Mesh susceptor assembly

Abstract

A susceptor assembly (12) for an aerosol generation system, the susceptor assembly (12) comprising an array of filaments of wicking material for conveying a liquid aerosol-forming substrate, the array of filaments forming a mesh (20). The susceptor assembly (12) includes at least one filament (16) of electrically conductive material heatable by penetration by an alternating magnetic field, the at least one filament (16) of electrically conductive material wrapped around and in contact with a first filament of the array of filaments of wicking material. An aerosol generation system is also provided.

Description

[Technical Field]

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

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

[0003] The induction heating system typically includes at least one inductor coil connected to a power source and configured to generate an alternating magnetic field. The induction heating system includes a susceptor assembly including a conductive material disposed adjacent to a wicking material for transporting the liquid aerosol-forming substrate to the conductive material. The susceptor assembly is positioned within the alternating magnetic field. When the susceptor material is penetrated by the alternating magnetic field, the conductive material is heated by at least one of Joule heating from an eddy current induced in the susceptor and hysteresis loss. The heated conductive material heats the aerosol-forming substrate, releasing volatile compounds from the aerosol-forming substrate, which cool to form an inhalable aerosol.

[0004] Some aerosol generation systems include an aerosol generating device and a cartridge configured for use with the device. When the aerosol generation system includes an aerosol generating device and a cartridge, the susceptor assembly may form part of the cartridge.

[0005] It would be desirable to provide a susceptor assembly for an aerosol generation system that has improved efficiency in heating a liquid aerosol-forming substrate. Summary of the Invention

[0006] According to one aspect of the present invention, there is provided a susceptor assembly for an aerosol generation system. The susceptor assembly may include an array of filaments of wicking material for transporting a liquid aerosol-forming substrate. The array of filaments may form a mesh. The susceptor assembly may include at least one filament of conductive material heatable by penetration by an alternating magnetic field, the at least one filament of conductive material being wrapped around and in contact with a first filament of the array of filaments of wicking material.

[0007] Typically, a susceptor assembly for a liquid aerosol-forming substrate requires a mesh wicking layer formed of a wicking material and a conductive layer formed of a conductive material. In such a configuration, the contact between the wicking layer and the conductive layer directly affects the amount and efficiency of aerosol generation. In the present disclosure, the conductive material may not form a separate layer from the wicking material. By wrapping the conductive material around the filaments of the wicking material, the contact between the wicking material and the conductive material may be improved, and therefore aerosol generation may be improved. The improved contact between the wicking material and the conductive material may also reduce the risk of overheating the conductive material, as the transfer of liquid aerosol-forming substrate from the wicking material to the conductive material may be improved compared to a system having separate wicking and conductive layers.

[0008] The present invention may provide improved control over which region or regions of the mesh of wicking material are in contact with the conductive material. For example, at least one filament of conductive material may be in contact with only a specific region of the mesh of wicking material. This may advantageously provide improved control over which portions of the susceptor assembly are heated by heating the conductive material. Advantageously, the amount of conductive material required for the susceptor assembly may be reduced, leading to reduced raw material usage, reduced costs, and improved sustainability.

[0009] The mesh may include a plurality of longitudinal filaments of wicking material extending substantially longitudinally and a plurality of lateral filaments of wicking material extending substantially transversely. At least one filament of conductive material may be wrapped around the longitudinal filaments of wicking material. Preferably, none of the transverse filaments have conductive material wrapped around them.

[0010] A first filament of the at least one filament of conductive material may be wound around only the first filament of wicking material. A second filament of the at least one filament of conductive material may be wound around and in contact with the first filament of wicking material. A second filament of the at least one filament of conductive material may be wound around only the first filament of wicking material. Advantageously, the heat generated within the susceptor assembly may be increased by the addition of a second filament of conductive material surrounding and in contact with the first filament of wicking material, compared to only a single filament of conductive material. In this manner, the amount of conductive material within the susceptor assembly may be increased, such that the heat generated within the susceptor assembly may be increased.

[0011] A second filament of the at least one filament of conductive material may be in contact with the first filament of conductive material. For example, the first filament of conductive material and the second filament of conductive material may be wound around the first filament of wicking material such that they cross each other and are therefore in physical contact with each other. For example, the second filament of conductive material may be wound around the filament of wicking material in a direction opposite to the winding direction of the first filament of conductive material. In this way, the two filaments of conductive material are in contact with each other.

[0012] The second filament of the at least one filament of conductive material may not be in contact with the first filament of conductive material. For example, the first filament and the second filament of conductive material may be wound around the first filament of wicking material so that they are not in physical contact with each other. For example, the second filament of conductive material may be wound around the filament of wicking material in the same direction as the winding direction of the first filament of conductive material. When an alternating magnetic field is applied to the susceptor assembly, the contact between the first filament of conductive material and the second filament of conductive material may prevent hot spots from occurring within the susceptor assembly. The lack of contact between the two filaments of conductive material may lead to uniform heat distribution along the length of the filament of wicking material.

[0013] At least one filament of conductive material may be a coil. At least one filament of conductive material may include a spiral shape. At least one filament of conductive material may include a helical shape.

[0014] The coil pitch may be regular, irregular, or may decrease along the axial length of the coil, or the coil pitch may be predetermined to achieve a desired heat generation within the susceptor assembly.

[0015] The coil pitch may be between 10 micrometers and 500 micrometers, and preferably between 50 micrometers and 100 micrometers.

[0016] As defined herein, the "pitch" of a coil is the distance traveled parallel to the axial direction of the coil in one revolution of the coil.

[0017] The diameter of at least one filament of conductive material may be between 5 micrometers and 100 micrometers, between 8 micrometers and 100 micrometers, between 20 micrometers and 100 micrometers, between 20 micrometers and 80 micrometers, or between 20 micrometers and 50 micrometers. The diameter of all of the filaments of conductive material may be between 5 micrometers and 100 micrometers.

[0018] The diameter of the filaments in the array of wicking material may be 5 micrometers to 100 micrometers, 8 micrometers to 100 micrometers, 20 micrometers to 100 micrometers, 20 micrometers to 800 micrometers, or 20 micrometers to 50 micrometers. The filaments of the mesh may have a diameter of 50 micrometers. The diameter of all filaments in the array of wicking material may be 5 micrometers to 100 micrometers.

[0019] The filaments of the array of wicking material may have any suitable cross-section, for example, the filaments may have a round cross-section or a flattened cross-section.

[0020] The susceptor assembly may be fluid permeable. The susceptor assembly may include a heating region. The heating region may include at least one filament of electrically conductive material.

[0021] The susceptor assembly may include at least one attachment region. The at least one attachment region may include a portion of an array of filaments of wicking material. The conductive material may be absent from the at least one attachment region. The at least one attachment region may consist of the wicking material.

[0022] The at least one attachment region may be at the periphery of the susceptor assembly. The at least one attachment region may be at the periphery of the heating region. Preferably, the heating region may be a central region of the susceptor assembly, and the at least one attachment region may be a peripheral region of the susceptor assembly. The array of filaments of wicking material may enable transport of the liquid aerosol-forming substrate from the at least one attachment region to the heating region. The at least one attachment region may be configured to enable transport of the liquid aerosol-forming substrate to the conductive material. Advantageously, liquid transport to the conductive material is achieved without requiring conductive material throughout the susceptor assembly.

[0023] The susceptor assembly may include a first attachment area on a first edge of the susceptor assembly. The susceptor assembly may include a second attachment area on a second edge opposite the first edge of the susceptor assembly. The heating area may be positioned between the first attachment area and the second attachment area. The first attachment area and the second attachment area may enable transfer of the liquid aerosol-forming substrate from the liquid reservoir to the heating area. The first attachment area and the second attachment area may enable transfer of the liquid aerosol-forming substrate from the liquid reservoir to the at least one filament of conductive material.

[0024] At least one mounting area may have a rectangular cross-section.The susceptor assembly may have a rectangular cross-section.The susceptor assembly may have a cruciform cross-sectional shape.

[0025] The wicking material may be non-conductive. The wicking material may be non-magnetic. Advantageously, the wicking material does not contribute to inductive heating within the susceptor assembly.

[0026] The heating region can be configured to heat to a substantially higher temperature than the attachment region in the presence of an alternating magnetic field. This can be due to material differences between the heating region and the attachment region, geometric differences between the heating region and the attachment region, or both material and geometric differences. For example, this can be due to the heating region including filaments of conductive material, and the attachment region including only filaments of wicking material.

[0027] The wicking material may comprise a hydrophilic material. The wicking material may comprise an oleophilic material, which advantageously facilitates transport of the aerosol-forming substrate through the susceptor assembly.

[0028] The wicking material may comprise a cellulosic material. The wicking material may comprise rayon. The wicking material may comprise cotton.

[0029] The conductive material filament may be heatable by at least one of Joule heating through the induction of eddy currents in the conductive material and hysteresis losses. Advantageously, the conductive material filament may have a relative permeability of 1 to 40,000. 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 hysteresis effects are desired. Preferably, the material has a relative permeability of 500 to 40,000. This may provide for efficient heating of the conductive material filament.

[0030] The conductive material may be a magnetic material. The term "magnetic material" is used herein to describe a material that can interact with a magnetic field, including both paramagnetic and ferromagnetic materials. The first material may be any suitable magnetic material that can be heated by penetration by an alternating magnetic field.

[0031] Preferably, the conductive material may comprise ferritic stainless steel. Suitable ferritic stainless steels include AISI 400 series stainless steels, such as AISI types 409, 410, 420, and 430 stainless steel. Preferably, the conductive material may comprise ferritic stainless steel 430.

[0032] The susceptor assembly may be substantially flat, which may be defined as a susceptor assembly with both a width and a height that are much greater than its depth. The susceptor assembly may be substantially planar.

[0033] According to a second embodiment of the present disclosure, a cartridge for an aerosol generation system is provided. The cartridge may include the susceptor assembly according to the first embodiment of the present disclosure. In other words, the cartridge may include a susceptor assembly including an array of filaments of wicking material for transporting a liquid aerosol-forming substrate, the array of filaments forming a mesh, and at least one filament of conductive material heatable by penetration by an alternating magnetic field, the at least one filament of conductive material being wound around and in contact with a first filament of the array of filaments of wicking material. The cartridge may also include a liquid reservoir for holding the liquid aerosol-forming substrate in fluid communication with the susceptor assembly.

[0034] The mesh may include a plurality of longitudinal filaments of wicking material extending substantially longitudinally and a plurality of lateral filaments of wicking material extending substantially transversely. At least one filament of conductive material may be wrapped around the longitudinal filaments of wicking material. Preferably, none of the transverse filaments have conductive material wrapped around them.

[0035] The liquid reservoir may be in fluid communication with the array of wicking material filaments of the susceptor assembly. Preferably, at least one of the plurality of lateral wicking material filaments may be in contact with the liquid reservoir. The liquid reservoir may be in fluid communication with the conductive material filaments of the susceptor assembly. The wicking material filaments may form gaps between the wicking material filaments. The gaps may draw the liquid aerosol-forming substrate from the liquid reservoir by capillary action. The gaps may allow the liquid aerosol-forming substrate to be transported from the liquid reservoir to the susceptor assembly. In particular, the gaps may allow the liquid aerosol-forming substrate to be transported from the liquid reservoir to the at least one conductive material filament. The susceptor assembly may transport the liquid aerosol-forming substrate in both the lateral and longitudinal directions. The longitudinal direction may be substantially parallel to the major axis of the susceptor assembly.

[0036] The cartridge may include an air inlet and an air outlet. The cartridge may include an airflow passage between the air inlet and the air outlet. A susceptor assembly may be positioned within the airflow passage. The susceptor assembly may at least partially span or extend across the cartridge airflow passage. The susceptor assembly may extend from one side of the cartridge airflow passage to another side of the cartridge airflow passage. During use of the cartridge, for example, when connected to an aerosol generating device, air may be drawn from the air inlet to the air outlet, through the cartridge airflow passage, and form an airflow across the surface of the susceptor assembly. The airflow may entrain vapors of the aerosol-forming substrate generated by the susceptor assembly. Within the airflow passage, the vapors may condense to form an aerosol. The longitudinal axis of the filament may be substantially parallel to the direction of airflow across the susceptor assembly.

[0037] The cartridge may further include a susceptor holder for mounting the susceptor assembly. The susceptor holder may at least partially define the cartridge airflow passage. The susceptor holder may be coupled to the susceptor assembly.

[0038] The susceptor holder may be in contact with at least one filament of the wicking material. The susceptor holder may not be in contact with any of the filaments of the conductive material. Advantageously, this minimizes heat transfer to the susceptor holder. The filaments of the wicking material may not be directly heated by the induction of eddy currents or hysteresis losses when the susceptor assembly is exposed to an alternating magnetic field. As a result, the filaments of the wicking material in contact with the susceptor holder transfer less heat to the susceptor holder than if the filaments were made of a conductive material.

[0039] As described above, the susceptor assembly may include a heating region, a first mounting region, and a second mounting region. In the cartridge, the heating region may be positioned at the center of the airflow passage. The heating region may be positioned near or within the axial center of the airflow passage.

[0040] The susceptor holder may contact the susceptor assembly at at least one attachment region. For example, the susceptor holder may be in contact with a first attachment region and a second attachment region. The first attachment region and the second attachment region may be arranged to transport the liquid aerosol-forming substrate from the liquid reservoir to the electrically conductive material. The susceptor holder may not be in physical contact with the at least one heating region. Advantageously, this may reduce heat transfer from the electrically conductive material to the susceptor holder, and therefore reduce heat loss from the susceptor assembly.

[0041] The cartridge airflow channel may extend along the longitudinal axis of the cartridge. The longitudinal direction of the filaments may be parallel to the longitudinal axis of the cartridge. The cartridge may be configured to be penetrated by an alternating magnetic field in a direction parallel to the longitudinal direction of the filaments. The cartridge may be connectable to an aerosol generating device, and the susceptor assembly may be heated by a magnetic field penetrating the susceptor assembly in a direction parallel to the longitudinal direction of the filaments. The susceptor assembly may be configured to be penetrated by an alternating magnetic field in a direction substantially perpendicular to the direction of the alternating magnetic field. Advantageously, in such an arrangement, it has been found that conductive filaments extending transversely, perpendicular to the direction of the changing magnetic field, contribute less to inductive heat generation than conductive filaments extending longitudinally. Therefore, since filaments of conductive material may be wound around filaments of an array of longitudinal wicking material filaments, it is beneficial to position the susceptor assembly so that the longitudinal direction is aligned with the generated alternating magnetic field.

[0042] The cartridge may have a mouth end and a connecting end, the connecting end configured to connect the cartridge to an aerosol generating device. An air outlet may be provided in the mouth end. The cartridge may further comprise a mouthpiece, the mouthpiece including the air outlet.

[0043] According to a third embodiment of the present invention, there is provided an aerosol generation system. The aerosol generation system may include a susceptor assembly according to the first embodiment of the present disclosure. The aerosol generation system may include a liquid reservoir for holding a liquid aerosol-forming substrate in fluid communication with the susceptor assembly, and an inductor coil disposed around the susceptor assembly for generating an alternating magnetic field that penetrates the susceptor assembly for heating the electrically conductive material. The aerosol generation system may include a control circuit connected to the inductor coil and configured to provide an alternating current to the inductor coil.

[0044] The liquid reservoir may be in fluid communication with the array of wicking material filaments of the susceptor assembly. Preferably, at least one of the plurality of lateral wicking material filaments may be in contact with the liquid reservoir. The liquid reservoir may be in fluid communication with the conductive material filaments of the susceptor assembly. The wicking material filaments may form gaps between the wicking material filaments. The gaps may draw the liquid aerosol-forming substrate from the liquid reservoir by capillary action. The gaps may allow the liquid aerosol-forming substrate to be transported from the liquid reservoir to the susceptor assembly. In particular, the gaps may allow the liquid aerosol-forming substrate to be transported from the liquid reservoir to the at least one filament of conductive material. The susceptor assembly may transport the liquid aerosol-forming substrate in both the lateral and longitudinal directions. The longitudinal direction may be substantially parallel to a major axis of the susceptor assembly. The longitudinal direction may be substantially parallel to a longitudinal axis of the aerosol generation system.

[0045] The aerosol generation system may further include an air inlet and an air outlet. The aerosol generation system may include an airflow passage extending between the air inlet and the air outlet. The susceptor assembly may be positioned within the airflow passage. The susceptor assembly may at least partially span or extend across the aerosol generation system airflow passage. The susceptor assembly may extend from one side of the aerosol generation system airflow passage to another side of the aerosol generation system airflow passage. During use, air may be drawn from the air inlet to the air outlet, through the airflow passage, and form an airflow across the surface of the susceptor assembly. The airflow may entrain vapors of the aerosol-forming substrate generated by the susceptor assembly. Within the airflow passage, the vapors may condense to form an aerosol. The longitudinal axes of the plurality of longitudinal filaments may be substantially parallel to the direction of airflow across the surface of the susceptor assembly during use. The transverse direction of the plurality of transverse filaments may be substantially perpendicular to the direction of airflow across the surface of the susceptor assembly in use.

[0046] The aerosol generation system may include a susceptor holder for mounting the susceptor assembly, the susceptor holder being connectable to the susceptor assembly.

[0047] The susceptor holder may be in contact with at least one filament of wicking material. The susceptor holder may not be in contact with a conductive material. Advantageously, this minimizes heat transfer to the susceptor holder. Preferably, the filament of wicking material is not made of a conductive material, so that the filament of wicking material is not directly heated by the induction of eddy currents or hysteresis losses when the susceptor assembly is exposed to an alternating magnetic field. As a result, the filament of wicking material in contact with the susceptor holder transfers less heat to the susceptor holder than if the filament were made of a conductive material.

[0048] As described above, the susceptor assembly may include a heating region, a first mounting region, and a second mounting region. In the aerosol generation system, the heating region may be positioned at the center of the airflow passage. The heating region may be positioned near or within the axial center of the airflow passage.

[0049] The susceptor holder may contact the susceptor assembly at at least one attachment region. For example, the susceptor holder may be in contact with a first attachment region and a second attachment region. The first attachment region and the second attachment region may be arranged to transport the liquid aerosol-forming substrate from the liquid reservoir to the electrically conductive material. The susceptor holder may not be in physical contact with the at least one heating region. Advantageously, this may reduce heat transfer from the electrically conductive material to the susceptor holder, and therefore reduce heat loss from the susceptor assembly.

[0050] The inductor coil may include a tubular coil. The inductor coil may include a helical coil. The inductor coil may include a spiral coil. Preferably, the inductor coil is both tubular and helical. Preferably, the aerosol generation system may include only one helical coil. The inductor coil may be disposed to surround the susceptor assembly. The inductor coil may include copper.

[0051] The inductor coil may be arranged to generate a magnetic field that penetrates the susceptor assembly in a direction substantially parallel to the plurality of longitudinal wicking material filaments. Advantageously, it has been found that longitudinally extending conductive filaments parallel to the direction of the changing magnetic field contribute more to inductive power and heat generation than do transversely extending conductive filaments. Therefore, it is beneficial to position the susceptor assembly so that its longitudinal axis is aligned with the generated alternating magnetic field.

[0052] The aerosol generating system may include a power source, such as a battery.

[0053] The system may further include a control circuit, which may control the temperature of the filament of conductive material.

[0054] The control circuit may be configured to supply an alternating current to the inductor to generate the magnetic field. The susceptor assembly may be at least partially within the magnetic field generated by the inductor coil. The filament of conductive material may be at least partially within the magnetic field generated by the inductor coil.

[0055] When an alternating current is supplied to the inductor coil, the temperature of the heating zone may rise above the temperature of the attachment zone, which may advantageously reduce the risk of overheating, particularly in the attachment zone.

[0056] The aerosol generation system may include a cartridge and an aerosol generation device. The cartridge may be connectable to the aerosol generation device. The cartridge may be a cartridge according to the second embodiment of the present disclosure. The aerosol generation device may include a device airflow inlet and a device airflow outlet. The aerosol generation device may include a device airflow passageway extending between the device air inlet and the device airflow outlet. The device air outlet may be in fluid communication with the cartridge air inlet when the cartridge is connected to the aerosol generation device, thereby defining a system airflow passageway between the device air inlet and the cartridge air outlet.

[0057] The aerosol generating device may include a cavity in which at least a portion of the cartridge is located when the cartridge is coupled to the aerosol generating device. The aerosol generating device may include an inductor coil and a control circuit connected to the inductor coil.

[0058] According to a fourth embodiment of the present disclosure, there is provided a method for manufacturing a susceptor assembly for an aerosol generation system. The method may include providing a plurality of filaments of wicking material for carrying a liquid aerosol-forming substrate. The method may include winding at least one filament of an electrically conductive material heatable by penetration by an alternating magnetic field around at least one of the plurality of filaments of wicking material. The method may further include assembling the plurality of filaments of wicking material to form a mesh.

[0059] According to a fourth embodiment of the present disclosure, an aerosol generation system is provided. The aerosol generation system may include a liquid reservoir for holding a liquid aerosol-forming substrate and a susceptor assembly including a mesh. The mesh may include a plurality of filaments of a first material extending in a first direction and a plurality of filaments of a second material extending in a second direction. The first material may be a conductive material heatable by penetration by an alternating magnetic field, and the second material may be a wicking material for transporting liquid from the liquid reservoir to the susceptor assembly. The aerosol generation system may further include an inductor coil disposed around the susceptor assembly to generate an alternating magnetic field for penetrating the susceptor assembly in a direction substantially parallel to the first direction, and a control circuit connected to the inductor coil and configured to provide a current to the inductor coil.

[0060] Typically, a susceptor assembly for a liquid aerosol-forming substrate requires a mesh wicking layer formed of a wicking material and a conductive layer formed of a conductive material. In such a configuration, the contact between the wicking layer and the conductive layer directly affects the amount and efficiency of aerosol generation. In the present invention, the conductive material may not form a layer separate from the wicking material. In this manner, the contact between the wicking material and the conductive material may be improved, and therefore aerosol generation may be improved. The improved contact between the wicking material and the conductive material may also reduce the risk of overheating the conductive material, since the transfer of liquid aerosol-forming substrate from the wicking material to the conductive material may be improved compared to a system having separate wicking and conductive layers.

[0061] It has been found that during penetration of a susceptor assembly, in which the conductive layer is comprised of filaments of conductive material, by an alternating magnetic field, the filaments of conductive material extending in a first direction parallel to the direction of the alternating magnetic field contribute more to inductive heat generation than filaments of conductive material that do not extend parallel to the direction of the alternating magnetic field.

[0062] The first direction is different from the second direction. By providing a conductive material extending in the first direction and a wicking material in the second direction, sufficient heating can be achieved by filaments of conductive material extending in the first direction, reducing the amount of conductive material required in the susceptor assembly, which may result in reduced raw material usage, reduced costs, and improved sustainability.

[0063] The first direction may be substantially perpendicular to the second direction. Advantageously, this provides a susceptor assembly that has a stable structure and provides good transport of liquid from the liquid reservoir to the susceptor assembly.

[0064] The diameter of each of the plurality of filaments of the first material may be between 5 micrometers and 100 micrometers, between 20 micrometers and 100 micrometers, between 20 micrometers and 80 micrometers, or between 20 micrometers and 50 micrometers.

[0065] The diameter of each of the plurality of filaments of the second material may be between 5 micrometers and 100 micrometers, between 20 micrometers and 100 micrometers, between 20 micrometers and 80 micrometers, or between 20 micrometers and 50 micrometers.

[0066] Each of the plurality of filaments of the first material may have any suitable cross-section. Each of the plurality of filaments of the second material may have any suitable cross-section. For example, the filaments may have a round cross-section or a flattened cross-section.

[0067] The susceptor assembly may be fluid permeable.

[0068] The liquid reservoir may be in fluid communication with the plurality of filaments of the second material of the susceptor assembly. The wicking material may be arranged to transport liquid from the liquid reservoir to the susceptor assembly. At least some of the plurality of transverse filaments of the second material may be in contact with the liquid reservoir. The liquid reservoir may be in fluid communication with the plurality of filaments of the second material. At least some of the plurality of transverse filaments of the second material may extend into the liquid reservoir.

[0069] The gap may draw the liquid aerosol-forming substrate from the liquid reservoir by capillary action. The gap may allow the liquid aerosol-forming substrate to be transported from the liquid reservoir to the susceptor assembly. In particular, the gap may allow the liquid aerosol-forming substrate to be transported from the liquid reservoir to a plurality of filaments of the first material. The susceptor assembly may transport the liquid aerosol-forming substrate in both a first direction and a second direction. The first direction may be substantially parallel to a major axis of the susceptor assembly. The first direction may be substantially parallel to a longitudinal axis of the aerosol generation system.

[0070] The susceptor assembly may include a heating region, which may include a plurality of filaments of a first material.

[0071] The susceptor assembly may include at least one attachment region. The at least one attachment region may include a portion of a plurality of filaments of a second material. Filaments of the first material may be absent from the at least one attachment region. The at least one attachment region may be comprised of the second material.

[0072] The at least one attachment region may be located at the periphery of the susceptor assembly. The at least one attachment region may be located at the periphery of the heating region. Preferably, the heating region may be located in a central region of the susceptor assembly, and the at least one attachment region may be located in a peripheral region of the susceptor assembly. The plurality of filaments of the second material may enable transport of the liquid aerosol-forming substrate from the at least one attachment region to the heating region. The at least one attachment region may be arranged to transport the liquid aerosol-forming substrate from a liquid reservoir to the heating region.

[0073] The susceptor assembly may include a first mounting area at a first edge of the susceptor assembly, a second mounting area at a second edge of the susceptor assembly opposite the first edge, and a heating area located between the first mounting area and the second mounting area.

[0074] The susceptor assembly may include a first mounting area at a first edge of the susceptor assembly. The susceptor assembly may include a second mounting area at a second edge opposite the first edge of the susceptor assembly. The heating area may be located between the first mounting area and the second mounting area. The first mounting area and the second mounting area may allow the liquid aerosol-forming substrate to be transported from a liquid reservoir to the heating area.

[0075] At least one mounting area may have a rectangular cross-section.The susceptor assembly may have a rectangular cross-section.The susceptor assembly may have a cruciform cross-sectional shape.

[0076] The second material may be a non-conductive material. The second material may be a non-magnetic material. Advantageously, the second material does not contribute to heat generation within the susceptor assembly.

[0077] The heating region may be configured to heat to a substantially higher temperature than the attachment region in the presence of an alternating magnetic field. This may be due to a material difference between the heating region and the attachment region, a geometric difference between the heating region and the attachment region, or both a material difference and a geometric difference. For example, this may be due to the heating region including a conductive first material, while the attachment region may include a wicking material. Alternatively, or additionally, this may be due to the first material extending in a first direction substantially parallel to the magnetic field generated by the inductor, while the attachment region may include a second wicking material that may extend in a second direction that is not substantially parallel to the magnetic field generated by the inductor and that is not heated by the alternating magnetic field.

[0078] The second material may comprise a hydrophilic material. The second material may comprise an oleophilic material. Advantageously, providing a hydrophilic or oleophilic second material may facilitate transport of the aerosol-forming substrate through the susceptor assembly.

[0079] The second material may include a cellulosic material. The second material may include rayon. The second material may include cotton.

[0080] The plurality of filaments of the first material may be heatable by at least one of Joule heating via eddy currents and hysteresis losses within the first material. Advantageously, the first material may have a relative permeability of 1 to 40,000. 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 hysteresis effects are desired. Preferably, the material has a relative permeability of 500 to 40,000. This may provide efficient heating of the first material.

[0081] The first material may be a non-magnetic material. The first material may be any suitable magnetic material that can be heated by penetration with an alternating magnetic field. Preferably, the first material may include ferritic stainless steel. The first material may include ferritic stainless steel 430. The first material may include other suitable ferritic stainless steels, including AISI 400 series stainless steels, such as AISI types 409, 410, and 420 stainless steel.

[0082] The mesh may be formed using different types of weaves or lattice structures. The mesh may be a woven mesh. At least one of the plurality of filaments of the second material may be woven above or below alternate filaments of the first material. This alternating weave may contribute to uniform heat distribution across the susceptor assembly.

[0083] At least one of the plurality of filaments of the second material may be woven over one or more filaments of the first material and then under one or more filaments of the second material, which may advantageously improve the structural integrity of the susceptor assembly.

[0084] The aerosol generation system may further include an air inlet and an air outlet. The aerosol generation system may include an airflow passage extending between the air inlet and the air outlet. The susceptor assembly may be positioned within the airflow passage. The susceptor assembly may at least partially span or extend across the aerosol generation system airflow passage. The susceptor assembly may extend from one side of the aerosol generation system airflow passage to another side of the aerosol generation system airflow passage. During use, air may be drawn from the air inlet to the air outlet, through the airflow passage, and form an airflow across the surface of the susceptor assembly. The airflow may entrain vapors of the aerosol-forming substrate generated by the susceptor assembly. Within the airflow passage, the vapors may condense to form an aerosol. The first direction may be substantially parallel to the direction of the airflow across the surface of the susceptor assembly during use. The second direction may be substantially perpendicular to a direction of airflow across a surface of the susceptor assembly in use. The first direction may be substantially parallel to a longitudinal axis of the airflow passage. The second direction may be substantially perpendicular to a longitudinal axis of the airflow passage.

[0085] When the susceptor assembly comprises a heating region and at least one mounting region, the heating region may be positioned at the center of the airflow passage. The heating region may be positioned near or within the axial center of the airflow passage.

[0086] The aerosol generation system may include a susceptor holder for mounting the susceptor assembly, the susceptor holder being connectable to the susceptor assembly.

[0087] The susceptor holder may be in contact with at least one filament of the second material. The susceptor holder may not be in contact with any of the filaments of the first material. Advantageously, this minimizes heat transfer to the susceptor holder.

[0088] The susceptor assembly may be substantially planar. The susceptor assembly may define a plane. The planar susceptor assembly may include a first side and an opposing second side. Both the first side and the second side of the susceptor assembly may be exposed to the airflow passage. In use, air may be drawn across both the first side and the second side of the susceptor assembly, thus enabling entrainment of the aerosol-generating substrate from both sides of the susceptor assembly. Advantageously, this may improve entrainment of the aerosol-generating substrate compared to a susceptor assembly that includes only one side exposed to the airflow passage.

[0089] The filaments of the first material and the filaments of the second material may be woven together such that the filaments of the second material extending in the second direction extend further outward from the plane of the susceptor assembly than the filaments extending in the first direction. In other words, the filaments extending in the second direction define the maximum thickness of the woven mesh. The filaments extending in the second direction define the maximum thickness of the susceptor woven mesh of the susceptor assembly, and the susceptor holder may contact only the filaments of the second material. Preferably, the filaments of the second material are not made of an electrically conductive material, so that they may not be directly heated by eddy currents or induced hysteresis losses when the susceptor assembly is exposed to an alternating magnetic field. As a result, the second filaments in contact with the susceptor holder transfer less heat to the susceptor holder than if the filaments were made of the first material.

[0090] The susceptor holder may contact the susceptor assembly at at least one attachment region. For example, the susceptor holder may be in contact with a first attachment region and a second attachment region. The first attachment region and the second attachment region may be arranged to transport the liquid aerosol-forming substrate from the liquid reservoir to the filament of the second material. The susceptor holder may not be in physical contact with the at least one heating region. Advantageously, this may reduce heat transfer from the second material to the susceptor holder, and therefore reduce heat loss from the susceptor assembly.

[0091] The inductor coil may include a tubular coil. The inductor coil may include a helical coil. Preferably, the inductor coil is both tubular and helical. The inductor may include at least one helical coil. Preferably, the inductor may include only one helical coil. The inductor coil may include a spiral coil. The inductor coil may be disposed to surround the susceptor assembly. The inductor coil may include copper.

[0092] Preferably, the aerosol generation system may include only one inductor coil.

[0093] The aerosol generating system may include a power source, such as a battery.

[0094] The system may further include a control circuit, which may control the temperature of the filament of the first material.

[0095] The control circuit may be configured to supply an alternating current to the inductor coil to generate the alternating magnetic field.

[0096] The susceptor assembly may be at least partially positioned within an alternating magnetic field generated by an inductor. The plurality of filaments of the first material may be at least partially within the alternating magnetic field generated by the inductor. The alternating magnetic field generated by the inductor may be parallel to a longitudinal axis of the airflow passage.

[0097] The aerosol generation system may include a mouthpiece. The mouthpiece may include an air outlet. The aerosol generation system may be configured to allow a user to draw inhales into the mouthpiece to draw the aerosol through the air outlet.

[0098] The aerosol generation system may include a cartridge and an aerosol generator.

[0099] The cartridge may include a susceptor assembly and a liquid reservoir. The cartridge may include an air inlet, an air outlet, and an air flow passage. The cartridge may be connectable to the device.

[0100] The aerosol generating device may include an inductor coil and a control circuit. The device may include a device air inlet and a device air outlet, with a device airflow passage defined therebetween. The device air outlet may be connectable to the air inlet of the cartridge.

[0101] The following features may be applied to any of the embodiments of the present disclosure.

[0102] As used herein, the term "mesh" encompasses lattices and arrangements of filaments with spaces between them. The term mesh may also include woven and nonwoven fabrics. The mesh may define gaps between the filaments, which may have widths of 10 micrometers to 100 micrometers. The filaments preferably create capillary action within the gaps so that, in use, the aerosol-forming liquid is drawn into the gaps, increasing the contact area between the mesh and the liquid.

[0103] The filaments of the mesh may form a mesh size of 160 to 600 mesh US5 (+ / - 10%) (i.e., 160 to 600 filaments per inch (+ / - 10%)). The gap width may be 35 micrometers to 140 micrometers, or 25 micrometers to 75 micrometers. For example, the gap width may be 40 micrometers or 63 micrometers. The open area of ​​the mesh, which is the ratio of the gap area to the total area of ​​the mesh, is preferably 25 to 56%.

[0104] The mesh may be a woven mesh. The mesh may be formed using different types of weave or lattice structures. The mesh may be fluid permeable.

[0105] As used herein, a "fluid-permeable" mesh refers to an element that allows liquids or gases to pass through it. In particular, the mesh may allow the aerosol-forming substrate, either in the gas phase or in both the gas and liquid phases, to pass through the openings.

[0106] 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. Advantageously, injection molding may simplify manufacturing of the aerosol generation system.

[0107] As used herein, a wicking material is a material that is not heated by an alternating magnetic field and that can be used to form a mesh for conveying a liquid aerosol-forming substrate.

[0108] As used herein in connection with the present invention, the term "aerosol" is used to describe a dispersion of solid particles, or liquid droplets, or a combination of solid particles and liquid droplets, in a gas. Aerosols can be visible or invisible. Aerosols may include vapors of substances that are normally liquids or solids at room temperature, as well as solid particles, or liquid droplets, or a combination of solid particles and liquid droplets.

[0109] As used herein, "aerosol-generating system" means a system that generates an aerosol from one or more aerosol-forming substrates.

[0110] As used herein, "aerosol-generating device" refers to a device that generates an aerosol from one or more aerosol-forming substrates. The aerosol-generating device may be configured to generate an aerosol from one or more aerosol-forming substrates when a cartridge containing the one or more aerosol-forming substrates is coupled to the aerosol-generating device.

[0111] As used herein, the term "aerosol-forming substrate" refers to a substrate capable of releasing volatile compounds that can form an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate.

[0112] As used herein, the term "puff" is used to describe the action of a user generating an aerosol using an aerosol-generating system or device. The user performs this action by drawing air through the aerosol-generating system or device by inhaling.

[0113] As used herein, the term "session" refers to a period of time during which an aerosol generating system or device is activated, for example, by a user, and includes at least one puff. During a session, the aerosol generating system or device may automatically detect a puff and provide power to the heated susceptor assembly accordingly, as described above.

[0114] 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.

[0115] 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 be disposable.

[0116] 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.

[0117] The liquid aerosol-forming substrate may contain 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 temperature of the system. Examples of suitable aerosol formers include glycerin and propylene glycol. Suitable aerosol formers are 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 contain water, solvents, ethanol, plant extracts, and natural or artificial flavors. The liquid aerosol-forming substrate may contain nicotine and at least one aerosol former. The aerosol former may be glycerin or propylene glycol. The aerosol former may include both glycerin and propylene glycol. The liquid aerosol-forming substrate may have a nicotine concentration of from about 0.5% to about 10%, for example about 2%.

[0118] The aerosol generation system may be a handheld aerosol generation system. The aerosol generation system may be a handheld aerosol generation system configured to allow a user to draw on the mouthpiece to draw the aerosol through the first 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 25 mm to about 150 mm. The aerosol generation system may have an outer diameter of about 5 mm to about 30 mm.

[0119] 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.

[0120] The control circuit may be configured to control the supply of power from the battery to the inductor. Advantageously, different power profiles may be supplied to the inductor by the control circuit depending on the required aerosol generation. The control circuit may further comprise a puff detector. The puff detector may be configured to be in fluid communication with the airflow passage. The aerosol generation system may be configured such that the power supplied to the inductor is based on a signal from the puff detector. Advantageously, power may then be supplied to the inductor by the control circuit only when a user is puffing on the aerosol generation system. The control circuit may comprise a microcontroller. The microcontroller may be a programmable microcontroller. [Brief explanation of the drawings]

[0121] [Figure 1A] FIG. 1A shows a schematic cross-sectional view of an aerosol generation system including a first embodiment of a susceptor assembly according to the present disclosure. [Figure 1B] FIG. 1B shows a cross-sectional schematic diagram of the aerosol generation system of FIG. 1A in an in-use configuration. [Figure 2A] FIG. 2A shows a schematic cross-sectional view of a cartridge with a susceptor assembly of the first embodiment. [Figure 2B] FIG. 2B shows a schematic view of an alternative cross section of the cartridge of FIG. 2A. [Figure 2C] FIG. 2C shows a further alternative cross-sectional schematic view of the cartridge of FIGS. 2A and 2B. [Figure 3A] FIG. 3A shows a schematic diagram of a first embodiment of a susceptor assembly according to the present disclosure. [Figure 3B] FIG. 3B shows a schematic side view of a second embodiment of a susceptor assembly according to the present disclosure. [Figure 3C] FIG. 3C shows a schematic diagram of a third embodiment of a susceptor assembly according to the present disclosure. [Figure 4A] FIG. 4A shows a schematic diagram of a portion of a fourth embodiment of a susceptor assembly according to the present disclosure. [Figure 4B] FIG. 4B shows a schematic diagram of a portion of a fifth embodiment of a susceptor assembly according to the present disclosure. [Figure 5A] FIG. 5A shows a perspective view of an exemplary filament according to the present disclosure. [Figure 5B] FIG. 5B shows a perspective view of an exemplary filament according to the present disclosure. [Figure 5C] FIG. 5C shows a perspective view of an exemplary filament according to the present disclosure. [Figure 6A] FIG. 6A shows a schematic cross-sectional view of a second aerosol generation system including a sixth embodiment of a susceptor assembly according to the present disclosure. [Figure 6B] FIG. 6B shows a schematic cross-sectional view of the aerosol generation system of FIG. 6A in an in-use configuration. [Figure 7A] FIG. 7A shows a schematic cross-sectional view of a cartridge for the aerosol generation system of FIG. 6A. [Figure 7B] FIG. 7B shows a schematic view of an alternative cross section of the cartridge of FIG. 7A. [Figure 7C] FIG. 7C shows a further alternative cross-sectional schematic view of the cartridge of FIGS. 7A and 7B. [Figure 8A] FIG. 8A shows a schematic diagram of a sixth embodiment of a susceptor assembly for the aerosol generation system of FIG. 6A. [Figure 8B] FIG. 8B shows a schematic cross-sectional view of the susceptor assembly of FIG. 8A. [Figure 9] FIG. 9 shows a schematic diagram of a seventh embodiment of a susceptor assembly for the aerosol generation system of FIG. 6A. [Figure 10A] FIG. 10A shows a schematic diagram of an eighth embodiment of a susceptor assembly for the aerosol generation system of FIG. 6A. [Figure 10B] FIG. 10B shows a schematic diagram of a ninth embodiment of a susceptor assembly for the aerosol generation system of FIG. 6A. [Figure 11] FIG. 11 shows a schematic cross-sectional view of a third embodiment of an aerosol generation system according to the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0122] The present invention is defined in the claims. However, below is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features described above, for example, with any one or more features of other examples, embodiments, or aspects described herein.

[0123] Example 1 1. A susceptor assembly for an aerosol generating system, the susceptor assembly comprising: an array of filaments of a wicking material for conveying a liquid aerosol-forming substrate, the array of filaments forming a mesh; and at least one filament of conductive material heatable by penetration by an alternating magnetic field, the at least one filament of conductive material being wound around and in contact with a first filament of an array of filaments of wicking material.

[0124] Example 2. 2. The susceptor assembly of claim 1, wherein the mesh comprises a plurality of longitudinal filaments of wicking material extending substantially in the longitudinal direction and a plurality of lateral filaments of wicking material extending substantially in the lateral direction.

[0125] Example 3. 3. The susceptor assembly of example 2, wherein at least one filament of conductive material is wound around the longitudinal filament of wicking material.

[0126] Example 4. 4. The susceptor assembly of any of Examples 1-3, wherein a first filament of the at least one filament of conductive material is wound only around the first filament of the wicking material.

[0127] Example 5. 5. The susceptor assembly of any of Examples 1-4, wherein a second filament of the at least one filament of the electrically conductive material is wrapped around and in contact with the first filament of the wicking material.

[0128] Example 6 6. The susceptor assembly of example 5, wherein a second filament of the at least one filament of conductive material is wound around only the first filament of wicking material.

[0129] Example 7 7. The susceptor assembly of any one of Examples 5 and 6, wherein a second filament of the at least one filament of electrically conductive material contacts the first filament of electrically conductive material.

[0130] Example 8 7. The susceptor assembly of any one of Examples 5 and 6, wherein a second filament of the at least one filament of electrically conductive material is not in contact with a first filament of electrically conductive material.

[0131] Example 9. 9. The susceptor assembly of any of Examples 1-8, wherein at least one filament of electrically conductive material is a coil.

[0132] Example 10. 10. The susceptor assembly of example example 9, wherein at least one filament of conductive material comprises a spiral shape.

[0133] Example 11 11. The susceptor assembly of any one of Examples 9 and 10, wherein at least one filament of electrically conductive material comprises a helical shape.

[0134] Example 12 12. The susceptor assembly of any one of Examples 9 to 11, wherein the coil has a regular pitch.

[0135] Example 13 The susceptor assembly of any one of Examples 9 to 11, wherein the coil has an irregular pitch.

[0136] Example 14. 14. The susceptor assembly of example embodiment 13, wherein the pitch of the coil decreases along the axial length of the coil.

[0137] Example 15. The susceptor assembly according to any one of Examples 12 to 14, wherein the pitch is 10 micrometers to 500 micrometers, preferably 50 micrometers to 100 micrometers.

[0138] Example 16. 16. The susceptor assembly of any of Examples 1-15, wherein the diameter of at least one filament of electrically conductive material is between 20 micrometers and 100 micrometers, preferably 50 micrometers.

[0139] Example 17. 17. The susceptor assembly of any of Examples 1-16, wherein the diameter of the filaments of the array of wicking material is between 20 micrometers and 100 micrometers, preferably 50 micrometers.

[0140] Example 18. The susceptor assembly of any of Examples 1-17, wherein the mesh is a woven mesh.

[0141] Example 19. The susceptor assembly of any of Examples 1-17, wherein the mesh is fluid permeable.

[0142] Example 20. 20. The susceptor assembly of any of Examples 1-19, wherein the susceptor assembly is fluid permeable.

[0143] Example 21. A susceptor assembly described in any of Examples 1 to 20, wherein the susceptor assembly comprises at least one mounting region and a heating region, wherein the at least one mounting region comprises a wicking material and the heating region comprises a conductive material.

[0144] Example 22. 22. The susceptor assembly of example embodiment 21, wherein at least one of the attachment regions is at the periphery of the susceptor assembly.

[0145] Example 23. 23. The susceptor assembly of example 21 or 22, wherein the heating region comprises a wicking material.

[0146] Example 24. 24. The susceptor assembly of any one of Examples 21-23, wherein at least one attachment region does not contain a conductive material.

[0147] Example 25. The susceptor assembly of any of Examples 1-24, wherein the susceptor assembly has a rectangular cross-section.

[0148] Example 26. 25. The susceptor assembly of any of Examples 1-24, wherein the susceptor assembly has a cruciform cross section.

[0149] Example 27. 26. The susceptor assembly of any of Examples 1-25, wherein the mounting region has a rectangular cross-section.

[0150] Example 28. The susceptor assembly of any one of Examples 1-27, wherein the wicking material is non-conductive.

[0151] Example 29. The susceptor assembly of any one of Examples 1-28, wherein the wicking material is a non-magnetic material.

[0152] Example 30. 30. The susceptor assembly of any one of Examples 1-29, wherein the wicking material comprises a hydrophilic material.

[0153] Example 31. The susceptor assembly of any one of Examples 1-30, wherein the wicking material comprises an oleophilic material.

[0154] Example 32. The susceptor assembly of any one of Examples 1-31, wherein the wicking material comprises a cellulosic material.

[0155] Example 33. The susceptor assembly of any one of Examples 1-31, wherein the wicking material comprises rayon.

[0156] Example 34. The susceptor assembly of any one of Examples 1-33, wherein the wicking material comprises cotton.

[0157] Example 35. The susceptor assembly of any one of Examples 1 to 34, wherein the conductive material is a magnetic material.

[0158] Example 36. The susceptor assembly of any one of Examples 1-35, wherein the conductive material comprises ferritic stainless steel.

[0159] Example 37. The susceptor assembly of any one of Examples 1-36, wherein the conductive material comprises ferritic stainless steel 430.

[0160] Example 38. 1. A cartridge for an aerosol generation system, comprising: A susceptor assembly according to any one of Examples 1 to 37; a liquid reservoir for holding a liquid aerosol-forming substrate in fluid communication with the susceptor assembly.

[0161] Example 39. 39. The cartridge of Example 38, wherein at least one of the plurality of lateral filaments of wicking material is in physical contact with the liquid reservoir.

[0162] Example 40. 40. The cartridge of example 38 or 39, comprising an air inlet, an air outlet, and an airflow passage extending between the air inlet and the air outlet.

[0163] Example 41. 41. The cartridge of example 40, wherein the susceptor assembly is positioned within the airflow passage.

[0164] Example 42. 42. The cartridge of claim 40 or 41, wherein the plurality of longitudinal filaments of wicking material are parallel to the longitudinal direction of the airflow passage.

[0165] Example 43. 43. The cartridge of any one of Examples 40-42, wherein the plurality of lateral filaments of wicking material are perpendicular to the longitudinal axis of the airflow passage.

[0166] Example 44. The cartridge of any one of Examples 38 to 43, further comprising a susceptor holder for mounting a mesh.

[0167] Example 45. 45. The cartridge of example 44, wherein the susceptor holder is in contact with at least one filament of the wicking material.

[0168] Example 46. 46. ​​The cartridge of example 44 or 45, wherein the susceptor holder is not in contact with the electrically conductive material.

[0169] Example 47. 47. The cartridge of any one of Examples 41 to 46, comprising a mouth end and a connecting end, the connecting end configured to connect the cartridge to an aerosol generation device.

[0170] Example 48. The cartridge of Example 47, wherein the air outlet is provided at the mouth end.

[0171] Example 49. The cartridge of any one of Examples 43 to 48, further comprising a mouthpiece, the mouthpiece comprising an air outlet.

[0172] Example 50. 1. An aerosol generating system comprising: A susceptor assembly according to any one of Examples 1 to 40; a liquid reservoir for holding a liquid aerosol-forming substrate in fluid communication with the susceptor assembly; an inductor coil disposed around the susceptor assembly to generate an alternating magnetic field that penetrates the susceptor assembly to heat the conductive material; a control circuit connected to the inductor coil and configured to provide a current to the inductor coil.

[0173] Example 51. An aerosol generation system as described in Example 50, wherein the inductor coil comprises a helical coil.

[0174] Example 52. 52. An aerosol generation system as described in Example 50 or 51, wherein the inductor coil is disposed to surround the susceptor assembly.

[0175] Example 53. An aerosol generation system described in any of Examples 50 to 52, wherein the inductor coil is arranged to generate an alternating magnetic field that penetrates the susceptor assembly in a direction substantially parallel to the plurality of longitudinal wicking material filaments.

[0176] Example 54. 1. A method for manufacturing a susceptor assembly for an aerosol generation system, the method comprising: providing a plurality of filaments of a wicking material for carrying a liquid aerosol-forming substrate; wrapping at least one filament of an electrically conductive material heatable by penetration by an alternating magnetic field around at least one filament of the plurality of filaments of wicking material; and assembling a plurality of filaments of wicking material to form a mesh.

[0177] Example 55. 1. An aerosol generating system comprising: a liquid reservoir for holding a liquid aerosol-forming substrate; a susceptor assembly comprising a mesh, the mesh including a plurality of filaments of a first material extending in a first direction and a plurality of filaments of a second material extending in a second direction, the first material being an electrically conductive material heatable by penetration by an alternating magnetic field, and the second material being a wicking material for transporting liquid from a liquid reservoir to the susceptor assembly; an inductor coil disposed around the susceptor assembly to generate an alternating magnetic field for passing through the susceptor assembly in a direction substantially parallel to the first direction; a control circuit connected to the inductor coil and configured to provide a current to the inductor coil.

[0178] Example 56. 56. The aerosol generation system of Example 55, wherein the first direction is substantially perpendicular to the second direction.

[0179] Example 57. 57. The aerosol generating system of any one of Examples 55-56, wherein the inductor coil comprises a tubular coil.

[0180] Example 58. 58. An aerosol generation system according to any one of Examples 55 to 57, wherein the inductor coil comprises a helical coil.

[0181] Example 59. 59. The aerosol generating system of any one of Examples 55 to 58, wherein the inductor coil comprises a spiral coil.

[0182] Example 60. 60. The aerosol generation system of any one of Examples 55 to 59, wherein the inductor coil is disposed to surround the susceptor assembly.

[0183] Example 61. 61. The susceptor assembly of any of Examples 55-60, wherein the susceptor assembly is fluid permeable.

[0184] Example 62. 62. The aerosol generating system of any one of Examples 55 to 61, wherein the mesh is substantially planar.

[0185] Example 63. An aerosol generating system described in any of Examples 55 to 62, wherein at least one of the plurality of filaments of the second material is in contact with the liquid reservoir.

[0186] Example 64. An aerosol generating system described in any one of Examples 55 to 63, wherein the mesh comprises a heating region and at least one attachment region, the heating region comprising a first material, and the at least one attachment region comprising a second material.

[0187] Example 65. An aerosol generation system as described in Example 64, wherein at least one attachment region is located around the heating region.

[0188] Example 66. 66. An aerosol generating system as described in Example 64 or 65, wherein the heating region comprises a second material.

[0189] Example 67. 67. An aerosol generating system according to any one of Examples 64 to 66, wherein at least one attachment region comprises a first material.

[0190] Example 68. 68. The susceptor assembly of any of Examples 64-67, wherein at least one attachment region has a rectangular cross-section.

[0191] Example 69. 69. The aerosol generating system of any one of Examples 55 to 68, wherein the susceptor assembly has a rectangular cross section.

[0192] Example 70. 70. The aerosol generating system of any one of Examples 55 to 69, wherein the susceptor assembly has a cruciform cross section.

[0193] Example 71. An aerosol generating system according to any one of Examples 55 to 70, wherein the second material is non-conductive.

[0194] Example 72. 72. The aerosol generating system of any one of Examples 55 to 71, wherein the second material is a non-conductive material.

[0195] Example 73. 73. The aerosol generating system of any one of Examples 55 to 72, wherein the second material comprises a hydrophilic material.

[0196] Example 74. The aerosol generating system of any one of Examples 55 to 73, wherein the second material comprises a lipophilic material.

[0197] Example 75. 75. The aerosol generating system of any one of Examples 55 to 74, wherein the second material comprises a cellulosic material.

[0198] Example 76. 76. The aerosol generating system of any one of Examples 55 to 75, wherein the second material comprises rayon.

[0199] Example 77. 77. The aerosol generating system of any one of Examples 55 to 76, wherein the second material comprises cotton.

[0200] Example 78. 78. The aerosol generating system of any one of Examples 55 to 77, wherein the first material is a magnetic material.

[0201] Example 79. 79. The aerosol generating system of any one of Examples 55-78, wherein the first material comprises ferritic stainless steel.

[0202] Example 80. 80. The aerosol generating system of any one of Examples 55-79, wherein the first material comprises ferritic stainless steel 430.

[0203] Example 81. 80. The aerosol generating system of any one of Examples 55 to 79, wherein the mesh is woven.

[0204] Example 82. An aerosol generating system as described in Example 81, wherein at least one of the plurality of filaments of the second material is woven above and below alternating filaments of the first material.

[0205] Example 83. An aerosol generating system as described in Example 81 or 82, wherein at least one of the plurality of filaments of the second material is woven over one or more filaments of the plurality of first material and then woven under one or more filaments of the second material.

[0206] Example 84. 84. The aerosol generating system of any one of Examples 55 to 83, comprising a susceptor holder for attachment to the susceptor assembly.

[0207] Example 85. 85. The aerosol generating system of Example 84, wherein the susceptor holder is in contact with at least one filament of the second material.

[0208] Example 86. 86. The susceptor assembly of example 84 or 85, wherein the susceptor holder is not in contact with the first material.

[0209] Example 87. 87. An aerosol generating system according to any one of Examples 55 to 86, comprising an air inlet, an air outlet, and an airflow passage between the air inlet and the air outlet.

[0210] Example 88. 88. The aerosol generating system of Example 87, wherein at least a portion of the susceptor assembly is positioned within the airflow passage.

[0211] Example 89. An aerosol generation system as described in Example 87 or 88, wherein a plurality of filaments of the first material are positioned within the airflow passage.

[0212] Example 90. 90. An aerosol generation system according to any one of Examples 87 to 89, wherein the first direction is substantially parallel to the longitudinal axis of the airflow passage.

[0213] Example 91. An aerosol generation system described in any one of Examples 87 to 90, wherein the second direction is substantially perpendicular to the longitudinal axis of the airflow passage.

[0214] Example 92. 92. An aerosol generating system according to any one of Examples 87 to 91, comprising a mouthpiece, the mouthpiece comprising an air outlet.

[0215] The embodiments will now be further described with reference to the figures.

[0216] 1A shows a schematic cross-sectional view of an aerosol generation system including a first embodiment of a susceptor assembly according to the present disclosure. The system 100 includes a cartridge 10 and a device 60. FIG. 1A shows the system in which the cartridge 10 is separate from the aerosol generation device 60. The aerosol generation system is portable and has a size comparable to that of a conventional cigar or cigarette.

[0217] The cartridge 10 includes a susceptor assembly 12 mounted on a susceptor holder 14. The susceptor assembly 12 is shown in more detail in Figures 2A, 2B, and 2C. The susceptor assembly 12 is planar and thin, having a thickness dimension substantially less than its length and width dimensions. The susceptor assembly 12 includes an array of filaments of wicking material for transporting a liquid aerosol-forming substrate. The array of filaments forms a mesh. The susceptor assembly 12 includes at least one filament of conductive material heatable by penetration by an alternating magnetic field. The at least one filament of conductive material is wrapped around and in contact with a first filament of the array of filaments of wicking material.

[0218] 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, as described in detail below. The susceptor assembly 12 and the susceptor holder 14 are located toward the connecting end of the cartridge 10. The susceptor assembly 12 contacts the susceptor holder 14 such that the susceptor holder 14 supports the susceptor assembly 12 in place within the cartridge 10.

[0219] 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 a sidewall defining an internal passageway 26 having an open end. A pair of openings 28 extend through the sidewall on opposite sides of the tubular susceptor holder 14. The openings 28 are centrally disposed along the length of the susceptor holder 14. The susceptor holder 14 includes a base 30 that partially closes one end of the internal passageway 26. The base 30 includes a plurality of air inlets 32 that allow air to be drawn into the internal passageway 26 through the partially closed end.

[0220] The susceptor assembly 12 is partially disposed inside the interior passage 26 of the susceptor holder 14 and extends in a plane parallel to the central longitudinal axis of the susceptor holder 14. At least one filament of conductive material is disposed completely within the interior passage 26 of the susceptor holder 14, and at least a portion of the array of filaments of wicking material forming the mesh extends through the opening 28 in the sidewall of the susceptor holder 14 and into one of the two channels 45.

[0221] The cartridge 10 further includes a liquid reservoir 44. The liquid reservoir 44 is defined within the cartridge 10 for holding the liquid aerosol-forming substrate 42. The liquid reservoir 44 extends from the mouth end of the outer housing 36 to the connecting end of the outer housing 36 and includes an annular space defined by the outer housing 36. The annular space has an internal passage 48 extending between the mouth end opening 38 and the open end of the internal passage 26 of the susceptor holder 14.

[0222] The liquid reservoir 44 further includes two channels 45, which are defined between the inner surface of the outer housing 36 and the outer surface of the susceptor holder 14. The two channels 45 extend from an annular space defined by the outer housing 36 at the mouth end of the cartridge 10 to the connecting end of the cartridge 10.

[0223] At least a portion of the array of filaments of wicking material forming the mesh extend through the opening 28 in the sidewall of the susceptor holder 14 and into one of two channels 45. The two channels 45 extend from the annular space defined by the outer housing 36 at the mouth end of the cartridge 10 opposite the interior passage 26 of the susceptor holder 14.

[0224] An airflow passage is formed through the cartridge 10 by the internal passage 26 of the susceptor holder 14 and the internal passage 48 of the liquid reservoir 44. The air passage extends from the air inlet 32 ​​in the base 30 of the susceptor holder 14, through the internal passage 26 of the susceptor holder 14, through the internal passage 48 of the liquid reservoir 44 to the mouth end opening 38. The airflow passage allows air to be drawn through the cartridge 10 from the connection end to the mouth end.

[0225] 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 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.

[0226] Device 60 further comprises an induction heating arrangement disposed within device outer housing 62. The induction heating arrangement includes an inductor coil 90, control circuitry 70, and a power source 72. Power source 72 includes a rechargeable lithium-ion battery that is rechargeable via an electrical connector (not shown) at the distal end of the device. Control circuitry 70 is connected to power source 72 and inductor coil 90 such that control circuitry 70 controls the supply of power to inductor coil 90. Control circuitry 70 is configured to supply alternating current to inductor coil 90.

[0227] 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 heating area of ​​the susceptor assembly. The inductor coil 90 is made of copper wire with a circular cross-section and is disposed on a coil former element (not shown). The inductor coil 90 is a helical coil and has a circular cross-section when viewed parallel to the longitudinal axis of the aerosol generating device.

[0228] 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 .

[0229] The induction heating arrangement further includes a magnetic flux concentrator element 91. The magnetic flux concentrator element 91 has a larger radius than the inductor coil 90, and therefore partially surrounds the inductor coil 90. The magnetic flux concentrator element 91 is configured to attenuate the alternating magnetic field outside the aerosol generation system. This may reduce interference between the alternating magnetic field and other nearby electronic devices and reduce the risk of the alternating magnetic field inductively heating nearby objects outside the aerosol generation system.

[0230] FIG. 1B shows a cross-sectional schematic view of the aerosol generation system 100 of FIG. 1A, but with the cartridge 10 coupled to an aerosol generation device 60, in an in-use configuration.

[0231] In operation, when a user draws on the air outlet 38 of the cartridge 10, ambient air is drawn through the device's air inlet 65 into the base of the cavity 64 and into the cartridge 10 through the air inlet 32 ​​in the base 30 of the cartridge 10. The ambient air flows through the cartridge 10 through the airflow passages, across the susceptor assembly 12, from the base 30 to the cartridge air outlet, to the mouth end opening 38.

[0232] 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.

[0233] The control circuit 70 includes an airflow sensor 63. The airflow sensor 63 is in fluid communication with the path of ambient air drawn through the system by the user. The control circuit 72 provides power to the inductor coil 90 when the airflow sensor 63 detects a puff by the user of the cartridge 10.

[0234] When the system is activated, an alternating current is established in the inductor coil 90, which generates an alternating magnetic field in the cavity 64 that penetrates the susceptor assembly 12 in a direction parallel to the longitudinal filaments of the susceptor assembly 12, heating the conductive material of the susceptor assembly. The liquid aerosol-forming substrate in the channel 45 is drawn into the susceptor assembly 12 by a mesh of filaments of wicking material and supplied to the filaments of conductive material. The liquid aerosol-forming substrate 42 is heated at the filaments of conductive material, and volatile compounds from the heated aerosol-forming substrate are released into the air passage of the cartridge 10, which cools and forms an aerosol. The aerosol is entrained in air drawn through the air passage of the cartridge 10 and drawn out of the cartridge 10 at the air outlet 38 for inhalation by the user.

[0235] 2A and 2B show two cross-sectional schematic views of a cartridge 10 according to a first embodiment of a susceptor assembly.

[0236] The two cross sections are taken in two planes perpendicular to each other. The description of cartridge 10 in Figures 1A and 1B can be applied to cartridge 10 in Figures 2A, 2B, and 2C. Further details of cartridge 10 are described with reference to Figures 2A-2C below.

[0237] The susceptor assembly 12 is formed in a rectangular configuration and includes an array of filaments of rayon wicking material forming a mesh 20. The mesh 20 includes a plurality of longitudinally extending filaments of wicking material and a plurality of transversely extending filaments of wicking material. The susceptor assembly 12 also includes filaments of conductive material 16, which in this embodiment is ferritic stainless steel. The filaments of conductive material 16 are heatable by penetration by an alternating magnetic field to vaporize the aerosol-forming substrate. The filaments of conductive material 16 are wrapped around and in contact with the substantially longitudinally extending filaments of wicking material. The longitudinal direction is parallel to the direction of airflow across the surface of the susceptor assembly 12 during use.

[0238] The mesh 20 includes two outer portions of the mesh, each protruding into one of the two channels 45. The mesh 20 is configured to deliver liquid from the outer, exposed surface of the mesh 20 to the filaments of conductive material 16. The mesh 20 contacts the susceptor holder 14 such that the susceptor holder 14 supports the susceptor assembly 12 in place within the cartridge 10. The susceptor holder 14 is in physical contact with the wicking material of the mesh 14 but is not in physical contact with the filaments of conductive material 16.

[0239] 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 conductive filaments 16 are disposed entirely within the interior passage 26 of the susceptor holder 14. A portion of the array of filaments of wicking material forming the mesh 20 extends through an opening 28 in the sidewall of the susceptor holder 14 into one of two channels 45.

[0240] The outer width of the outer housing 36 is greater at the mouth end of the cartridge 10 than at the connecting end, where they are joined by a shoulder 37. The connecting end of the cartridge 10 is received in a cavity of the aerosol generating device, and the shoulder 37 positions the cartridge in the correct position within the device. The mouth end of the cartridge 10 is external to the aerosol generating device and conforms to the exterior shape of the aerosol generating device.

[0241] Figure 2C shows a schematic view of a further alternative cross section of cartridge 10 of Figures 2A and 2B, with cartridge 10 viewed perpendicular to the views shown in Figures 2A and 2B, such that the cross section shown in Figure 2A is indicated by dashed line AB and the cross section shown in Figure 2B is indicated by dashed line CD.

[0242] An opening 28 in the sidewall 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. Due to the friction fit between the susceptor assembly 12 and the susceptor holder 14, an outer portion of the susceptor assembly is in direct contact with the susceptor holder 14 at the opening 28. The outer portion of the susceptor assembly includes a portion of the array of filaments of wicking material that form the mesh 20. The outer portion does not include the filaments of conductive material 16. An inner portion of the susceptor assembly 12 positioned within the interior passage 26 includes a portion of the array of filaments of wicking material that form the mesh 20 and the conductive filaments 16 that are wrapped around and provide physical contact with the filaments of wicking material. The susceptor assembly 12 and the susceptor holder 14 are secured together such that movement of the susceptor holder 14 also moves the susceptor assembly 12.

[0243] 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 22 of the susceptor assembly 12 such that the attachment region is in indirect contact with the susceptor holder 14.

[0244] Two channels 45 are positioned on either side of the internal passage 26, and in use, the two channels 45 supply a liquid aerosol-forming substrate to the susceptor assembly 12. The mesh 20 extends out of the internal passage 26 through the openings 28 and into both of the channels 45. The channels 45 are shown empty in FIG. 2C, but can be understood to be filled with a liquid aerosol-forming substrate prior to use.

[0245] The cartridge 10 is shown from the mouth end to the connecting end in Figure 2C, and thus the air inlets 32 in the base 30 are visible in Figure 2C.

[0246] A cross section of the susceptor assembly 12 can be seen more clearly in FIG. 2C, where the mesh 20 extends into two channels 45 of the liquid reservoir.

[0247] 3A shows a schematic diagram of a first embodiment of a susceptor assembly. The susceptor assembly 12 includes a plurality of longitudinal filaments 21 of wicking material extending substantially in a longitudinal direction and a plurality of transverse filaments 23 of wicking material extending substantially in a transverse direction. The longitudinal filaments extend at right angles to the transverse filaments. The plurality of longitudinal filaments 21 and transverse filaments 23 are woven to form a woven mesh of filaments 20. Both the transverse and longitudinal filaments are non-conductive filaments comprising rayon.

[0248] Multiple filaments 16 of conductive material are wound around a longitudinal filament 21 of wicking material. As shown in FIG. 3A, one filament of conductive material is wound around one longitudinal filament 21 of wicking material. Each of the conductive filaments forms a helical coil around and in contact with the longitudinal filament 21 of wicking material. The coil pitch is between 10 micrometers and 500 micrometers. The diameter of at least one filament of conductive material is between 5 micrometers and 100 micrometers. The conductive material filament is a ferritic stainless steel 430 filament.

[0249] The diameter of the filaments of the wicking material is between 5 micrometers and 100 micrometers. The filaments of the wicking material may define gaps between the filaments, the gaps having a width between 10 micrometers and 100 micrometers. The filaments of the wicking material create capillary action within the gaps such that, in use, the liquid aerosol-forming liquid is drawn into the gaps, increasing the contact area between the susceptor assembly and the liquid.

[0250] The susceptor assembly 12 includes a pair of mounting regions 22 and a heating region 24. The susceptor assembly 12 is substantially rectangular. The heating region 24 is a substantially rectangular region located in the center of the susceptor assembly. The pair of mounting regions 22 are also substantially rectangular regions located on opposite sides of the heating region 24 and around the periphery of the heating region 24. In this embodiment, the mounting regions 22 are disposed at the same central location along the length of the heating region 24.

[0251] Each of the pair of attachment regions 22 has a surface area smaller than that of the heating region 24. The width w ma is the width w of the heating area 24 h1 In this embodiment, the heating region 24 and attachment region have a length l of about 6.50 millimeters. mha The heating area has a width w of about 3.50 mm. ha The mounting area has a width of about 1.15 millimeters, so that the susceptor assembly 12 has an overall length of about 6.50 millimeters and an overall width of about 5.80 millimeters.

[0252] The heating region 24 is configured to be heatable by penetration by an alternating magnetic field to vaporize the aerosol-forming substrate. The pair of mounting regions 22 is configured to contact the susceptor holder so that the susceptor holder can support the susceptor assembly 12 in place within the aerosol-generating system, e.g., a cartridge. The pair of mounting regions 22 is configured to minimize heat transfer from the susceptor assembly to the susceptor holder.

[0253] Heating region 24 includes a portion of mesh 20 and filaments of conductive material 16. Outer attachment region 22 includes a portion of mesh 20 that includes longitudinal wicking material filaments 21 and lateral wicking material filaments 23, but does not include filaments of conductive material 16. Attachment region 22 is thus configured to transport a liquid aerosol-forming substrate. The outer attachment region is configured not to heat due to application of an alternating magnetic field. Due to the inclusion of filaments of conductive material 16, heating region 24 is configured to be heatable by penetration by an alternating magnetic field.

[0254] Providing the susceptor element 12 with a mounting region 22 having a reduced cross section compared to the heating region 24 and comprising the mounting region 22 from a non-magnetic material helps to reduce heating of the mounting region 22 when the susceptor assembly is penetrated by an alternating magnetic field. Such a configuration also helps to reduce heat transfer from the susceptor assembly 12 to the susceptor holder.

[0255] The susceptor assembly of the first embodiment of the present disclosure can be manufactured according to the following method. The method includes providing a plurality of filaments of a wicking material for transporting a liquid aerosol-forming substrate. A portion of the plurality of filaments of the wicking material can be selected to be wound around the filament of the conductive material. For example, one-third of the plurality of filaments can be selected.

[0256] The method further includes winding a filament of electrically conductive material that can be heated by passing an alternating magnetic field through each of the filaments of the wicking material selected for this purpose. For example, the filament of electrically conductive material is wound around the filaments of the wicking material. This is done for a selected number of the filaments of the wicking material, for example, 1 / 3 of the total number of filaments of the wicking material.

[0257] The method further includes assembling a plurality of filaments of wicking material to form a mesh. The mesh is assembled by providing a plurality of filaments of wicking material in a transverse direction, and a plurality of filaments of wicking material in a longitudinal direction, which are woven with the filaments.

[0258] 3B shows a schematic diagram of a second embodiment of a susceptor assembly according to the present disclosure. In this embodiment, the susceptor assembly 112 is shaped in the form of a cross. The susceptor assembly 112 is substantially the same as the susceptor assembly of FIG. 3A, except that it has a different shape and positioning of the conductive filaments, as described below.

[0259] The susceptor assembly 112 may include a pair of mounting regions 122 and a heating region 124. The susceptor assembly 112 is substantially planar with a cruciform cross section. The heating region 124 is a substantially rectangular region located in the center of the susceptor assembly. The pair of mounting regions 122 are also substantially rectangular regions located on either side of the heating region 124 and around the heating region 124. In this embodiment, the mounting regions 122 are disposed at the same central position along the length of the heating region 124.

[0260] Each of the pair of attachment regions 122 has a smaller surface area than the heating region 124. The width w of the attachment region 122 mb is the width w of the heating area 124 hb In this embodiment, the heated region 124 has a total length l of about 8.8 millimeters. hb , and a width w of approximately 3.50 mm hb Each of the attachment regions 122 has a length l of about 6.50 millimeters. mb , and a width w of about 1.15 mm mb Thus, the susceptor assembly 112 has an overall length of about 8.80 millimeters and an overall width of about 5.80 millimeters.

[0261] The heating region 124 is configured to be heatable by penetration by an alternating magnetic field to vaporize the aerosol-forming substrate. The pair of mounting regions 122 is configured to contact the susceptor holder so that the susceptor holder can support the susceptor assembly 112 in place within the aerosol-generating system, e.g., a cartridge. The pair of mounting regions 122 is configured to minimize heat transfer from the susceptor assembly to the susceptor holder.

[0262] Providing the susceptor assembly 112 with a mounting region 122 having a reduced cross section compared to the heating region 124 and comprising the mounting region 122 from a non-magnetic material helps to reduce heating of the mounting region 122 when the susceptor element is penetrated by an alternating magnetic field. Such a configuration also helps to reduce heat transfer from the susceptor assembly 112 to the susceptor holder.

[0263] 3C shows a schematic diagram of a third embodiment of a susceptor assembly according to the present disclosure. In this embodiment, the susceptor assembly 212 is shaped in the form of a cross. The susceptor assembly 212 is substantially the same as the susceptor assembly of FIG. 3B, except that it has a different positioning of the conductive filaments, as described below.

[0264] The susceptor assembly 212 may include a pair of mounting regions 222 and a heating region 224. The susceptor assembly 212 is substantially planar with a cross-shaped cross section. The heating region 224 is shaped in the form of a cross and is located in the center of the susceptor assembly. The pair of mounting regions 222 are also substantially rectangular regions located on either side of the heating region 224 and around the heating region 224. In this embodiment, the mounting regions 222 are disposed at the same central location along the length of the heating region 224.

[0265] Each of the pair of attachment regions 122 has a smaller surface area than the heating region 124. The width w mc is the width w of the heating area 124 hcIn this embodiment, the heated region 124 has a total length l of about 8.8 millimeters. hc , and a width w of about 4.75 mm hc Each of the attachment regions 122 has a length l of about 6.50 millimeters. mc , and a width w of about 0.5 mm mc Thus, the susceptor assembly 112 has an overall length of about 8.80 millimeters and an overall width of about 5.80 millimeters.

[0266] FIG. 4A shows a schematic diagram of a portion of a fourth embodiment of a susceptor assembly according to the present disclosure.

[0267] A portion of the susceptor assembly 312 includes a plurality of longitudinal filaments 321 of wicking material extending in a substantially longitudinal direction and a plurality of transverse filaments 323 of wicking material extending in a substantially transverse direction. The longitudinal filaments extend at right angles to the transverse filaments. The plurality of longitudinal filaments 321 and transverse filaments 323 are woven to form a woven mesh 320 of filaments. Both the transverse and longitudinal filaments are non-conductive filaments comprising rayon.

[0268] A plurality of filaments of conductive material 316 are wound around a longitudinal filament of wicking material 321. One filament of conductive material is wound around one longitudinal filament of wicking material 321 to carry the liquid aerosol-forming substrate. Each of the conductive filaments forms a helical coil around and in contact with the longitudinal filament of wicking material 321. The coil pitch P a is approximately 200 micrometers and is regular along the length of the coil. Each coil of conductive material has the same pitch along the length of the coil. PaThe diameter of at least one filament of conductive material is between 5 micrometers and 100 micrometers. The filament of conductive material is a filament of ferritic stainless steel 430.

[0269] The diameter of the filaments of the wicking material is between 5 micrometers and 100 micrometers. The filaments of the wicking material may define gaps between the filaments, which may have a width between 10 micrometers and 100 micrometers. The filaments of the wicking material create capillary action within the gaps such that, in use, the liquid aerosol-forming liquid is drawn into the gaps, increasing the contact area between the susceptor assembly and the liquid.

[0270] Figure 4A shows a schematic diagram of a portion of a fifth embodiment of a susceptor assembly according to the present disclosure. The portion of the susceptor assembly in Figure 4B is the same as that in Figure 4A, except as described below.

[0271] A portion of the susceptor assembly 412 includes a plurality of longitudinal wicking material filaments 421 extending substantially in a longitudinal direction and a plurality of lateral wicking material filaments 423 extending substantially in a transverse direction. The conductive filaments 416 are wound around and in contact with the longitudinal wicking material filaments 421. The conductive filaments form a helical coil. The helical coil has a pitch P b The coil pitch Pb is about 200 micrometers and is regular along the length of the coil.

[0272] 5A, 5B, and 5C show perspective views of exemplary filaments according to the present disclosure.

[0273] 5A shows a filament of wicking material 471. A filament of conductive material 466 is wrapped around and in contact with the filament of wicking material 471. The filament of conductive material 466 forms a helical coil around the filament of wicking material 471.

[0274] 5B shows a filament of wicking material 481 having two filaments 476, 478 of conductive material wound around and in contact with the filament of wicking material 481. The two filaments 476, 478 of conductive material are wound around the filament of wicking material 481 such that the two filaments 476, 478 overlap. For example, during manufacturing, a first filament 476 is wound around the filament of wicking material 481, and then a second filament 478 is wound around the filament of wicking material 481 in a direction opposite to the winding direction of the first filament 476. In this manner, the two filaments of conductive material 476, 478 are in contact with each other. Overlapping filaments can cause hot spots during use when an alternating magnetic field is applied to the susceptor assembly.

[0275] FIG. 5C shows a filament 491 of wicking material having two filaments 486, 488 of conductive material wound around and in contact with a filament of wicking material 491. The first filament 486 of conductive material is not in contact with the second filament 488 of conductive material. Both filaments 486, 488 of conductive material are wound around the filament 491 of wicking material in the same direction so that the two filaments do not overlap. For example, during manufacturing, the first filament 486 is wound around the filament of wicking material 491, and then the second filament 488 is wound around the filament of wicking material 491 in the opposite direction to the winding direction of the first filament 486. In this way, the two filaments 486, 488 of conductive material are not in contact with each other, which can prevent hot spots from occurring in the susceptor assembly. The lack of contact between the two filaments 486, 488 of conductive material can lead to uniform heat distribution along the length of the filament 491 of wicking material.

[0276] 6A shows a cross-sectional schematic view of a second aerosol generation system including a sixth embodiment of a susceptor assembly according to the present disclosure. System 500 includes cartridge 510 and device 560. FIG. 6A shows the system in which cartridge 510 is separate from aerosol generation device 650. The aerosol generation system is portable and has a size comparable to a conventional cigar or cigarette.

[0277] The cartridge 510 includes a susceptor assembly 512 mounted in a susceptor holder 514. The susceptor assembly 512 is shown in more detail in FIGS. 7A-8B. The susceptor assembly 512 is planar and thin, having a thickness dimension substantially less than its length and width dimensions. The susceptor assembly 512 includes a mesh. The mesh includes a plurality of filaments of a conductive material that can be heated by penetration by an alternating magnetic field. The plurality of filaments of the conductive material extend in a first direction. The mesh also includes a plurality of filaments of a wicking material for transporting liquid from a liquid reservoir to the susceptor assembly. The plurality of filaments of the wicking material extend in a second direction. The first direction is perpendicular to the second direction. The first direction is parallel to the direction of airflow across the surface of the susceptor assembly 512 during use.

[0278] The cartridge 510 has a mouth end and a connecting end opposite the mouth end. An outer housing 536 defines a mouth end opening 538 at the mouth end of the cartridge 510. The connecting end is configured to connect the cartridge 510 to an aerosol generating device, as described in detail below. A susceptor assembly 512 and a susceptor holder 514 are located toward the connecting end of the cartridge 510. The susceptor assembly 512 contacts the susceptor holder 514 such that the susceptor holder 514 supports the susceptor assembly 512 in place within the cartridge 510.

[0279] The susceptor holder 514 includes a tubular body formed from a moldable plastic material, such as polypropylene. The outer housing 536 defines an interior space within which the susceptor assembly 512 and the susceptor holder 514 are contained.

[0280] The outer width of the outer housing 536 is greater at the mouth end of the cartridge 510 than at the connecting end where they are joined by a shoulder 537. This allows the connecting end of the cartridge 510 to be received in a cavity of the aerosol generation device, with the shoulder 537 locating the cartridge in the correct position on the device. This also allows the mouth end of the cartridge 510 to remain outside the aerosol generation device, allowing the mouth end to conform to the exterior shape of the aerosol generation device.

[0281] The tubular body of the susceptor holder 514 includes a sidewall that defines an internal passageway 526 having an open end. A pair of openings 528 extend through the sidewall on either side of the tubular susceptor holder 514. The openings 528 are centrally disposed along the length of the susceptor holder 514. The susceptor holder 514 includes a base 530 that partially closes one end of the internal passageway 526. The base 530 includes a plurality of air inlets 532 that allow air to be drawn into the internal passageway 526 through the partially closed end.

[0282] The susceptor assembly 512 is disposed inside an interior passage 526 of the susceptor holder 514 and extends in a plane parallel to the central longitudinal axis of the susceptor holder 514. A portion of the susceptor assembly 520 extends through an opening 528 in the sidewall of the susceptor holder 514 into one of two channels 545.

[0283] The cartridge 510 further includes a liquid reservoir 544. The liquid reservoir 544 is defined within the cartridge 510 for holding a liquid aerosol-forming substrate 542. The liquid reservoir 544 extends from the mouth end of the outer housing 536 to the connecting end of the outer housing 536 and includes an annular space defined by the outer housing 536. The annular space has an internal passageway 548 extending between the mouth end opening 538 and the open end of the internal passageway 526 of the susceptor holder 514.

[0284] The liquid reservoir 544 further includes two channels 545 defined between the inner surface of the outer housing 536 and the outer surface of the susceptor holder 514. The two channels 545 extend from the annular space defined by the outer housing 536 at the mouth end of the cartridge 510 to the connecting end of the cartridge 510, whereby the susceptor assembly 512 extends through an opening 528 in the sidewall of the susceptor holder 514 into one of the two channels 545. The two channels 545 extend from the annular space defined by the outer housing 536 at the mouth end of the cartridge 510 on either side of the internal passage 526 of the susceptor holder 514.

[0285] An air passageway is formed through the cartridge 510 by the internal passageway 526 of the susceptor holder 514 and the internal passageway 548 of the liquid reservoir 544. The air passageway extends from the air inlet 532 in the base 530 of the susceptor holder 514, through the internal passageway 526 of the susceptor holder 514, through the internal passageway 548 of the liquid reservoir 544, to the mouth end opening 538. The air passageway allows air to be drawn through the cartridge 510 from the connection end to the mouth end.

[0286] The aerosol generating device 560 includes a generally cylindrical device outer housing 562 having a connecting end and a distal end opposite the connecting end. A cavity 564 for receiving the connecting end of the cartridge is located at the connecting end of the device 560, and an air inlet 565 is provided through the outer housing 562 at the base of the cavity 564 to allow ambient air to be drawn into the cavity 564.

[0287] Apparatus 560 further includes an induction heating arrangement disposed within apparatus outer housing 562. The induction heating arrangement includes an inductor coil 590, a control circuit 570, and a power source 572. In use, inductor coil 590 is disposed around susceptor assembly 512 to generate an alternating magnetic field for penetrating susceptor assembly 512 in a direction substantially parallel to the first direction. Power source 572 includes a rechargeable lithium-ion battery that is rechargeable via an electrical connector (not shown) at the distal end of the apparatus. Control circuit 570 is connected to power source 572 and to inductor coil 590 such that control circuit 570 controls the supply of power to inductor coil 590. Control circuit 570 is configured to supply an alternating current to inductor coil 590.

[0288] A single inductor coil 590 is positioned around the susceptor assembly 512 when the cartridge 510 is received in the cavity 564. The inductor coil 590 has a size and shape that matches the size and shape of the heating area of ​​the susceptor assembly. The inductor coil 590 is made of copper wire with a circular cross-section and disposed on a coil former element (not shown). The inductor coil 590 is a helical coil and has a circular cross-section when viewed parallel to the longitudinal axis of the aerosol generation device.

[0289] The inductor coil 590 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 512 when the cartridge 510 is received within the cavity 564 .

[0290] The induction heating arrangement further includes a magnetic flux concentrator element 591. The magnetic flux concentrator element 591 has a larger radius than the inductor coil 590, and therefore partially surrounds the inductor coil 590. The magnetic flux concentrator element 591 is configured to attenuate the alternating magnetic field outside the aerosol generation system. This may reduce interference between the alternating magnetic field and other nearby electronic devices and reduce the risk of the alternating magnetic field inductively heating nearby objects outside the aerosol generation system.

[0291] FIG. 6B shows a cross-sectional schematic view of the aerosol generation system 500 of FIG. 6A, but with the cartridge 510 coupled to the aerosol generation device 560, in an in-use configuration.

[0292] In operation, when a user draws on the air outlet 538 of the cartridge 510, ambient air is drawn into the base of the cavity 64 through the air inlet 565 of the device and into the cartridge 510 through the air inlet 532 in the base 530 of the cartridge 510. Ambient air flows through the cartridge 510 from the base 530 to the cartridge air outlet, mouth end opening 538, through the airflow passages and across the susceptor assembly 512.

[0293] Control circuit 570 controls the supply of power from power supply 572 to inductor coil 590 when the system is activated.

[0294] The control circuit 570 includes an airflow sensor 563. The airflow sensor 563 is in fluid communication with the path of ambient air drawn through the system by the user. The control circuit 572 provides power to the inductor coil 590 when the airflow sensor 563 detects a puff by the user of the cartridge 510.

[0295] When the system is activated, an alternating current is established in inductor coil 90, which generates an alternating magnetic field in cavity 564 that penetrates susceptor assembly 512, heating the conductive material of the susceptor assembly. Liquid aerosol-forming substrate in channel 545 is drawn into susceptor assembly 512 by a mesh of filaments of wicking material and fed to the filaments of conductive material. The liquid aerosol-forming substrate 542 is heated in the filaments of conductive material, and volatile compounds from the heated aerosol-forming substrate are released into the air passage of cartridge 510, which cools and forms an aerosol. The aerosol is entrained in air drawn through the air passage of cartridge 510 and drawn from cartridge 510 at air outlet 538 for inhalation by the user.

[0296] 7A and 7B show schematic diagrams of two cross sections of a cartridge for the aerosol generation system of FIG. 6A. The two cross sections are taken in two planes perpendicular to each other. The description of cartridge 510 in FIGS. 6A and 6B can be applied to cartridge 510 in FIGS. 7A, 7B, and 7C. Further details of cartridge 510 are described with reference to FIGS. 7A-7C below.

[0297] The susceptor assembly 512 is shaped in a rectangular configuration and comprises a mesh. The mesh includes a plurality of filaments 516 of conductive material that are heatable by penetration by an alternating magnetic field. The plurality of filaments of conductive material extend in a first direction. The mesh also includes a plurality of filaments 520 of wicking material for transporting liquid from a liquid reservoir to the susceptor assembly 512. The plurality of filaments 520 of wicking material extend in a second direction. The first direction is perpendicular to the second direction. The first direction is parallel to the direction of airflow across the surface of the susceptor assembly 512 during use.

[0298] The susceptor assembly 512 includes two outer portions of a mesh that each protrude into one of the two channels 545. The mesh is configured to deliver liquid from the outer, exposed surface of the mesh to the filaments of conductive material 516. The mesh contacts the susceptor holder 514 such that the susceptor holder 514 supports the susceptor assembly 512 in place within the cartridge 510. The susceptor holder 514 is in physical contact with the wicking material of the mesh 514 but is not in physical contact with the filaments of conductive material 516.

[0299] The outer width of the outer housing 536 is greater at the mouth end of the cartridge 510 than at the connecting end where they are joined by a shoulder 537. This allows the connecting end of the cartridge 510 to be received in a cavity of the aerosol generation device, with the shoulder 537 locating the cartridge in the correct position on the device. This also allows the mouth end of the cartridge 510 to remain outside the aerosol generation device, allowing the mouth end to conform to the exterior shape of the aerosol generation device.

[0300] Figure 7C shows a schematic view of a further alternative cross section of cartridge 510 of Figures 7A and 7B, with cartridge 510 viewed perpendicular to the views shown in Figures 7A and 7B, with the cross section shown in Figure 7A indicated by dashed line AB and the cross section shown in Figure 7B indicated by dashed line CD.

[0301] The cartridge 510 is shown from the mouth end to the connecting end in Figure 7C, and thus the air inlets 532 in the base 530 are visible in Figure 7C.

[0302] An opening 528 in the sidewall of the susceptor holder 514 is sized to receive the susceptor assembly 512 by a friction fit such that the susceptor assembly 512 is secured within the susceptor holder 514. The friction fit between the susceptor assembly 512 and the susceptor holder 514 causes an outer portion of the susceptor assembly to directly contact the susceptor holder 514 at the opening 528. The susceptor assembly 512 and the susceptor holder 514 are secured together such that movement of the susceptor holder 514 also causes movement of the susceptor assembly 512.

[0303] The susceptor assembly 512 and the susceptor holder 514 may be secured together by other means. For example, in some embodiments, the susceptor assembly 512 is secured to the susceptor holder 514 by an adhesive at an attachment region 522 of the susceptor assembly 512 such that the attachment region is in indirect contact with the susceptor holder 514.

[0304] Two channels 545 are positioned on either side of the internal passage 526, and in use, the two channels 545 supply a liquid aerosol-forming substrate to the susceptor assembly 512. The susceptor assembly 512 extends out of the internal passage 526 through openings 528 into both of the channels 545. The channels 545 are shown empty in FIG. 7C but can be understood to be filled with a liquid aerosol-forming substrate prior to use.

[0305] FIG. 8A shows a schematic diagram of a sixth embodiment of a susceptor assembly for the aerosol generation system of FIG. 6A.

[0306] The susceptor assembly 512 comprises a mesh. The mesh includes a plurality of filaments 516 of conductive material that are heatable by penetration by an alternating magnetic field. The plurality of filaments of conductive material 516 extend in a first direction. The mesh also includes a plurality of filaments 520 of wicking material for transporting liquid from a liquid reservoir to the susceptor assembly 512. The plurality of filaments 520 of wicking material extend in a second direction. The first direction is perpendicular to the second direction.

[0307] As shown in FIG. 8A , a first filament of conductive material 516 extending in a first direction is woven across multiple rows of filaments of wicking material 520 extending in a second direction. The first filament of conductive material 516 is woven above the first filaments of wicking material 520 and then below the second filaments of wicking material 520. This pattern is repeated along the length of the first filament of conductive material 516. The second filament of conductive material 516 extending in the first direction is woven across multiple rows of filaments of wicking material 520 extending in the second direction. The second filament of conductive material 516 is woven below the first filaments of wicking material 520 and then above the second filaments of wicking material 520. This pattern is repeated along the length of the second filament of conductive material 516. Each subsequent filament of conductive material 516 is woven above and below multiple rows of filaments of wicking material 520 extending in the second direction. The woven conductive material filaments 516 and wicking material filaments 520 form a mesh. The mesh includes gaps between the filaments. The gaps have widths of 10 micrometers to 100 micrometers. The wicking material filaments create capillary action within the gaps so that, in use, liquid aerosol-forming liquid is drawn into the gaps, increasing the contact area between the susceptor assembly and the liquid aerosol-forming substrate.

[0308] The diameter of the at least one filament 516 of conductive material is between 5 micrometers and 100 micrometers. The filament 516 of conductive material is a filament of ferritic stainless steel 430. The filament 520 of wicking material comprises rayon.

[0309] In use, the inductor coil is disposed around the susceptor assembly 512 and generates an alternating magnetic field to penetrate the susceptor assembly 512 in a direction parallel to a first direction. The filaments 516 of conductive material extending in the first direction are inductively heated, leading to an increase in temperature throughout the susceptor assembly 512. The liquid aerosol-forming substrate drawn into the susceptor assembly 512 is vaporized.

[0310] FIG. 8B shows a schematic cross-sectional view of a portion of the susceptor assembly of FIG. 8A.

[0311] The susceptor assembly 512 comprises a woven mesh of filaments. Woven filaments 516 of a first material extend in a first direction, which is parallel to the direction of the alternating magnetic field. Woven filaments 520 of a second material extend in a second direction, which is substantially perpendicular to the first direction.

[0312] The susceptor assembly 512 is a planar assembly. The second filaments 520 extending in the first direction are woven with the first filaments 516 extending in the first direction such that the second filaments 520 extending in the second direction extend further outward from the plane of the woven mesh of the susceptor assembly 512 than the first filaments extending in the first direction. In other words, the second filaments 520 extending in the second direction define the maximum thickness of the woven mesh.

[0313] The second filaments 520 extending in the second direction define the maximum thickness of the woven mesh of the susceptor assembly 512, and the susceptor holder in contact with the susceptor assembly only contacts the second filaments 520 extending in the second direction.

[0314] The second filaments 520 extending in the second direction are made of a wicking material, such as rayon, which is not electrically conductive, so that the second filaments 520 extending in the second direction are not directly heated by the induction of eddy currents or hysteresis losses when the susceptor assembly is exposed to an alternating magnetic field. As a result, the second filaments 520 extending in the second direction in contact with the susceptor holder transfer less heat to the susceptor holder than if the filaments were made of an electrically conductive material.

[0315] FIG. 9 shows a schematic diagram of a seventh embodiment of a susceptor assembly for the aerosol generation system of FIG. 6A.

[0316] The susceptor assembly 612 comprises a mesh. The mesh includes a plurality of filaments 616 of conductive material that are heatable by penetration by an alternating magnetic field. The plurality of filaments 616 of conductive material extend in a first direction. The mesh also includes a plurality of filaments 620 of wicking material for transporting liquid from a liquid reservoir to the susceptor assembly 612. The plurality of filaments 620 of wicking material extend in a second direction. The first direction is perpendicular to the second direction. In use, the susceptor assembly 612 is placed in an alternating magnetic field that penetrates the susceptor assembly 616 in the first direction.

[0317] As shown in FIG. 9 , a first filament 616 of conductive material extending in a first direction is woven across multiple rows of filaments of wicking material 620 extending in a second direction. The first filament 616 of conductive material is woven over the first filament 620 of wicking material, over the second filament 620 of wicking material, under the third filament 620 of wicking material, and under the fourth filament 620 of wicking material. This pattern is repeated along the length of the first filament 616 of conductive material. The second filament 516 of conductive material is woven under the first filament 520 of wicking material and then over the second filament 520 of wicking material. This pattern is repeated along the length of the second filament 516 of conductive material. The woven filaments 516 of conductive material and filaments 520 of wicking material form a mesh. The mesh includes gaps between the filaments. The gaps have a width of 10 micrometers to 100 micrometers. The filaments of wicking material create capillary action within the gaps such that, in use, liquid aerosol-forming liquid is drawn into the gaps, increasing the contact area between the susceptor assembly and the liquid aerosol-forming substrate.

[0318] The diameter of the at least one filament 516 of conductive material is between 5 micrometers and 100 micrometers. The filament 516 of conductive material is a filament of ferritic stainless steel 430. The filament 520 of wicking material comprises rayon.

[0319] FIG. 10A shows a schematic diagram of an eighth embodiment of a susceptor assembly for the aerosol generation system of FIG. 6A.

[0320] The susceptor assembly 612 includes a pair of mounting regions 622 and a heating region 624. The susceptor assembly 612 is shaped in the form of a cross. The heating region 624 is a substantially rectangular region located in the center of the susceptor assembly 612. The pair of mounting regions 622 are also substantially rectangular regions located on either side of the heating region 624 and around the periphery of the heating region 624. In this embodiment, the mounting regions 622 are disposed at the same central location along the length of the heating region 624.

[0321] Each of the pair of attachment regions 622 has a smaller surface area than the heating region 624. The width w ma is the width w of the heating area 624 ha In this embodiment, the heated region 624 has a total length l of about 8.8 millimeters. ha , and a width w of approximately 3.50 mm ha Each of the attachment regions 622 has a length l of about 6.50 millimeters. ma , and a width w of about 1.15 mm ma As such, the susceptor assembly 612 has a maximum overall length of about 8.80 millimeters and a maximum overall width of about 5.80 millimeters.

[0322] The heating region 624 is configured to be heatable by penetration by an alternating magnetic field to vaporize the aerosol-forming substrate. The pair of mounting regions 622 is configured to contact the susceptor holder so that the susceptor holder can support the susceptor assembly 612 in place within the aerosol-generating system, e.g., a cartridge. The pair of mounting regions 622 is configured to minimize heat transfer from the susceptor assembly to the susceptor holder.

[0323] The heating region 624 comprises a portion of the woven mesh of the susceptor assembly 612. The heating region includes filaments of a first conductive material extending in a first direction and filaments of a second wicking material extending in a second direction. The first direction is substantially parallel to an alternating magnetic field generated by an inductor coil surrounding the susceptor assembly (not shown in FIG. 10A ). The filaments of the first magnetic material are inductively heated by the alternating magnetic field. There are more and longer filaments of the first material in the heating region compared to the two attachment regions 622.

[0324] The outer attachment area 622 includes a portion of the woven mesh of the susceptor assembly 612. The woven mesh, including the wicking material and gaps defined between the filaments, transports liquid aerosol-forming substrate from the liquid reservoir to the susceptor assembly by capillary action across the susceptor assembly 612.

[0325] The susceptor assembly 612 is planar and extends substantially in a plane. The second filaments 620 extending in the first direction are woven with the first filaments 616 extending in the first direction such that the second filaments 620 extending in the second direction extend further outward from the plane of the woven mesh of the susceptor assembly 612 than the first filaments extending in the first direction. In other words, the second filaments 620 extending in the second direction define the maximum thickness of the woven mesh.

[0326] The second filaments 620 extending in the second direction define the maximum thickness of the woven mesh of the susceptor assembly 612, and the susceptor holder in contact with the susceptor assembly 612 is in contact only with the second filaments 620 extending in the second direction. The second filaments 620 do not include conductive material. They are not directly heated by the induction of eddy currents or hysteresis losses when the susceptor assembly 612 is exposed to an alternating magnetic field.

[0327] Providing the susceptor assembly 612 with an attachment region 622 that has a reduced cross-section compared to the heating region 624 and has only the second filament in contact with the susceptor holder helps to reduce heating of the attachment region 622 when the susceptor assembly is penetrated by an alternating magnetic field and helps to reduce heat transfer from the susceptor assembly 612 to the susceptor holder.

[0328] 10B shows a schematic diagram of a ninth example of a susceptor assembly for the aerosol generation system of FIG. 6A. The susceptor assembly 712 includes a pair of mounting regions 722 and a heating region 724. The susceptor assembly 712 is substantially rectangular. The heating region 724 is a substantially rectangular region located in the center of the susceptor assembly. The pair of mounting regions 722 are also substantially rectangular regions located on either side of the heating region 724 and around the heating region 724. In this embodiment, the mounting regions 722 are disposed at the same central position along the length of the heating region 724.

[0329] Each of the pair of attachment regions 722 has a smaller surface area than the heating region 724. The width w of the attachment region 722 mb is the width of the heating area 724 hb In this embodiment, the heating region 724 and attachment region have a length l of about 6.50 millimeters. mhb The heating region has a width whb of about 3.50 millimeters. The mounting region has a width of about 1.15 millimeters. Thus, the susceptor assembly 712 has an overall length of about 6.50 millimeters and an overall width of about 5.80 millimeters.

[0330] The heating region 724 is configured to be heatable by penetration by an alternating magnetic field to vaporize the aerosol-forming substrate. The pair of mounting regions 22 is configured to contact the susceptor holder so that the susceptor holder can support the susceptor assembly 12 in place within the aerosol-generating system, e.g., a cartridge. The pair of mounting regions 22 is configured to minimize heat transfer from the susceptor assembly to the susceptor holder.

[0331] The heating region 724 includes a woven mesh of first and second filaments, as described in FIG. 8A. Briefly, the heating region includes filaments of a first conductive material extending in a first direction and filaments of a second wicking material extending in a second direction perpendicular to the first direction. The first direction is substantially parallel to an alternating magnetic field generated by an inductor coil surrounding the susceptor assembly (not shown in FIG. 10B). The filaments of the first magnetic material are inductively heated by the alternating magnetic field. The second material is a non-conductive wicking material.

[0332] The outer attachment region 722 includes a woven mesh of filaments of a second material. The woven mesh includes filaments of a wicking material and gaps defined between the filaments, and the mesh transports liquid aerosol-forming substrate by capillary action from the liquid reservoir to the susceptor assembly and across the susceptor assembly 712. The attachment region in FIG. 10b does not include filaments of the first material or conductive material. Therefore, no heat is generated in the attachment region 722 of the susceptor assembly 712.

[0333] Providing the susceptor assembly 712 with a mounting region 722 that has a reduced cross-section compared to the heating region 724 and that does not have any electrically conductive material in the mounting region 722 helps to reduce heating of the mounting region 722 when the susceptor assembly is penetrated by an alternating magnetic field. Such a configuration also helps to reduce heat transfer from the susceptor assembly 712 to the susceptor holder.

[0334] Figure 11 shows a cross-sectional schematic diagram of a third embodiment of an aerosol generation system according to the present disclosure. Aerosol generation system 800 includes most of the components of aerosol generation system 500 shown in Figures 6A and 6B and operates in a similar manner. One difference is that aerosol generation system 800 does not include a separate cartridge; instead, most of the features of cartridge 510 according to Figures 6A-7B are incorporated into aerosol generation system 800.

[0335] As previously described, the aerosol generation system 800 includes a generally cylindrical system outer housing 862 having an oral end and a distal end opposite the oral end. An air inlet 865 is provided into the system 800 through the system outer housing 862.

[0336] System 800 further comprises an induction heating arrangement disposed within system outer housing 862. The induction heating arrangement includes an inductor coil 890, a control circuit 870, and a power supply 872. Control circuit 870 is connected to power supply 872 and to inductor coil 890 such that control circuit 870 controls the supply of power to inductor coil 890. Control circuit 870 is configured to supply an alternating current to inductor coil 890.

[0337] A single inductor coil 890 is positioned around the susceptor assembly 812. The inductor coil 890 has a size and shape that matches the size and shape of the heating region of the susceptor assembly 812. The inductor coil 890 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 812.

[0338] The induction heating arrangement further includes a flux concentrator element 891 as previously described.

[0339] The susceptor assembly 812 and the susceptor holder 814 are identical to the susceptor assembly 512 and the susceptor holder 514 shown in Figures 6A-8B. The susceptor assembly depicted in Figures 9-10B is another example of a susceptor assembly suitable for the aerosol generation system according to this embodiment.

[0340] As previously mentioned, the susceptor holder 814 also includes a base 830 that partially closes one end of the interior passageway 826. The base 830 includes a plurality of air inlets that allow air to be drawn into the interior passageway 826 through the partially closed end. However, those skilled in the art will appreciate that since the system 800 does not include a removable cartridge, the susceptor holder may instead be integrally formed with the system 800, and in particular the system outer housing 862.

[0341] Similarly, the aerosol-generation system 800 further includes a liquid reservoir 844. The liquid reservoir 844 is defined by a system outer housing 862 for holding a liquid aerosol-forming substrate 842. The liquid reservoir includes an annular space defined by the system outer housing 862. The annular space has an internal passageway 848 extending between the mouth-end opening 838 and the open end of the internal passageway 826 of the susceptor holder 814. The liquid reservoir 844 further includes two channels 845, which are defined between the outer surface of the susceptor holder 814 and the internal surface of the system. The two channels 845 extend from the annular space defined by the system outer housing 862 at the mouth end of the system 800 to the connecting end of the system 800, thereby allowing a portion of the susceptor assembly 812 to extend into the two channels 845 through openings in the sidewall of the susceptor holder 814. Two channels 845 extend from an annular space defined by the system outer housing 862 at the mouth end of the system 800 on either side of the interior passage 826 of the susceptor holder 814 .

[0342] Similarly, an air passageway is formed through the system 800 by the internal passageway 826 of the susceptor holder 814 and the internal passageway 848 of the liquid reservoir 844. The air passageway extends from an air inlet in the base 830 of the susceptor holder 814, through the internal passageway 826 of the susceptor holder 814, through the internal passageway 848 of the liquid reservoir 844, to the mouth end opening 838. The air passageway allows air to be drawn through the system 800 from the air inlet 865 to the mouth end opening 838.

[0343] Similarly, control circuit 872 includes airflow sensor 863. Airflow sensor 863 is in fluid communication with the path of ambient air drawn through system 800 by a user. Control circuit 872 provides power to heated susceptor assembly 812 when airflow sensor 863 detects a puff by a user of system 800.

[0344] When the system is activated, an alternating current is established in the inductor coil 890, which inductively heats the susceptor assembly 812. A liquid aerosol-forming substrate 842 in the channel 845 is drawn into the susceptor assembly 812. The liquid aerosol-forming substrate 842 is heated at the first filament of conductive material, and volatile compounds from the heated aerosol-forming substrate are released into the air passages 826, 848 of the system 800, which cool and form an aerosol. The aerosol is entrained in air drawn through the air passages 826, 848 of the system 800 and drawn from the system 800 at the oral end opening 838 for inhalation by the user.

[0345] Any of the sixth through ninth exemplary susceptor assemblies may be implemented in the aerosol generation system of FIG.

[0346] For purposes of this specification and the appended claims, unless otherwise indicated, all numerical values ​​expressing amounts, quantities, percentages, and the like are to be understood as being modified in all instances by the term "about." Also, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein. Thus, in this context, the number A is to be understood as A±10%. Within this context, the number A may be considered to include numerical values ​​that are within the common standard error for measurement of the property that the number A modifies. In some instances, as used in the appended claims, the number A may deviate by the percentages recited above, provided that the amount by which A deviates does not materially affect the basic and novel characteristics of the claimed invention. Also, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein.

Claims

1. 1. A susceptor assembly for an aerosol generating system, the susceptor assembly comprising: an array of filaments of a wicking material for conveying a liquid aerosol-forming substrate, the array forming a mesh; and at least one filament of conductive material heatable by penetration by an alternating magnetic field, the at least one filament of conductive material being wound around and in contact with a first filament of the array of filaments of the wicking material.

2. 2. The susceptor assembly of claim 1, wherein the mesh includes a plurality of longitudinal filaments of the wicking material extending in a substantially longitudinal direction and a plurality of lateral filaments of the wicking material extending in a substantially lateral direction.

3. The susceptor assembly of claim 2 , wherein the at least one filament of the electrically conductive material is wound around a longitudinal filament.

4. The susceptor assembly of any one of claims 1 to 3, wherein a first filament of the at least one filament of the electrically conductive material is wound around only a first filament of the wicking material.

5. 5. The susceptor assembly of claim 4, wherein a second filament of said at least one filament of said electrically conductive material is wrapped around and in contact with said first filament of said wicking material.

6. The susceptor assembly of any one of claims 1 to 5, wherein the at least one filament of electrically conductive material comprises a helical coil.

7. The susceptor assembly of any one of claims 1 to 6, wherein the mesh is a fluid-permeable woven mesh.

8. 1. A cartridge for an aerosol generation system, comprising: A susceptor assembly according to any one of claims 1 to 7; a liquid reservoir for holding a liquid aerosol-forming substrate in fluid communication with the susceptor assembly.

9. The cartridge of claim 8 , wherein at least one of the plurality of lateral filaments of the wicking material is in physical contact with the liquid reservoir.

10. 1. An aerosol generating system comprising: A susceptor assembly according to any one of claims 1 to 7; a liquid reservoir for holding a liquid aerosol-forming substrate in fluid communication with the susceptor assembly; an inductor coil disposed around the susceptor assembly to generate an alternating magnetic field that penetrates the susceptor assembly to heat the conductive material; a control circuit connected to the inductor coil and configured to provide a current to the inductor coil.

11. 11. The aerosol generation system of claim 10, wherein the inductor coil is arranged to generate a magnetic field that penetrates the susceptor assembly in a direction substantially parallel to the plurality of longitudinal filaments of the wicking material.

12. 1. An aerosol generating system comprising: a liquid reservoir for holding a liquid aerosol-forming substrate; a susceptor assembly comprising a mesh, the mesh including a plurality of filaments of a first material extending in a first direction and a plurality of filaments of a second material extending in a second direction, the first material being an electrically conductive material heatable by penetration by an alternating magnetic field, and the second material being a wicking material for transporting liquid from the liquid reservoir to the susceptor assembly; an inductor coil disposed around the susceptor assembly to generate an alternating magnetic field for passing through the susceptor assembly in a direction substantially parallel to the first direction; a control circuit connected to the inductor coil and configured to provide a current to the inductor coil.

13. 13. The aerosol generating system of claim 12, wherein the first direction is substantially perpendicular to the second direction.

14. 14. The aerosol generation system of claim 12, wherein the inductor coil is disposed to surround the susceptor assembly.

15. 15. The aerosol generating system according to any one of claims 12 to 14, wherein the mesh is woven.

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