[0126] Example 21: 21. The susceptor assembly of any of Examples 1-20, wherein the spacer element comprises a porous material.

[0127] Example 22: 22. The susceptor assembly of any of Examples 1-21, wherein the spacer element comprises a mesh.

[0128] Example 23: 23. The susceptor assembly of any of Examples 1-22, wherein the spacer elements comprise cotton.

[0129] Example 24: 24. The susceptor assembly of any of Examples 1-23, wherein the spacer element comprises a plastic material.

[0130] Example 25: The susceptor assembly of any of Examples 1-24, wherein the spacer element comprises a PEEK film.

[0131] Example 26: The susceptor assembly of any of Examples 1-25, wherein the spacer element comprises a fibrous sheet.

[0132] Example 27: 27. The susceptor assembly of any one of Examples 1 to 26, wherein the spacer element comprises an opening configured to allow the liquid aerosol-forming substrate to move between the first wicking layer and the second wicking layer.

[0133] Example 28: 28. The susceptor assembly of example 27, wherein the spacer element comprises a plurality of openings configured to allow movement of the liquid aerosol-forming substrate between the first wicking layer and the second wicking layer.

[0134] Example 29: 29. The susceptor assembly of example 27 or 28, wherein the aperture or apertures have a circular cross-section.

[0135] Example 30: 30. The susceptor assembly of example example 29, wherein the aperture or apertures have a diameter of about 0.1 millimeters.

[0136] Example 31: 29. The susceptor assembly of example 27 or 28, wherein the aperture or apertures have a rectangular cross-section.

[0137] Example 32: The susceptor assembly of any one of Examples 1-31, wherein the spacer elements include curves or creases.

[0138] Example 33: 33. The susceptor assembly of any one of Examples 1-32, wherein the spacer element comprises a corrugation or a plurality of corrugations.

[0139] Example 34: 34. The susceptor assembly of example embodiment 33, wherein the spacer elements comprise wave-like corrugations or triangular corrugations.

[0140] Example 35: 35. The susceptor assembly of any of Examples 1-34, wherein the spacer element has a thickness of 0.1 to 0.5 millimeters, preferably 0.2 to 0.4 millimeters.

[0141] Example 36: 36. The susceptor assembly of any of Examples 1-35, wherein the depth of the spacer elements is 0.1 to 0.5 millimeters, preferably 0.2 to 0.4 millimeters.

[0142] Example 37: 37. The susceptor assembly of any of Examples 1-36, wherein the distance between the first wicking layer and the second wicking layer is 0.1 to 0.5 millimeters.

[0143] Example 38: 38. The susceptor assembly of example example 37, wherein the distance between the first wicking layer and the second wicking layer is 0.2 to 0.4 millimeters.

[0144] Example 39: The susceptor assembly of any of Examples 1-38, wherein the susceptor element is fluid permeable.

[0145] Example 40: 40. The susceptor assembly of any of Examples 1-39, wherein the susceptor element comprises a conductive filament.

[0146] Example 41: 41. The susceptor assembly of example 40, wherein the susceptor element comprises a mesh.

[0147] Example 42: 1. A cartridge for an aerosol generation system, the cartridge comprising: A susceptor assembly according to any one of Examples 1 to 41; a liquid reservoir for holding a liquid aerosol-forming substrate, wherein one or more wicking elements are in fluid communication with the liquid reservoir and configured to transport the liquid aerosol-forming substrate from the liquid reservoir to a susceptor element.

[0148] Example 43: 43. The cartridge of example 42, further comprising an air inlet, an air outlet, and an airflow passage extending between the air inlet and the air outlet.

[0149] Example 44: 44. The cartridge of example 43, wherein the susceptor assembly is positioned within the airflow passage.

[0150] Example 45: 45. The cartridge of example 44, wherein the susceptor element is in contact with air within the airflow passage.

[0151] Example 46: 46. The cartridge of any of Examples 42-45, comprising a mouth end and a connecting end, the connecting end configured to connect the cartridge to an aerosol generation device.

[0152] Example 47: 47. The cartridge of Example 46, wherein the air outlet is provided at the mouth end.

[0153] Example 48: 48. The cartridge of any one of Examples 43-47, further comprising a mouthpiece, wherein the air outlet is defined within the mouthpiece.

[0154] Example 49: 1. An aerosol generating system comprising: A susceptor assembly according to any one of Examples 1 to 41; a liquid reservoir for holding a liquid aerosol-forming substrate, wherein one or more wicking elements are in fluid communication with the liquid reservoir and configured to transport the liquid aerosol-forming substrate; an inductor coil; An aerosol generation system comprising: a power supply connected to an inductor coil and configured to provide an alternating current to the inductor coil to generate an alternating magnetic field, wherein the susceptor element is configured to be heated by the alternating magnetic field.

[0155] Example 50: 50. The aerosol generation system of Example 49, further comprising a system air inlet, a system air outlet, and a system airflow passage extending between the system air inlet and the system air outlet.

[0156] Example 51: 51. The aerosol generation system of Example 50, wherein the susceptor assembly is positioned within the system airflow passage.

[0157] Example 52: 52. An aerosol generation system as described in Example 50 or 51, further comprising a mouthpiece, wherein the air outlet is defined within the mouthpiece.

[0158] Example 53: 53. An aerosol generation system according to any one of Examples 49 to 52, wherein the inductor coil surrounds the susceptor assembly.

[0159] Example 54: 54. The aerosol generating system of any one of Examples 49 to 53, wherein the inductor coil is a helical coil.

[0160] Example 55: A method for manufacturing a susceptor assembly, the method including: providing a susceptor element; placing one or more wicking elements, including a first wicking layer and a second wicking layer, on the susceptor element; placing a spacer element on the first wicking layer; and folding the susceptor element so that the spacer element is positioned between and in contact with the first wicking layer and the second wicking layer, and the susceptor element forms the first susceptor layer and the second susceptor layer.

[0161] The embodiments will now be further described with reference to the figures.

[0162] 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 are 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.

[0163] FIG. 1B shows a schematic diagram of the aerosol generation system of FIG. 1A, with cartridge 10 and device 60 coupled together to form the aerosol generation system.

[0164] Cartridge 10 includes a susceptor assembly 12 mounted on 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.

[0165] The susceptor assembly 12 is planar and thin, having a thickness dimension that is substantially smaller than its length and width dimensions, and is shaped in a rectangular configuration.

[0166] The susceptor assembly includes a susceptor element including a first susceptor layer 16 and a second susceptor layer 18. The susceptor assembly also includes a wicking element for transporting a liquid aerosol-forming substrate, the wicking element including a first wicking layer 20 and a second wicking layer 22. The susceptor assembly further includes a spacer element, 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 susceptor elements 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 element, 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 element 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 susceptor elements 16, 18.

[0167] The first susceptor element 16 and the second susceptor element 18 are configured to be heatable by penetration by an alternating magnetic field to vaporize the aerosol-forming substrate. The wicking element 20 contacts the susceptor holder 14 such that the susceptor holder 14 supports the susceptor assembly 12 in place within the cartridge 10.

[0168] The susceptor assembly 12 is disposed inside the interior passage 26 of the tubular susceptor holder 14 and extends in a plane parallel to the central longitudinal axis of the susceptor holder 14. The first susceptor element 16 and the second susceptor element 18 are disposed entirely within the interior passage 26 of the susceptor holder 14. The first wicking layer 20 and the second wicking layer 22 of the wicking element extend through openings in the sidewall of the susceptor holder 14 into one of two channels 45.

[0169] 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 located toward the connecting end of the cartridge 10.

[0170] 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.

[0171] The external 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 generating device, with the shoulder 37 positioning the cartridge in the correct position on the device. This also allows the mouth end of the cartridge 10 to remain outside the aerosol generating device, allowing the mouth end to conform to the external shape of the aerosol generating device.

[0172] 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.

[0173] 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 .

[0174] 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 .

[0175] 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 an 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 element extends into the two channels 45 through openings in the sidewall of the susceptor holder 14. The two channels 45 extend from an 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.

[0176] 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.

[0177] 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.

[0178] 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 the 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.

[0179] 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.

[0180] 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 element. The inductor coil 90 is made of copper wire with a circular cross-section and disposed on a coil former 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.

[0181] 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 .

[0182] 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.

[0183] 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 into the base of cavity 64 through system air inlet 65 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.

[0184] 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.

[0185] 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.

[0186] 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 elements, including the first and second susceptor layers. The liquid aerosol-forming substrate in the channel 45 is drawn into the susceptor assembly 12 through the wicking elements and into the susceptor elements. In particular, the liquid is drawn through the first and second wicking layers 20 and 22 into 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 elements. The liquid aerosol-forming substrate 42 is heated in the susceptor elements, 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 withdrawn from the cartridge 10 at the mouth-end air outlet 38 for inhalation by the user.

[0187] FIG. 2A shows a schematic diagram of the cartridge 10 separate from the aerosol generating device.

[0188] 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, with a thickness dimension substantially smaller than its length and width dimensions. The susceptor assembly includes a susceptor element including a first susceptor layer 16 and a second susceptor layer 18, and a wicking element for transporting the liquid aerosol-forming substrate. The wicking element includes a first wicking layer 20 and a second wicking layer 22, with a spacer element 24 positioned between and in contact with the first and second wicking layers.

[0189] The spacer element 24 is fluid permeable and is configured to allow the liquid aerosol forming substrate to move between the first wicking layer 20 and the second wicking layer 22. The spacer element 24 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 element 24 includes a cotton porous body.

[0190] 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 components that are substantially identical. The first wicking layer 20 and the second wicking layer 22 are separate components that are substantially parallel.

[0191] 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 the differences in the wicking elements and the susceptor elements, as described below.

[0192] The susceptor element of FIG. 4 includes a first susceptor layer 116 and a second susceptor layer 118 that are substantially parallel. The susceptor element 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 element is formed by bending or folding a single piece of material to form a susceptor element that includes the first susceptor layer 116, the second susceptor layer 118, and the connection section 117. The connection section 117 includes a sintered mesh formed from a ferromagnetic stainless steel filament and an austenitic stainless steel filament.

[0193] In this embodiment, the wicking element 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 element is formed by bending or folding a single piece of material to form the wicking element 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 element and susceptor element may be possible. For example, a susceptor assembly may include a susceptor element including a connecting section that connects the first susceptor layer to the second susceptor layer, and the wicking element includes the first wicking layer and the second wicking layer as separate components.

[0194] FIG. 5 shows a schematic cross-section of a susceptor assembly according to a third embodiment of the present disclosure. The wicking element and susceptor element may be the same as those of FIGS. 3 or 4. The spacer element 224 shown in FIG. 5 is substantially planar and includes a first side of the spacer element that contacts the first wicking layer 20, 120 and a second side of the spacer element 224 that contacts the second wicking layer 22, 122, with the first side of the spacer element 224 facing the second side of the spacer element 224. The spacer element 224 in FIG. 5 includes a plurality of openings 226 defined therethrough. The openings extend between the first side of the spacer element 224 and the second side of the spacer element 224.

[0195] In use, the openings 226 allow or enhance the movement of a liquid aerosol-forming substrate between the first wicking layer 20, 120 and the second wicking layer 22, 122. In this example, the spacer element 224 may comprise a fluid-permeable material comprising a woven mesh of cotton filaments, and the liquid aerosol-forming substrate can move through the spacer element and through the openings 224 via the spaces between the filaments of the spacer element. Alternatively, the spacer material may comprise a plastic material such as a PEEK film, and the liquid aerosol-forming substrate can move through the spacer element 224 only via the openings 226.

[0196] 6 shows a schematic cross-sectional view of a susceptor assembly according to a fourth embodiment of the present disclosure. The spacer elements 234 shown in FIG. 6 include triangular corrugations 234. The triangular corrugations 234 are formed from folds in the spacer elements 234, which are "V"-shaped step changes in direction.

[0197] 7 shows a schematic cross-section of a susceptor assembly according to a fifth embodiment of the present disclosure. The spacer elements 244 shown in FIG. 7 include wavy corrugations. The wavy corrugations are formed by multiple curves within the spacer elements. The curves are gradual changes in arc or "C" shape in the direction of the spacer elements 244.

[0198] Figure 8 shows a schematic cross-section of a susceptor assembly according to a sixth embodiment of the present disclosure. The spacer element 254 shown in Figure 8 includes a curve configured to act as a spring element between the first wicking layer 20, 120 and the second wicking layer 22, 122. The spring is resiliently biased to hold the first wicking layer 20, 120 and the second wicking layer 22, 122 a predetermined distance apart.

[0199] 9 shows a schematic plan view of a spacer element 264 according to a seventh embodiment of the present disclosure. The spacer element 264 includes finger-like openings 266 therethrough. The openings 266 have a rectangular cross-section and are defined through the spacer element 264 between the first and second sides of the spacer element to enhance transport of the liquid aerosol-forming substrate between the first and second wicking layers.

[0200] 10a shows a perspective view of a susceptor assembly according to an eighth embodiment of the present disclosure, where the susceptor assembly is shaped in the form of a cross. Each of the first susceptor layer 216, the second susceptor layer 218, the first wicking layer 220, the second wicking layer 222, and the spacer elements 334 are shaped in the form of a cross.

[0201] 10b shows a top view of a spacer element of the susceptor assembly of FIG. 10a. The spacer element 334 includes a pair of mounting regions 330 and a heating region 332. The heating region 332 is substantially rectangular and located at the center of the spacer element. The pair of mounting regions 330 are also substantially rectangular regions located on either side of the heating region 332 and around the heating region 332. In this embodiment, the mounting regions 330 are disposed at the same central position along the length of the heating region 332. Each of the pair of mounting regions 330 has a smaller surface area than the heating region 332.

[0202] The cross section of the spacer element 334 in this embodiment is identical to the cross section of each of the first susceptor layer 216, the second susceptor layer 218, the first wicking layer 220, and the second wicking layer 222. The first susceptor layer 216, the second susceptor layer 218, the first wicking layer 220, and the second wicking layer 222 each have respective attachment and heating areas corresponding to the attachment and heating areas of the spacer element 334.

[0203] The heating regions of the first susceptor layer 216 and the second susceptor layer 218 are configured to be heatable by penetration by an alternating magnetic field to vaporize the aerosol-forming substrate. The pair of mounting regions of the first susceptor layer 216 and the second susceptor layer 218 are configured to contact a susceptor holder so that the susceptor holder can support a susceptor assembly in place within the cartridge. The pair of mounting regions are configured to minimize heat transfer from the susceptor assembly to the susceptor holder.

[0204] 11-16B show spacer elements in the shape of a cross, with various numbers and shapes of openings defined therethrough.

[0205] 11-14 show plan views of exemplary spacer elements according to the present disclosure.

[0206] 11 shows a cross-shaped spacer element 344 according to a ninth embodiment of the present disclosure. The cross-shaped spacer element 344 includes finger-like openings 346 defined therethrough. The openings 346 are defined through the spacer element 344 between the first and second sides of the spacer element to enhance transfer of the liquid aerosol-forming substrate between the first and second wicking layers. The cross-shaped spacer element 344 includes six finger-like openings having a rectangular cross-section. The finger-like openings 346 are contained mostly within the attachment region 340 of the spacer element 344. At least a portion of the finger-like openings 346 extend into the heating region 342 of the spacer element 344. The finger-like openings 346 are perpendicular to the longitudinal plane of the susceptor assembly. Finger-like openings 346 extend from opposite ends of the spacer elements 344 toward the center of the spacer elements 344. The opposite ends located within the attachment region 340 are configured to be the ends of the spacer elements that extend into the liquid reservoir. In this manner, the finger-like openings enhance the transport of the liquid aerosol-forming substrate from the liquid reservoir to the heating region 342 in the center of the spacer elements 344 and, therefore, to the center of the susceptor assembly, which is the hottest portion of the susceptor assembly during operation.

[0207] 12 shows a plan view of a cross-shaped spacer element 354 according to a tenth embodiment of the present disclosure. The cross-shaped spacer element 354 includes two finger-like openings 356 defined therethrough and four "L"-shaped openings 358 defined therethrough. The openings 354, 356 are defined through the spacer element 354 between the first and second sides of the spacer element 354. The finger-like openings 356 are contained mostly within the attachment region 350 of the spacer element 354. At least a portion of the finger-like openings 356 extend into the heating region 352 of the spacer element 354. The finger-like openings 356 are perpendicular to the longitudinal plane of the susceptor assembly. The finger-like openings 356 extend from opposite ends of the spacer element 354 toward the center of the spacer element 354. The opposing ends are located within the mounting region 350 of the spacer element 354 and are configured to be the ends of the spacer element 354 that extend into the liquid reservoir. A first section of the "L"-shaped opening 358 extends from the opposing end of the spacer element 354 toward the center of the spacer element 354. The opposing ends are located within the mounting region 350 of the spacer element 354 and are configured to be the ends of the spacer element 354 that extend into the liquid reservoir. At least a portion of the first section of the finger-like opening 358 extends into the heating region 352 of the spacer element 354. The first section of the "L"-shaped opening is parallel to the finger-like openings 356. The second section of the "L"-shaped opening 358 is perpendicular to the finger-like openings 356. The second section of the "L"-shaped opening 358 extends in a plane parallel to the longitudinal axis of the susceptor assembly. A second section of the "L" shaped opening is contained within the heating region 352. In this configuration, the "L" shaped opening is configured to, in use, draw liquid from the liquid reservoir through the spacer element to provide a more uniform distribution of the liquid aerosol-forming substrate across the susceptor assembly.

[0208] 13 shows a plan view of a cross-shaped spacer element 364 according to an eleventh embodiment of the present disclosure. The cross-shaped spacer element 364 includes two finger-like openings 366 defined therethrough and four "L"-shaped openings 368 defined therethrough. The finger-like openings 366 and the "L"-shaped openings 368 are substantially identical to the openings of the tenth embodiment, except as described below.

[0209] The difference between the openings of the eleventh embodiment and the openings of the tenth embodiment is that the finger-like openings 366 and the "L" shaped openings 368 of the eleventh embodiment further include openings having a circular cross section 367.

[0210] 14 shows a plan view of a cross-shaped spacer element 384 according to a twelfth embodiment of the present disclosure. In this embodiment, the cross-sectional area of the openings 376 is relatively large compared to the total cross-sectional area of the spacer element 374.

[0211] 15A shows a perspective view of a spacer element according to a thirteenth embodiment of the present disclosure. In this embodiment, a spacer element 384 includes six openings 386. The openings 386 are configured to allow the liquid aerosol-forming substrate to move from a first side of the spacer element to a second side of the spacer element, and to allow the liquid aerosol-forming substrate to move from the first end or the second end of the spacer element 384 to a central portion of the spacer element 384.

[0212] Figure 15B shows a top view of the spacer element 384 of Figure 15A. An aperture 386 is defined through the spacer element in both the attachment region 380 and the heating region 382. The aperture 386 is similar to the "L" shaped aperture shown in Figure 12, except that the aperture 386 includes a curve between a first section of the "L" shaped aperture and a second section of the "L" shaped aperture.

[0213] 16A shows a perspective view of a spacer element 394 according to a fourteenth embodiment of the present disclosure. The spacer element 394 includes three apertures 396 defined therethrough. The apertures 396 have a gradually varying cross-section. The cross-section of the apertures 396 gradually decreases from the outer portions of the spacer element 394 to the central portion of the spacer element 394.

[0214] FIG. 16B shows a plan view of the spacer element of FIG. 16A.

[0215] For purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, and the like are understood to be modified in all instances 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 understood as A ± 10 percent of A. Within this context, the number A can be considered to include numerical values that are 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 susceptor assembly for an aerosol generation system, the susceptor assembly comprising: one or more wicking elements for transporting a liquid aerosol-forming substrate, the one or more wicking elements comprising a first wicking layer and a second wicking layer; a spacer element positioned between and in contact with the first and second wicking layers, the spacer element configured to allow the liquid aerosol-forming substrate to move between the first and second wicking layers; and a susceptor element in contact with at least a portion of the one or more wicking elements.

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

3. 3. The susceptor assembly of claim 1, wherein the first wicking layer contacts a first side of the spacer element and the second wicking layer contacts a second side of the spacer element.

4. 4. The susceptor assembly of claim 3, wherein the spacer element includes an opening or a plurality of openings defined therethrough between the first side of the spacer element and the second side of the spacer element, the opening or plurality of openings configured to allow movement of a liquid aerosol-forming substrate between the first wicking layer and the second wicking layer.

5. The susceptor assembly of any one of claims 1 to 4, wherein the spacer elements include curves or creases.

6. The susceptor assembly of claim 5 , wherein the spacer elements include corrugations.

7. The susceptor assembly of any preceding claim, wherein the spacer elements are fluid permeable.

8. The susceptor assembly of any preceding claim, wherein the spacer elements comprise cotton.

9. A susceptor assembly according to any preceding claim, wherein the thickness of the spacer elements is between 0.1 and 0.5 mm, preferably between 0.2 and 0.4 mm.

10. The susceptor assembly of any of claims 1 to 9, wherein the susceptor element comprises a first susceptor layer and a second susceptor layer.

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

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

13. The cartridge of claim 12 , further comprising an air inlet, an air outlet, and an airflow passage extending between the air inlet and the air outlet, the susceptor assembly being positioned within the airflow passage.

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

15. 15. The aerosol generation system of claim 14, further comprising a system air inlet, a system air outlet, and a system airflow passage extending between the system air inlet and the system air outlet, the susceptor assembly being positioned within the system airflow passage.

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