Susceptor assembly for an aerosol generating system and method of manufacturing same

Abstract

Susceptor assembly for an aerosol generating system and method of manufacturing same A susceptor assembly (12) for an aerosol generation system (100) is provided. The susceptor assembly includes a wicking element (18) having first and second planar surfaces. The first and second surfaces define opposite outwardly facing surfaces of the wicking element. The susceptor assembly further includes a susceptor element (16) including an arrangement of one or more strips of susceptor material. The arrangement of one or more strips is wrapped around a central region of the wicking element, covering the first and second outwardly facing surfaces of the wicking element and surrounding the central region of the wicking element.

Description

[Technical Field]

[0001] TECHNICAL FIELD The present disclosure relates to a susceptor assembly for an aerosol generating system and a method for manufacturing the same, and more particularly, the present disclosure relates to a susceptor assembly for an inductively heated aerosol generating system. [Background technology]

[0002] Aerosol generating systems configured to generate inhalable aerosols from liquid aerosol-forming substrates are known in the art. Such systems are known to employ an induction heating mechanism to generate heat for vaporizing the aerosol-forming substrate. The induction heating mechanism typically includes a coil disposed around a susceptor element. When the aerosol-forming substrate is a liquid aerosol-forming substrate, a wicking element is provided to transport liquid from a reservoir of the liquid aerosol-forming substrate toward the susceptor element. The flow of alternating current through the driving coil induces eddy currents in the susceptor element, thereby heating the susceptor element. The heat from the susceptor element vaporizes the liquid aerosol-forming substrate entrained on the wicking element near the susceptor element. Airflow passing over the susceptor element entrains vapor. The entrained vapor cools and condenses to form an aerosol, which is inhaled by a user.

[0003] It is desirable to provide an improved thermal coupling between the susceptor element and the wicking element used in an induction aerosol generating system. Summary of the Invention

[0004] According to a first embodiment of the present disclosure, there is provided a susceptor assembly for an aerosol generation system, the susceptor assembly comprising: a wicking element having first and second planar surfaces, the first and second surfaces defining opposite outwardly facing surfaces of the wicking element; a susceptor element comprising an arrangement of one or more strips of susceptor material, the arrangement of one or more strips being wrapped around a central region of a wicking element, covering the first and second outwardly facing surfaces of the wicking element and surrounding the central region of the wicking element;

[0005] Arranging one or more strips wrapped around and surrounding the central region of the wicking element may increase the surface area of the susceptor element in contact with the wicking element, thereby facilitating increased heat transfer between the susceptor element and the wicking element. In use, increased heat transfer from the susceptor element to the wicking element may enhance vapor generation from a liquid aerosol-forming substrate entrained in the wicking element.

[0006] As used herein, the term "aerosol-generating device" is used to describe a device that interacts with an aerosol-forming substrate to generate an aerosol. Preferably, the aerosol-generating device is a smoking device that interacts with an aerosol-forming substrate to generate an aerosol that is inhalable directly through the user's mouth into the user's lungs.

[0007] As used herein, the term "aerosol-forming substrate" refers to a substrate made of or including an aerosol-forming material that has the ability to release volatile compounds upon heating to generate an aerosol.

[0008] As used herein, the term "liquid" refers to a substance provided in liquid form, and includes a substance provided in the form of a gel.

[0009] 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 due to the induction of eddy currents in the susceptor element and hysteresis losses. Suitable materials for disposing the one or more strips that form the susceptor element include graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, and other conductive materials. Advantageously, the one or more strips may be formed of a ferromagnetic material. Preferably, the one or more strips may be formed of AISI 430 stainless steel.

[0010] The one or more strips forming the susceptor element may have a relative permeability of 1 to 40,000 when measured at an appropriate frequency and temperature, for example, when measured at a frequency of up to 10 kHz at a temperature of 20 degrees Celsius. A material with a lower permeability may be used when it is desired to rely on eddy currents for the majority of the heating, and a material with a higher permeability may be used when a hysteresis effect is desired. Preferably, the material has a relative permeability of 500 to 40,000. This may provide for efficient heating of the one or more strips forming the susceptor element.

[0011] One or more strips forming the susceptor element may be fluid-permeable. As used herein, a "fluid-permeable" element means an element that allows a liquid or gas to permeate therethrough. A fluid-permeable susceptor element may advantageously allow the vaporized aerosol-forming substrate to escape through the susceptor element. One or more strips forming the susceptor element may comprise a mesh. As used herein, the term "mesh" encompasses grids and arrays of filaments having spaces between them. The term mesh also includes woven and non-woven materials. In use, the vaporized aerosol-forming substrate may advantageously escape from the wicking element through gaps present in the susceptor element when a mesh structure is employed for one or more strips.

[0012] The wicking element provides wetting of the susceptor element during use of the susceptor assembly. The wicking element may comprise a capillary material. A capillary material is a material capable of transferring 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 move by capillary action. If one or more strips comprise gaps, the capillary material may extend into the gaps. During use, the liquid aerosol-forming substrate can be drawn into the gaps by capillary action. The wicking element may comprise or consist of an electrically insulating material. The wicking element may comprise a non-metallic material. The wicking element may comprise a hydrophilic or oleophilic material, which may advantageously facilitate the transfer of the aerosol-forming substrate by the wicking element.

[0013] The wicking element may preferably comprise or consist of cotton, rayon, or glass fiber.

[0014] Advantageously, the one or more strips may be wrapped around the central region of the wicking element to compress the central region. Compression of the wicking element by the one or more strips increases contact pressure between corresponding surfaces of the one or more strips and the wicking element. Such increased contact pressure may facilitate enhanced heat transfer between the one or more strips and the wicking element, thereby providing enhanced vapor generation from a liquid aerosol-forming substrate entrained in the wicking element.

[0015] Each of the one or more strips may extend a length between a first end and a second end, and either or both of the first end and the second end of at least one of the one or more strips of susceptor material is folded inward toward the wicking element. Folding the end of a given strip inward toward the wicking element may obscure the free end of the strip from view, reducing the risk of debris getting caught on the free end, as well as providing a smoother appearance to the susceptor element of the susceptor assembly.

[0016] Preferably, each of the one or more strips may extend a length between a first end and a second end, and either or both of the first end and the second end of at least one of the one or more strips may be folded inward and embedded within the wicking element. Folding the one or more strips inward and embedding them within the wicking element may strengthen the mechanical bond between the strip and the wicking element and inhibit detachment of the strip from the wicking element. Embedding within the wicking element may also inhibit debris from becoming caught on the ends of the respective strips. For example, if the strips have a woven mesh structure or a similar structure, fraying of the strips may also be inhibited as a result of embedding the ends of the strips within the wicking element.

[0017] Advantageously, each of the one or more strips may extend a length between a first end and a second end, and the wicking element may comprise a first planar layer overlying a second planar layer. One or both of the first and second ends of at least one of the one or more strips may be folded inward and wrapped around one side of the first and second layers, wedging the end between the first and second layers. Wrapping the end of a given strip around one side of the first and second layers and wedging it between the layers may strengthen the mechanical bond between the strip and the wicking element, potentially preventing detachment of the strip from the wicking element. Additionally, wedging the end of the strip between the first and second layers may also prevent debris from getting caught on the end of the strip. For example, if the strip has a woven mesh or similar structure, fraying of the strip may also be prevented.

[0018] Each of the one or more strips may extend a length between a first end and a second end, and either or both of the first end and the second end of at least one of the one or more strips may be folded inwardly onto the strip to cover the inward-facing surface of the strip and form a folded edge. In this manner, the free end of the folded edge of the strip may be obscured from view, thereby inhibiting debris from catching on the free end. The use of a folded edge on the strip may also inhibit fraying of the strip, for example, if the strip has a woven mesh or similar structure.

[0019] The susceptor element preferably comprises a single strip arrangement of susceptor material.

[0020] The single strip may be formed as a continuous loop.

[0021] The single strip may extend the length between the first and second ends, and the strip wraps around the central region of the wicking element such that the first and second ends extend toward each other in opposite directions along the sides of the wicking element, the sides extending between the first and second planar outward-facing surfaces of the wicking element. In this manner, the strip may surround the central region of the wicking element.

[0022] The wicking element may have a thickness defined by the sides of the wicking element.

[0023] The first and second ends may be folded ends.

[0024] Conveniently, the first and second ends may be separated from one another by a gap along a side of the wicking element, the gap being smaller than the thickness of the wicking element.

[0025] The first and second ends may be in surface contact, or may cover or interlock with one another, or a combination thereof, In this manner, inadvertent detachment of debris from the wicking element may be inhibited.

[0026] Each of the first and second ends of the strip may be folded inward toward the side of the wicking element. Folding each end of the strip inward toward the wicking element may obscure the free end of each respective end of the strip from view, thereby not only inhibiting debris from catching on the free end, but also providing a smoother appearance to the susceptor element of the susceptor assembly.

[0027] Preferably, each of the first and second ends may be folded inward and embedded into the sides of the wicking element. Embedding both ends of the strip into the sides of the wicking element strengthens the mechanical bond between the strip and the wicking element and may prevent the strip from detaching from the wicking element. If the strip has a woven mesh or similar structure, it may also prevent the strip from fraying.

[0028] Each of the first and second ends may be folded inwardly onto the strip to cover the inward-facing surface of the strip and form a folded edge. In this manner, the free end of each folded edge of the strip may be obscured from view, thereby inhibiting snagging on the free end. Providing both ends of the strip as folded edges may also inhibit fraying of the strip, for example, if the strip has a woven mesh or similar structure.

[0029] Advantageously, the wicking element may comprise a first planar layer overlying a second planar layer. A first end of the strip may be folded inward, wrapped around a side of the first layer, and tucked between the first and second layers. A second end of the strip may be folded inward, wrapped around a side of the second layer, and tucked between the first and second layers. Tucked ends of the strip between the first and second layers not only strengthens the mechanical and thermal bond between the strip and the wicking element, but may also inhibit inadvertent detachment of the strip from the wicking element. Furthermore, fraying of the strip may also be inhibited, for example, if the strip has a woven mesh or similar structure.

[0030] Preferably, the respective sides of the first and second planar layers are aligned with each other.

[0031] The indented first and second ends of the strip may be arranged to maintain a gap between the opposing surfaces of the first and second planar layers of the wicking element.

[0032] The wicking element may be folded about a fold line. A first planar layer of the wicking element may extend from the fold line to a side of the first layer, and a second planar layer of wicking material may extend from the fold line to a side of the second layer. The first layer is preferably aligned parallel to the second layer.

[0033] Advantageously, a first end of the strip may include a first leg and a second end of the strip may include a second leg. The first and second legs may be laterally offset from one another and extend in opposite directions from respective first and second adjacent portions of the strip to wrap around a side of the wicking element. The configuration of the strip may inhibit inadvertent detachment of the susceptor element from the wicking element and may strengthen the mechanical bond between the susceptor and the wicking element.

[0034] Preferably, the first and second legs may be of reduced lateral width compared to the respective adjacent portions of the strip. Furthermore, the first and second legs may be of equal length and arranged in a side-by-side, non-overlapping relationship. The use of a side-by-side, non-overlapping arrangement of the first and second legs facilitates minimizing local increases in the thickness of the susceptor element. Minimizing the thickness of the susceptor element may be desirable when the susceptor element is arranged in an airflow channel of an aerosol generation system, as it may prevent the susceptor element from obstructing the passage of air through the airflow channel.

[0035] The wicking element may be folded about a fold line to define a first planar layer overlying a second planar layer. The first layer may extend from the fold line to a side of the first layer, and the second layer may extend from the fold line to a side of the second layer. The sides of the first and second layers may be aligned with one another to form a common side. The first and second legs may extend in opposite directions and wrap around the common side.

[0036] Preferably, the first and second legs wrap around a common side such that opposing surfaces of the first and second planar layers of the wicking element are forced into surface contact with one another.

[0037] Although the use of a single strip in the susceptor element is preferred, in various alternative embodiments the susceptor element may comprise a multiple strip arrangement.

[0038] While any number of strips may be used in a susceptor element, reducing the number of strips reduces the manufacturing complexity of the susceptor assembly. Preferably, the susceptor element may include an arrangement of first and second strips. Each of the first and second strips may extend a length between a first end and a second end. The first strip may extend along a first planar outward-facing surface of the wicking element, and the second strip may extend along a second planar outward-facing surface of the wicking element. Thus, the first strip is positioned to primarily thermally couple with the first outward-facing surface of the wicking element, while the second strip is positioned to primarily thermally couple with the second outward-facing surface of the wicking element.

[0039] Preferably, first ends of the first and second strips may be positioned to extend in opposite directions toward each other along a first side of the wicking element, and second ends of the first and second strips may be positioned to extend in opposite directions toward each other along a second side of the wicking element, each of the first and second sides may extend between first and second planar outward-facing surfaces of the wicking element.

[0040] The wicking element may have a thickness defined by the first and second sides of the wicking element.

[0041] The first and second ends of the first and second strips may be folded ends.

[0042] In one embodiment, one or both of the following conditions may apply: a) First ends of the first and second strips are separated from one another by a gap along a first side of the wicking element. b) second ends of the first and second strips are separated from one another by a gap along a second side of the wicking element;

[0043] Alternatively, in another embodiment, one or both of the following conditions apply: a) The first ends of the first and second strips are in surface contact with, overlay, or interlock with one another, or a combination thereof. b) The second ends of the first and second strips are in surface contact with, overlay, or interlock with one another, or a combination thereof.

[0044] The wicking element may preferably be folded about a fold line to define a first planar layer overlying a second planar layer. The first layer may extend from the fold line onto a side of the first layer, and the second layer may extend from the fold line onto a side of the second layer. The sides of the first and second layers may be aligned to form a common side, with the first legs extending in opposite directions and wrapping around the common side. Wrapping the first legs around the common side may inhibit the first and second strips from detaching from the wicking element and help maintain the first and second layers of the wicking element positioned over each other.

[0045] Advantageously, the first legs may wrap around the common side such that opposing surfaces of the first and second planar layers of the wicking element are forced into surface contact with each other, which may also enhance the contact pressure between the opposing surfaces of the first and second strips and the wicking element, thereby enhancing the thermal coupling between the susceptor element and the wicking element.

[0046] Whether a single strip or two or more strips form the susceptor element, the susceptor assembly may preferably further comprise a pair of unrolled portions of the wicking element extending laterally outward from opposite sides of the rolled central region of the wicking element. Advantageously, the pair of unrolled portions may be configured for engagement with a pair of corresponding openings provided on opposite sides of an airflow channel. Such an airflow channel may form part of a cartridge adapted to receive the susceptor assembly.

[0047] According to a further embodiment of the present disclosure, there is provided a cartridge comprising a susceptor assembly according to any one of the variations described herein, the cartridge comprising an airflow channel positioned therein and a reservoir for a liquid aerosol-forming substrate, the cartridge being configured to receive the susceptor assembly such that the susceptor element is positioned in the airflow channel with the reservoir in fluid communication with a wicking element of the susceptor assembly.

[0048] The susceptor assembly may preferably include a pair of unrolled portions of the wicking element extending laterally outward from opposite sides of the rolled central region of the wicking element. The cartridge may further include a pair of openings positioned on opposite sides of the airflow channel, the pair of unrolled portions of the wicking element being received in the pair of openings.

[0049] Advantageously, the cartridge may comprise a removable holder, the holder at least partially defining the airflow channel, the holder configured to receive the susceptor assembly such that the susceptor elements are positioned in the airflow channel.

[0050] According to a further embodiment of the present disclosure, there is provided an aerosol generation system comprising an aerosol generation device and a cartridge according to any one of the variations described herein, wherein the aerosol generation device comprises an inductor that at least partially surrounds the susceptor element when the cartridge is connected to the aerosol generation device.

[0051] The inductor may be provided in the form of an inductor coil. The inductor coil may include a planar spiral inductor coil. The inductor coil may have a tubular or helical shape. Preferably, the inductor coil is both tubular and helical. Preferably, the tubular and helical coils have a non-circular cross section when viewed perpendicular to the longitudinal length of the coil, i.e., perpendicular to the central magnetic axis of the coil.

[0052] According to a further embodiment of the present disclosure, there is provided a method of manufacturing a susceptor assembly, comprising the steps of: providing a wicking element having first and second planar surfaces, the first and second planar surfaces defining opposite outwardly facing surfaces of the wicking element; providing one or more strips of susceptor material; and wrapping one or more strips around a central region of the wicking element to form an arrangement of the one or more strips covering the first and second outwardly facing surfaces of the wicking element and surrounding the central region of the wicking element.

[0053] Such a method may be employed to manufacture a susceptor assembly as described in the preceding paragraph of this disclosure.

[0054] Preferably, the step of wrapping one or more strips around the central region of the wicking element may include performing a series of folding operations on the one or more strips.

[0055] Advantageously, the step of wrapping the one or more strips around the central region of the wicking element may be performed such that the one or more strips compress the central region of the wicking element.

[0056] According to a further embodiment of the present disclosure, there is provided a method of manufacturing a susceptor assembly, comprising the steps of: providing a sheet of wicking material; providing one or more strips of susceptor material; and forming a wicking element from the sheet of wicking material by winding one or more strips together with the sheet of wicking material and folding a first portion of the sheet of wicking material over a second portion of the sheet of wicking material, wherein the one or more strips are wrapped around a central region of the wicking element to form an arrangement of the one or more strips covering the first and second outwardly facing surfaces of the wicking element and surrounding the central region of the wicking element.

[0057] Preferably, wrapping the one or more strips around the central region of the wicking element may include performing a series of folding operations on the one or more strips.

[0058] Advantageously, wrapping the one or more strips around the central region of the wicking element may be performed such that the one or more strips compress the central region of the wicking element. [Brief explanation of the drawings]

[0059] [Figure 1A] FIG. 1A shows a schematic cross-sectional view of a cartridge for an aerosol generation system, the cartridge including a heater holder. [Figure 1B] FIG. 1B shows a schematic diagram of an alternative cross section of the cartridge of FIG. 1A. [Figure 2] FIG. 2 shows a further alternative cross-sectional schematic view of the cartridge of FIGS. 1A and 1B. [Figure 3A] FIG. 3A shows a schematic cross-sectional view of an aerosol generation system formed from a cartridge and an aerosol generation device, with the cartridge separated from the aerosol generation device. [Figure 3B] FIG. 3B shows a schematic diagram of a cross-sectional view of the aerosol generation system of FIG. 3A, in which the cartridge is coupled to an aerosol generation device. [Figure 4] FIG. 4 shows a schematic perspective view of one embodiment of a susceptor assembly according to the present disclosure, in which susceptor element strips are wrapped around a wicking element. [Figure 5] FIG. 5 shows a schematic perspective view of the susceptor element fragments and wicking elements of the susceptor assembly of FIG. 4 before the strips are wrapped around the wicking elements. [Figure 6A] FIG. 6A shows a schematic side view of one embodiment illustrating how susceptor element strips are gradually wrapped around a wicking element by one or more folding operations to form a susceptor assembly. [Figure 6B]FIG. 6B shows a schematic side view along section AA of FIG. 6A, again showing how the susceptor element strips are gradually wrapped around the wicking element to form the susceptor assembly. [Figure 6C] Figure 6C shows a schematic side view of one embodiment of a susceptor assembly resulting from one or more folding operations shown in Figure 6A in which a susceptor element strip is wrapped around a wicking element, resulting in the first and second ends of the strip facing each other along the side of the wicking element. [Figure 7] Figure 7 shows a schematic side view of an alternative embodiment of a susceptor assembly resulting from the wrapping of a susceptor element strip around a wicking element, with one or more additional folding operations performed relative to that shown in Figure 6A so that the first and second ends of the strip are embedded in the sides of the wicking element. [Figure 8] Figure 8 shows a schematic side view of a further alternative embodiment of a susceptor assembly resulting from the wrapping of a susceptor element strip around a wicking element, with one or more additional folding operations performed relative to that shown in Figure 6A, such that the first and second ends of the strip are folded inwardly over the strip to cover the inward-facing surface of the strip. [Figure 9A] Figure 9A shows a schematic side view of one embodiment in which a susceptor element strip is gradually folded around a sheet of wicking material so that the wicking material is folded around the crease to form a wicking element having a first planar layer covering a second planar layer, and the strip is wrapped around the wicking element so that the first and second ends of the strip wrap around the respective sides of the first and second layers and are tucked between the first and second layers. [Figure 9B] FIG. 9B shows a schematic side view of one embodiment of a resulting susceptor assembly in which the susceptor element strips are gradually folded around the sheet of wicking material by one or more of the folding actions shown in FIG. 9A. [Figure 9C] FIG. 9C shows a schematic perspective view of the susceptor assembly of FIG. 9B. [Figure 10A] Figure 10A shows a schematic side view of one embodiment in which a susceptor element strip is gradually folded around a sheet of wicking material such that the wicking material is folded around a fold to form a wicking element having a first planar layer overlying a second planar layer, with the first and second ends of the strip each having corresponding legs laterally offset from each other. [Figure 10B] FIG. 10B shows a schematic side view along section BB of FIG. 10A, illustrating the laterally offset legs provided at the first and second ends of the susceptor element strips. [Figure 10C] FIG. 10C shows a schematic perspective view of the susceptor assembly resulting from the folding action illustrated in FIG. 10A. [Figure 11] FIG. 11 illustrates steps of a first exemplary method for manufacturing a susceptor assembly according to the present disclosure. [Figure 12] FIG. 12 illustrates steps of a second exemplary method for manufacturing a susceptor assembly according to the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0060] The present invention is defined in the claims. However, the following provides 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.

[0061] Example 1: A susceptor assembly for an aerosol generation system comprising: a wicking element having first and second planar surfaces, the first and second surfaces defining opposite outwardly facing surfaces of the wicking element; A susceptor assembly comprising: a susceptor element comprising an arrangement of one or more strips of susceptor material, the arrangement of the one or more strips being wrapped around a central region of a wicking element, covering first and second outwardly facing surfaces of the wicking element and surrounding the central region of the wicking element.

[0062] Example 2: The susceptor assembly of Example 1, wherein the arrangement of one or more strips is wrapped around the central region of the wicking element to compress the central region.

[0063] Example 3: A susceptor assembly described in either Example 1 or Example 2, wherein each of the one or more strips extends a length between a first end and a second end, and either or both of the first end and the second end of at least one of the one or more strips of susceptor material is folded inward toward the wicking element.

[0064] Example 4: A susceptor assembly described in any one of Examples 1 to 3, wherein each of the one or more strips extends a length between a first end and a second end, and either or both of the first end and the second end of at least one of the one or more strips is folded inward and embedded within the wicking element.

[0065] Example 5: A susceptor assembly described in any one of Examples 1 to 4, wherein each of the one or more strips extends a length between a first end and a second end, the wicking element comprises a first planar layer covering a second planar layer, and either or both of the first end and the second end of at least one of the one or more strips is folded inward and wrapped around one side of the first layer and the second layer and tucked between the first layer and the second layer.

[0066] Example 6: A susceptor assembly described in any one of Examples 1 to 5, wherein each of the one or more strips extends a length between a first end and a second end, and either or both of the first end and the second end of at least one of the one or more strips is folded inwardly over the strip to cover the inward surface of the strip and form a folded end.

[0067] Example 7: The susceptor assembly of any one of Examples 1-6, wherein the susceptor element comprises a single strip arrangement of susceptor material.

[0068] Example 8: A susceptor assembly as described in Example 7, where a single strip is formed as a continuous loop.

[0069] Example 9: A susceptor assembly as described in Example 7, wherein a single strip extends the length between the first end and the second end, the strip wraps around a central region of the wicking element such that the first end and the second end extend toward each other from opposite directions along the sides of the wicking element, and the sides extend between the first and second planar outward facing surfaces of the wicking element.

[0070] Example 10: The susceptor assembly of Example 9, wherein the wicking element has a thickness defined by a side surface of the wicking element.

[0071] Example 11: The susceptor assembly of either Example 9 or Example 10, wherein the first and second ends are folded ends.

[0072] Example 12: A susceptor assembly described in any one of Examples 9 to 11, wherein the first and second ends are separated from each other by a gap along the side of the wicking element, the gap being smaller than the thickness of the wicking element.

[0073] Example 13: The susceptor assembly of any one of Examples 9-11, wherein the first and second ends are in surface contact with, cover, or interlock with one another, or a combination thereof.

[0074] Example 14: The susceptor assembly of any one of Examples 9-13, wherein each of the first and second ends of the strip is folded inward toward a side of the wicking element.

[0075] Example 15: A susceptor assembly according to any one of Examples 9 to 14, wherein each of the first and second ends is folded inward and embedded within a side of the wicking element.

[0076] Example 16: A susceptor assembly described in any one of Examples 9 to 13, wherein each of the first and second ends is folded inwardly onto the strip so as to cover the inward surface of the strip and form a folded end.

[0077] Example 17: A susceptor assembly described in any one of Examples 9 to 14, wherein the wicking element comprises a first planar layer covering a second planar layer, a first end of the strip folded inward, wrapped around a side of the first layer, and tucked between the first and second layers, and a second end of the strip folded inward, wrapped around a side of the second layer, and tucked between the first and second layers.

[0078] Example 18: The susceptor assembly of Example 17, wherein the respective sides of the first and second planar layers are aligned with one another.

[0079] Example 19: A susceptor assembly described in either Example 17 or Example 18, wherein the pressed first and second ends of the strip are arranged to maintain a gap between the opposing surfaces of the first and second planar layers of the wicking element.

[0080] Example 20: A susceptor assembly described in any one of Examples 17 to 19, wherein the wicking element is folded about a fold line, such that a first planar layer of the wicking element extends from the fold line to a side of the first layer, and a second planar layer of wicking material extends from the fold line to a side of the second layer.

[0081] Example 21: The susceptor assembly of any one of Examples 17-20, wherein the first layer is aligned parallel to the second layer.

[0082] Example 22: A susceptor assembly described in either Example 9 or Example 10, wherein a first end of the strip has a first leg and a second end of the strip has a second leg, the first and second legs being laterally offset from each other and extending in opposite directions from respective first and second adjacent portions of the strip and wrapping around the sides of the wicking element.

[0083] Example 23: A susceptor assembly as described in Example 22, wherein the first and second legs are of reduced lateral width compared to respective adjacent portions of the strip.

[0084] Example 24: The susceptor assembly of either Example 22 or Example 23, wherein the first and second legs are of equal length and are disposed in a side-by-side, non-overlapping relationship.

[0085] Example 25: A susceptor assembly described in any one of Examples 22 to 24, wherein the wicking element is folded about a fold to define a first planar layer covering a second planar layer, the first layer extending from the fold to a side of the first layer, the second layer extending from the fold to a side of the second layer, the sides of the first and second layers aligned with each other to form a common side, and the first and second legs extending in opposite directions and wrapping around the common side.

[0086] Example 26: A susceptor assembly as described in Example 25, wherein the first and second legs wrap around a common side such that opposing surfaces of the first and second planar layers of the wicking element are forced into surface contact with one another.

[0087] Example 27: The susceptor assembly of any one of Examples 1-6, wherein the susceptor element comprises a plurality of strip arrangements.

[0088] Example 28: A susceptor assembly as described in Example 27, wherein the susceptor element comprises an arrangement of first strips and second strips, each of the first and second strips extending over a length between a first end and a second end, the first strip extending along a first planar outward surface of the wicking element, and the second strip extending along a second planar outward surface of the wicking element.

[0089] Example 29: A susceptor assembly as described in Example 28, wherein first ends of the first and second strips are positioned to extend in opposite directions toward each other along a first side of the wicking element, and second ends of the first and second strips are positioned to extend in opposite directions toward each other along a second side of the wicking element, each of the first and second sides extending between a first planar outward surface and a second planar outward surface of the wicking element.

[0090] Example 30: The susceptor assembly of Example 29, wherein the wicking element has a thickness defined by the first and second sides of the wicking element.

[0091] Example 31: The susceptor assembly of either Example 29 or Example 30, wherein the first and second ends of the first and second strips are folded ends.

[0092] Example 32: The following conditions: a) first ends of the first and second strips are separated from one another by a gap along a first side of the wicking element; b) the second ends of the first and second strips are separated from each other by a gap along the second side of the wicking element, a susceptor assembly described in any one of Examples 29 to 31, wherein one or both of the following applies.

[0093] Example 33: The following conditions: a) first ends of the first and second strips are in surface contact with, covering, or interlocking with one another, or a combination thereof; b) A susceptor assembly described in any one of Examples 29 to 31, wherein one or both of the second ends of the first and second strips are in surface contact with, cover, or interlock with each other, or a combination thereof.

[0094] Example 34: A susceptor assembly described in any one of Examples 29 to 31, or Example 33, wherein the wicking element comprises a first planar layer covering a second planar layer, at least one of the first and second ends of the first strip being folded inward, wrapped around the side of the first layer, and tucked between the first and second layers, and at least one of the first and second ends of the second strip being folded inward, wrapped around the side of the second layer, and tucked between the first and second layers.

[0095] Example 35: The susceptor assembly of Example 34, wherein the respective sides of the first and second planar layers are aligned with one another.

[0096] Example 36: A susceptor assembly described in either Example 34 or Example 35, wherein the pressed ends of the first and second strips are arranged to maintain a gap between the opposing surfaces of the first and second planar layers of the wicking element.

[0097] Example 37: A susceptor assembly described in any one of Examples 34 to 36, wherein the wicking element is folded about a fold line, such that a first planar layer of the wicking element extends from the fold line to a side of the first layer, and a second planar layer of wicking material extends from the fold line to a side of the second layer.

[0098] Example 38: The susceptor assembly of any one of Examples 34-37, wherein the first layer is aligned parallel to the second layer.

[0099] Example 39: The following conditions: a) a first end of each of the first and second strips having a first leg, the first legs of the first and second strips being laterally offset from one another and extending in opposite directions from adjacent portions of the respective strips to wrap around a first side of the wicking element; b) A susceptor assembly described in either Example 29 or Example 30, wherein one or both of the following is applied: the second end of each of the first and second strips has a second leg, the second legs of the first and second strips are laterally offset from each other, extend in opposite directions from adjacent portions of the respective strips, and wrap around the second side of the wicking element.

[0100] Example 40: The following conditions: a) the first legs of the first and second strips being of reduced lateral width compared to adjacent portions of the respective strips; b) the second legs of the first and second strips are of reduced lateral width compared to adjacent portions of each strip, and

[0101] Example 41: The following conditions: a) the first legs of the first and second strips are of equal length and are disposed in a side-by-side, non-overlapping relationship; b) A susceptor assembly described in either Example 39 or Example 40, wherein one of the following applies: the second legs of the first and second strips are of equal length and are arranged in a side-by-side, non-overlapping relationship.

[0102] Example 42: A susceptor assembly described in any one of Examples 39 to 41, wherein the wicking element is folded about a fold to define a first planar layer covering a second planar layer, the first layer extending from the fold to a side of the first layer, the second layer extending from the fold to a side of the second layer, the sides of the first and second layers aligned with each other to form a common side, and the first legs extending in opposite directions and wrapping around the common side.

[0103] Example 43: A susceptor assembly as described in Example 42, wherein the first leg wraps around the common side such that opposing surfaces of the first and second planar layers of the wicking element are forced into surface contact with one another.

[0104] Example 44: A susceptor assembly described in any one of Examples 1 to 43, comprising a pair of unwound portions of the wicking element extending laterally outward from opposite sides of the wound central region of the wicking element.

[0105] Example 45: A susceptor assembly as described in Example 44, wherein the pair of unrolled portions are configured to engage with a pair of corresponding openings provided on opposite sides of the airflow channel.

[0106] Example 46: A cartridge for coupling to an aerosol generating device, the cartridge comprising a susceptor assembly as described in any one of Examples 1 to 45, the cartridge comprising an airflow channel positioned therein and a reservoir for a liquid aerosol-forming substrate, the cartridge being configured to receive the susceptor assembly such that the susceptor element is positioned in the airflow channel with the reservoir in fluid communication with a wicking element of the susceptor assembly.

[0107] Example 47: A cartridge as described in Example 46, wherein the susceptor assembly comprises a pair of unrolled portions of the wicking element extending laterally outward from opposite sides of the rolled central region of the wicking element, and the cartridge comprises a pair of openings located on opposite sides of the airflow channel, the pair of unrolled portions of the wicking element being received in the pair of openings.

[0108] Example 48: A cartridge described in either Example 46 or Example 47, wherein the cartridge comprises a removable holder, the holder at least partially defining an airflow channel, and the holder is configured to receive a susceptor assembly such that the susceptor element is positioned in the airflow channel.

[0109] Example 49: An aerosol generating system comprising an aerosol generating device and a cartridge described in any one of Examples 46 to 49, wherein the aerosol generating device comprises an inductor that at least partially surrounds the susceptor element when the cartridge is connected to the aerosol generating device.

[0110] Example 49a: The aerosol generation system of Example 49, wherein the inductor is or comprises a helical coil.

[0111] Example 50: A method of manufacturing a susceptor assembly, comprising: providing a wicking element having first and second planar surfaces, the first and second planar surfaces defining opposite outwardly facing surfaces of the wicking element; providing one or more strips of susceptor material; and wrapping one or more strips around a central region of the wicking element to form an arrangement of the one or more strips covering the first and second outwardly facing surfaces of the wicking element and surrounding the central region of the wicking element.

[0112] Example 51: The method described in Example 50, wherein the step of wrapping one or more strips around the central region of the wicking element comprises performing a series of folding operations on the one or more strips.

[0113] Example 52: A method described in either Example 50 or Example 51, wherein the step of wrapping one or more strips around the central region of the wicking element is carried out so that the one or more strips compress the central region of the wicking element.

[0114] Example 53: A method of manufacturing a susceptor assembly, comprising: providing a sheet of wicking material; providing one or more strips of susceptor material; and forming a wicking element from the sheet of wicking material by rolling one or more strips together with the sheet of wicking material and folding a first portion of the sheet of wicking material over a second portion of the sheet of wicking material, wherein the one or more strips are wrapped around a central region of the wicking element to form an arrangement of the one or more strips covering the first and second outwardly facing surfaces of the wicking element and surrounding the central region of the wicking element.

[0115] Example 54: The method described in Example 53, wherein wrapping one or more strips around the central region of the wicking element comprises performing a series of folding operations on the one or more strips.

[0116] Example 55: A method described in either Example 53 or Example 54, wherein wrapping one or more strips around the central region of the wicking element is performed so that the one or more strips compress the central region of the wicking element.

[0117] The embodiments will now be further described with reference to the following figures:

[0118] 1A and 1B show schematic views of two cross sections of a cartridge 10 for an aerosol generation system, the cartridge 10 being in accordance with a first embodiment of the present disclosure. The two cross sections are taken in two planes perpendicular to each other.

[0119] FIG. 1 shows a cartridge 10 comprising a heater holder 14 and a heater assembly 12 mounted to the heater holder 14. The heater assembly 12 is planar and thin, having a thickness dimension that is significantly smaller than its length and width dimensions. The heater assembly 12 is shaped in a rectangular configuration and comprises a susceptor element 16 wrapped around a wicking element 18. The width w of the susceptor element 16 is SE The width of the wicking element is 18 WEThe susceptor element 16 is smaller than the wicking element 16, and the susceptor element 16 is wrapped around a central region of the wicking element 18, defining an outer exposed portion 20 of the wicking element 18 that is not surrounded by the susceptor element 16. The outer exposed portion 20 of the wicking element 18 protrudes into one of two channels 45 through a pair of openings 28 disposed on opposite sides of an interior sidewall 27 of the heater holder 14. The interior sidewall 27 defines an interior passage 26 of the heater holder 14. The susceptor element 16 comprises a sintered mesh formed from ferritic stainless steel filaments and austenitic stainless steel filaments. The wicking element 18 comprises a porous body of rayon filaments. The wicking element 18 is configured to deliver liquid to the susceptor element 16 via the outer exposed portion 20 of the wicking element 18.

[0120] Because the heater assembly 12 employs a susceptor element 16 , the heater assembly 12 will hereinafter be referred to as a susceptor assembly 12 .

[0121] The susceptor element 16 is configured to be heatable by penetration by an alternating magnetic field to vaporize the aerosol-forming substrate. The outer exposed portion 20 of the wicking element 18 protrudes through a pair of openings 28 in the heater holder 14 such that the heater holder 14 supports the heater assembly 12 in place on the cartridge 10.

[0122] The susceptor assembly 12 is partially disposed within the interior passage 26 of the tubular heater holder 14 and extends in a plane parallel to the central longitudinal axis of the heater holder 14. The susceptor element 16 is completely disposed within the interior passage 26 of the heater holder 14, and the outer exposed portion 20 of the wicking element 18 extends into two channels 45 through a pair of openings 28 in the interior sidewall 27 of the heater holder 14. The outer exposed portion 20 of the wicking element 18 defines a mounting area 20 of the susceptor assembly 12 for mounting the susceptor assembly in the heater holder 14.

[0123] The cartridge 10 has a mouth end and a connecting end opposite the mouth end. An outer housing 36 defines a mouth end opening 38 at the mouth end of the cartridge 10. The connecting end is configured for connecting the cartridge 10 to an aerosol generating device, as described in detail below. The susceptor assembly 12 and heater holder 14 are located toward the connecting end of the cartridge 10.

[0124] 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 heater holder 14 are contained.

[0125] The external width of the outer housing 36 is greater at the mouth end of the cartridge 10 than at the connecting end, where they are joined by a shoulder 37. This allows the connecting end of the cartridge 10 to be received within the cavity of the aerosol generating device, with the shoulder 37 locating the cartridge in the correct position within 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.

[0126] 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.

[0127] The liquid reservoir 44 extends from the mouth end of the outer housing 36 to the connecting end of the outer housing 36 and comprises an annular space defined by the outer housing 36 and the interior sidewall of the cartridge 10 .

[0128] The interior sidewall of cartridge 10 defines an interior passageway 48 that extends between mouth end opening 38 and the open end of interior passageway 26 of heater holder 14 .

[0129] The liquid reservoir 44 further includes two channels 45 defined between the outer housing 36 at the connection end and the interior sidewall 27 of the heater holder 14, which defines the interior passageway 26. The two channels 45 extend from the annular space defined by the outer housing 36 and the interior sidewall of the cartridge 10 at the mouth end of the cartridge 10 to the connection end of the cartridge 10. The outer exposed portion 20 of the wicking element 18 extends into the two channels 45 through an opening 28 in the interior sidewall 27 of the heater holder 14. The two channels 45 extend from the annular space defined by the outer housing 36 and the interior sidewall of the cartridge 10 at the mouth end of the cartridge 10 on opposite sides of the interior passageway 26 of the heater holder 14.

[0130] The heater holder 14 includes a base 30 that partially closes one end of the interior passage 26. The base 30 includes a plurality of air inlets 32 that allow air to be drawn into the interior passage 26 through the partially closed end.

[0131] An air passageway is formed through cartridge 10 by interior passageway 26 of heater holder 14 and interior passageway 48. The air passageway extends from air inlet 32 in base 30 of heater holder 14, through interior passageway 26 of heater holder 14, and through interior passageway 48 to mouth end opening 38. The air passageway allows air to be drawn through cartridge 10 from the connecting end to the mouth end.

[0132] Figure 2 shows a schematic view of a further alternative cross section of cartridge 10 of Figures 1A and 1B. Cartridge 10 is viewed perpendicular to the views shown in Figures 1A and 1B, with the cross section shown in Figure 1A being indicated by dashed line AB and the cross section shown in Figure 1B being indicated by dashed line CD.

[0133] Cartridge 10 includes a heater holder 14. Heater holder 14 includes a tubular body formed from a moldable plastic material, such as polypropylene. The tubular body of heater holder 14 includes an interior sidewall 27 that defines an interior passageway 26 having an open end. A pair of openings 28 extend through interior sidewall 27 on opposite sides of tubular heater holder 14. Openings 28 are centrally disposed along the length of heater holder 14.

[0134] A pair of openings 28 in the sidewalls 27 of the heater holder 14 are sized to receive the susceptor assembly 12 by a friction fit such that the susceptor assembly is secured within the heater holder 14. The friction fit between the susceptor assembly 12 and the heater holder 14 causes the mounting area 20 to directly contact the heater holder 14 at the openings 28. The susceptor assembly 12 and the heater holder 14 are secured together such that movement of the heater holder 14 also moves the susceptor assembly 12.

[0135] Of course, the susceptor assembly 12 and heater holder 14 may be secured together by other means. For example, in some embodiments, the susceptor assembly 12 is secured to the heater holder 14 by adhesive at the mounting area 20 of the susceptor assembly 12 such that the mounting area 20 is in indirect contact with the heater holder 14.

[0136] The two channels 45 are positioned on opposite sides of the internal passage 26, and in use, the two channels 45 supply a liquid aerosol-forming substrate to the heater assembly 12. The outer exposed portion of the wicking element 18, which forms the mounting region 20 of the susceptor assembly 12, extends from the internal passage 26 into the channels 45 through the openings 28. The channels 45 are shown empty in Figure 2, but can be understood to be filled with a liquid aerosol-forming substrate before use.

[0137] The cartridge 10 is viewed from the mouth end towards the connecting end in Figure 2. Thus, the air inlets 32 in the base 30 are visible in Figure 2.

[0138] FIG. 3A shows a cross-sectional schematic view of an aerosol generation system 100 according to the present disclosure, with the cartridge 10 separated from the aerosol generation device 60.

[0139] Cartridge 10 is identical to the cartridges presented in Figures 1A, 1B and 2 and their corresponding descriptions.

[0140] The aerosol generating device 60 includes a generally cylindrical outer 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 10 is located at the connecting end of the device 60, and an air inlet 65 is provided through the outer housing 62 at the base of the cavity 64 to allow ambient air to be drawn into the cavity 64.

[0141] 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 or lithium-ion battery, which 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 to 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.

[0142] A single inductor coil 90 is positioned around the susceptor assembly 12 when the cartridge 10 is received in the cavity 64. The inductor coil 90 has a size and shape that matches the size and shape of the susceptor element 16. The inductor coil 90 is made of copper wire having a circular cross-section and is disposed on a coil former element (not shown). The inductor coil 90 is both tubular and helical and defines a circular cross-section when viewed along the longitudinal axis of the aerosol generating device.

[0143] 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 .

[0144] 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.

[0145] FIG. 3B shows a schematic diagram of a cross-sectional view of the aerosol generation system 100 of FIG. 3A, but with the cartridge 10 coupled to an aerosol generation device 60.

[0146] In operation, when a user draws on mouth end opening 38 of cartridge 10, ambient air is drawn into the base of cavity 64 through 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 opening 38 through an air passage defined by internal passage 26 and over susceptor assembly 12.

[0147] 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.

[0148] The control circuit 72 is coupled to the airflow sensor 63. The airflow sensor 63 is in fluid communication with the path of ambient air drawn through the system by the user. The control circuit 72 provides power to the inductor coil 90 when the airflow sensor 63 detects a puff by the user on the cartridge 10.

[0149] When the system 100 is activated, an alternating current is established in the inductor coil 90, which generates an alternating current in the cavity 64 in which the susceptor assembly 12 is located, causing the susceptor element 16 to heat. The liquid aerosol-forming substrate in the channel 45 is drawn through the wicking element 18 and into the susceptor assembly 12 toward the susceptor element 16. The liquid aerosol-forming substrate 42 in the susceptor element 16 is heated, and volatile compounds from the heated aerosol-forming substrate are released into the air passage defined by the internal passage 48 of the cartridge 10, where they cool and form an aerosol. The aerosol is entrained in air drawn through the internal passage 48 of the cartridge 10 and drawn from the cartridge 10 at the mouth-end opening 38 for inhalation by the user.

[0150] 4 is a perspective view of one embodiment of a susceptor assembly 12 suitable for use in the cartridge 10 of FIGS. 1A, 1B, and 2, and as part of the aerosol generation system 100 of FIGS. 3A and 3B. The susceptor assembly 12 has a susceptor element 16 defined by a single strip 160 of susceptor material wrapped around a central region of a wicking element 18. The strip 160 of susceptor material covers opposing upper and lower planar surfaces of the wicking element 18, as well as opposing side surfaces of the wicking element 18. A first end 161 and a second end 162 of the strip 160 extend toward each other in opposite directions along a downstream side 181 of the wicking element 18. The wicking element 18 is formed of a uniform thickness t defined by the side surfaces 181 of the wicking element. WE4, the free ends of the first end 161 and second end 162 of the strip 160 face each other along the downstream side 181 of the wicking element 18 and are separated by a gap "d". In this manner, the susceptor element 16 defined by the strip 160 of susceptor material surrounds the central region of the wicking element 18. The width w of the susceptor element 16 formed by the strip 160 SE The width of the wicking element is 18 WE 4 includes arrows representing the passage of airflow over the susceptor element 16 between the upstream and downstream directions, and the flow of liquid aerosol-forming substrate through the wicking element 18 via the laterally opposed exposed portions 20 of the wicking element 18. The wicking element 18 is smaller than the central region of the wicking element 18 that is wrapped around and surrounded by the susceptor element 16, leaving outer exposed portions 20 of the wicking element 18 that extend laterally outward from the central region of the wicking element 18 that is wrapped around and surrounded by the susceptor element 16. As discussed above, these outer exposed portions 20 of the wicking element 18 function as mounting areas by which the susceptor assembly 12 may be held within the heater holder 14 of the cartridge 10 (see FIGS. 1A, 1B, and 2). FIG. 4 includes arrows representing the passage of airflow over the susceptor element 16 between the upstream and downstream directions, and the flow of liquid aerosol-forming substrate through the wicking element 18 via the laterally opposed exposed portions 20 of the wicking element 18.

[0151] 5 shows a schematic perspective view of the susceptor element strip 160 and wicking element 18 before the strip 160 is wrapped around the central region of the wicking element 18. The lateral extent of the central region of the wicking element 18 covered by the strip 160 is generally indicated by the dashed line on the upper outwardly facing surface 182 of the wicking element 18 in FIG. 5. The strip 160 of susceptor material has a length L of about 14.3 cm. SE and a width of approximately 2.8 cm SE However, the dimensions of the strip 160 may vary depending on factors such as the size of the cartridge 10 of which the susceptor assembly 12 is intended to form a part, and the size of the inductor coil 90 of the aerosol generating device 60. It will be appreciated that the strip 160 of susceptor material may be cut or stamped from a larger sheet of material to form multiple susceptor element strips, such as the individual strips 160.

[0152] As shown in Figures 5 and 6A, the strip 160 of susceptor material is initially positioned against one of the sides of the wicking element 18. The strip 160 then undergoes a series of folding operations (represented by the arrows in Figure 6A). The first of these folding operations folds the upper portion 163 of the strip 160 onto the upper outwardly facing surface 182 of the wicking element 18 and the lower portion 164 of the strip 160 onto the lower outwardly facing surface 183 of the wicking element 18. After this first folding operation, the first end 161 and the second end 162 of the strip 160 extend parallel to and away from the surfaces 182, 183 of the wicking element 18 (shown by dashed lines in Figure 6A). In one or more subsequent folding operations, the first end 161 and the second end 162 of the strip 160 are folded over the edge of the wicking element 18 and positioned against the downstream side 181 of the wicking element 18. In the embodiment shown in FIG. 6A , the free ends of the first end 161 and the second end 162 of the strip 160 face each other along the downstream side 181 of the wicking element 18 and are separated by a gap "d." It will be appreciated that in other embodiments, the free ends of the first end 161 and the second end 162 of the strip 160 may be disposed in an end-to-end relationship, or the first end 161 and the second end 162 may overlap each other. If the first end 161 and the second end 162 overlap each other, it may be preferable that the overlap be limited to a side of the wicking element 18 (e.g., side 181) to avoid excessive obstruction of airflow through the internal passageway 26 of the heater holder 14 during use. Figure 6B provides a view of the strip of susceptor material 160 and the wicking element 18 along section AA of Figure 6A. In Figures 6A and 6B, the strip of susceptor material 160 before being folded around the wicking element 18 is shown in solid, undashed outline, while the strip 160 after different ones of the folding operations is shown in dashed outline. Figure 6C shows a side view of the susceptor assembly 12 resulting from the strip of susceptor material 160 being wrapped around the central region of the wicking element 18 to form the susceptor element 16.

[0153] FIG. 7 illustrates an embodiment of a susceptor assembly 121 that replaces the embodiment of FIGS. 6A-C , resulting from a first end 161 and a second end 162 of a strip 160 of susceptor material undergoing a further folding operation and being embedded within a side 181 of a wicking element 18 to form a susceptor element 16.

[0154] 8 illustrates a further alternative embodiment of susceptor assembly 122 resulting from a first end 161 and a second end 162 of strip 160 undergoing a further folding operation, folding each of first end 161 and second end 162 onto an inwardly facing surface of the strip to form susceptor element 16. In this manner, first end 161 and second end 162 of strip define folded ends, with the free ends of each of first end 161 and second end 162 hidden from view.

[0155] 9A shows a further alternative embodiment in which a strip 160 of susceptor material is initially positioned adjacent to a corresponding sheet 180 of wicking material. A series of folding operations is then performed (represented by arrows in FIG. 9A ). In a first of the folding operations, the strip 160 of susceptor material and the sheet 180 of wicking material are folded together such that the sheet 180 of wicking material is folded about a fold line 184 (extending into and out of the page in FIG. 9A ) to form a wicking element 18 having a first planar layer 185 overlying a second planar layer 186. After this first folding operation, the first and second ends 161, 162 of the strip extend parallel to and away from the upper and lower outward-facing surfaces 182, 183 of the wicking element. In one or more subsequent folding operations, the first end 161 and the second end 162 of the strip 160 are folded over and wrapped around the respective sides 187, 188 of the first layer 185 and the second layer 186, respectively, and tucked between the first and second layers. In Figure 9A, the strip 160 of susceptor material and the sheet 180 of wicking material before any folding operations are shown in solid, undashed outline, while the strip 160 and the wicking element 18 after different ones of the folding operations are shown in dashed outline. Figures 9B and 9C show side and perspective views of the susceptor assembly 123 resulting from the strip 160 of susceptor material being folded together with the sheet 180 of wicking material to form the susceptor element 16 that wraps around the central region of the wicking element 18. The indented ends 161 , 162 of the strip 160 maintain a gap “e” between the opposing surfaces of the first layer 185 and the second layer 186 of the wicking element 18 .

[0156] FIG. 10A shows a further alternative embodiment in which a strip 160 of susceptor material is initially positioned against a corresponding sheet of wicking material 180. First and second legs 165, 166 are defined at first and second ends 161, 162, respectively, of the strip 160. The first and second legs 165, 166 are laterally offset from one another, as shown in FIG. 10B. The strip 160 undergoes a series of folding operations (represented by arrows in FIG. 10A). In a first of the folding operations, the strip 160 of susceptor material and the sheet 180 of wicking material are folded together such that the sheet 180 of wicking material is folded about a fold line 184 (extending into and out of the page in FIG. 10A ) to form a wicking element 18 having a first planar layer 185 overlying a second planar layer 186. After this folding operation, the first end 161 and the second end 162 of the strip 160 extend parallel to and away from the upper and lower outwardly facing surfaces 182, 183 of the wicking element 18. In one or more subsequent folding operations, the first leg 165 and the second leg 166 of the first end 161 and the second end 162 are folded over and wrap around the combination of the sides 187, 188 of the first layer 185 and the second layer 186. The first leg 165 extends around the combination of the sides 187, 188 to cover a portion of the lower outwardly facing surface 183 of the wicking element 18, and the second leg 166 extends around the combination of the sides 187, 188 to cover a portion of the upper outwardly facing surface 182 of the wicking element 18. Figure 10B provides a view of the susceptor material strip 160 and the wicking element 18 along section BB of Figure 10A. As can be seen in FIG. 10B, each of the first and second legs 165, 166 are of equal length but have a width w SE10A and 10B, the strip 160 of susceptor material and the sheet 180 of wicking material are shown in solid, non-dashed outline before any folding operations are performed, while the strip 160 and wicking element 18 are shown in dashed outline after different ones of the folding operations are performed. FIG. 10C shows a perspective view of the susceptor assembly 124 resulting from the strip 160 of susceptor material being folded together with the sheet 180 of wicking material to form the susceptor element 16. The first and second legs 165, 166 are sized and arranged in a side-by-side, non-overlapping relationship.

[0157] Although the embodiment described in connection with Figures 1A-10C uses a single strip 160 of susceptor material to form the susceptor element 16, in other embodiments, an arrangement of multiple strips 160 of susceptor material may be employed, with the multiple strips being wrapped around and surrounding the central region of the wicking element 18.

[0158] For any of the embodiments described with reference to the figures, the strips of susceptor material 160 are preferably tightly wrapped around the wicking material 18 because this will enhance the contact pressure and thermal bond between the susceptor elements 16 and the wicking material 18. Such tight wrapping of the strips of susceptor material 160 around the wicking elements 18 will cause the susceptor elements 16 to compress the wicking elements 18.

[0159] The previous discussion of embodiments of the present disclosure with reference to Figures 1A-10C discusses the structural features of different features of susceptor assemblies, as well as the various steps involved in manufacturing the susceptor assemblies.

[0160] FIG. 11 illustrates various steps in a first embodiment of a method 1000 for manufacturing a susceptor assembly, such as the susceptor assemblies 12, 121, 122, 123, and 124 described with reference to FIGS. 1A-10C. In a first step 1001, a wicking element is provided, the wicking element having first and second planar surfaces defining opposite outwardly facing surfaces of the wicking element. In a second step 1002, one or more strips 160 of susceptor material are provided. In a third step 1003, the one or more strips are wrapped around a central region of the wicking element to form an arrangement of the one or more strips covering the first and second outwardly facing surfaces of the wicking element and surrounding the central region of the wicking element. Step 1003 may include one or a series of folding operations performed on the one or more strips.

[0161] 12 illustrates various steps in a second embodiment of a method 2000 for manufacturing a susceptor assembly, which is particularly applicable to the embodiments of FIGS. 9A-9C and 10A-10C. In a first step 2001, a sheet of wicking material is provided. In a second step 2002, one or more strips of susceptor material are provided. In a third step 2003, the one or more strips are rolled together with the sheet of wicking material to form a wicking element from the sheet of wicking material by folding a first portion of the sheet of wicking material over a second portion of the sheet of wicking material, and further, the one or more strips are wrapped around a central region of the wicking element to form an arrangement of the one or more strips covering the first and second outward-facing surfaces of the wicking element and surrounding the central region of the wicking element.

[0162] 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. Accordingly, in this context, the number "A" is to be understood as "A" ± 10%. Within this context, the number "A" may be considered to include numerical values that are within the common standard error for measurement of the property that the number "A" modifies. The number "A," as used in the appended claims, may, in some cases, deviate by the percentages recited above, provided that the amount by which "A" deviates does not materially affect the basic and novel property(ies) 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. A susceptor assembly for an aerosol generation system, A wicking element having first and second planes, wherein the first surface and the second surface define the opposite outward-facing surface of the wicking element, A susceptor element comprising an arrangement of a single strip of susceptor material, wherein the arrangement of the single strip is wrapped around the central region of the wicking element, covering the first outward-facing surface and the second outward-facing surface of the wicking element, and surrounding the central region of the wicking element, A susceptor assembly in which the single strip extends over a length between a first end and a second end, the strip wraps around the central region of the wicking element such that the first and second ends extend in opposite directions along the side surface of the wicking element, and the side surface extends between the first planar outward surface and the second planar outward surface of the wicking element.

2. The susceptor assembly according to claim 1, wherein the arrangement of the single strip is wrapped around the central region of the wicking element so as to compress the central region.

3. The susceptor assembly according to claim 1, wherein either or both of the first and second ends of the strip are folded inward and embedded within the wicking element.

4. The susceptor assembly according to claim 1, wherein the wicking element comprises a first planar layer covering a second planar layer, and either or both of the first and second ends of the strip are folded inward and wrapped around one side of the first and second layers, and pressed between the first and second layers.

5. The susceptor assembly according to claim 1, wherein the first end and the second end are in surface contact with, covering, interlocking with, or a combination thereof.

6. The susceptor assembly according to claim 1, wherein each of the first end and the second end is folded inward and embedded within the side surface of the wicking element.

7. The susceptor assembly according to claim 1, wherein the wicking element comprises a first planar layer covering a second planar layer, the first end of the strip is folded inward and wrapped around the side of the first layer and pushed between the first and second layers, and the second end of the strip is folded inward and wrapped around the side of the second layer and pushed between the first and second layers.

8. The susceptor assembly according to claim 1, wherein the first end of the strip is provided with a first leg, the second end of the strip is provided with a second leg, the first leg and the second leg are laterally offset from each other and extend in opposite directions from the respective first and second adjacent portions of the strip to wrap around the side surface of the wicking element.

9. The susceptor assembly according to claim 8, wherein the first leg and the second leg are of equal length and are arranged side by side without overlapping.

10. The susceptor assembly according to claim 8, wherein the wicking element is folded at a fold, defining a first planar layer covering a second planar layer, the first layer extending from the fold to the side of the first layer, the second layer extending from the fold to the side of the second layer, the sides of the first layer and the second layer align with each other to form a common side, and the first leg and the second leg extend in opposite directions and wrap around the common side.

11. The susceptor assembly according to claim 10, wherein the first leg and the second leg wrap around the common side such that the opposing surfaces of the first planar layer and the second planar layer of the wicking element are forced to be in surface contact with each other.

12. A cartridge for coupling with an aerosol generator, wherein the cartridge comprises a susceptor assembly according to any one of claims 1 to 11, the cartridge comprising an internally positioned airflow channel and a storage section for a liquid aerosol forming substrate, and the cartridge is configured to receive the susceptor assembly such that the susceptor element is positioned in the airflow channel with the storage section in fluid communication with the wicking element of the susceptor assembly.

13. An aerosol generating system comprising an aerosol generator and a cartridge according to claim 12, wherein the aerosol generator includes an inductor, and the inductor at least partially surrounds the susceptor element when the cartridge is connected to the aerosol generator.

14. A method for manufacturing a susceptor assembly, A step of providing a wicking element having first and second planes, wherein the first plane and the second plane define the opposite outward-facing surface of the wicking element; A process of providing fragments of susceptor material, A method comprising the step of wrapping the strip around the central region of the wicking element to form a single strip arrangement that covers the first outward-facing surface and the second outward-facing surface of the wicking element and surrounds the central region of the wicking element, wherein the single strip extends over a length between a first end and a second end, the strip is wrapped around the central region of the wicking element such that the first end and the second end extend along the side surface of the wicking element from opposite directions, and the side surface extends between the first planar outward-facing surface and the second planar outward-facing surface of the wicking element.

15. A method for manufacturing a susceptor assembly, The process of providing a sheet of wicking material, A process of providing fragments of susceptor material, A method comprising the steps of winding the strip together with a sheet of wicking material, folding a first portion of the sheet of wicking material over a second portion of the sheet of wicking material to form a wicking element from the sheet of wicking material, wherein the strip is wound around a central region of the wicking element, covering the first and second outward-facing surfaces of the wicking element and surrounding the central region of the wicking element, the strip is wound around the central region of the wicking element such that the single strip extends over a length between a first end and a second end, the first and second ends extend in opposite directions along the side surface of the wicking element, and the side surface extends between the first planar outward-facing surface and the second planar outward-facing surface of the wicking element.

Images