Susceptor assembly with fluid channels for an aerosol generation system and method of manufacture - Patent Application 20070122997

Abstract

A susceptor assembly (212) for an aerosol generation system is provided, comprising a susceptor element (216) in the form of a sheet and at least one channel (221) formed in or on a surface of the sheet. The at least one channel is configured to transport a liquid aerosol-forming substrate across the surface of the sheet by capillary action. The at least one channel extends from an edge of the susceptor element, where it is in fluid communication with a liquid aerosol-forming substrate located in a liquid reservoir, and extends to a central region of the susceptor element. The susceptor assembly may further comprise a plurality of openings (223), each of which connects to at least one channel. A cartridge for an aerosol generation system, an aerosol generation device, and a method 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, an aerosol generation device, and a method for manufacturing a susceptor assembly. [Background technology]

[0002] Aerosol generating systems that use induction heating to generate inhalable aerosols from liquid aerosol-forming substrates are known in the art. Some aerosol generating systems include a cartridge that can be coupled to an aerosol generator to provide electrical power. A typical cartridge includes an aerosol-forming substrate and a heater assembly. In many aerosol generating systems, the heating element is induction heated, in which case the heating element is a susceptor element.

[0003] Induction heating systems typically include a coil disposed around a susceptor element to which a liquid aerosol-forming substrate is supplied. An alternating current is passed through the coil, inducing eddy currents in the susceptor element, thereby heating the susceptor element.

[0004] The aerosol-forming substrate may be a liquid held in a liquid reservoir. The cartridge or device may include a wicking material in fluid communication with the liquid reservoir and also in contact with the susceptor element. The wicking element is configured to draw the aerosol-forming substrate from the liquid reservoir to the susceptor element for vaporization. Airflow passing through the susceptor element entrains the generated vapor. The entrained vapor cools and condenses to form an aerosol, which can be inhaled by a user.

[0005] It is also known in the art to use susceptors in the form of woven meshes made of ferritic stainless steel wires that are heated with an alternating magnetic field. The woven mesh may provide some capillary action to draw liquid across the susceptor. A disadvantage of woven susceptors is that they are fragile and therefore difficult to manufacture.

[0006] It would be desirable to reduce overall manufacturing complexity and cost by creating a susceptor assembly with fewer components and therefore a simpler design. It is also desirable to provide susceptor elements that are robust and easy to handle during manufacturing. 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 comprising a susceptor element in the form of a sheet and at least one channel formed in or on a surface of the sheet and configured to transport a liquid aerosol-forming substrate across the surface of the sheet.

[0008] Advantageously, having a susceptor assembly in which both heating and fluid delivery are provided by a single component means that the manufacturing process can be simpler than previous susceptor assemblies. Sheet susceptors, particularly nonwoven sheets, can be made more robust compared to mesh susceptors while providing the same heating characteristics. Sheet susceptors with improved mechanical properties allow for easier handling during manufacturing.

[0009] The susceptor element may be substantially flat, which may be defined as the susceptor element having both a width and a height that is much greater than its depth. The susceptor element may be substantially planar.

[0010] 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.

[0011] As used herein, "aerosol-generating system" means a system that generates an aerosol from one or more aerosol-forming substrates.

[0012] As used herein, the term "aerosol-forming substrate" refers to a substrate made of or including an aerosol-forming material capable of releasing volatile compounds upon heating to generate an aerosol.

[0013] 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.

[0014] As used herein, "susceptor element" means an element that can be heated by penetration by an alternating magnetic field. Susceptor elements are 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 the susceptor element include graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, and other electrically conductive materials. Advantageously, the susceptor element may be formed of a ferromagnetic material.

[0015] The susceptor assembly may include multiple channels. Multiple channels may increase the flow of the aerosol-forming substrate across the surface of the susceptor, resulting in more of the susceptor being wetted compared to a single channel. Increased evaporation can occur when a larger portion of the susceptor element is wet. Multiple channels also reduce the likelihood of areas of the susceptor drying out and overheating.

[0016] The channels are preferably connected to one another, which allows the liquid aerosol-forming substrate to be spread widely and uniformly over the heated area of ​​the susceptor element.

[0017] The plurality of channels may form a network of channels, which advantageously allows for an even distribution of liquid throughout the network.

[0018] The susceptor assembly may have at least one channel extending from an edge of the susceptor element to a central region of the susceptor element. Advantageously, having a channel extending from the edge of the susceptor element to the center reduces the likelihood of overheating because the liquid aerosol-forming substrate can flow to the center of the susceptor element, which is prone to overheating, and absorb heat.

[0019] The susceptor assembly may have a thickness, and the plurality of channels may have a depth that is less than the thickness of the susceptor element. A channel having a thickness that is less than the thickness of the susceptor element may be able to hold more liquid aerosol-forming substrate than a channel that extends through the entire thickness of the susceptor element.

[0020] The susceptor assembly may comprise a plurality of wires or wire sections disposed on a surface of a susceptor element, with at least one channel formed between one or more of the wires or wire sections. Advantageously, manufacturing a susceptor assembly including wires for forming at least one channel may be less complicated than creating a susceptor assembly having channels formed in the surface of the susceptor element, particularly when the susceptor is a thin sheet.

[0021] Multiple wires or wire sections may be arranged parallel to one another. Parallel channels can provide uniform distribution of the liquid aerosol-forming substrate across the surface of the susceptor element. Parallel, straight channels can also provide rapid transport of liquid across the susceptor assembly.

[0022] The plurality of wires or wire sections may comprise an electrically conductive material. The wires comprising an electrically conductive material may contribute to heating the liquid aerosol-forming substrate. In this manner, the overall efficiency of the susceptor assembly may be improved. The plurality of wires or wire sections may comprise an iron material.

[0023] The plurality of wires or wire sections may include at least one wire on or around the susceptor element, for example, the plurality of wires or wire sections may include at least one wire wrapped around the susceptor element, or the plurality of wires or wire sections may include at least one wire adhered to the susceptor element.

[0024] At least one channel may be formed between successive windings of the wire.

[0025] At least one channel may be formed between successive rows of bonded wires.

[0026] The process of providing multiple wires or wire sections on or around the susceptor element by wrapping or gluing can be accomplished simply as part of the manufacturing process, as only one wire may be required to create multiple channels.

[0027] The susceptor assembly may further comprise one or more openings extending from one surface of the sheet to the opposite surface. The openings extending from one surface of the susceptor element to the opposite surface allow vaporized liquid to escape on both sides of the susceptor assembly. Each of the one or more openings may be connected to at least one channel.

[0028] The susceptor assembly may include a plurality of openings, the plurality of openings having a different size, shape, or arrangement in a first region of the sheet than in a second region of the sheet. Advantageously, different sized openings in different regions may allow for a more uniform distribution of evaporation across the surface of the susceptor element. The susceptor assembly may include a first region having a first density of openings and a second region having a second density of openings. The opening density may be defined as the number of openings per unit area. In some embodiments, the susceptor assembly includes three or more opening regions having different densities. A configuration with smaller openings having a higher density may generate more heat compared to a configuration with larger openings having a lower density. Adjusting the size of the openings in the first and second regions may be used to control how and where heat is generated across the susceptor element, enabling a susceptor element design that can be optimized to reduce the risk of overheating the susceptor element.

[0029] The size of each opening of the plurality of openings may be equal. The size of each opening in the first region may be different from the size of each opening in the second region. The size of each opening in the first region may be smaller than the size of each opening in the second region. A first average size of the openings in the first region may be smaller than a second average size of the openings in the second region. The size of each opening may be a cross-sectional area of ​​each opening parallel to a first side of the at least one susceptor element.

[0030] The first region may include a first regular array of openings of the plurality of openings. The first regular array of openings may be a hexagonal array of openings. The first regular array of openings may be a square array of openings. The second region may include a second regular array of openings of the plurality of openings. The second regular array of openings may be a hexagonal array of openings. The second regular array of openings may be a square array of openings. Advantageously, such a regular array may facilitate manufacturing of both the first region and the second region. Each opening of the plurality of openings may be circular in shape. Each opening of the plurality of openings may be rectangular or square in shape. Advantageously, such a simple shape may facilitate manufacturing, particularly with respect to stamping, for example. The susceptor element may have a thickness. The thickness may be between 25 micrometers and 100 micrometers. Each opening of the plurality of openings may be formed via laser cutting. Each opening of the plurality of openings may be formed via chemical etching. Each opening of the plurality of openings may be formed via stamping or wire discharge. Each of the plurality of openings may be formed via laser engraving.

[0031] Each opening of the plurality of openings may extend a first distance in a first direction parallel to the first and second sides of the susceptor element. Each opening of the plurality of openings may extend a second distance in a second direction parallel to the first and second sides of the susceptor element and perpendicular to the first direction. The first distance may be greater than the second distance. The susceptor assembly may be configured to be heated by a magnetic field that varies in a direction parallel to the first direction. The susceptor assembly may be configured to be disposed within a cartridge in an aerosol generation system, and the susceptor element may be heated by a magnetic field that varies in a direction parallel to the first direction. Advantageously, in such an arrangement, it has been found that the extension of the opening in the second direction perpendicular to the direction of the varying magnetic field does not significantly contribute to induced power and heat generation. Therefore, it is beneficial to arrange the susceptor element so that the elongated direction of the opening is aligned with the direction of the varying magnetic field.

[0032] The distance between the edge of an opening and the edge of a neighboring opening may be 0.05 mm to 0.5 mm. Preferably, the distance between the edge of an opening and the edge of a neighboring opening may be 0.1 to 0.4 mm. The openings may be holes, notches, or channels. The openings may be defined through the wicking layer. The openings may have a circular cross section. The openings may have a diameter of at least 0.1 millimeters.

[0033] The opening may have a rectangular cross-section. The opening may have a triangular cross-section. The opening may have any suitable cross-section. The opening may have a cross-sectional area of ​​at least 0.005 square millimeters. The opening may have a cross-sectional area of ​​at least 0.01 square millimeters.

[0034] The susceptor sheet may have a nonwoven structure. The susceptor sheet may include etched foil. Wires wrapped around the foil may create small gaps, which may be used to create capillary action. The susceptor sheet may be folded so that at least one channel is positioned on the inner surface of the susceptor assembly. The susceptor sheet may have an elongated slot provided along at least one fold. The at least one fold is preferably parallel to the direction in which the one or more wires are disposed. The susceptor sheet may be folded along the fold to form a susceptor layer. The susceptor assembly may include at least one layer. Each susceptor layer may have a different arrangement or openings. A susceptor layer may have more or fewer openings than another susceptor layer. The susceptor assembly may include one or more intermediate layers, each having one or more susceptor layers on each side. The one or more intermediate layers may have an area without openings.

[0035] The susceptor element may include a ferrous material. The susceptor element may include hardened steel. Advantageously, hardened steel has increased ductility, allowing it to be formed more easily than hardened steel or steel that has not undergone heat treatment. Hardened steel also has improved toughness, allowing it to withstand greater forces before permanent deformation occurs. The susceptor element may include ferritic stainless steel. Due to its chemical makeup, ferritic stainless steel is relatively inexpensive compared to other stainless steels. Another advantage of stainless steel is its corrosion resistance, which is a desirable characteristic for a susceptor element material.

[0036] The susceptor element may include at least one of graphite, molybdenum, silicon carbide, stainless steel, niobium, and aluminum.

[0037] The susceptor assembly may include one or more ferromagnetic materials, the use of which is advantageous due to its magnetic properties as utilized in heating the susceptor elements.

[0038] Preferably, the susceptor element comprises AISI 430 stainless steel.

[0039] The susceptor element may have a relative permeability of 1 to 40,000 when measured at a suitable frequency and temperature, for example, at a temperature of 20 degrees Celsius and a frequency of up to 10 kHz. A material with a lower permeability may be used when it is desired to rely mostly on eddy currents for heating, and a material with a higher permeability may be used when a hysteresis effect is desired. Preferably, the material may have a relative permeability of 500 to 40,000 when measured at a suitable frequency and temperature, for example, at a temperature of 20 degrees Celsius and a frequency of up to 10 kHz. This may provide efficient heating of the susceptor element.

[0040] The susceptor element may be heatable by at least one of Joule heating due to the induction of eddy currents in the susceptor element and hysteresis losses.

[0041] According to a second embodiment of the present disclosure, there is provided a cartridge for an aerosol generation system, the cartridge may include the susceptor assembly according to the first embodiment and a liquid reservoir for holding a liquid aerosol-forming substrate, the channel being in fluid communication with the liquid aerosol-forming substrate in the liquid reservoir and arranged to transport the liquid aerosol-forming substrate across a surface of the susceptor element by capillary action.

[0042] The cartridge may include a liquid reservoir housing. The cartridge may include a retention material contained within the reservoir, the retention material for retaining the liquid aerosol-forming substrate. The retention material may be a foam, a sponge, or a fiber mass. The retention material may be formed of a polymer or copolymer. The retention material may be a spun polymer.

[0043] The susceptor element may be continuously wetted by the liquid aerosol-forming substrate contained in the reservoir by a wicking element in direct contact with both the liquid reservoir and the susceptor element.

[0044] The cartridge may include an air inlet, an air outlet, and an airflow path extending from the air inlet, through the susceptor element, and to the air outlet. Advantageously, this arrangement allows air to flow over the susceptor assembly when the susceptor assembly is in use, allowing aerosolized liquid aerosol-forming substrate to travel continuously to the air outlet and to the user during a puff.

[0045] As used herein, the term "puff" is used to describe the act of a user drawing air through an aerosol generating system by inhalation.

[0046] As used herein, the terms "air inlet" and "air outlet" are used to describe one or more openings through which air may be drawn into and out of a component or portion of a component of a cartridge, an aerosol generation system, or an aerosol generation device, respectively.

[0047] The cartridge may further include a susceptor holder that holds a susceptor assembly, and at least a portion of the airflow path is defined by the susceptor holder. The susceptor holder may have an elongated shape. The susceptor holder may be a tubular susceptor holder. The susceptor holder may be coupled to the susceptor assembly.

[0048] The susceptor holder may include a thermally insulating material. The susceptor holder may include an electrically insulating material. The susceptor holder may include at least one polymer. The susceptor holder may include polyetheretherketone (PEEK). The susceptor holder may be formed by injection molding.

[0049] A susceptor holder may be positioned within the susceptor housing. The susceptor holder may support a susceptor assembly. The susceptor holder may be in contact with a susceptor element. The susceptor holder may hold the susceptor assembly such that the susceptor element is in direct fluid communication with a liquid aerosol-forming substrate in the liquid reservoir.

[0050] The susceptor holder can provide a liquid seal around the susceptor assembly to prevent leakage of the liquid aerosol-forming substrate from the liquid reservoir except through the at least one channel. The seal can prevent leakage of the liquid from the cartridge and extend the life of the cartridge.

[0051] The susceptor holder may be configured to internally hold the susceptor assembly such that at least a portion of the susceptor element is positioned within the airflow path and such that the at least one channel is in fluid communication with the liquid aerosol-forming substrate. Advantageously, this arrangement allows fluid to flow across the susceptor element because the one or more channels can draw fluid from the fluid reservoir by capillary action. The at least one channel may extend from a periphery of the susceptor element positioned within the liquid reservoir to a central region of the susceptor element positioned within the airflow path through the cartridge. This reduces the likelihood of overheating of the susceptor element as the liquid aerosol-forming substrate moves to the central region and absorbs heat.

[0052] The at least one channel may extend transversely to a direction of airflow in the airflow channel passing through the susceptor assembly. The direction of liquid supply from the liquid reservoir may be perpendicular to a direction of airflow in the airflow channel passing through the susceptor assembly. The direction of liquid supply may be substantially perpendicular to an axis about which the plurality of wires are wound around the susceptor element.

[0053] Opposite ends of the susceptor element may be in fluid communication with a liquid reservoir. Advantageously, this may increase capillary action and thus allow wetting of the susceptor element.

[0054] Preferably, the cartridge comprises a mouthpiece, the mouthpiece comprising an air outlet.

[0055] During use, air may enter the cartridge through the cartridge air inlet, flow through the airflow channel, across the susceptor assembly, and exit the cartridge through the air outlet defined by the mouthpiece. Vaporized liquid aerosol-forming substrate generated by the susceptor assembly may be entrained in the airflow within the airflow channel. The entrained vapor condenses to form an aerosol for inhalation by the user, and the aerosol exits the cartridge through the air outlet defined by the mouthpiece.

[0056] The cartridge may include at least one seal extending across a portion of the airflow channel. The cartridge may include an upstream seal extending across the cartridge air inlet. The upstream seal may be sealed to the holder. The upstream seal may be sealed to the cartridge outer housing. The upstream seal may be sealed to both the holder and the cartridge outer housing. The upstream seal may be frangible or removable. The upstream seal may be arranged to automatically rupture upon insertion of the cartridge into the aerosol generating device.

[0057] The cartridge may include a downstream seal. The downstream seal may extend across an air outlet defined by the mouthpiece. The downstream seal may be sealed to the mouthpiece. The downstream seal may be frangible or removable.

[0058] In embodiments where the cartridge includes a cartridge outer housing, the mouthpiece may be integrally formed with the cartridge outer housing, the mouthpiece may be formed separately from and connected to the cartridge outer housing, or the mouthpiece may be connected to the cartridge outer housing by an interference fit.

[0059] In embodiments in which the cartridge includes a mouthpiece, a cartridge outer housing, or both a mouthpiece and a cartridge outer housing, the mouthpiece and the cartridge outer housing may each be formed from any suitable material or combination of materials. Preferably, the mouthpiece and the cartridge outer housing are formed from a plastic or thermoplastic material suitable for food or pharmaceutical applications. For example, the mouthpiece and the cartridge outer housing may include at least one of polypropylene, polyetheretherketone (PEEK), and polyethylene. The material is preferably lightweight and not brittle.

[0060] According to a third aspect of the present disclosure, there is provided an aerosol generation system. The aerosol generation system may include the cartridge and an aerosol generation device according to the second aspect of the present disclosure. The aerosol generation device may include an inductor coil and 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. The cartridge and the aerosol generation device may be configured to be connected to each other such that the susceptor assembly is disposed within the alternating magnetic field. Advantageously, less power is required to heat the susceptor element in this arrangement compared to when the susceptor is disposed elsewhere in the system.

[0061] The aerosol generation system may include a control circuit, the control circuit connected to the inductor coil and configured to control power delivery to the inductor coil. The control circuit may include a sensor for detecting when a user puffs on the aerosol generation system. The sensor may be configured to be in fluid communication with the device airflow passage when the cartridge is coupled to the aerosol generation device. The control circuit may be configured to detect that a user is puffing on the system based on a signal from the sensor. The sensor may be an airflow sensor. The sensor may be a pressure sensor. The sensor may enable the aerosol generation system to provide power for each puff.

[0062] The control circuitry may be configured to power the inductor coil continuously after system startup, or may be configured to 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 circuitry may advantageously comprise a DC / AC inverter, which may comprise a class D or class E power amplifier. The control circuitry may comprise further electronic components. For example, in some embodiments, the control circuitry may comprise a sensor element, a switch element, or a display element.

[0063] The inductor coil may be a helical coil, at least a portion of which surrounds the susceptor assembly when the aerosol generation device and cartridge are connected to each other. The helical coil may have a circular cross section when viewed parallel to the longitudinal axis of the aerosol generation system. The inductor coil may include one or more coils.

[0064] The magnetic field generated by the inductor may be parallel to the longitudinal axis of the airflow passage. The susceptor assembly may be configured to be disposed within the cartridge such that the susceptor elements can be heated by a magnetic field that varies in a direction parallel to the first direction.

[0065] Advantageously, in such an arrangement, it has been found that the extension of the opening in a second direction perpendicular to the direction of the changing magnetic field does not significantly contribute to the induced power and heat generation, and therefore it is beneficial to position the susceptor element so that the largest dimension of the opening is aligned with the direction of the changing magnetic field.

[0066] The aerosol generation system may be a handheld aerosol generation system configured to allow a user to draw on a mouthpiece to draw aerosol through the system air outlet. The aerosol generation system may have a size comparable to a conventional cigar or cigarette. The aerosol generation system may have an overall length of about 30 millimeters to about 150 millimeters. The aerosol generation system may have an outer diameter of about 5 millimeters to about 30 millimeters. The aerosol generation system may be an electrically operated smoking system.

[0067] According to a fourth aspect of the present disclosure, there is provided an aerosol generation system. The aerosol generation system may include a susceptor assembly according to the first aspect of the present disclosure and a liquid reservoir for holding a liquid aerosol-forming substrate, the channel being in fluid communication with the liquid aerosol-forming substrate in the liquid reservoir and arranged to transport the liquid aerosol-forming substrate across a surface of the susceptor element by capillary action. The aerosol generation system includes an inductor coil and 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, the susceptor assembly being positioned within the alternating magnetic field.

[0068] The aerosol generation system may include a control circuit. The control circuit may include a sensor for detecting when a user puffs on the aerosol generation system. The sensor may be configured to be in fluid communication with the device airflow path. The control circuit may be configured to detect that a user is puffing on the system based on a signal from the sensor. The sensor may be an airflow sensor. The sensor may be a pressure sensor. The sensor may enable the aerosol generation system to provide power for each puff.

[0069] The control circuit may be configured to power the inductor coil continuously after activation of the device, or may be configured to supply power intermittently, such as between puffs. 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 comprise a DC / AC inverter, which may comprise a class D or class E power amplifier. The control circuit may comprise further electronic components. For example, in some embodiments, the control circuit may comprise a sensor element, a switch element, or a display element.

[0070] The inductor coil may be a 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 device.

[0071] The aerosol generation system may further comprise an air inlet, an air outlet, and an airflow path extending from the air inlet through the susceptor assembly, the airflow path being perpendicular to the direction of liquid supply from the liquid reservoir.

[0072] The aerosol-generating system may include a susceptor holder that holds the susceptor assembly, and at least a portion of the airflow path is defined by the susceptor holder, which is advantageous because the vaporized aerosol-forming substrate that leaves the susceptor assembly immediately mixes with air in the airflow path and is inhaled by the user.

[0073] The susceptor holder may provide a liquid seal around the susceptor assembly to prevent leakage of the liquid aerosol-forming substrate from the liquid reservoir except through the at least one wicking layer.

[0074] At least one channel of the susceptor assembly may extend transversely to a direction of airflow in the airflow channel through the susceptor assembly. A direction of liquid supply from the liquid reservoir may be perpendicular to a direction of airflow in the airflow channel through the susceptor assembly. The direction of liquid supply may be substantially perpendicular to an axis about which the plurality of wires are wound around the susceptor element.

[0075] Opposite ends of the susceptor element may be in fluid communication with a liquid reservoir. Advantageously, this may increase capillary action and thus allow wetting of the susceptor element.

[0076] The aerosol generation system may include a mouthpiece. The aerosol generation system may include a mouthpiece. The aerosol generation system may be a handheld aerosol generation system configured to allow a user to draw on the mouthpiece to draw aerosol through the device air outlet. The aerosol generation system may have a size comparable to a conventional cigar or cigarette. The aerosol generation system may have a total length of about 30 millimeters to about 150 millimeters. The aerosol generation device may have an outer diameter of about 5 millimeters to about 30 millimeters.

[0077] In all aspects of the present disclosure, the liquid aerosol-forming substrate may comprise a volatile compound capable of forming an aerosol. The volatile compound may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may comprise both liquid and solid components. The liquid aerosol-forming substrate may comprise nicotine. The nicotine-containing liquid aerosol-forming substrate may be a nicotine salt matrix. The liquid aerosol-forming substrate may comprise a plant-derived material. The liquid aerosol-forming substrate may comprise tobacco. The liquid aerosol-forming substrate may comprise a tobacco-containing material containing volatile tobacco flavour compounds that are released from the aerosol-forming substrate upon heating. The liquid aerosol-forming substrate may comprise a homogenised tobacco material. The liquid aerosol-forming substrate may comprise a non-tobacco-containing material. The liquid aerosol-forming substrate may comprise a homogenised plant-derived material. [Brief explanation of the drawings]

[0078] [Figure 1A] 1 shows a schematic diagram of a cartridge for an aerosol generation system, the cartridge comprising a susceptor assembly. [Figure 1B] 1B shows a schematic diagram of an alternative cross section of the cartridge of FIG. 1A. [Figure 2] 1C shows a further alternative cross-sectional schematic view of the cartridge of FIGS. 1A and 1B. FIG. [Figure 3A]1 shows a schematic diagram of an aerosol generation system formed from a cartridge and an aerosol generation device, the cartridge being separated from the aerosol generation device. [Figure 3B] 3B shows a schematic cross-sectional view of the aerosol generation system of FIG. 3A, in which the cartridge is coupled to the aerosol generation device. [Figure 4] 1 shows a schematic cross-sectional view of an aerosol generation system, the system comprising a susceptor assembly. [Figure 5] 1 shows a schematic diagram of an embodiment of a susceptor assembly according to a first aspect of the present disclosure; [Figure 6A] 1 shows a schematic diagram of a further embodiment of a susceptor assembly according to a first aspect of the present disclosure; [Figure 6B] 1 shows a schematic diagram of a further embodiment of a susceptor assembly according to a first aspect of the present disclosure; [Figure 7A] 1 shows a schematic diagram of one embodiment of a susceptor assembly in which a susceptor element is folded along a crease to form a folded susceptor element having at least one layer. [Figure 7B] 1 shows a schematic diagram of one embodiment of a susceptor assembly in which a susceptor element is folded along a crease to form a folded susceptor element having at least one layer. [Figure 7C] 1 shows a schematic diagram of one embodiment of a susceptor assembly in which a susceptor element is folded along a crease to form a folded susceptor element having at least one layer. DETAILED DESCRIPTION OF THE INVENTION

[0079] The embodiments will now be further described with reference to the following figures:

[0080] 1A and 1B show schematic views of two cross sections of a cartridge 10 for an aerosol generation system, the cartridge comprising a susceptor assembly according to a first embodiment of the present disclosure. The two cross sections are taken in two planes perpendicular to each other.

[0081] FIG. 1 shows a cartridge 10 comprising a susceptor holder 14 and a susceptor assembly 12 attached to the susceptor holder 14. The susceptor assembly 12 in this embodiment is planar and thin, having a thickness dimension substantially smaller than its length and width dimensions. The susceptor assembly 12 is rectangular and includes a susceptor element 16. An outer side 20 of the susceptor element 16 protrudes into one of two channels 45 through a pair of openings 28 disposed on opposite sides of an interior sidewall 27 of the susceptor holder 14. The interior sidewall 27 defines an interior passage 26 of the susceptor holder 14. The susceptor element 16 comprises a nonwoven sheet formed from ferritic stainless steel. The susceptor assembly 12 comprises a plurality of channels configured to deliver a liquid aerosol-forming substrate by capillary action across the surface of the susceptor element 16.

[0082] The susceptor element 16 is configured to be heatable by penetration with an alternating magnetic field to vaporize the aerosol-forming substrate. The outer sides 20 of the susceptor element protrude through a pair of openings 28 in the susceptor holder 14 so that the susceptor holder 14 supports the susceptor assembly 12 in place in the cartridge 10.

[0083] The susceptor assembly 12 is partially 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 susceptor element 16 is completely disposed within the interior passage 26 of the susceptor holder 14, with the outer sides 20 of the susceptor element 16 extending into two channels 45 through a pair of openings 28 in the interior sidewall 27 of the susceptor holder 14. The outer sides 20 of the susceptor element 16 define a mounting area for the susceptor assembly 12 for mounting the susceptor assembly in the susceptor holder 14.

[0084] 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 to connect the cartridge 10 to an aerosol generating device 60, as described in detail below. The susceptor assembly 12 and susceptor holder 14 are located toward the connecting end of the cartridge 10.

[0085] 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 housed.

[0086] The outer width of the outer housing 36 is greater at the mouth end of the cartridge 10 than at the connecting end, and they are joined by a shoulder 37. This allows the connecting end of the cartridge 10 to be received in a cavity in the aerosol generation device 60, and the shoulder 37 allows the cartridge to be correctly positioned in the aerosol generation device 60. This also allows the mouth end of the cartridge 10 to remain outside the aerosol generation device 60, allowing the mouth end to conform to the external shape of the aerosol generation device 60.

[0087] 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.

[0088] 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 .

[0089] 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 susceptor holder 14 .

[0090] The liquid reservoir 44 further includes two channels 45 defined between the outer housing 36 at the connecting end and the interior sidewall 27 that defines the interior passage 26 of the susceptor 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 to the connecting end of the cartridge 10. The outer side 20 of the susceptor element 16 extends into the two channels 45 through openings 28 in the interior sidewall 27 of the susceptor 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 passage 26 of the susceptor holder 14.

[0091] The susceptor 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.

[0092] An air passageway is formed through the cartridge 10 by the internal passageway 26 of the susceptor holder 14 and the internal passageway 48. The air passageway extends from the air inlet 32 ​​in the base 30 of the susceptor holder 14, through the internal passageway 26 of the susceptor holder 14, and through the internal passageway 48 to the mouth end opening 38. The air passageway allows air to be drawn through the cartridge 10 from the connection end to the mouth end.

[0093] Figure 2 shows a schematic diagram of a further alternative cross section of cartridge 10 of Figures 1A and 1B, with cartridge 10 viewed perpendicular to the views shown in Figures 1A and 1B, such that the cross section shown in Figure 1A is indicated by dashed line AB and the cross section shown in Figure 1B is indicated by dashed line CD.

[0094] The cartridge 10 includes a susceptor holder 14. The susceptor holder 14 includes a tubular body formed from a moldable plastic material, such as polypropylene. The tubular body of the susceptor holder 14 includes an interior sidewall 27 that defines an interior passageway 26 having an open end. A pair of openings 28 extend through the interior sidewall 27 on opposite sides of the tubular susceptor holder 14. The openings 28 are centrally disposed along the length of the susceptor holder 14.

[0095] A pair of openings 28 in the sidewalls 27 of the susceptor holder 14 are sized to receive the susceptor assembly 12 by a friction fit such that the susceptor assembly is secured within the susceptor holder 14. The friction fit between the susceptor assembly 12 and the susceptor holder 14 causes the mounting area to directly contact the susceptor holder 14 at the openings 28. The susceptor assembly 12 and the susceptor holder 14 are secured together such that movement of the susceptor holder 14 also causes movement of the susceptor assembly 12.

[0096] It will be appreciated that the susceptor assembly 12 and the susceptor holder 14 may be secured together by other means. For example, in some embodiments, the susceptor assembly 12 is secured to the susceptor holder 14 by an adhesive at an attachment region of the susceptor assembly 12 such that the attachment region is in indirect contact with the susceptor holder 14.

[0097] 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 susceptor assembly 12. The outer side 20 of the susceptor element 16, which forms the mounting area 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 prior to use.

[0098] 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.

[0099] 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.

[0100] Cartridge 10 is identical to the cartridges presented in Figures 1A, 1B and 2 and their corresponding descriptions.

[0101] 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.

[0102] The aerosol generating device 60 further comprises an induction heating arrangement disposed within the device outer housing 62. The induction heating arrangement includes an inductor coil 90, a control circuit 70, and a power source 72. The power source 72 comprises a rechargeable nickel-cadmium battery or a lithium-ion battery, which is rechargeable via an electrical connector (not shown) at the distal end of the device. The control circuit 70 is connected to the power source 72 and to the inductor coil 90 such that the control circuit 70 controls the supply of power to the inductor coil 90. The control circuit 70 is configured to supply an alternating current to the inductor coil 90.

[0103] 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-forming 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 generation device 60.

[0104] 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 .

[0105] 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.

[0106] 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.

[0107] 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.

[0108] 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.

[0109] 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.

[0110] When the system 100 is activated, an alternating current is established in the inductor coil 90, which generates an alternating magnetic field in the cavity 64 in which the susceptor assembly 12 is located, heating the susceptor element 16. The liquid aerosol-forming substrate in the liquid reservoir 44 is drawn into the susceptor assembly 12 by capillary action. The liquid aerosol-forming substrate 42 of 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.

[0111] 4 shows a cross-sectional schematic view of an aerosol-generation system 200, the system 200 including a susceptor assembly 112. As used herein, the terms aerosol-generation system and system are used interchangeably.

[0112] During operation, when a user draws a puff on the mouth end opening 138 of the system, ambient air is drawn into the system 200 through the air inlet 165. The ambient air flows through the system 200 from the air inlet 165 to the mouth end opening 138 through an air passage defined by the internal passage 126, over the susceptor assembly 112.

[0113] Control circuit 170 controls the supply of power from power supply 172 to inductor coil 190 when the system is activated.

[0114] The control circuit 172 is coupled to the airflow sensor 163. The airflow sensor 163 is in fluid communication with the path of ambient air drawn through the system by a user. The control circuit 172 provides power to the inductor coil 190 when the airflow sensor 163 detects a puff by the user on the aerosol generation system 200.

[0115] When the aerosol-generation system 200 is activated, an alternating current is established in the inductor coil 190, which generates an alternating magnetic field in the cavity 64 in which the susceptor assembly 112 is located, causing the susceptor element 116 to heat. Liquid aerosol-forming substrate in the liquid reservoir 144 is drawn into the susceptor assembly 112 by capillary action. The liquid aerosol-forming substrate 142 of 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 148 of the aerosol-generation system 200, where they cool and form an aerosol. The aerosol is entrained in air drawn through the internal passage 148 of the aerosol-generation system 200 and is drawn from the internal passage 148 at the mouth-end opening 138 for inhalation by the user.

[0116] The aerosol generation system 200 includes a generally cylindrical device outer housing 162 having a connecting end and a distal end opposite the connecting end. An air inlet 65 is provided through the device outer housing 62 at the base of the cavity 64 to allow ambient air to be drawn into the cavity 64.

[0117] The aerosol generation system 200 further comprises an induction heating arrangement disposed within the system outer housing 162. The induction heating arrangement includes an inductor coil 190, a control circuit 170, and a power source 172. The power source 172 comprises a rechargeable nickel-cadmium battery or a lithium-ion battery, which is rechargeable via an electrical connector (not shown) at the distal end of the system. The control circuit 170 is connected to the power source 172 and the inductor coil 190 such that the control circuit 170 controls the supply of power to the inductor coil 190. The control circuit 170 is configured to supply an alternating current to the inductor coil 190.

[0118] A single inductor coil 190 is positioned around the susceptor assembly 112 within the aerosol generation system 200. The inductor coil 190 has a size and shape that matches the size and shape of the susceptor element 116. The inductor coil 190 is made of copper wire with a circular cross-section and is disposed on a coil-forming element (not shown). The inductor coil 190 is both tubular and helical, and defines a circular cross-section when viewed along the longitudinal axis of the aerosol generation system 200.

[0119] The inductor coil 190 is configured such that when an alternating current is supplied to the inductor coil, the inductor coil generates an alternating magnetic field in the region of the susceptor assembly 112 .

[0120] The induction heating arrangement further includes a flux concentrator element 191. The flux concentrator element 191 has a larger radius than the inductor coil 190, and therefore partially surrounds the inductor coil 190. The flux concentrator element 191 is configured to reduce stray power losses from the generated magnetic field.

[0121] FIG. 5 shows a schematic diagram of an embodiment of a susceptor assembly 212 according to a first aspect of the present disclosure. The susceptor element 216 is a nonwoven fabric sheet. In the embodiment shown in FIG. 5, the susceptor element has a flat, rectangular shape. The susceptor assembly includes a plurality of channels 221. The channels 221 are configured to apply capillary forces to the liquid aerosol-forming substrate so as to assist the channels 221 in transporting the liquid aerosol-forming substrate across the surface of the susceptor element 216. The channels in this embodiment have a depth that is less than the thickness of the susceptor element 216. Each channel is formed in the susceptor element by etching, for example, chemical etching. In other embodiments, each channel may be formed by laser engraving, stamping, or wire discharge. 1A, 1B, 3A, 3B, and 4, with peripheral channel 225 located on side 20, 120 of the susceptor assembly so as to be in direct fluid communication with a liquid aerosol-forming substrate located in liquid reservoir 44. The proximal end of peripheral channel 225 connects to opening 223, and the distal end extends into liquid reservoir 44. A liquid supply 270 from liquid reservoir 44 travels parallel to the direction in which peripheral channel 225 extends until it reaches opening 223.

[0122] The susceptor assembly of FIG. 5 further includes a plurality of openings 223. The openings 223 extend from one surface of the susceptor element 216 to the opposite surface of the susceptor element 216. Each opening 223 has the same cross-section, which in this embodiment is circular. The openings 223 act as vaporization sites for the liquid aerosol-forming substrate. The openings 223 are connected to at least one channel 221. Each channel 221 of the plurality of channels 221 extends from one opening 223 to an adjacent opening 223, creating a network of channels 221 and openings 223 across the surface of the susceptor element 216. The network of channels 221 and openings 223 extends across the entire surface of the susceptor element. Alternative embodiments may exist in which the susceptor assembly includes a first region that does not include any channels 221 or openings 223 and a second region that includes channels 221 and openings 223.

[0123] 6A shows a schematic diagram of a further embodiment of a susceptor assembly according to a first aspect of the present disclosure, the susceptor assembly comprising longitudinal channels 321. The susceptor element 312 is a nonwoven sheet. In the embodiment shown in FIG. 6, the susceptor element has a flat, rectangular shape. The longitudinal channels 321 are parallel to each other and all extend in the same direction as the liquid supply 370. Each longitudinal channel 321 extends across the entire width of the susceptor, with opposing ends of the longitudinal channels 321 extending to the edges of the susceptor element 312. The channels act in the same manner as channels 221 in FIG. 5 to transport the liquid aerosol-forming substrate across the face of the susceptor element 316. The longitudinal channels 321 act as vaporization sites for the liquid aerosol-forming substrate.

[0124] The longitudinal channels 321 in Figure 6A have a depth that is less than the thickness of the susceptor element 312. Each channel is formed by etching, for example, chemical etching. In other embodiments, each channel may be formed by laser engraving, stamping, or wire discharge.

[0125] 6B shows a schematic diagram of another view of the embodiment of FIG. 6A. The susceptor element 316 has an eye-shaped cross-section. The longitudinal channels 321 are located on the inner surface 399 and the outer surface 398 of the eye-shaped susceptor element 316. In some embodiments, the channels are located only on the inner surface 399 or the outer surface 398. The susceptor element 316 extends into an opening in the inner sidewall 327 such that a portion of the longitudinal channel is in fluid communication with the liquid reservoir.

[0126] FIG. 7A shows a schematic diagram of another embodiment of a susceptor assembly 412 in which the susceptor element 416 is folded along creases to provide multiple layers, as shown in FIG. 7B. The susceptor assembly 412 of this embodiment includes a first crease 458 and a second crease 459. The first crease 458 joins the first layer 481 and the second layer 482. The second crease 459 joins the second layer 482 and the third layer 483. In other embodiments, there may be more than two creases to provide three or more layers. The susceptor element 416 of FIG. 7 is a perforated foil strip. As used herein, the terms perforation and aperture are used interchangeably. The perforations in this embodiment are achieved by photochemical etching (PCE). Of course, other thin foil hole fabrication processes are possible, such as laser micromachining / drilling and expanding metal sheet production.

[0127] Multiple wires 460 are wound around the susceptor element 416 of FIG. 7A so that they are parallel to each other and to the direction of liquid supply. The wires 460 comprise a magnetic material. The wires 460 comprise ferritic stainless steel. The wires 460 contribute to inductive heating. In this embodiment, the multiple wires 460 act as channels, and the small gaps created by the wires allow capillary action. This capillary action transports the liquid aerosol-forming substrate across the surface of the susceptor element 416 of FIG. 7A. In some embodiments, a single wire is wound around the susceptor element 416, and the single wire may comprise multiple sections.

[0128] The susceptor assembly 412 comprises a first region 451 and a second region 452. The first region 451 includes a first array of first openings 423. The openings 423 in the first region 451 are identical to one another. The openings 423 in the first region 451 are arranged in a uniform pattern. In some embodiments, the openings 423 are arranged in a non-uniform pattern. The susceptor element 716 further comprises a second region 752. The second region 752 does not include any openings. The second region 752 has a lower density of openings 423 than the first region 651 due to the absence of openings in the second region 752. Heat conduction is greater in the second region due to the absence of openings, reducing the possibility of overheating in the second region. In some embodiments, the second region includes openings 423. The first region 451 surrounds the second region 452. 7 is circular, but may be different shapes, for example, hexagonal, quadrilateral, triangular, etc. If a hole fabrication process such as expanded metal mesh is used, the opening may also be quadrilateral.

[0129] Figure 7B shows a schematic view of the susceptor assembly 412 shown in Figure 7A from a side view during folding. The susceptor element 416 in Figure 7B is folded along fold lines 458 and 459. The partially folded susceptor element 416 in Figure 7B comprises a first layer 481, a second layer 482, and a third layer 483, with the second layer 482 positioned between the first layer 481 and the third layer 483. The second region 482 shown in Figure 7B is covered on both sides by the first region 481. At the first fold line 458, the first layer 481 is folded over the second layer 482. At the second fold line 459, the third layer 483 is folded under the second layer 482.

[0130] Figure 7C shows a schematic diagram of the susceptor assembly shown in Figures 7A and 7B with the susceptor element 416 fully folded. The susceptor element 416 in Figure 7C has been folded until it is substantially flat. The first, second, and third layers 481, 482, 483 of the susceptor element 416 are substantially parallel in the horizontal plane of Figure 7C.

[0131] The liquid aerosol-forming substrate may include one or more aerosol formers. The aerosol former is any suitable known compound or mixture of compounds that facilitates the formation of a dense, stable aerosol during use and is substantially resistant to thermal decomposition at the operating temperatures of the system. Examples of suitable aerosol formers include glycerin and propylene glycol. Suitable aerosol formers are well known in the art and include, but are not limited to, polyhydric alcohols (e.g., triethylene glycol, 1,3-butanediol, glycerin), esters of polyhydric alcohols (e.g., glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of monocarboxylic, dicarboxylic, or polycarboxylic acids (e.g., dimethyl dodecanedioate, dimethyl tetradecanedioate). The liquid aerosol-forming substrate may include water, solvents, ethanol, plant extracts, and natural or artificial flavors.

[0132] The liquid aerosol-forming substrate may comprise nicotine and at least one aerosol former. The aerosol former may be glycerin or propylene glycol. The aerosol former may comprise both glycerin and propylene glycol. The liquid aerosol-forming substrate may have a nicotine concentration of about 0.5% to about 10%, for example about 2%.

[0133] In all aspects of the present disclosure, 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 and 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 example, the power source may have a capacity sufficient to allow for a predetermined number of puffs or discontinuous activations of the susceptor assembly.

[0134] According to a further aspect of the present disclosure, there is provided a method of manufacturing an aerosol generating device, the method comprising: providing a sheet of material that is heatable through the induction of eddy currents and hysteresis losses to vaporize an aerosol-forming substrate; forming channels of width and depth in the sheet of material, the channels capable of transporting liquid across the surface of the sheet by capillary action.

[0135] The channels may be formed, for example, by etching or laser engraving.

[0136] According to a further aspect of the present disclosure, there is provided a method of manufacturing an aerosol generating device, the method comprising: providing a sheet of material that is heatable through the induction of eddy currents and hysteresis losses to vaporize an aerosol-forming substrate; providing one or more wires on or around the sheet of material to provide capillary channels on the surface of the sheet of material between portions of the one or more wires, the channels being capable of transporting liquid across the surface of the sheet by capillary action.

[0137] Providing one or more wires may be, for example, by wrapping the wires around the sheet of material or by gluing the wires onto the sheet of material. [Example]

[0138] 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, for example, with any one or more features of any other example, embodiment, or aspect described herein.

[0139] Example 1: 1. A susceptor assembly for an aerosol generating system, comprising: The susceptor element has the form of a sheet and at least one channel formed in or on a surface of the sheet and configured to transport a liquid aerosol-forming substrate across the surface of the sheet. Example 2: 10. The susceptor assembly of example 1, wherein at least one channel is formed in a surface of the susceptor element. Example 3: The susceptor assembly of example 1 or example 2, comprising a plurality of channels configured to transport a liquid aerosol-forming substrate across a surface of the sheet. Example 4: The susceptor assembly of example 3, wherein the plurality of channels are connected to each other. Example 5: The susceptor assembly of example 3 or example 4, wherein the plurality of channels form a network of channels. Example 6: The susceptor assembly of any one of Examples 3-5, wherein at least one channel extends from an end of the susceptor element to a central region of the susceptor element. Example 7: 7. The susceptor assembly of any one of Examples 1-6, wherein the susceptor element has a thickness and the channel has a depth that is less than the thickness of the susceptor element. Example 8: A susceptor assembly described in any one of Examples 1 to 7, comprising a plurality of wires or wire sections arranged on the surface of a susceptor element, and at least one channel formed between the plurality of wires or wire sections. Example 9: The susceptor assembly of example 8, comprising a plurality of wires or wire sections arranged parallel to one another. Example 10: The susceptor assembly of example 8 or example 9, wherein the plurality of wires or wire sections comprises an electrically conductive material. Example 11: The susceptor assembly of example 8, example 9, or example 10, wherein the plurality of wires or wire sections comprises a ferrous material. Example 12: The susceptor assembly of any one of Examples 8-11, wherein the plurality of wires or wire sections comprises at least one wire wound around the susceptor element. Example 13: 13. The susceptor assembly of example embodiment 12, wherein at least one channel is formed between successive windings of wire. Example 14: 14. The susceptor assembly of any one of Examples 1-13, further comprising one or more openings extending from a surface of the sheet to an opposite surface. Example 15: 17. The susceptor assembly of example 16, wherein each of the one or more openings is connected to at least one channel. Example 16: A susceptor assembly as described in Example 16 or Example 17, wherein the one or more openings include a plurality of openings, and the plurality of openings have a different size, shape, or arrangement in a first region of the sheet than in a second region of the sheet. Example 17: 17. The susceptor assembly of any one of Examples 1-16, wherein the sheet comprises a nonwoven structure. Example 18: The susceptor assembly of any one of Examples 1-17, wherein the sheet comprises an etched foil. Example 19: 19. The susceptor assembly of any one of Examples 1-18, wherein the sheet is folded along at least one crease to provide multiple layers of the susceptor element. Example 20: 22. The susceptor assembly of example 21, wherein the sheet is folded such that the at least one channel is positioned on an interior surface of the susceptor assembly. Example 21: The susceptor assembly of example 21 or example 22, wherein the sheet includes an elongated slot disposed along at least one fold. Example 22: 22. The susceptor assembly of any of Examples 1-21, wherein the susceptor element comprises a perforated foil strip. Example 23: 23. The susceptor assembly of any one of Examples 1-22, wherein the susceptor element comprises a ferrous material. Example 24: 24. The susceptor assembly of any one of Examples 1-23, wherein the susceptor element comprises ferritic stainless steel. Example 25: 25. The susceptor assembly of any one of Examples 1-24, wherein at least one susceptor element is heatable by at least one of Joule heating due to induction of eddy currents in the susceptor element and hysteresis losses. Example 26: 26. The susceptor assembly of any one of Examples 1-25, wherein at least one susceptor element comprises at least one of graphite, molybdenum, silicon carbide, stainless steel, niobium, and aluminum. Example 27: 27. The susceptor assembly of any one of Examples 1-26, wherein at least one susceptor element comprises at least one ferromagnetic material. Example 28: 28. The susceptor assembly of any one of Examples 1-27, wherein at least one susceptor element comprises AISI 430 stainless steel. Example 29: 29. A susceptor assembly according to any one of Examples 1 to 28, wherein at least one susceptor element has a relative magnetic permeability of 1 to 40,000 when measured at a temperature of 20 degrees Celsius and a frequency of up to 10 kHz. Example 30: 30. The susceptor assembly of any one of Examples 1 to 29, wherein at least one susceptor element has a relative magnetic permeability of 500 to 40,000 when measured at a temperature of 20 degrees Celsius and a frequency of up to 10 kHz. Example 31: 1. A cartridge for an aerosol generation system, comprising: A susceptor assembly according to any one of Examples 1 to 30; a liquid reservoir for holding a liquid aerosol-forming substrate, the channel being in fluid communication with the liquid aerosol-forming substrate in the liquid reservoir and arranged to transport the liquid aerosol-forming substrate across the surface of the susceptor element by capillary action. Example 32: 32. The cartridge of example 31, further comprising an air inlet, an air outlet, and an airflow path extending from the air inlet, through the susceptor element, and to the air outlet. Example 33: 33. The cartridge of example 32, wherein the cartridge further comprises a susceptor holder that holds a susceptor assembly, and wherein at least a portion of the airflow path is defined by the susceptor holder. Example 34: 34. The cartridge of Example 33, wherein the susceptor holder holds the susceptor assembly such that at least a portion of the susceptor element is positioned within the airflow path and at least one channel is in fluid communication with the liquid aerosol-forming substrate in the liquid reservoir. Example 35: The cartridge of example 33 or example 34, wherein the susceptor holder provides a liquid seal around the susceptor assembly to prevent leakage of the liquid aerosol-forming substrate from the liquid reservoir except through at least one channel. Example 36: A cartridge described in Example 34 or Example 35, wherein at least one channel extends from the periphery of the susceptor element positioned within the liquid reservoir to a central region of the susceptor element positioned within the airflow path through the cartridge. Example 37: The cartridge of any one of Examples 34 to 36, wherein at least one channel extends transversely to the direction of airflow through the susceptor element. Example 38: The cartridge of any one of Examples 31 to 37, wherein opposing ends of the susceptor element communicate with the reservoir. Example 39: The cartridge of any one of Examples 31 to 38, further comprising a mouthpiece, the mouthpiece comprising an air outlet. Example 40: 1. An aerosol generating system comprising: A cartridge according to any one of Examples 32 to 39, An aerosol generating device, comprising: an inductor coil; An aerosol generation system comprising: an aerosol generating device comprising: a power source connected to an inductor coil and configured to provide an alternating current to the inductor coil to generate an alternating magnetic field; and a power source configured to connect to each other so that the susceptor assembly is positioned within the alternating magnetic field. Example 41: An aerosol generation system as described in Example 40, further comprising a control circuit, the control circuit connected to the inductor coil and configured to control power delivery to the inductor coil. Example 42: 43. The aerosol generation system of claim 41 or 42, wherein the inductor coil is a helical coil positioned around the susceptor assembly when the aerosol generator and cartridge are coupled together. Example 43: 1. An aerosol generating system comprising: A susceptor assembly according to any one of Examples 1 to 30; a liquid reservoir for holding a liquid aerosol-forming substrate, the channel being in fluid communication with the liquid aerosol-forming substrate in the liquid reservoir and being arranged to transport the liquid aerosol-forming substrate across the surface of the susceptor element by capillary action; an inductor coil; an electrical power source connected to the inductor coil and configured to provide an alternating current to the inductor coil to generate an alternating magnetic field, wherein the susceptor assembly is positioned within the alternating magnetic field; Example 44: An aerosol generation system as described in Example 43, further comprising a control circuit, the control circuit connected to the inductor coil and configured to control power delivery to the inductor coil. Example 45: An aerosol generation system as described in Example 44, wherein the control circuit comprises a sensor and is configured to deliver power from the power source to the coil upon detection of puffing by the sensor. Example 46: The aerosol generation system of any one of Examples 43 to 45, wherein the inductor coil is a helical coil positioned around the susceptor element. Example 47: The aerosol generation system of any one of Examples 43 to 46, further comprising an air inlet, an air outlet, and an airflow path extending from the air inlet, through the susceptor element, to the air outlet. Example 48: 48. The aerosol generation system of Example 47, further comprising a susceptor holder for holding the susceptor assembly, wherein at least a portion of the airflow path is defined by the susceptor holder. Example 49: An aerosol generating system as described in Example 48, wherein the susceptor holder holds the susceptor assembly so that at least a portion of the susceptor element is positioned within the airflow path and at least one channel is in fluid communication with a liquid aerosol-forming substrate in the liquid reservoir. Example 50: 50. The aerosol generating system of Example 49, wherein the susceptor holder provides a liquid seal around the susceptor assembly to prevent leakage of the liquid aerosol-forming substrate from the liquid reservoir except through at least one channel. Example 51: An aerosol generation system as described in Example 49 or Example 50, wherein at least one channel extends from the periphery of the susceptor element positioned within the liquid reservoir to a central region of the susceptor element positioned within the airflow path through the cartridge. Example 52: 52. The aerosol generation system of any one of Examples 49 to 51, wherein at least one channel extends transversely to the direction of airflow through the susceptor element. Example 53: An aerosol generation system according to any one of Examples 43 to 52, wherein opposing ends of the susceptor element are in communication with the reservoir. Example 54: An aerosol generating system according to any one of Examples 44 to 53, further comprising a mouthpiece, the mouthpiece comprising an air outlet. Example 55: 1. A method for manufacturing a susceptor assembly for an aerosol generating device, comprising: providing a sheet of material that is heatable through the induction of eddy currents and hysteresis losses to vaporize an aerosol-forming substrate; A method comprising: forming, for example by etching or laser engraving, channels of width and depth in a sheet of material, the channels being capable of transporting liquid across the surface of the sheet by capillary action. Example 56: 1. A method for manufacturing a susceptor assembly for an aerosol generating device, comprising: providing a sheet of material that is heatable through the induction of eddy currents and hysteresis losses to vaporize an aerosol-forming substrate; providing, for example by wrapping or bonding, one or more wires on or around a sheet of material to provide capillary channels on a surface of the sheet of material between portions of the one or more wires, the channels being capable of transporting liquid across the surface of the sheet by capillary action.

Claims

1. 1. A susceptor assembly for an aerosol generating system, comprising: a susceptor element in the form of a sheet, and at least one channel formed on a surface of said sheet and configured to transport a liquid aerosol-forming substrate across said surface of said sheet; a plurality of wires or wire sections disposed on the surface of the susceptor element, wherein the at least one channel is formed between one or more of the wires or wire sections;

2. 10. The susceptor assembly of claim 1, comprising a plurality of channels formed on a surface of the sheet and configured to transport a liquid aerosol-forming substrate across the surface of the sheet.

3. The susceptor assembly of claim 2 , wherein the plurality of channels are connected to one another.

4. The susceptor assembly of any one of claims 1 to 3, wherein the at least one channel extends from an end of the susceptor element to a central region of the susceptor element.

5. The susceptor assembly of any one of claims 1 to 4, further comprising one or more openings extending from said surface to an opposite surface of said sheet.

6. 6. The susceptor assembly of claim 5, wherein the one or more openings include a plurality of openings, the plurality of openings having a different size, shape, or arrangement in a first region of the sheet than in a second region of the sheet.

7. The susceptor assembly of any one of claims 1 to 6, wherein the sheet is folded along at least one crease to provide multiple layers of the susceptor element.

8. The susceptor assembly of claim 7 , wherein the sheet is folded so that the at least one channel is positioned on an interior surface of the susceptor assembly.

9. 1. A cartridge for an aerosol generation system, comprising: A susceptor assembly according to any one of claims 1 to 8; a liquid reservoir for holding a liquid aerosol-forming substrate, the channel being in fluid communication with the liquid aerosol-forming substrate in the liquid reservoir and being arranged to transport the liquid aerosol-forming substrate across the surface of the susceptor element by capillary action.

10. an air inlet, an air outlet, and an air flow path extending from the air inlet through the susceptor element to the air outlet; The cartridge of claim 9 , further comprising a susceptor holder that holds the susceptor assembly, wherein at least a portion of the airflow path is defined by the susceptor holder.

11. 11. The cartridge of claim 9 or 10, wherein the susceptor holder holds the susceptor assembly such that at least a portion of the susceptor element is positioned within the airflow path and the at least one channel is in fluid communication with the liquid aerosol-forming substrate in the liquid reservoir.

12. 12. A cartridge according to any one of claims 9 to 11, wherein the at least one channel extends from a periphery of the susceptor element positioned within the liquid reservoir to a central region of the susceptor element positioned within an airflow path through the cartridge.

13. 1. An aerosol generating system comprising: A cartridge according to any one of claims 9 to 12; A main unit, An induction coil; An aerosol generation system comprising: a main unit comprising: a power source connected to an inductor coil and configured to provide an alternating current to the inductor coil to generate an alternating magnetic field; and the cartridge and main unit configured to be coupled to each other so that the susceptor assembly is positioned within the alternating magnetic field.

14. 1. An aerosol generating system comprising: A susceptor assembly according to any one of claims 1 to 8; a liquid reservoir for holding a liquid aerosol-forming substrate, the channel being in fluid communication with the liquid aerosol-forming substrate in the liquid reservoir and being arranged to transport the liquid aerosol-forming substrate across the surface of the susceptor element by capillary action; An induction coil; an electrical power source 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 assembly is positioned within the alternating magnetic field.

15. 1. A method for manufacturing a susceptor assembly for an aerosol generating device, comprising: providing a sheet of material that is heatable through the induction of eddy currents and hysteresis losses to vaporize an aerosol-forming substrate; providing one or more wires on or around the sheet of material by wrapping or bonding to provide capillary channels on the surface of the sheet of material between portions of the one or more wires, the channels being capable of transporting liquid across the surface of the sheet by capillary action.

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