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

Abstract

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

Description

[Technical Field]

[0001] The present disclosure relates to a susceptor assembly for an aerosol generation system and a method for manufacturing the 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. Such electrically heated smoking systems are typically handheld and include a power source, a reservoir for holding the aerosol-forming substrate, and an induction heating system. The induction heating system typically includes a coil disposed around a susceptor element to which the liquid aerosol-forming substrate is supplied. An alternating current is passed through the coil, inducing eddy currents in the susceptor element, which heats the susceptor element. The liquid aerosol-forming substrate in contact with or in close proximity to the susceptor element is thereby heated and vaporized. The aerosol generating system typically also includes a wicking element configured to draw the aerosol-forming substrate from the liquid reservoir onto the susceptor element for heating. The airflow passing over the susceptor element entrains the generated vapor. The entrained vapor cools and condenses to form an aerosol, which can be inhaled by a user.

[0003] Typically, a susceptor assembly of an induction aerosol generation system may include a single wicking element that includes a single wicking layer.

[0004] The susceptor assembly includes a susceptor element wrapped around a central wicking element to cover an outward-facing surface of the wicking element, the susceptor element including a mesh, and in use, vaporized aerosol-forming substrate can advantageously escape from the wicking element through gaps present when the susceptor element employs a mesh structure.

[0005] Susceptors are woven meshes made from ferritic stainless steel wire and are known in the art to heat up when an alternating magnetic field is applied. A disadvantage of woven susceptors is that they are fragile and difficult to manufacture.

[0006] To reduce manufacturing complexity and cost, it is desirable to use components of simpler design in the susceptor assembly. Summary of the Invention

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

[0008] Preferably, the wicking element includes a plurality of openings that expose a portion of the susceptor element. The wicking layer has openings that allow generated vapor to mix with the airflow.

[0009] The opening may have a diameter of 0.05 mm to 1.0 mm. Preferably, the opening has a diameter of 0.1 mm to 0.5 mm.

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

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

[0012] Advantageously, susceptor elements in the form of blank sheets have superior mechanical properties to woven susceptors. This allows for easier handling of the susceptor elements during the manufacturing process. Susceptor sheets allow for greater flexibility in sourcing parts and reduce overall manufacturing difficulty. Another advantage of susceptor sheets over woven susceptors is that there is no risk of loose parts of the susceptor element becoming lost in the main flow of the system during use. Nonwoven susceptors allow for the possibility of more complex shapes than simply a flat rectangle, such as S-shapes.

[0013] The susceptor element can be sandwiched between a top wicking layer and a bottom wicking layer, the top and bottom wicking layers substantially covering opposing surfaces of the susceptor element. The wicking elements provide wetting of the susceptor element during use of the susceptor assembly. This advantageously means that the susceptor element is wet on two sides during operation. This can increase the amount of aerosol-forming substrate vaporized in a given time, compared to a susceptor assembly including only one wicking layer.

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

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

[0016] As used herein, the term "aerosol-generating device" is used to describe a device that interacts with an aerosol-forming substrate to generate an aerosol. The aerosol-generating device is preferably 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.

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

[0018] As used herein, the term "aerosol-forming substrate" refers to a substrate made of or including an aerosol-forming material that has the ability to release volatile compounds upon heating to generate an aerosol.

[0019] 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.

[0020] 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 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 can be formed of a ferromagnetic material.

[0021] The wicking element may comprise a porous material. The wicking element may comprise a capillary material. A capillary material is a material that has the ability to transfer 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.

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

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

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

[0025] The wicking element may include a mesh, with gaps present in the mesh allowing the liquid aerosol-forming substrate to pass through the mesh and be vaporized toward the susceptor element.

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

[0027] The wicking element may include a plurality of fibers, and the diameter of the openings may be larger than the diameter of the fibers.

[0028] The distance between the edge of an opening and the edge of an adjacent opening may be 0.05 mm to 0.5 mm. Preferably, the distance between the edge of an opening and the edge of an adjacent 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.

[0029] The opening may have a circular cross section. The opening may have a diameter of at least 0.1 millimeters.

[0030] 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.

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

[0032] The wicking element is folded around the susceptor element to cover its outwardly facing surface. Advantageously, this increases the surface area of ​​the susceptor element in contact with the wicking element, facilitating heat transfer between the susceptor element and the wicking element. During use, increased heat transfer from the susceptor element to the wicking element can facilitate vapor generation from a liquid aerosol-forming substrate entrained in the wicking element.

[0033] From a manufacturing standpoint, a wicking layer with openings evenly distributed across its surface is easier to manufacture.

[0034] The susceptor assembly may include a heated region and an unheated region. The heated region is a region of the susceptor assembly configured to be heated to a temperature required to vaporize the aerosol-forming substrate upon penetration by a suitable alternating magnetic field. The heated region of the susceptor assembly may include at least a portion of the susceptor element.

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

[0036] The length of the susceptor element and the wicking element may be the same. The width of the wicking element may be greater than the width of the susceptor element.

[0037] In some embodiments, the wicking element includes a first region that overlaps the susceptor element and at least a second region that does not overlap the susceptor element, with the openings located over the first region and each of the second regions not including an opening. The first region may be located between two of the second regions. Advantageously, this configuration can increase the flow of liquid to the center of the susceptor element, reducing the risk of overheating.

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

[0039] The susceptor element may be a blank piece of metal. The susceptor element may comprise an iron-based material.

[0040] The susceptor element may comprise annealed steel. Advantageously, annealed steel has improved ductility, making it easier to form than hardened or unheat-treated steel. Annealed steel also has improved toughness, allowing it to withstand greater forces before permanent deformation occurs.

[0041] The susceptor element may comprise a ferritic stainless steel, which, due to its chemical makeup, 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.

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

[0043] 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.

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

[0045] 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. Materials with lower permeability may be used when it is desired to rely mostly on eddy currents for heating, and materials with 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 efficient heating of the susceptor element.

[0046] The susceptor element is heatable by at least one of Joule heating through the induction of eddy currents in the susceptor element and hysteresis losses.

[0047] 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.

[0048] The term "cartridge" as used herein also refers to an article that includes an aerosol-forming substrate capable of emitting a volatile compound capable of forming an aerosol. The cartridge may also be disposable.

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

[0050] 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.

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

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

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

[0054] 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.

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

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

[0057] 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 for the at least one wicking layer.

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

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

[0060] 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. A 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.

[0061] The liquid aerosol-forming substrate may comprise one or more aerosol formers. An 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 (such as triethylene glycol, 1,3-butanediol, and glycerin), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of monocarboxylic, dicarboxylic, or polycarboxylic acids (such as dimethyl dodecanedioate and dimethyl tetradecanedioate). The liquid aerosol-forming substrate may contain water, solvents, ethanol, plant extracts, and natural or artificial flavors.

[0062] The liquid aerosol-forming substrate may comprise nicotine and at least one aerosol former. The aerosol former may be 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%.

[0063] At least one wicking layer of the susceptor assembly may extend transversely to a direction of airflow in the airflow channel passing through the susceptor assembly, and a liquid supply direction from the liquid reservoir may be perpendicular to a direction of airflow in the airflow channel passing through the susceptor assembly.

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

[0065] 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.

[0066] The cartridge may include at least one seal extending across a portion of the airflow channel. The cartridge may include an upstream seal extending across the cartridge air inlet. The upstream seal may be sealed to 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.

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

[0068] 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.

[0069] In embodiments in which the cartridge includes a mouthpiece, a cartridge outer housing, or both a mouthpiece and a cartridge outer housing, each of the mouthpiece and the cartridge outer housing may 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 non-brittle.

[0070] 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 the aerosol generation device according to the second embodiment 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 supply current to the inductor coil to generate an alternating magnetic field, and the cartridge and the aerosol generation device are connectable to each other such that the susceptor assembly is disposed within the 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.

[0071] The cartridge of the aerosol generation system may include a mouth end and a connecting end, the connecting end configured to connect the cartridge to an aerosol generation device.

[0072] The aerosol generation system may include a control circuit. The control circuit may include a sensor for detecting when a user has taken a puff on the aerosol generation system. The sensor may be configured to be in fluid communication with the device airflow path when the cartridge is coupled to the aerosol generation device. The control circuit may be configured to detect when a user has taken a puff on the system based on a signal from the sensor. The sensor may include an airflow sensor. The sensor may be a pressure sensor. The sensor may enable the aerosol generation system to provide power for each puff.

[0073] The control circuit may be configured to continuously power the inductor coil after system startup, or may be configured to provide power intermittently, such as with each puff. Power may be provided to the induction heating assembly in the form of current pulses, for example, by pulse width modulation (PWM). The control circuit may advantageously include a DC / AC inverter, which may include a class D or class E power amplifier. The control circuit may include additional electronic components. For example, in some embodiments, the control circuit may include a sensor, a switch, or a display element.

[0074] 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.

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

[0076] The power source can be a DC power source. The power source can be a battery. The battery can 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 can be a nickel-metal hydride battery or a nickel-cadmium battery. The power source can be another form of charge storage device, such as a capacitor. The power source can be rechargeable and configured to undergo multiple charge-discharge cycles. The power source can have a capacity that allows for the storage of energy sufficient for one or more user experiences with the aerosol generation system; for example, the power source can 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 can have a capacity sufficient to allow for a predetermined number of puffs or discontinuous activation of the susceptor assembly.

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

[0078] The aerosol generation device may include a control circuit. The control circuit may include a sensor for detecting when a user has puffed on the aerosol generation system. The sensor may be configured to be in fluid communication with the device airflow path when the cartridge is coupled to the aerosol generation device. The control circuit may be configured to detect when a user has puffed on the system based on a signal from the sensor. The sensor may include an airflow sensor. The sensor may be a pressure sensor. The sensor may enable the aerosol generation system to provide power for each puff.

[0079] The control circuitry may be configured to power the inductor coil continuously after activation of the device, 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 additional electronic components. For example, in some embodiments, the control circuitry may comprise a sensor, a switch, or a display element.

[0080] 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.

[0081] The aerosol generating device may further include 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.

[0082] The aerosol-generating device may include a susceptor holder that holds a 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.

[0083] 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 for the at least one wicking layer.

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

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

[0086] providing a first sheet of material heatable by induction of eddy currents and hysteresis losses to vaporize an aerosol-forming substrate;

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

[0088] The method includes assembling a first sheet of material with at least one layer of wicking material, wherein the at least one layer of wicking material at least partially covers an outer surface of the first sheet of material, and the wicking element forms an outer surface of the susceptor assembly. [Example]

[0089] The present invention is defined in the claims. However, the following provides a non-exhaustive list of non-limiting examples. Any one or more features of these examples may be combined with any one or more features of other examples, embodiments, or aspects described herein.

[0090] Example 1: 1. A susceptor assembly for an aerosol generation system, the susceptor assembly comprising: a susceptor element in the form of a sheet; a wicking element including at least one wicking layer for transporting a liquid aerosol-forming substrate across a surface of the sheet, the wicking element forming an outer surface of the susceptor assembly. Example 2: 10. The susceptor assembly of example 1, wherein the wicking element comprises a plurality of openings exposing a portion of the susceptor element. Example 3: The susceptor assembly of any one of Examples 1 to 2, wherein the wicking element is comprised of a top wicking layer and a bottom wicking layer. Example 4: The susceptor assembly of Example 3, wherein the top and bottom wicking layers are separate components. Example 5: 5. The susceptor assembly of any one of Examples 1 to 4, wherein the susceptor element is a blank sheet. Example 6: The susceptor assembly of any one of Examples 3-5, wherein the susceptor element, the top wicking layer, and the bottom wicking layer are substantially parallel. Example 7: The susceptor assembly of any one of Examples 3-6, wherein the susceptor element is sandwiched between a top wicking layer and a bottom wicking layer, the top wicking layer and the bottom wicking layer substantially covering a surface of the susceptor element. Example 8: The susceptor assembly of any one of Examples 1-7, wherein the susceptor assembly is substantially planar. Example 9: 9. The susceptor assembly of any one of Examples 1-8, wherein the susceptor element has an S-shape. Example 10: The susceptor assembly of any one of Examples 1-9, wherein the wicking element comprises a porous material. Example 11: The susceptor assembly of any one of Examples 1-10, wherein the wicking element comprises cotton. Example 12: The susceptor assembly of any one of Examples 1-11, wherein the wicking element comprises a mesh. Example 13: The susceptor assembly of any one of Examples 1-12, wherein the openings are arranged in a uniform pattern. Example 14: 14. The susceptor assembly of any one of Examples 1-13, wherein the wicking element comprises a plurality of fibers, and wherein the diameter of each of the openings is greater than the diameter of each of the fibers. Example 15: 15. The susceptor assembly according to any one of Examples 1 to 14, wherein the distance between the edge of an opening and an adjacent opening is 0.05 mm to 0.5 mm. Example 16: 16. The susceptor assembly of any one of Examples 1-15, wherein the width of the wicking element is greater than the width of the susceptor element. Example 17: 17. The susceptor assembly of any one of Examples 1-16, wherein the susceptor element comprises a central opening. Example 18: A susceptor assembly described in any one of Examples 1 to 17, wherein the wicking element has a first region that covers the susceptor element and at least one second region that does not cover the susceptor element, the openings being positioned within the first region, and each of the second regions not including an opening. Example 19: 19. The susceptor assembly of example embodiment 18, wherein the first region is positioned between two second regions. Example 20: 20. The susceptor assembly of any one of Examples 1-19, wherein the susceptor element comprises an iron-based material. Example 21: 21. The susceptor assembly of any one of Examples 1-20, wherein the susceptor element comprises annealed steel. Example 22: 22. The susceptor assembly of any one of Examples 1-21, wherein the susceptor element comprises ferritic stainless steel. Example 23: 23. The susceptor assembly of any one of Examples 1-22, wherein the susceptor element comprises at least one of graphite, molybdenum, silicon carbide, stainless steel, niobium, and aluminum. Example 24: 24. The susceptor assembly of any one of Examples 1-23, wherein the susceptor element comprises at least one ferromagnetic material. Example 25: The susceptor assembly of any one of Examples 1-24, wherein the susceptor element comprises AISI 430 stainless steel. Example 26: 26. The susceptor assembly of any one of Examples 1-25, wherein the susceptor element has a relative magnetic permeability of 1 to 40,000 when measured at a temperature of 20 degrees Celsius and at frequencies up to 10 kHz. Example 27: 27. The susceptor assembly of any one of Examples 1-26, wherein the susceptor element has a relative magnetic permeability of 500 to 40,000 when measured at a temperature of 20 degrees Celsius and at frequencies up to 10 kHz. Example 28: The susceptor assembly of any one of Examples 1-27, wherein the wicking element is folded around the susceptor element. Example 29: 29. The susceptor assembly of any one of Examples 1-28, wherein the 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 30: 1. A cartridge for an aerosol generation system, comprising: A susceptor assembly according to any one of Examples 1 to 29; a liquid reservoir that holds the liquid aerosol-forming substrate in the liquid reservoir. A cartridge in which the wicking element of the susceptor assembly is disposed in fluid communication with a liquid aerosol-forming substrate within the liquid reservoir. Example 31: 31. The cartridge of example 30, wherein the cartridge further comprises an air inlet, an air outlet, and an airflow path extending from the air inlet, through the susceptor assembly, and to the air outlet. Example 32: 32. The cartridge of example 31, 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 33: 33. The cartridge of Example 32, wherein the susceptor holder holds the susceptor assembly such that at least a portion of the susceptor assembly is positioned within the airflow path and the at least one wicking layer is in direct fluid communication with the liquid aerosol-forming substrate in the liquid reservoir. Example 34: 34. The cartridge of example 33, 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 for the at least one wicking layer. Example 35: The cartridge of example 30 or 34, wherein at least one wicking layer extends transversely to the direction of airflow through the susceptor assembly. Example 36: 36. The cartridge of any one of Examples 30 to 35, wherein opposing ends of at least one wicking layer are in fluid communication with the liquid reservoir. Example 37: 37. The cartridge of any one of Examples 30 to 36, further comprising a mouthpiece, the mouthpiece comprising an air outlet. Example 38: 1. An aerosol generating system comprising: A cartridge according to any one of Examples 30 to 37, and An aerosol generating device, comprising: an inductor coil; An aerosol generation system comprising an aerosol generator, the aerosol generator comprising: a power supply connected to the inductor coil and configured to supply current to the inductor coil to generate an alternating magnetic field, the power supply being connectable to each other so that the cartridge and the aerosol generator are positioned within the alternating magnetic field. Example 39: An aerosol generation system as described in Example 38, further comprising a control circuit, the control circuit being connected to the inductor coil and configured to control the supply of power to the inductor coil. Example 40: 41. An aerosol generation system as described in Example 39 or 40, wherein the inductor coil is a helical coil positioned around the susceptor assembly when the aerosol generator and cartridge are coupled to each other. Example 41: An aerosol generating device, comprising: The susceptor assembly of any one of Examples 1 to 30, and a liquid reservoir for holding the liquid aerosol-forming substrate in the liquid reservoir, a susceptor assembly and a liquid reservoir, wherein the wicking element of the susceptor assembly is in fluid communication with a liquid aerosol-forming substrate in the liquid reservoir; an inductor coil; An aerosol generating device comprising: a power supply connected to an inductor coil and configured to supply 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 42: An aerosol generating device as described in Example 41, further comprising a control circuit, the control circuit being connected to the inductor coil and configured to control the supply of power to the inductor coil. Example 43: An aerosol generating device as described in Example 42, wherein the control circuit includes a sensor and is configured to deliver power from the power source to the coil when puffing is detected by the sensor. Example 44: 44. The aerosol generating apparatus according to any one of Examples 41 to 43, wherein the inductor coil is a helical coil positioned around the susceptor element. Example 45: 45. The aerosol generating device of any one of Examples 41 to 44, further comprising an air inlet, an air outlet, and an airflow path extending from the air inlet, through the susceptor assembly, and to the air outlet. Example 46: 46. ​​The aerosol generating apparatus of any one of Examples 41 to 45, further comprising a susceptor holder for holding a susceptor assembly, wherein at least a portion of the airflow path is defined by the susceptor holder. Example 47: An aerosol generating device as described in Example 46, 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 the wicking layer is in fluid communication with the liquid aerosol-forming substrate in the liquid reservoir. Example 48: 48. The aerosol generating apparatus of embodiment 47, 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 for the at least one wicking layer. Example 49: 1. A method for manufacturing a susceptor assembly for an aerosol generating device, the method comprising: providing a first sheet of material heatable by eddy currents and hysteresis losses to vaporize an aerosol-forming substrate; providing at least one layer of wicking material for transporting the aerosol-forming substrate across the surface of the sheet; and assembling a first sheet of material with at least one layer of wicking material, wherein the at least one layer of wicking material at least partially covers an outer surface of the first sheet of material, and the wicking element forms an outer surface of the susceptor assembly. [Brief explanation of the drawings]

[0091] The embodiments will be further explained below with reference to the drawings.

[0092] [Figure 1A] FIG. 1A shows a cross-sectional schematic view of a cartridge for an aerosol generation system, the cartridge including a susceptor assembly. [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 cross-sectional view of an aerosol generating device, the device comprising a susceptor assembly. [Figure 5A] FIG. 5A shows a schematic diagram of one embodiment of a susceptor assembly according to the present disclosure, in which a wicking element substantially covers the top and bottom surfaces of the susceptor element. [Figure 5B] FIG. 5B shows an exploded view of the susceptor assembly of FIG. 5A. [Figure 6] FIG. 6 shows a schematic diagram of one embodiment of a susceptor assembly according to the present disclosure, in which the wicking element substantially covers the top and bottom surfaces of the susceptor element, and the sides of the wicking layer are free of perforations. [Figure 7] FIG. 7 shows a schematic diagram of one embodiment of an S-shaped susceptor element. DETAILED DESCRIPTION OF THE INVENTION

[0093] 1A and 1B show schematic views of two cross sections of a cartridge 10 for an aerosol generation system, the cartridge including 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.

[0094] 1 shows a cartridge 10 including 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 that is substantially smaller than its length and width dimensions. The susceptor assembly 12 is rectangular in shape and includes susceptor elements 16 sandwiched between wicking elements. The width w of the susceptor element 16 is SE The wicking element has a width of 18 WE The smaller susceptor element 16 is sandwiched between the central region of the wicking element 18 and defines an outer, exposed portion 20 of the wicking element 18 that is not in contact with 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 susceptor holder 14. The interior sidewall 27 defines an interior passage 26 of the susceptor holder 14. The susceptor element 16 comprises a blank sheet formed from ferritic stainless steel. 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.

[0095] 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 susceptor holder 14 such that the susceptor holder 14 supports the susceptor assembly 12 in place in the cartridge 10.

[0096] The susceptor assembly 12 is disposed inside the interior passage 26 of the tubular susceptor holder 14 and extends in a plane parallel to the central longitudinal axis of the susceptor holder 14. The susceptor element 16 is disposed completely within the interior passage 26 of the susceptor 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 susceptor holder 14. The outer exposed portion of the wicking element 18 defines the mounting area 20 of the susceptor assembly 12 for mounting the susceptor assembly in the susceptor holder 14.

[0097] 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.

[0098] The outer housing 36 is formed from a moldable plastic material, such as polypropylene, and defines an interior space within which the susceptor assembly 12 and susceptor holder 14 are contained.

[0099] The outer width of the outer housing 36 is greater at the mouth end of the cartridge 10 than at the connecting end where it is joined by the shoulder 37. This allows the connecting end of the cartridge 10 to be received in the cavity of the aerosol generation device 60, with the shoulder 37 positioning the cartridge in the correct position on 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.

[0100] 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.

[0101] 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 .

[0102] 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 .

[0103] 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 an 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 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 susceptor holder 14. The two channels 45 extend from an 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.

[0104] The susceptor holder 14 includes a base 30 that partially closes one end of the internal passage 26. The base 30 includes a plurality of air inlets 32 that allow air to be drawn into the internal passage 26 through the partially closed end.

[0105] An air passageway is formed through cartridge 10 by internal passageway 26 of susceptor holder 14 and internal passageway 48. The air passageway extends from air inlet 32 ​​in base 30 of susceptor holder 14, through internal passageway 26 of susceptor holder 14, and through internal 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.

[0106] 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.

[0107] 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.

[0108] An opening 28 in a sidewall 27 of the susceptor holder 14 is 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 opening 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.

[0109] 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 a mounting area of ​​the susceptor assembly 12 such that the mounting area is in indirect contact with the susceptor holder 14.

[0110] 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 exposed portion of the wicking element 18, which forms the mounting area of ​​the susceptor assembly 12, extends from the internal passage 26 into the channels 45 through the openings 28. Although the channels 45 are shown empty in FIG. 2, they can be understood to be filled with a liquid aerosol-forming substrate before use.

[0111] 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.

[0112] 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.

[0113] Cartridge 10 is identical to the cartridges presented in Figures 1A, 1B and 2 and their corresponding descriptions.

[0114] 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.

[0115] 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 or 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.

[0116] 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 generation device 60.

[0117] 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 .

[0118] 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.

[0119] 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.

[0120] 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.

[0121] 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.

[0122] 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.

[0123] 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, 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.

[0124] 4 shows a cross-sectional schematic view of an aerosol generating device 200, the device 200 including a susceptor assembly 112. As used herein, aerosol generating device and device are used interchangeably.

[0125] During operation, when a user draws a puff on opening 138 at the mouth end of the device, ambient air is drawn into device 200 through air inlet 165. Ambient air flows through device 200 from air inlet 165 to mouth end opening 138 through an air passage defined by internal passage 126, over susceptor assembly 112, and so on.

[0126] Control circuit 170 controls the supply of power from power supply 172 to inductor coil 190 when the system is activated.

[0127] 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 the user. The control circuit 172 provides power to the inductor coil 190 when the airflow sensor 163 detects a puff taken by a user of the aerosol generating device 200.

[0128] When the aerosol-generating device 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. The liquid aerosol-forming substrate in the channel 145 is drawn into the susceptor assembly 112, through the wicking element 118, and toward the susceptor element 116. As the liquid aerosol-forming substrate 142 in the susceptor element 116 heats, volatile compounds from the heated aerosol-forming substrate are released into the air passage defined by the internal passage 148 of the aerosol-generating device 200, where they cool and form an aerosol. The aerosol is entrained in air drawn through the internal passage 148 of the aerosol-generating device 200 and withdrawn from the internal passage 148 at the mouth-end opening 138 for inhalation by the user.

[0129] The aerosol generating device 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.

[0130] The aerosol generating device 200 further comprises an induction heating arrangement disposed within the device 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 device. 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.

[0131] A single inductor coil 190 is positioned around the susceptor assembly 112 of the aerosol generation device 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 former element (not shown). The inductor coil 190 is both tubular and helical, and defines a circular cross-section when viewed along the longitudinal axis of the aerosol generation device 200.

[0132] 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 .

[0133] 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.

[0134] 5A shows a schematic diagram of one embodiment of a susceptor assembly 212 according to the present disclosure in which wicking elements substantially cover the top and bottom surfaces of the susceptor element 16. A top wicking layer 221 covers the top surface of the susceptor, and a bottom wicking layer 222 covers the bottom surface of the susceptor.

[0135] Figure 5B shows an exploded view of the susceptor assembly of Figure 5A. Each wicking layer is independent. The susceptor element 16 has a smaller surface area than the wicking element.

[0136] The openings 280 cover substantially the entire surface of the wicking element 18. The openings 280 are distributed in a uniform pattern across the surface of the wicking element. The openings 280 extend from one surface of the wicking layers 221, 222 to the opposite surface of the wicking layers 221, 222, with the areas of the openings 280 exposing portions of the susceptor element 16. In this embodiment, the cross section of the openings 280 is circular.

[0137] The width of the wicking element 218 is greater than the susceptor element 16, and the length of the wicking element 218 is substantially equal to the length of the susceptor element.

[0138] The susceptor element 16 is a blank sheet. In this embodiment, the susceptor element 16 has a planar rectangular shape. The susceptor element 16 is positioned in the middle of the wicking element 218, so that the sides 20 of the wicking element have equal widths. The sides 20 of the wicking element 218 are in fluid communication with the liquid reservoir 44. The liquid aerosol-forming substrate travels from the liquid reservoir 44 across the wicking element 16 to the susceptor element 16 where it is aerosolized. The top wicking layer 221 and the bottom wicking layer 222 allow the susceptor element 16 to be wetted on both surfaces.

[0139] 6 shows a schematic diagram of one embodiment of a susceptor assembly according to the present disclosure in which the wicking element 318 substantially covers the top and bottom surfaces of the susceptor element 16. In this embodiment, the openings 380 are present only in the areas of the wicking element 318 that cover the surface of the susceptor element 16. The areas of the wicking element 318 that do not cover the surface of the susceptor element 16 do not have the openings 380. The wicking element 318 comprises a top layer 321 and a bottom layer 322.

[0140] The airflow path 330 is parallel to the length of the susceptor assembly 312 and perpendicular to the width of the susceptor assembly 312. Liquid is supplied to the susceptor assembly 312 parallel to the width of the susceptor assembly 312. The thickness of the susceptor assembly is substantially the same throughout.

[0141] The openings 380 are distributed in a uniform pattern across the area of ​​the wicking element 318 covering the susceptor element 16. The openings 380 extend from one surface to the opposite surface of the wicking layer such that the openings 380 expose a portion of the susceptor element 16. In this embodiment, the openings 380 are circular in cross section.

[0142] Although the susceptor assembly is shown as rectangular in the previous figures, the susceptor assembly may take any other suitable shape or form. For example, the susceptor may take the form of an S-shape. An example of this arrangement is shown in Figure 7.

[0143] FIG. 7 shows a schematic diagram of another embodiment of a susceptor assembly 612. The susceptor assembly 612 includes a planar, S-shaped susceptor element 616. The wicking element 618 substantially covers the top and bottom surfaces of the S-shaped susceptor element 616, similar to the embodiment of FIG. 6. In this embodiment, the wicking element 616 is rectangular. Other embodiments are possible in which the wicking element has a different planar polygonal shape. In this embodiment, the opening 680 covers the rectangular area where the S-shaped susceptor element 616 is located. Other embodiments are possible in which the opening covers only the surface of the wicking element that covers the S-shaped susceptor element 616. The wicking element 618 in this embodiment includes a top layer 621 and a bottom layer 622.

Claims

1. 1. A susceptor assembly for an aerosol generation system, the susceptor assembly comprising: a susceptor element in the form of a sheet; a wicking element including at least one wicking layer for transporting a liquid aerosol-forming substrate across a surface of the sheet, the wicking element forming an outer surface of the susceptor assembly; The susceptor assembly, wherein the wicking element has a width greater than a width of the susceptor element.

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

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

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

5. The susceptor assembly according to any one of claims 1 to 4, wherein the susceptor element is a blank sheet.

6. The susceptor assembly of any one of claims 1 to 5, wherein the susceptor assembly is substantially planar.

7. The susceptor assembly of any preceding claim, wherein the susceptor element has an S-shape.

8. The susceptor assembly of any preceding claim, wherein the susceptor element comprises a central opening.

9. A susceptor assembly described in any one of Examples 2 to 8, wherein the wicking element comprises a first region that covers the susceptor element and at least one second region that does not cover the susceptor element, the plurality of openings being positioned within the first region, and each of the second regions not including an opening.

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

11. The susceptor assembly of any preceding claim, wherein the wicking element is folded around the susceptor element.

12. 1. A cartridge for an aerosol generation system, comprising: A susceptor assembly according to any one of claims 1 to 11; a liquid reservoir for holding a liquid aerosol-forming substrate in the liquid reservoir, wherein the wicking element of the susceptor assembly is arranged in fluid communication with the liquid aerosol-forming substrate in the liquid reservoir.

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

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

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

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