Susceptor assembly for an aerosol generating system

Abstract

A susceptor assembly (12) for an aerosol generation system is provided, the susceptor assembly (12) including at least one nonwoven susceptor element (616). The at least one nonwoven susceptor element (616) is in the form of a sheet and includes a plurality of openings (650). Each opening extends from a first surface of the sheet to a second surface of the sheet. The susceptor assembly (12) further includes a wicking element (20) coupled to the at least one nonwoven susceptor element (616), the wicking element configured to transport an aerosol-forming liquid across a surface of the at least one nonwoven susceptor element (616). Each opening of the plurality of openings (650) extends in a first direction (655) parallel to at least one of the first surface and the second surface of the at least one susceptor element (616), and each opening of the plurality of openings extends in a second direction (656) parallel to at least one of the first surface and the second surface of the at least one susceptor element (616) and perpendicular to the first direction (655), and each opening extends a greater distance in the first direction than in the second direction (656).

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 an aerosol generation device. [Background technology]

[0002] Aerosol-generating systems and devices configured to generate inhalable aerosols from an aerosol-forming substrate are known in the art. Some prior aerosol-generating systems include an aerosol-generating device connectable to a cartridge. A typical cartridge for use in an aerosol-generating device includes an aerosol-forming substrate and a heater assembly, where the heater assembly includes a heating element. In many aerosol-generating systems, the heating element is inductively heated, in which case the heating element is a susceptor element.

[0003] The aerosol-forming substrate may be a liquid. In this case, the cartridge or device may further include a wicking material in fluid communication with the aerosol-forming substrate and in contact with the susceptor element. The wicking material is configured to transport the liquid aerosol-forming substrate to the susceptor element. During use, the susceptor element is configured to vaporize the liquid aerosol-forming substrate. An airflow is provided past the susceptor element to entrain the generated vapor. The vapor condenses in the airflow, forming an aerosol. The aerosol may then be inhaled by a user. Aerosol generating devices typically include a power supply configured to provide power to the susceptor element by induction heating. In aerosol generating systems including a device and a cartridge, the power supply is often configured to provide power to the susceptor element when the device and cartridge are coupled together via an electrical connector. In this type of aerosol generating system, the system is often configured to activate the susceptor element only when a user is puffing on the system.

[0004] Woven susceptor elements are known in the art and generally comprise a plurality of filaments woven to create a mesh. Gaps within the mesh allow the vaporized liquid aerosol-forming substrate to pass through the susceptor element and into the airflow path. However, there is a compromise between efficiently heating the liquid aerosol-forming substrate by providing filaments with an optimal gauge and filament density and efficiently allowing the vaporized substrate to enter the airflow path by varying the mesh gap size.

[0005] It is therefore desirable to provide a susceptor assembly for an aerosol generating system, a cartridge for an aerosol generating system, an aerosol generating system, and an aerosol generating device that efficiently heats and vaporizes a liquid aerosol-forming substrate and allows the vaporized substrate to efficiently enter an airflow path. Summary of the Invention

[0006] According to a first embodiment of the present disclosure, there is provided a susceptor assembly for an aerosol generation system. The susceptor assembly may include at least one nonwoven susceptor element. The at least one nonwoven susceptor element may be in the form of a sheet. The at least one nonwoven susceptor element may include a plurality of apertures. Each aperture may extend from a first surface of the sheet to a second surface of the sheet. The susceptor assembly may include a wicking element coupled to the at least one nonwoven susceptor element. The wicking element may be configured to transport an aerosol-forming liquid across a surface of the at least one nonwoven susceptor element. Each aperture of the plurality of apertures may extend in a first direction parallel to at least one of the first surface and the second surface of the at least one susceptor element. Each aperture of the plurality of apertures may extend in a second direction parallel to at least one of the first surface and the second surface of the at least one susceptor element and perpendicular to the first direction. Each opening of the plurality of openings may extend a greater distance in the first direction than in the second direction. Advantageously, such an arrangement of elongated openings in the first direction has been found to improve the induction heating response of the susceptor when exposed to an alternating magnetic field in the first direction. The improved induction heating response may then result in more favorable aerosol characteristics of the aerosol generated by the aerosol generation system. Therefore, it is beneficial to position the susceptor elements so that the elongated direction of the openings is aligned with the direction of the varying magnetic field. The susceptor assembly may be configured to be heated by a magnetic field that varies in a direction parallel to the first direction. The susceptor assembly may be configured to be disposed within a cartridge in the aerosol generation system, and the susceptor elements may be heated by a magnetic field that varies in a direction parallel to the first direction.

[0007] Each aperture of the plurality of apertures may extend a first distance in a first direction. Each aperture of the plurality of apertures may extend a second distance in a second direction. The first distance may be greater than the second distance. The first distances may not all be equal. The second distances may not all be equal. Alternatively, the first distances may be equal or substantially equal. The second distances may be equal or substantially equal.

[0008] The first distance may be 1.5 to 10 times the second distance. The first distance may be 2 to 5 times the second distance. The first distance may be 2.5 to 4 times the second distance. The susceptor element may be planar and may define a first plane such that the first direction and the second direction lie within the first plane. The plurality of openings may form a regular array of openings in at least one susceptor element. The plurality of openings may be spaced apart in the first direction by a first spacing distance that is 0.05 to 1 times the first distance. The plurality of openings may be spaced apart in the first direction by a first spacing distance that is 0.1 to 0.5 times the first distance. The plurality of openings may be spaced apart in the second direction by a second spacing distance that is 0.2 to 5 times the second distance. The plurality of openings may be spaced apart in the second direction by a second spacing distance that is 1 to 3 times the second distance.

[0009] An average value of the first distances for all of the plurality of apertures may be greater than an average value of the second distances for all of the plurality of apertures. An average value of the first distances for all of the plurality of apertures may be greater than an average value of the second distances for all of the plurality of apertures. A median value of the first distances for all of the plurality of apertures may be greater than a median value of the second distances for all of the plurality of apertures.

[0010] The susceptor element may include a regular array of apertures. The regular array of apertures may be an array of hexagonal apertures. The regular array of apertures may be an array of square apertures. Advantageously, such a regular array may allow for ease of manufacturing of the susceptor element.

[0011] The wicking element may include a first surface and a second surface. The first surface and the second surface define opposing outwardly facing surfaces of the wicking element. The at least one susceptor element may include first and second planar susceptor elements. The susceptor assembly may be arranged such that the first surface of the wicking element contacts the first susceptor element and the second surface of the wicking element contacts the second susceptor element. Advantageously, such an arrangement may provide efficient aerosol generation due to the relatively large surface area provided by the two planar surfaces of the susceptor elements.

[0012] At least one susceptor element may be folded around the wicking element such that a first surface of the wicking element contacts a first portion of the at least one susceptor element and a second surface of the wicking element contacts a second portion of the at least one susceptor element, the first portion being substantially parallel to the second portion. Advantageously, such a folded arrangement may facilitate manufacturing of the susceptor assembly and increase the mechanical strength of the assembly.

[0013] The at least one susceptor element may further include a folded portion. The folded portion may be connected between the first portion and the second portion. The folded portion may include an elongated opening. The elongated opening may extend in a direction parallel to at least one of the first surface and the second surface of the wicking element. The folded portion may include at least one connecting portion between the first portion and the second portion of the susceptor element. The first portion of the at least one susceptor element and the second portion of the at least one susceptor element may be integrally formed. The first portion of the at least one susceptor element and the second portion of the at least one susceptor element and the at least one connecting portion may be integrally formed. Advantageously, when the susceptor element is folded around the wicking element, the at least one connecting portion may therefore be easily deformed, allowing for ease of manufacturing.

[0014] Each opening of the plurality of apertures may be circular or oval in shape. Each opening of the plurality of apertures may be rectangular or square in shape. Advantageously, such simple shapes may be particularly easy to manufacture, for example, with respect to stamping. The at least one susceptor element may have a first thickness. The first thickness may be between 25 micrometers and 100 micrometers. Each opening of the plurality of apertures may be formed via laser cutting. Each opening of the plurality of apertures may be formed via chemical etching. Each opening of the plurality of apertures may be formed via stamping or wire discharge.

[0015] The at least one susceptor element may include at least one outward protrusion. The at least one outward protrusion may be on a peripheral edge of the at least one susceptor element. The at least one outward protrusion is configured to engage with a susceptor holder component of the cartridge. The at least one outward protrusion may occupy a percentage of the peripheral edge of the at least one susceptor element. The percentage may be 1% to 20% of the peripheral edge of the at least one susceptor element. The percentage may be 2% to 10% of the peripheral edge of the at least one susceptor element. Advantageously, such outward protrusions may minimize the amount of heat transferred from the susceptor element to a susceptor holder within the cartridge.

[0016] The at least one susceptor element may be heatable by at least one of Joule heating through induction of eddy currents in the susceptor element and hysteresis losses. The at least one susceptor element may include at least one of graphite, molybdenum, silicon carbide, stainless steel, niobium, and aluminum. The at least one susceptor element may include at least one ferromagnetic material. The at least one susceptor element may include AISI 430 stainless steel. The at least one susceptor element may have a relative permeability of 1 to 40,000 when measured at a temperature of 20 degrees Celsius and a frequency of up to 10 kHz. The at least one susceptor element may have a relative permeability of 500 to 40,000 when measured at a temperature of 20 degrees Celsius and a frequency of up to 10 kHz.

[0017] The susceptor elements may be planar. The susceptor elements may define a first plane. At least one susceptor element may be substantially flat. Substantially flat may be defined as a susceptor element including both a width and a height that is much greater than its depth. The susceptor assembly may be substantially planar. The susceptor assembly may substantially define a first plane. Advantageously, such an arrangement has been found to be beneficial for efficient aerosol generation having a high surface area to volume ratio.

[0018] At least one nonwoven susceptor element may include a first region. The first region may include a first configuration of openings in the plurality of openings. At least one nonwoven susceptor element may include a second region. The second region may include a second configuration of openings in the plurality of openings. The openings in the second configuration may be different from the openings in the first configuration. It has been found that varying configurations of openings in the first and second regions vary the amount of heat generated by inductive heating of the susceptor element in those regions. Advantageously, this can be used to control how and where heat is actually generated across the susceptor element and enable a susceptor element design that can be optimized to reduce the risk of overheating and scorching of the wicking element.

[0019] The apertures in the second configuration may be free of apertures, such that the second region does not include apertures. Advantageously, the second region may act as a heat sink or channel for transporting heat due to the absence of apertures, which may reduce the risk of overheating and scorching of the wicking element.

[0020] The openings of the second configuration may be different from the openings of the first configuration such that when the first region is exposed to the same alternating magnetic field as the second region, and when the alternating magnetic field is uniform across the first and second regions, the temperature of the first region increases more than the temperature of the second region. The first region may include a first density of openings in the plurality of openings. The density of the openings may be defined as the number of openings per unit area. The second region includes a second density of openings in the plurality of openings. The second density of openings may be different from the first density of openings. The second density of openings may be less than the first density of openings. Advantageously, it has been found that configurations including a higher density of openings can generate more heat compared to configurations including a lower density of openings. Adjusting the density of openings in the first and second regions can be used to control how and where heat is actually generated across the susceptor element and enable a susceptor element design that can be optimized to reduce the risk of overheating and scorching of the wicking element. The second density of openings may be equal to zero, such that the second region does not include any openings.

[0021] The second region may include a shape that includes a central region of the susceptor element. The second region may include a central region of the susceptor element. The second region may surround the central region of the susceptor element. Advantageously, because core burning or overheating of the susceptor element typically occurs in the central region of the susceptor element, the susceptor element may be modified using the second region to reduce these risks.

[0022] The first region may at least partially surround the second region in the plane of the susceptor element. The first region may completely surround the second region in the plane of the susceptor element. The first region may be located between the second region and at least one peripheral edge of the susceptor element.

[0023] The shape of the second region may further include a plurality of radial portions. The plurality of radial portions may extend across the susceptor element from a central region toward a periphery of the planar susceptor element. The plurality of radial portions may extend across the susceptor element from a central region toward a periphery of the planar susceptor element in a first plane. Each of the radial portions of the plurality of radial portions may be uniformly spaced apart from one another in the first plane around the central region. The second region may include 2 to 8 radial portions. The second region may include 4 to 6 radial portions.

[0024] The susceptor element may include two or more regions. For example, the susceptor element may include three or more regions. Each of the two or more regions may include a configuration of a plurality of apertures. Each of the two or more regions may include a configuration different from the configuration of at least one other region. Advantageously, the susceptor element may be designed to spatially configure the heat generated by the uniformly varying magnetic field. The susceptor element may include a third region. The second region may include a shape that includes or surrounds the third region. The third region may include a third array of apertures identical to the arrangement of the first apertures. The apertures in the third region may be identical to each other. The apertures in the third region may be identical to the apertures in the first region, such that the apertures in the third region may have the same diameter as the apertures in the first region.

[0025] Each opening of the plurality of openings may be of equal size. The size of each opening in the first region may be different from the size of each opening in the second region. The size of each opening in the first region may be smaller than the size of each opening in the second region. The first average size of the openings in the first region may be less than the second average size of the openings in the second region. The size of each opening may be the cross-sectional area of ​​each opening parallel to the first surface of the at least one susceptor element. Advantageously, it has been found that a configuration including small openings with a higher density can generate more heat compared to a configuration including large openings with a lower density. Adjusting the size of the openings in the first and second regions can be used to control how and where heat is actually generated across the susceptor element and enable a susceptor element design that can be optimized to reduce the risk of overheating and scorching of the wicking element.

[0026] The first region may include a first regular array of apertures of the plurality of apertures. The first regular array of apertures may be an array of hexagonal apertures. The first regular array of apertures may be an array of square apertures. The second region may include a second regular array of apertures of the plurality of apertures. The second regular array of apertures may be an array of hexagonal apertures. The second regular array of apertures may be an array of square apertures. Advantageously, such regular arrays may allow for ease of manufacturing of both the first region and the second region. Each aperture of the plurality of apertures may be circular or oval in shape. Each aperture of the plurality of apertures may be rectangular or square in shape. Advantageously, such simple shapes may be particularly easy to manufacture, for example with respect to stamping.

[0027] At least one nonwoven susceptor element may further include a plurality of channels. Each of the plurality of channels may extend between at least two of the plurality of openings. Advantageously, the channels may contribute to the transport of the liquid aerosol-forming substrate across the susceptor element, particularly increasing the amount of liquid supplied to the center of the susceptor element. Liquid aerosol-forming substrate transported from the wicking element toward, for example, the first susceptor element, may reach the first opening and then travel along the channel to the proximal opening. This transport may therefore minimize the number of openings to which insufficient liquid is supplied during heating of the susceptor element, which may contribute to minimizing overheating of the susceptor element and, consequently, scorching of the wicking element. The channels may further generate a liquid meniscus of the liquid aerosol-forming substrate. This liquid meniscus may generate an aerosol during heating of the susceptor. Therefore, the channels may also constitute an evaporation zone. The first surface may be on the opposite side of the sheet from the second surface. At least one susceptor element may include a first thickness extending between the first surface and the second surface. Each of the plurality of channels may be at least partially defined on the first surface. Each of the plurality of channels may extend from the first surface toward the second surface 0.25 to 0.75 times the first thickness. Advantageously, the channel does not pass entirely through the susceptor element, maintaining the robustness of the susceptor element. At least one of the plurality of channels may extend entirely from the first surface to the second surface. Advantageously, when at least one of the plurality of channels extends entirely from the first surface to the second surface, it is possible to have vaporization of the liquid aerosol-forming substrate through the channel as well as transport of the liquid aerosol-forming substrate through the channel. To ensure that all portions of the susceptor element are connected by at least one portion of material, not all of the plurality of channels may extend entirely from the first surface to the second surface. The first surface of the susceptor element may be in contact with a wicking element. Preferably, the second surface of the susceptor element may be in contact with a wicking element.

[0028] The at least one susceptor element may define a first plane. The plurality of channels may be configured to transport the aerosol-forming liquid in at least one direction within the first plane. Each channel of the plurality of channels may be obtained by chemical etching. Advantageously, the desired depth of the channels may be easily controlled. Each channel of the plurality of channels may extend between two openings of the plurality of openings. Each channel of the plurality of channels may extend between two adjacent openings of the plurality of openings. Each channel of the plurality of channels may extend between two nearest adjacent openings of the plurality of openings. Each opening of the plurality of openings may be connected to at least one adjacent opening by at least one channel. The plurality of channels may form a regular array of channels. Each channel of the plurality of channels may be configured to apply a capillary force to the aerosol-forming liquid. Each channel may be a capillary channel. Each channel of the plurality of channels may be configured to transport the liquid across a surface of the at least one susceptor element.

[0029] The plurality of channels may further include a plurality of peripheral channels, each of the plurality of peripheral channels extending between one of the plurality of openings and a peripheral edge of the at least one susceptor element. Advantageously, such peripheral channels may facilitate transport of the liquid aerosol-forming substrate between the peripheral edge of the at least one susceptor element, which may contact a reservoir of the liquid aerosol-forming substrate, and a center of the at least one susceptor element.

[0030] Each channel of the plurality of channels may not extend between two of the plurality of openings. Each channel of the plurality of channels may not contact any of the plurality of openings. In such an arrangement, liquid may still be transported across the susceptor element and may be vaporized from the channel. In embodiments in which each channel does not extend entirely from the first surface to the second surface and the second surface of the susceptor element contacts the wicking element, it may be advantageous for at least some of the plurality of channels to contact at least one peripheral edge of the susceptor element. Advantageously, such a channel arrangement may facilitate transport of liquid aerosol-forming substrate between the peripheral edge of the at least one susceptor element, which may contact a reservoir of liquid aerosol-forming substrate, and toward the center of the at least one susceptor element.

[0031] According to a second embodiment of the present disclosure, there is provided a heating assembly including a susceptor assembly according to the present disclosure. In other words, the heating assembly may include a susceptor assembly, and the susceptor assembly may include at least one nonwoven susceptor element. The at least one nonwoven susceptor element may be in the form of a sheet. The at least one nonwoven susceptor element may include a plurality of apertures. Each aperture may extend from a first surface of the sheet to a second surface of the sheet. The susceptor assembly may include a wicking element coupled to the at least one nonwoven susceptor element. The wicking element may be configured to transport the aerosol-forming liquid across a surface of the at least one nonwoven susceptor element. Each aperture of the plurality of apertures may extend in a first direction parallel to at least one of the first surface and the second surface of the at least one susceptor element. Each opening of the plurality of openings may extend in a second direction parallel to at least one of the first surface and the second surface of the at least one susceptor element and perpendicular to the first direction, and each opening of the plurality of openings may extend a greater distance in the first direction than in the second direction.

[0032] The heating assembly may further include an inductor at least partially surrounding the susceptor element. The inductor may be configured to generate a magnetic field that varies in a direction parallel to the first direction. The inductor may include at least one helical coil.

[0033] According to a third aspect of the present disclosure, there is provided a cartridge for connection to an aerosol generating device. The cartridge may include the heating assembly according to the second embodiment. The cartridge may include the susceptor assembly according to the first embodiment. In other words, the cartridge may include a susceptor assembly, and the susceptor assembly may include at least one nonwoven susceptor element. The at least one nonwoven susceptor element may be in the form of a sheet. The at least one nonwoven susceptor element may include a plurality of openings. Each opening may extend from a first surface of the sheet to a second surface of the sheet. The susceptor assembly may include a wicking element connected to the at least one nonwoven susceptor element. The wicking element may be configured to transport the aerosol-forming liquid across a surface of the at least one nonwoven susceptor element. Each opening of the plurality of openings may extend in a first direction parallel to at least one of the first surface and the second surface of the at least one susceptor element. Each opening of the plurality of openings may extend in a second direction parallel to at least one of the first surface and the second surface of the at least one susceptor element and perpendicular to the first direction, and each opening of the plurality of openings may extend a greater distance in the first direction than in the second direction.

[0034] The heating assembly may further include an inductor at least partially surrounding the susceptor element. The inductor may be configured to generate a magnetic field that varies in a direction parallel to the first direction. The inductor may include at least one helical coil.

[0035] The cartridge may include an air inlet and an air outlet. The cartridge may include a cartridge airflow passage positioned therein extending between the air inlet and the air outlet. The cartridge may include a reservoir for the liquid aerosol-forming substrate. A susceptor element may be positioned at least partially within the cartridge airflow passage. The susceptor element may be positioned within the cartridge airflow passage. The reservoir may be in fluid communication with a wicking element of the susceptor assembly.

[0036] The cartridge may include a reservoir housing containing a reservoir. The cartridge may include a susceptor holder positioned within the reservoir housing. The susceptor holder may at least partially define a cartridge airflow passage. The susceptor holder may be coupled to a susceptor assembly. A susceptor element may be at least partially positioned within the cartridge airflow passage. The susceptor element may at least partially span or extend across the cartridge airflow passage. The susceptor element may extend from one side of the cartridge airflow passage to another side of the cartridge airflow passage. If the susceptor element is a planar susceptor element, the longitudinal axis of the airflow passage may lie in a plane formed by the susceptor element.

[0037] 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 cartridge manufacturing. The susceptor element may extend across the cartridge airflow passage. The second region may be positioned at the center of the cartridge airflow passage. The second region may be positioned near or within the axial center of the cartridge airflow passage. It is this region near or at the axial center of the cartridge airflow passage that is prone to overheating and scorching of the wicking element due to insufficient liquid supply. By locating the second region near or at the axial center of the cartridge airflow passage, this risk may be reduced. The first region may be positioned at least partially within the cartridge airflow passage between the second region and the reservoir.

[0038] The susceptor element may include a first attachment region on a first edge of the susceptor element that contacts the second susceptor holder and a second attachment region on a second edge of the susceptor element that contacts the susceptor holder, opposite the first edge. The cartridge airflow passage may extend substantially along the longitudinal axis. The susceptor element may be substantially planar, and the susceptor element may extend parallel to the longitudinal axis. The first direction may be parallel to the longitudinal axis. The cartridge may be configured to be heated by a magnetic field that varies in a direction parallel to the first direction. The cartridge may be configured to couple to an aerosol generation system, and the susceptor element may be heated by a magnetic field that varies in a direction parallel to the first direction. Advantageously, in such an arrangement, it has been found that the extension of the opening in a second direction perpendicular to the direction of the varying magnetic field does not significantly contribute to induced power and heat generation. Therefore, it is beneficial to position the susceptor element so that the elongated direction of the opening is aligned with the direction of the varying magnetic field.

[0039] Each channel of the plurality of channels may extend from a peripheral region of the susceptor element toward the center of the susceptor element. Each channel of the plurality of channels may extend from a region of the susceptor element adjacent to the reservoir toward a region of the susceptor element farthest from the reservoir. Thus, the channels may advantageously assist in delivering the aerosol-forming substrate across the susceptor element to regions farthest from the reservoir where supply of the liquid aerosol-forming substrate may otherwise be hindered by slow diffusion rates. Each channel of the plurality of channels may extend substantially perpendicular to the longitudinal axis. The liquid aerosol-forming substrate may be delivered from the reservoir to the susceptor assembly in a direction perpendicular to the longitudinal axis of the airflow passage. Thus, the plurality of channels extending substantially perpendicular to the longitudinal axis may advantageously assist in delivering the aerosol-forming substrate throughout the susceptor element. Each channel of the plurality of channels may extend either substantially parallel to the longitudinal axis or substantially perpendicular to the longitudinal axis. When the liquid supply in the reservoir is low, the liquid aerosol-forming substrate supplied to the susceptor assembly may be supplied only onto the portion of the peripheral edge of the susceptor assembly that contacts the reservoir. Thus, the channels extending parallel to the longitudinal axis of the airflow passage may assist in delivering the aerosol-forming substrate throughout the susceptor element to regions farthest from the portion of the peripheral edge where the liquid aerosol-forming substrate is supplied. Each channel of the plurality of channels may be at least partially positioned within the cartridge airflow passage.

[0040] At least one of the plurality of peripheral channels may extend from at least one of the plurality of openings towards the reservoir. At least one of the plurality of peripheral channels may be in fluid communication with the reservoir. Advantageously, at least one of the plurality of peripheral channels may apply a capillary force to liquid in the reservoir to draw liquid from the reservoir into the airflow passage.

[0041] The liquid reservoir may surround the cartridge airflow passage. The aerosol-forming substrate is liquid at room temperature. The aerosol-forming substrate may include nicotine. The aerosol-forming substrate may include one or more aerosol formers. The one or more aerosol formers may include glycerin and / or propylene glycol.

[0042] According to a fourth embodiment of the present disclosure, an aerosol generation system is provided. The aerosol generation system may include the aerosol generator according to the third embodiment of the present disclosure and a cartridge. In other words, the aerosol generation system may include the aerosol generator and a cartridge, and the cartridge may include a susceptor assembly, and the susceptor assembly may include at least one nonwoven susceptor element. The at least one nonwoven susceptor element may be in the form of a sheet. The at least one nonwoven susceptor element may include a plurality of openings. Each opening may extend from a first surface of the sheet to a second surface of the sheet. The susceptor assembly may include a wicking element coupled to the at least one nonwoven susceptor element. The wicking element may be configured to transport the aerosol-forming liquid across a surface of the at least one nonwoven susceptor element. Each opening of the plurality of openings may extend in a first direction parallel to at least one of the first surface and the second surface of the at least one susceptor element. Each of the plurality of apertures may extend in a second direction parallel to at least one of the first surface and the second surface of the at least one susceptor element and perpendicular to the first direction. Each of the plurality of apertures may extend a greater distance in the first direction than in the second direction. The cartridge may be configured to be connectable to an aerosol generation device. The aerosol generation device may include an apparatus airflow inlet and an apparatus airflow outlet. The aerosol generation device may include an apparatus airflow passage extending between the apparatus airflow inlet and the apparatus airflow outlet. The aerosol generation device may include an inductor. The inductor may at least partially surround the susceptor element when the cartridge is connected to the aerosol generation device. The aerosol generation device may include a power source, such as a battery. 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.

[0043] The device may further comprise a control circuit. 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 sensor. The sensor may be configured to be in fluid communication with the airflow passage when the cartridge is coupled to the aerosol generation device. The control circuit may be configured to detect when a user is puffing on the system based on a signal from the sensor. The sensor may be an airflow sensor. The sensor may be a pressure sensor. The aerosol generation system may be configured such that power supplied to the inductor is based on the signal from the sensor. 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 control the temperature of the susceptor element. The control circuit may comprise a microcontroller. The microcontroller may be a programmable microcontroller.

[0044] The control circuit can be configured to supply an alternating current to the inductor to generate a magnetic field, and when the cartridge is coupled to the aerosol generation device, the susceptor element can be at least partially within the magnetic field generated by the inductor.

[0045] When an alternating current is supplied to the inductor, the temperature of the first region may increase more than the temperature of the second region, which may advantageously reduce the risk of overheating, particularly in the second region, and therefore reduce the risk of burning the wick adjacent to the second region.

[0046] The inductor may include at least one helical coil. The inductor may include only one helical coil. The inductor may include copper.

[0047] The aerosol generating device may comprise a cavity within which at least a portion of the cartridge is located when the cartridge is coupled to the aerosol generating device.

[0048] The device air outlet may be in fluid communication with the cartridge air inlet when the cartridge is connected to the aerosol generating device such that a system airflow passage is defined between the device air inlet and the cartridge air outlet.

[0049] The magnetic field generated by the inductor may be parallel to the longitudinal axis of the airflow passage. The susceptor assembly may be configured to be disposed within the cartridge so that the susceptor elements can be heated by a magnetic field that varies in a direction parallel to the first direction. Advantageously, in such an arrangement, it has been found that the extension of the opening in a second direction perpendicular to the direction of the varying magnetic field does not significantly contribute to the induced power and heat generation. Therefore, it is beneficial to position the susceptor elements so that the elongated direction of the opening is aligned with the direction of the varying magnetic field.

[0050] According to a fifth embodiment of the present disclosure, there is provided an aerosol generating device, which may include the susceptor assembly according to the first embodiment.

[0051] In other words, the aerosol generating device may include a susceptor assembly, and the susceptor assembly may include at least one nonwoven susceptor element. The at least one nonwoven susceptor element may be in the form of a sheet. The at least one nonwoven susceptor element may include a plurality of apertures. Each aperture may extend from a first surface of the sheet to a second surface of the sheet. The susceptor assembly may include a wicking element coupled to the at least one nonwoven susceptor element. The wicking element may be configured to transport the aerosol-forming liquid across the surface of the at least one nonwoven susceptor element. Each aperture of the plurality of apertures may extend in a first direction parallel to at least one of the first surface and the second surface of the at least one susceptor element. Each aperture of the plurality of apertures may extend in a second direction parallel to at least one of the first surface and the second surface of the at least one susceptor element and perpendicular to the first direction. Each aperture of the plurality of apertures may extend a greater distance in the first direction than in the second direction.

[0052] The aerosol generating device may further include an air inlet and an air outlet. The aerosol generating device may further include an internally positioned airflow passage extending between the air inlet and the air outlet. The aerosol generating device may further include a reservoir for the liquid aerosol-forming substrate. The reservoir may be in fluid communication with the wicking element of the susceptor assembly. The aerosol generating device may further include an inductor. The inductor may at least partially surround the susceptor element. The aerosol generating device may further include a power source, such as a battery. 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.

[0053] The device may further comprise a control circuit. 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 sensor. The sensor may be configured to be in fluid communication with the device airflow path. The control circuit may be configured to detect when a user is taking a puff on the device based on a signal from the sensor. The sensor may be an airflow sensor. The sensor may be a pressure sensor. The aerosol generation device may be configured such that power supplied to the inductor is based on the signal from the sensor. Advantageously, power may then be supplied to the inductor by the control circuit only when the user is taking a puff on the aerosol generation device. The control circuit may control the temperature of the susceptor element. The control circuit may comprise a microcontroller. The microcontroller may be a programmable microcontroller.

[0054] The control circuit may be configured to supply an alternating current to the inductor to generate the magnetic field. The susceptor element may be positioned within the airflow passage such that the susceptor element is at least partially within the magnetic field generated by the inductor.

[0055] When an alternating current is supplied to the inductor, the temperature of the first region may increase more than the temperature of the second region, which may advantageously reduce the risk of overheating, particularly in the second region, and therefore reduce the risk of burning the wick adjacent to the second region.

[0056] The inductor may include at least one helical coil. The inductor may include only one helical coil. The inductor may include copper.

[0057] The apparatus may include a reservoir housing containing a reservoir. The apparatus may include a susceptor holder positioned within the reservoir housing. The susceptor holder may at least partially define an apparatus airflow passage. The susceptor holder may be coupled to a susceptor assembly. The susceptor element may be at least partially positioned within the apparatus airflow passage. The susceptor element may span or extend at least partially across the apparatus airflow passage. The susceptor element may extend from one side of the apparatus airflow passage to another side of the apparatus airflow passage. If the susceptor element is a planar susceptor element, the longitudinal axis of the airflow passage may lie in a plane formed by the susceptor element.

[0058] 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 cartridge manufacture. The susceptor element may extend across the cartridge airflow passage. The second region may be positioned at the center of the device airflow passage. The second region may be positioned near or within the axial center of the cartridge airflow passage. It is in this region near or at the axial center of the device airflow passage that overheating and scorching of the wicking element due to insufficient liquid supply is likely to occur. By locating the second region near or at the axial center of the device airflow passage, this risk may be reduced. The first region may be positioned at least partially within the device airflow passage between the second region and the reservoir.

[0059] The susceptor element may include a first attachment region on a first edge of the susceptor element that contacts the second susceptor holder and a second attachment region on a second edge of the susceptor element that contacts the susceptor holder, opposite the first edge. The apparatus airflow passage may extend substantially along a longitudinal axis. The susceptor element may be substantially planar, and the susceptor element may extend parallel to the longitudinal axis. The first direction may be parallel to the longitudinal axis. The susceptor element may be configured to be heated by a magnetic field that varies in a direction parallel to the first direction. The magnetic field generated by the inductor may be parallel to the longitudinal axis of the airflow passage. The susceptor assembly may be configured to be disposed within the apparatus such that the susceptor element can be heated by a magnetic field that varies in a direction parallel to the first direction. Advantageously, it has been found that in such an arrangement, the extension of the opening in a second direction perpendicular to the direction of the varying magnetic field does not significantly contribute to inductive power and heat generation. It is therefore beneficial to position the susceptor element so that the elongated direction of the opening is aligned with the direction of the changing magnetic field.

[0060] Each channel of the plurality of channels may extend either substantially parallel to the longitudinal axis or substantially perpendicular to the longitudinal axis. Each channel of the plurality of channels may be positioned at least partially within the device airflow passageway.

[0061] At least one of the plurality of peripheral channels may extend from at least one of the plurality of openings towards the reservoir. At least one of the plurality of peripheral channels may be in fluid communication with the reservoir. Advantageously, at least one of the plurality of peripheral channels may apply a capillary force to liquid in the reservoir to draw liquid from the reservoir into the airflow passage.

[0062] The liquid reservoir may surround the device airflow passage. The aerosol-forming substrate may be liquid at room temperature. The aerosol-forming substrate may comprise nicotine. The aerosol-forming substrate may comprise one or more aerosol formers. The one or more aerosol formers may comprise glycerin and / or propylene glycol.

[0063] 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.

[0064] As used herein, "aerosol-generating system" means a system that generates an aerosol from one or more aerosol-forming substrates.

[0065] As used herein, "aerosol-generating device" may refer to a device that generates an aerosol from one or more aerosol-forming substrates. An "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." In other embodiments, an "aerosol-generating device" may comprise one or more aerosol-forming substrates.

[0066] 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.

[0067] 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.

[0068] 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 susceptor element accordingly, as described above.

[0069] 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.

[0070] The term "cartridge" as used herein also refers to an article that includes an aerosol-forming substrate capable of emitting a volatile compound capable of forming an aerosol. The cartridge may also be disposable.

[0071] The cartridge may contain a liquid. The liquid may include a volatile compound capable of forming an aerosol. The liquid may form an aerosol upon heating the liquid. The aerosol-forming substrate may be a liquid. The aerosol-forming substrate may be a liquid at room temperature. The aerosol-forming substrate may be in another condensed form, such as a solid, at room temperature, or in another condensed form, such as a gel, at room temperature. The volatile compound may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may include both liquid and solid components. The liquid aerosol-forming substrate may include nicotine. The nicotine-containing liquid aerosol-forming substrate may be a nicotine salt matrix. The liquid aerosol-forming substrate may include a plant-derived material. The liquid aerosol-forming substrate may include tobacco. The liquid aerosol-forming substrate may include a tobacco-containing material containing volatile tobacco flavor compounds that are released from the aerosol-forming substrate upon heating. The liquid aerosol-forming substrate may include a homogenized tobacco material. The liquid aerosol-forming substrate may include a non-tobacco-containing material. The liquid aerosol-forming substrate may include a homogenized plant-derived material.

[0072] 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 well known in the art and include, but are not limited to, polyhydric alcohols (e.g., triethylene glycol, 1,3-butanediol, glycerin), esters of polyhydric alcohols (e.g., glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of monocarboxylic, dicarboxylic, or polycarboxylic acids (e.g., dimethyl dodecanedioate, dimethyl tetradecanedioate). The liquid aerosol-forming substrate may 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%.

[0073] The aerosol generating system or device may be a handheld aerosol generating system or device. The aerosol generating system or device may be a handheld aerosol generating system or device configured to allow a user to draw on the mouthpiece to draw the aerosol through the first air outlet. The aerosol generating system or device may have a size comparable to a conventional cigar or cigarette. The aerosol generating system or device may have a total length of about 25 mm to about 150 mm. The aerosol generating system or device may have an outer diameter of about 5 mm to about 30 mm. [Example]

[0074] 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.

[0075] Example 1 1. A susceptor assembly for an aerosol generation system, comprising: at least one nonwoven susceptor element, the at least one nonwoven susceptor element being in the form of a sheet and including a plurality of apertures, each aperture extending from a first surface of the sheet to a second surface of the sheet; a wicking element coupled to the at least one nonwoven susceptor element, the wicking element configured to transport an aerosol-forming liquid across a surface of the at least one nonwoven susceptor element; each opening of the plurality of openings extends in a first direction parallel to at least one of the first surface and the second surface of the at least one susceptor element; each opening of the plurality of openings extends in a second direction parallel to at least one of the first surface and the second surface of the at least one susceptor element and perpendicular to the first direction; A susceptor assembly, wherein each opening of the plurality of openings extends a greater distance in the first direction than in the second direction. Example 2. A susceptor assembly as described in Example 1, wherein each opening of the plurality of openings extends a first distance in a first direction and each opening of the plurality of openings extends a second distance in a second direction, the first distance being greater than the second distance. Example 3 3. The susceptor assembly of example 2, wherein the first distance is 1.5 to 10 times the second distance. Example 4. The susceptor assembly of example 3, wherein the first distance is 2 to 5 times the second distance. Example 5. 5. The susceptor assembly of example 4, wherein the first distance is 2.5 to 4 times the second distance. Example 6 6. The susceptor assembly of any of Examples 2-5, wherein the susceptor element is planar and defines a first plane such that the first direction and the second direction lie within the first plane. Example 7 7. The susceptor assembly of any of Examples 2-6, wherein the plurality of openings form a regular array of openings in at least one susceptor element. Example 8 8. The susceptor assembly of example 7, wherein the plurality of openings are spaced apart in the first direction by a first spacing distance that is 0.05 to 1 times the first distance. Example 9. 9. The susceptor assembly of example 8, wherein the plurality of openings are spaced apart in the first direction by a first spacing distance that is 0.1 to 0.5 times the first distance. Example 10. 10. The susceptor assembly of any of Examples 7-9, wherein the plurality of openings are spaced apart in the second direction by a second spacing distance that is 0.2 to 5 times the second distance. Example 11 11. The susceptor assembly of example example 10, wherein the plurality of openings are spaced apart in the second direction by a second spacing distance that is 1 to 3 times the second distance. Example 12 12. The susceptor assembly of any of Examples 7-11, wherein the regular array of openings is an array of hexagonal openings. Example 13 The susceptor assembly of any one of Examples 7 to 11, wherein the array of regular apertures is an array of square or rectangular apertures. Example 14. A susceptor assembly according to any one of Examples 1 to 13, wherein the wicking element comprises a first plane and a second plane, the first plane and the second plane defining opposite outward facing surfaces of the wicking element. Example 15. A susceptor assembly as described in Example 14, wherein at least one susceptor element includes a first planar susceptor element and a second planar susceptor element, and the susceptor assembly is arranged so that a first surface of the wicking element contacts the first susceptor element and a second surface of the wicking element contacts the second susceptor element. Example 16. A susceptor assembly as described in Example 15, wherein at least one susceptor element is folded around the wicking element so that a first surface of the wicking element contacts a first portion of the at least one susceptor element and a second surface of the wicking element contacts a second portion of the at least one susceptor element, the first portion being substantially parallel to the second portion. Example 17. 17. The susceptor assembly of example 16, wherein the at least one susceptor element further comprises a folded portion, the folded portion being connected between the first portion and the second portion. Example 18. 18. The susceptor assembly of Example 17, wherein the folded portion includes an elongated opening, the elongated opening extending in a direction parallel to at least one of the first surface and the second surface of the wicking element. Example 19. 19. The susceptor assembly of any of Examples 16-18, wherein the first portion of the at least one susceptor element and the second portion of the at least one susceptor element are integrally formed. Example 20. 20. The susceptor assembly of any of Examples 1-19, wherein each opening of the plurality of openings is circular or oval in shape. Example 21. 20. The susceptor assembly of any of Examples 1-19, wherein each opening of the plurality of openings is rectangular or square in shape. Example 22. 22. The susceptor assembly of any of Examples 1-21, wherein the at least one susceptor element has a first thickness, the first thickness being between 25 micrometers and 100 micrometers. Example 23. 23. The susceptor assembly of any of Examples 1-22, wherein each opening of the plurality of openings is formed via laser cutting. Example 24. 23. The susceptor assembly of any of Examples 1-22, wherein each opening of the plurality of openings is formed via chemical etching. Example 25. 23. The susceptor assembly of any of Examples 1-22, wherein each aperture of the plurality of apertures is formed via stamping or wire discharge. Example 26. A susceptor assembly described in any of Examples 1 to 25, wherein at least one susceptor element includes at least one outward protrusion, and the at least one outward protrusion is positioned on a peripheral edge of the at least one susceptor element. Example 27. 27. The susceptor assembly of example embodiment 26, wherein the at least one outward protrusion is configured to engage a susceptor holder component of a cartridge. Example 28. 28. The susceptor assembly of example 26 or 27, wherein the at least one outward protrusion occupies a percent of the peripheral edge of the at least one susceptor element. Example 29. 29. The susceptor assembly of example embodiment 28, wherein the percentage is between 1% and 20% of the peripheral edge of the at least one susceptor element. Example 30. 30. The susceptor assembly of example embodiment 29, wherein the percentage is between 2% and 10% of the peripheral edge of the at least one susceptor element. Example 31. 31. The susceptor assembly of any of Examples 1-30, wherein at least one susceptor element is heatable by at least one of Joule heating through the induction of eddy currents in the susceptor element and hysteresis losses. Example 32. 32. The susceptor assembly of any of Examples 1-31, wherein the at least one susceptor element comprises at least one of graphite, molybdenum, silicon carbide, stainless steel, niobium, and aluminum. Example 33. 33. The susceptor assembly of any of Examples 1-32, wherein at least one susceptor element comprises at least one ferromagnetic material. Example 34. 34. The susceptor assembly of any of Examples 1-33, wherein at least one susceptor element comprises AISI 430 stainless steel. Example 35. 35. The susceptor assembly of any of Examples 1-34, wherein at least one susceptor element has a relative permeability of 1 to 40,000 when measured at a temperature of 20 degrees Celsius and a frequency of up to 10 kHz. Example 36. 36. The susceptor assembly of claim 35, wherein at least one susceptor element has a relative permeability of 500 to 40,000 when measured at a temperature of 20 degrees Celsius and a frequency of up to 10 kHz. Example 37. 37. The susceptor assembly of any of Examples 1-36, wherein at least one susceptor element is substantially flat. Example 38. The susceptor assembly of any of Examples 1-37, wherein at least one susceptor element is fluid permeable. Example 39. A susceptor assembly described in any of Examples 1 to 38, wherein at least one nonwoven susceptor element includes a first region, the first region including openings of a first configuration of the plurality of openings, and at least one nonwoven susceptor element includes a second region, the second region including openings of a second configuration of the plurality of openings, the openings of the second configuration being different from the openings of the first configuration. Example 40. 39. The susceptor assembly of example embodiment 39, wherein the second configuration of apertures does not include apertures such that the second region does not include apertures. Example 41. A susceptor assembly as described in Example 39 or 40, wherein the openings of the second configuration are different from those of the first configuration such that when the first region is exposed to the same alternating magnetic field as the second region, and when the alternating magnetic field is uniform across the first region and the second region, the temperature of the first region increases more than the temperature of the second region. Example 42. A susceptor assembly described in any of Examples 39 to 41, wherein the first region includes a first density of openings in the plurality of openings, and the second region includes a second density of openings in the plurality of openings, and the second density of openings is different from the first density of openings. Example 43. 43. The susceptor assembly of example embodiment 42, wherein the second density of openings is less than the first density of openings. Example 44. 44. The susceptor assembly of example embodiment 43, wherein the second density of openings is equal to zero such that the second region does not include any openings. Example 45. 45. The susceptor assembly of any of Examples 39-44, wherein the second region comprises a shape that includes a central region of the susceptor element. Example 46. A susceptor assembly as described in Example 45, wherein the shape of the second region includes a plurality of radial portions, the plurality of radial portions extending in a first plane across the susceptor element from a central region of the planar susceptor element toward the periphery. Example 47. 47. The susceptor assembly of example 46, wherein each of the radial portions of the plurality of radial portions are uniformly spaced apart from one another in the first plane about the central region. Example 48. 48. The susceptor assembly of example 46 or 47, wherein the second region comprises 2 to 8 radial portions. Example 49. 49. The susceptor assembly of example embodiment 48, wherein the second region comprises 4 to 6 radial portions. Example 50. 50. The susceptor assembly of any of Examples 1-49, wherein each opening of the plurality of openings is equal in size. Example 51. 51. The susceptor assembly of any of Examples 1-50, wherein a size of each of the openings in the first region is different from a size of each of the openings in the second region. Example 52. 52. The susceptor assembly of Example 51, wherein a size of each of the openings in the first region is less than a size of each of the openings in the second region. Example 53. 53. The susceptor assembly of Example 52, wherein a first average size of the openings in the first region is less than a second average size of the openings in the second region. Example 54. 54. The susceptor assembly of any of Examples 51-53, wherein the size of each of the openings is a cross-sectional area of ​​each of the openings parallel to the first surface of the at least one susceptor element. Example 55. 55. The susceptor assembly of any of Examples 1-54, wherein the first region comprises a first regular array of the plurality of apertures. Example 56. 56. The susceptor assembly of example embodiment 55, wherein the first regular array of openings is an array of hexagonal openings. Example 57. 56. The susceptor assembly of Example 55, wherein the regular array of apertures is an array of square apertures. Example 58. 58. The susceptor assembly of any of Examples 1-57, wherein the second region comprises a second regular array of the plurality of apertures. Example 59. 59. The susceptor assembly of Example 58, wherein the second regular array of openings is an array of hexagonal openings. Example 60. 59. The susceptor assembly of Example 58, wherein the second regular array of apertures is an array of square apertures. Example 61. A susceptor assembly according to any one of Examples 1 to 60, wherein at least one nonwoven susceptor element further comprises a plurality of channels, each channel of the plurality of channels extending between at least two openings of the plurality of openings. Example 62. A susceptor assembly as described in Example 61, wherein the first surface is opposite the second surface of the sheet, at least one susceptor element includes a first thickness extending between the first surface and the second surface, and each channel of the plurality of channels is at least partially defined on the first surface. Example 63. 63. The susceptor assembly of embodiment 62, wherein each channel of the plurality of channels extends from the first surface toward the second surface between 0.25 and 0.75 times the first thickness. Example 64. 63. The susceptor assembly of embodiment 62, wherein at least one channel of the plurality of channels extends completely from the first surface to the second surface. Example 65. 65. The susceptor assembly of any of Examples 62-64, wherein the second surface of the susceptor element contacts the wicking element. Example 66. 65. The susceptor assembly of any of Examples 62-64, wherein at least one susceptor element defines a first plane. Example 67. 67. A susceptor assembly according to any one of Examples 61 to 66, wherein each channel of the plurality of channels is configured to transport the aerosol-forming liquid in at least one direction within a first plane. Example 68. 68. The susceptor assembly of any of Examples 61-67, wherein each channel of the plurality of channels is obtained by chemical etching. Example 69. A susceptor assembly described in any of Examples 61 to 68, wherein each channel of the plurality of channels extends between two openings of the plurality of openings, and preferably each channel of the plurality of channels extends between two adjacent openings of the plurality of openings. Example 70. 70. The susceptor assembly of embodiment 69, wherein each opening of the plurality of openings is connected to at least one adjacent opening by at least one channel. Example 71. 71. The susceptor assembly of any of Examples 61-70, wherein the plurality of channels form a regular array of channels. Example 72. 72. The susceptor assembly of any of Examples 61-71, wherein each channel of the plurality of channels is configured to apply a capillary force to the aerosol-forming liquid. Example 73. A susceptor assembly described in any of Examples 61 to 72, wherein the plurality of channels further includes a plurality of peripheral channels, each of the plurality of peripheral channels extending between one of the plurality of openings and the peripheral edge of at least one susceptor element. Example 74. A susceptor assembly described in any of Examples 1 to 73, wherein the heating assembly further includes an inductor at least partially surrounding the susceptor element, the inductor configured to generate a magnetic field that varies in a direction parallel to the first direction. Example 75. 75. The heating assembly of embodiment 74, wherein the inductor comprises at least one helical coil. Example 76. 10. A cartridge for coupling to an aerosol generating device, comprising the susceptor assembly of any one of Examples 1 to 73, wherein the cartridge comprises: an air inlet and an air outlet; an internally positioned cartridge airflow passageway extending between an air inlet and an air outlet; a reservoir for a liquid aerosol-forming substrate; The cartridge is configured to receive a susceptor assembly such that the susceptor element is positioned within the cartridge airflow passage and the reservoir is in fluid communication with a wicking element of the susceptor assembly. Example 77. A cartridge as described in Example 76, wherein the cartridge includes a reservoir housing containing a reservoir, a susceptor holder positioned within the reservoir housing, the susceptor holder at least partially defining a cartridge airflow passage, the susceptor holder coupled to a susceptor assembly, and a susceptor element positioned at least partially within the cartridge airflow passage. Example 78. 78. The cartridge of example 77, wherein the susceptor holder comprises a thermally insulating material. Example 79. 79. The cartridge of example 77 or 78, wherein the susceptor holder comprises an electrically insulating material. Example 80. 80. The cartridge of any of Examples 76-79, wherein the susceptor element extends across the cartridge airflow passage. Example 81. The cartridge of Example 80 when dependent from Example 39, wherein the second region is positioned at the center of the cartridge airflow passage. Example 82. 82. The cartridge of example 81, wherein the first region is positioned within the cartridge airflow passageway at least partially between the second region and the reservoir. Example 83. A cartridge described in any of Examples 77 to 82, wherein the susceptor element includes a first attachment area on a first edge of the susceptor element that is in contact with the second susceptor holder, and a second attachment area on a second edge of the susceptor element that is in contact with the susceptor holder, opposite the first edge. Example 84. The cartridge of any of Examples 76-83, wherein the cartridge airflow passage extends substantially along the longitudinal axis and the susceptor element is substantially planar and extends parallel to the longitudinal axis. Example 85. The cartridge of Example 84, wherein the first direction is parallel to the longitudinal axis. Example 86. A cartridge described in Example 84 or 85 when dependent on Example 63, wherein each channel of the plurality of channels extends either substantially parallel to the longitudinal axis or substantially perpendicular to the longitudinal axis. Example 87. 87. The cartridge of Example 86, wherein each channel of the plurality of channels is positioned within the cartridge airflow passage. Example 88. A cartridge described in Example 86 or 87 when dependent on Example 73, wherein at least one peripheral channel of the plurality of peripheral channels extends from at least one opening of the plurality of openings toward the reservoir. Example 89. 89. The cartridge of Example 88, wherein at least one peripheral channel of the plurality of peripheral channels is in fluid communication with the reservoir. Example 90. 90. The cartridge of any of Examples 76-89, wherein the liquid reservoir surrounds the cartridge airflow passage. Example 91. A cartridge according to any one of Examples 76 to 90, wherein the aerosol-forming substrate is liquid at room temperature. Example 92. A cartridge according to any one of Examples 76 to 91, wherein the aerosol-forming substrate comprises nicotine. Example 93. The cartridge of any of Examples 786 to 92, wherein the aerosol-forming substrate comprises one or more aerosol formers. Example 94. The cartridge of example 93, wherein the one or more aerosol formers comprise glycerin and / or propylene glycol. Example 95. An aerosol generating device and the cartridge according to any one of Examples 76 to 94, wherein the cartridge is configured to be connectable to the aerosol generating device, and the aerosol generating device comprises: a device airflow inlet and a device airflow outlet; a device airflow passageway extending between the device airflow inlet and the device airflow outlet; an inductor that at least partially surrounds the susceptor element when the cartridge is coupled to the aerosol generating device; An aerosol generation system comprising: a battery configured to supply an alternating current to an inductor to generate a magnetic field so that, when the cartridge is connected to the aerosol generation device, the susceptor element is at least partially within the magnetic field generated by the inductor. Example 96. An aerosol generation system as described in Example 95 when dependent on Example 39, wherein when an alternating current is supplied to the inductor, the temperature of the first region increases more than the temperature of the second region. Example 97. An aerosol generation system as described in Example 95 or 6, wherein the inductor comprises at least one helical coil. Example 98. An aerosol generation system as described in Example 97, wherein the inductor includes only one helical coil. Example 99. The aerosol generating system of any one of Examples 95 to 198, wherein the inductor comprises copper. Example 100. An aerosol generation system described in any of Examples 95 to 99, wherein the aerosol generation device has a cavity in which at least a portion of the cartridge is located when the cartridge is connected to the aerosol generation device. Example 101. An aerosol generation system described in any of Examples 95 to 100, wherein the device air outlet may be fluidly connected to the cartridge air inlet when the cartridge is connected to the aerosol generation device, such that a system airflow passage is defined between the device air inlet and the cartridge air outlet. Example 102. An aerosol generation system described in any of Examples 95 to 101, wherein the device further comprises a control circuit, the control circuit configured to control the power supply from the battery to the inductor. Example 103. An aerosol generation system as described in Example 102, wherein the control circuit further includes a sensor, the sensor configured to be fluidly connected to the device airflow passage when the cartridge is connected to the aerosol generation device, and the aerosol generation system is configured such that the power supplied to the inductor is based on a signal from the sensor. Example 104. An aerosol generation system according to any one of Examples 95 to 103, wherein the magnetic field generated by the inductor varies in a direction parallel to the first direction. Example 105. An aerosol generating apparatus, comprising the susceptor assembly according to any one of Examples 1 to 73, wherein the aerosol generating apparatus comprises: an air inlet and an air outlet; an internally positioned airflow passageway extending between the air inlet and the air outlet; a reservoir for a liquid aerosol-forming substrate, the reservoir being in fluid communication with a wicking element of the susceptor assembly; an inductor that at least partially surrounds the susceptor element when the cartridge is coupled to the aerosol generating device; a battery configured to supply an alternating current to the inductor to generate a magnetic field; An aerosol generating device, wherein the susceptor element is positioned within the airflow passageway such that the susceptor element is at least partially within a magnetic field generated by the inductor. Example 106. An aerosol generating device as described in Example 105 when dependent on Example 39, wherein when an alternating current is supplied to the inductor, the temperature of the first region increases more than the temperature of the second region. Example 107. An aerosol generating device as described in Example 105 or 106, wherein the inductor comprises at least one helical coil. Example 108. An aerosol generating device as described in Example 107, wherein the inductor includes only one helical coil. Example 109. 109. The aerosol generating device of any one of Examples 105 to 108, wherein the inductor comprises copper. Example 110. An aerosol generating device described in any of Examples 105 to 109, wherein the device air outlet may be fluidly connected to the cartridge air inlet when the cartridge is connected to the aerosol generating device, such that a system airflow passage is defined between the device air inlet and the cartridge air outlet. Example 111. An aerosol generating device according to any one of Examples 105 to 110, wherein the device further comprises a control circuit, the control circuit being configured to control the supply of power from the battery to the inductor. Example 112. An aerosol generating device as described in Example 111, wherein the control circuit further includes a sensor, the sensor being in fluid communication with the airflow passage, and the aerosol generating device is configured such that the power supplied to the inductor is based on a signal from the sensor. Example 113. 113. An aerosol generating apparatus according to any one of Examples 105 to 112, wherein the airflow passage extends substantially along the longitudinal axis and the susceptor element is substantially planar and extends parallel to the longitudinal axis. Example 114. An aerosol generating device as described in Example 113, wherein the magnetic field generated by the inductor changes in a direction parallel to the first direction.

[0076] The embodiments will now be further described with reference to the figures. [Brief explanation of the drawings]

[0077] [Figure 1A] FIG. 1A shows a schematic diagram of a cross-sectional view of a cartridge for an aerosol generation system, the cartridge comprising a susceptor assembly according to a first embodiment of the present disclosure. [Figure 1B] FIG. 1B shows a schematic diagram of an alternative cross section of the cartridge of FIG. 1A. [Figure 2] FIG. 2 shows a further alternative cross-sectional schematic view of the cartridge of FIGS. 1A and 1B. [Figure 3] FIG. 3 shows a schematic diagram of a susceptor element according to the present disclosure. [Figure 4] FIG. 4 shows a schematic diagram of a susceptor element according to a first embodiment of the present disclosure. [Figure 5] FIG. 5 shows a schematic diagram of a susceptor element according to a second embodiment of the present disclosure. [Figure 6] FIG. 6 shows a schematic diagram of a further susceptor element according to a second embodiment of the present disclosure. [Figure 7A] FIG. 7A shows a schematic diagram of a susceptor element according to a third embodiment of the present disclosure. [Figure 7B] FIG. 7B shows a schematic diagram of a susceptor element according to a third embodiment of the present disclosure. [Figure 7C] FIG. 7C shows a schematic diagram of a susceptor element according to a third embodiment of the present disclosure. [Figure 7D] FIG. 7D shows a schematic diagram of a further susceptor element according to the present disclosure. [Figure 8] FIG. 8 shows a schematic diagram of a susceptor element according to the present disclosure. [Figure 9] FIG. 9 shows a schematic diagram of a susceptor element according to the present disclosure. [Figure 10A] FIG. 10A shows a cross-sectional schematic view of an aerosol generation system according to the present disclosure, with the cartridge separated from the aerosol generation device. [Figure 10B] FIG. 10B shows a cross-sectional schematic diagram of an aerosol generation system according to the present disclosure, in which the cartridge is coupled to an aerosol generation device. [Figure 11] FIG. 11 shows a schematic cross-sectional view of an aerosol generating device according to the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0078] 1A and 1B show schematic diagrams of two cross sections of a cartridge 10 for an aerosol generation system, the cartridge 10 being in accordance with the present disclosure. The two cross sections are taken in two planes perpendicular to each other.

[0079] The cartridge 10 includes a susceptor holder 14 and a susceptor assembly 12 attached to the susceptor holder 14. The susceptor assembly 12 is planar and thin, having a thickness dimension substantially smaller than its length and width dimensions. The susceptor assembly 12 is shaped in a rectangular configuration and includes three layers: a first susceptor element 16, a second susceptor element 18, and a wicking element 20 disposed between the first susceptor element 16 and the second susceptor element 18. The first susceptor element 16, the second susceptor element 18, and the wicking element 20 each form a generally rectangular shape, each susceptor element having the same length and width dimensions, with the width of the susceptor elements 16, 18 being smaller than the width of the wicking element 20. Thus, the wicking element 20 includes an outer, exposed portion that each protrudes into one of the two channels 45. The first susceptor element 16 and the second susceptor element 18 are substantially identical and comprise stainless steel plates, e.g., ferritic stainless steel plates. The stainless steel plates include a plurality of openings or holes formed therein, each extending from one surface of the plate to the other. The wicking element 20 comprises a body of porous rayon filaments. The wicking element 20 is configured to deliver liquid from its outer, exposed surface to the first susceptor element 16 and the second susceptor element 18.

[0080] Each of the first susceptor element 16 and the second susceptor element 18 is configured to be heatable by penetration by an alternating magnetic field to vaporize the aerosol-forming substrate. A wicking element 20 contacts the susceptor holder 14 such that the susceptor holder 14 supports the susceptor assembly 12 in place within the cartridge 10.

[0081] The susceptor assembly 12 is disposed inside an internal passage 26 of the tubular susceptor holder 14 and extends in a plane parallel to the central longitudinal axis of the susceptor holder 14. The first susceptor element 16 and the second susceptor element 18 are disposed entirely within the internal passage 26 of the susceptor holder 14, and the wicking element extends through an opening 28 in the sidewall of the susceptor holder 14 into one of two channels 45.

[0082] 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 susceptor holder 14 are located toward the connecting end of the cartridge 10.

[0083] The outer housing 36 is formed from a moldable plastic material, such as polypropylene, and defines an interior space within which the susceptor assembly 12 and susceptor holder 14 are contained.

[0084] The outer width of the outer housing 36 is greater at the mouth end of the cartridge 10 than at the connecting end where it is joined by the shoulder 37. This allows the connecting end of the cartridge 10 to be received in the cavity of the aerosol generation device, with the shoulder 37 locating the cartridge in the correct position on the device. This also allows the mouth end of the cartridge 10 to remain outside the aerosol generation device, allowing the mouth end to conform to the external shape of the aerosol generation device.

[0085] The cartridge 10 further comprises a liquid reservoir 44. The liquid reservoir 44 is defined within the cartridge 10 for holding the liquid aerosol-forming substrate 42.

[0086] 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 .

[0087] The annular space has an interior passageway 48 extending between the mouth end opening 38 and the open end of the interior passageway 26 of the susceptor holder 14 .

[0088] The liquid reservoir 44 further includes two channels 45 defined between the inner surface of the outer housing 36 and the outer surface of the susceptor holder 14. The two channels 45 extend from the annular space defined by the outer housing 36 at the mouth end of the cartridge 10 to the connecting end of the cartridge 10 such that the wicking element extends into the two channels 45 through the opening 28 in the sidewall of the susceptor holder 14. 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 internal passage 26 of the susceptor holder 14.

[0089] The susceptor holder 14 includes a base 30 that partially closes one end of the internal passage 26. The base 30 includes a plurality of air inlets 32 that allow air to be drawn into the internal passage 26 through the partially closed end.

[0090] An air passageway is formed through the cartridge 10 by the internal passageway 26 of the susceptor holder 14 and the internal passageway 48 of the liquid reservoir 44. The air passageway extends from the air inlet 32 ​​in the base 30 of the susceptor holder 14, through the internal passageway 26 of the susceptor holder 14, through the internal passageway 48 of the liquid reservoir 44, to the mouth end opening 38. The air passageway allows air to be drawn through the cartridge 10 from the connecting end to the mouth end.

[0091] Figure 2 shows a schematic view of a further alternative cross section of cartridge 10 of Figures 1A and 1B. Cartridge 10 is viewed perpendicular to the views shown in Figures 1A and 1B, with the cross section shown in Figure 1A being indicated by dashed line AB and the cross section shown in Figure 1B being indicated by dashed line CD.

[0092] The cartridge 10 includes a susceptor holder 14. The susceptor holder 14 includes a tubular body formed from a moldable plastic material, such as polypropylene. The tubular body of the susceptor holder 14 includes a sidewall 27 that defines an interior passageway 26 having an open end. A pair of openings 28 extend through the sidewall 27 on opposite sides of the tubular susceptor holder 14. The openings 28 are centrally disposed along the length of the susceptor holder 14.

[0093] 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. The friction fit between the susceptor assembly 12 and the susceptor holder 14 causes the mounting area 22 to directly contact the susceptor holder 14 at the opening 28. The susceptor assembly 12 and the susceptor holder 14 are secured together such that movement of the susceptor holder 14 also causes movement of the susceptor assembly 12.

[0094] It will be appreciated that the susceptor assembly 12 and the susceptor holder 14 may be secured together by other means. For example, in some embodiments, the susceptor assembly 12 is secured to the susceptor holder 14 by an adhesive at the attachment region 22 of the susceptor assembly 12 such that the attachment region 22 is in indirect contact with the susceptor holder 14.

[0095] 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 wicking element 20 extends from the internal passage 26 through the opening 28 and into both of the channels 45. Although the channels 45 are shown empty in Figure 2, it can be understood that they are filled with a liquid aerosol-forming substrate prior to use.

[0096] The cartridge 10 is shown from the mouth end to the connecting end in Figure 2. Thus, the multiple air inlet ports 32 in the base 30 are visible in Figure 2.

[0097] A cross section of the susceptor assembly 12 can be seen more clearly in Figure 2, where the wicking element 20 is disposed between the first susceptor element 16 and the second susceptor element 18. However, it can be understood that the first susceptor element 16 and the second susceptor element 18 may instead be a single susceptor element wrapped around the wicking element 20, the single susceptor element including a first portion on a first side of the susceptor assembly 12 and a second portion on a second side of the susceptor assembly 12.

[0098] Although susceptor assembly 12 is shown as being substantially planar in Figures 1A, 1B, and 2, it will be appreciated that susceptor assembly 12 may take on any other suitable shape or form.

[0099] FIG. 3 shows a schematic diagram of a susceptor element 216 according to the present disclosure. The susceptor element 216 may comprise a first susceptor element 16 or a second susceptor element 18, as in FIGS. 1A, 1B, and 2. The susceptor element 216 is in the form of a nonwoven sheet. For example, the susceptor element 216 is in the form of a sheet of ferritic stainless steel. The susceptor element 216 includes an array of regular apertures 250. The schematic diagram of the susceptor element 216 (and any of the following exemplified susceptor elements) is schematic; the apertures 250 may be much smaller or larger, or much more or less numerous, compared to the dimensions of the nonwoven sheet. The apertures 250 in this example are shown as circular apertures. However, apertures of any shape may be used, such as square, triangular, or rectangular apertures. The array of regular apertures 250 extends across the entire extent of the nonwoven sheet. In the illustrated embodiment, the regular array of apertures 250 may be described as a square array, with each aperture having four nearest neighbors unless the aperture is located at an edge of the sheet. Other types of arrays may also be used, such as a hexagonal array, with each aperture having six nearest neighbors unless the aperture is located at an edge of the sheet. The sheet is 25 micrometers to 100 micrometers thick. Each aperture 250 is 20 micrometers to 510 micrometers in diameter. Each aperture is formed by either laser cutting, chemical etching, stamping, or wire discharge. Susceptor elements containing multiple apertures may also be formed by additive manufacturing methods such as laser sintering or laser melting.

[0100] FIG. 4 shows a schematic diagram of a susceptor element 616 according to a first embodiment of the present disclosure. The susceptor element 616 of FIG. 4 is similar to the susceptor element 216 shown in FIG. 3 and will be described only with respect to its differences. The susceptor element 616 includes a plurality of openings 650, each of which has an oval or elongated shape. In other words, each opening 650 extends a first distance 655 in a first direction, and each opening extends a second distance 656 in a second direction, with the first distance 655 being greater than the second distance 656. Both the first direction and the second direction lie within the plane of the susceptor element 616 such that both the first direction and the second direction are parallel to the first and second surfaces of the susceptor element 616. In this example, the first distance 655 is 1.5 to 10 times the second distance 656. Preferably, the first distance 655 is approximately 5 times the second distance 656. While the apertures are shown as being oval in shape, the apertures 650 may alternatively be rectangular in shape, for example. The plurality of apertures 650 are arranged in an array, such as the rectangular array shown in FIG. 4, with each aperture 650 having two nearest neighbors in a first direction. The apertures 650 are spaced apart in the first direction by a first spacing distance that is 0.05 to 1 times the first distance 655. The apertures 650 are spaced apart in the second direction by a second spacing distance that is 0.2 to 5 times the second distance 656.

[0101] The susceptor element 616 of FIG. 4 is configured to be disposed within the cartridge 10 of FIGS. 1A, 1B, and 2 so that the first direction is parallel to the axial direction of the internal airflow passage 26. When the cartridge 10 is received within an aerosol generation system (see FIGS. 10A and 10B below), the first direction is parallel to the direction of the changing magnetic field. It has been found that extending the opening 650 in the second direction (perpendicular to the direction of the changing magnetic field) does not significantly contribute to inductive power and heat generation. Such an arrangement of the elongated opening in the first direction improves the induction heating response of the susceptor when exposed to an alternating magnetic field in the first direction. The improved induction heating response can then result in more favorable aerosol characteristics of the aerosol generated by the aerosol generation system. Therefore, it is beneficial to position the susceptor element 616 so that the elongated direction of the opening 650 is aligned with the direction of the changing magnetic field.

[0102] 5 shows a schematic side view of a susceptor element 416 according to a second embodiment of the present disclosure. The susceptor element 416 of FIG. 4 is similar to the susceptor element 616 shown in FIG. 4 and will be described only with respect to its differences. The susceptor element 416 includes a first region 451. The first region 451 includes a first array of square first openings 450. The openings 450 in the first region 451 are identical to one another. The susceptor element 416 further includes a second region 452. The second region 452 includes a second array of square second openings 417. The openings 417 in the second region 452 are identical to one another. The openings in the second region 452 are larger than the openings in the first region 451 such that the openings in the second region 452 have larger diameters than the openings in the first region 451. The openings 417 in the second region 452 have a lower density than the openings 450 in the first region 451, resulting in fewer openings per unit area in the second region 452 than in the first region 451. The first region 451 surrounds the second region 452. The second region 452 is located at the center of the susceptor element 416 such that when the susceptor element 416 is positioned in a susceptor holder, the second region 452 is located near at least the axial center of the airflow passage, as shown in FIGS. 1A, 1B, and 2. When the susceptor element 416 is positioned in the susceptor holder of a cartridge, the cartridge is positioned in an aerosol generating device, and the susceptor element is heated by an induction heating arrangement (see FIGS. 10A and 10B), the first region 451 heats more than the second region 452, resulting in more heat being generated in the first region 451 than in the second region 452. As a result, the risk of scorching the wicking element due to excessive heat generation near the center of the susceptor element is reduced.

[0103] FIG. 6 shows a schematic diagram of a further susceptor element according to a second embodiment of the present disclosure. The susceptor element 516 of FIG. 6 is similar to the susceptor element 416 shown in FIG. 5 and will be described only with respect to its differences. A first region 551 includes a first array of hexagonal openings 550. The openings 550 in the first region 551 are identical to one another. The susceptor element 516 further includes a second region 552. The second region 552 includes a shape that does not include openings. In other words, the second region 552 is made of an unperforated nonwoven sheet of stainless steel. The openings in the second region 552 have a lower density than the openings 550 in the first region 551 because there are no openings per unit area in the second region 552. The first region 551 surrounds the second region 552. The second region 552 is located at the center of the susceptor element 516 such that when the susceptor element 516 is positioned in a susceptor holder, the second region 552 is located near at least the axial center of the airflow passage, as shown in FIGS. 1A, 1B, and 2 . The susceptor element 516 further includes a third region 554. The second region 552 surrounds the third region 554. The third region 554 includes an array of hexagonal third openings 519. The array of hexagonal third openings 519 is identical in arrangement to the array of hexagonal first openings 550. The openings 519 in the third region 554 are identical to each other. The openings 519 in the third region 554 are identical to the openings 550 in the first region 551 such that the openings in the third region have the same shape as the openings 550 in the first region 551.

[0104] The second region 552 includes six radial portions 553. Each radial portion 553 extends from the center of the second region 552 to near the center of the susceptor element 516 toward the periphery of the susceptor element 516. Thus, in this embodiment, the radial portions are distributed in a configuration such that heat generated near the center of the susceptor element 516 is efficiently transported from the central region (hottest region) of the susceptor element 516 to adjacent regions of the opening, i.e., along a predetermined path that is not perforated in the first region of the opening 551. In other words, the radial portions 553 constitute heat sink channels through which heat is dissipated toward the peripheral region of the susceptor element 516. As a result, heat is quickly dissipated from the center of the susceptor element 516, thereby avoiding core burning or overheating of the center of the susceptor element 516.

[0105] 7A and 7B show schematic diagrams of a susceptor element according to a third embodiment of the present disclosure. The susceptor element 716 in FIGS. 7A and 7B is similar to the susceptor element 616 shown in FIG. 4 and will be described only with respect to the differences. In FIG. 7A, the susceptor element 716 further includes a plurality of channels 757. Each channel 757 of the plurality of channels 757 extends between the two nearest adjacent openings 750. Each channel 757 extends from a first surface of the nonwoven sheet approximately halfway through the nonwoven sheet toward a second surface of the nonwoven sheet. In other words, the channels 757 in FIG. 7A do not extend through the nonwoven sheet from the first surface to the second surface.

[0106] The channel 757 is configured to apply a capillary force to the liquid aerosol-forming substrate to assist the channel 757 in transporting the liquid aerosol-forming substrate across the first surface of the susceptor element 716. The channel 757 is a capillary channel. The capillary channel has dimensions such that a capillary force is applied to the liquid aerosol-forming substrate within the channel. The optimal dimensions of the capillary channel depend on factors such as the viscosity of the liquid aerosol-forming substrate and the viscosity of the material used in the susceptor element. The susceptor element 716 may be arranged with identical susceptor elements 716, as shown in FIGS. 1A, 1B, and 2, and the wicking element 20 may be sandwiched between two identical susceptor elements 716. The two identical susceptor elements 716 may be oriented such that the first surfaces contact the wicking element 20. In other words, the channel 757 is located on the surface of the susceptor element 716 that contacts the wicking element 20. However, it is contemplated that two identical susceptor elements 716 may be oriented with the second surface in contact with the wicking element 20. In other words, the channel 757 is located on the surface of the susceptor element 716 that does not contact the wicking element 20.

[0107] It is also contemplated that an arrangement without a wicking element 20 may be used. In FIG. 7B , the susceptor element 716 further includes a plurality of peripheral channels 758. Each peripheral channel 758 extends between an edge of the nonwoven sheet and one of the openings 750 closest to the edge of the nonwoven sheet. Each peripheral channel 758 extends from a first surface of the nonwoven sheet approximately halfway through the nonwoven sheet toward a second surface of the nonwoven sheet. In other words, the peripheral channels 758 in FIG. 7B do not extend through the nonwoven sheet from the first surface to the second surface. Each peripheral channel is similar in form and function to each channel of the plurality of channels 757 in that each peripheral channel 758 assists in transporting the liquid aerosol-forming substrate across the first surface of the susceptor element 716. However, in an arrangement without a wicking element 20, the susceptor element 716 extends into two channels 45. Thus, the peripheral channel 758 functions to apply capillary forces to the liquid aerosol-forming substrate in the two channels 45, drawing the liquid across the first surface of the susceptor element 716 and into the internal airflow passage 26 where the liquid aerosol-forming substrate can be vaporized. Each channel and the peripheral channel are formed by etching, for example, chemical etching.

[0108] FIG. 7C shows a schematic diagram of a further susceptor element according to a third embodiment of the present disclosure. The susceptor element 716 of FIG. 7C is similar to the susceptor element 716 shown in FIG. 7A and will be described only with respect to its differences. In FIG. 7C, the susceptor element 716 includes multiple vertical channels 759. Each vertical channel 759 extends from a first surface of the nonwoven sheet to a second surface of the nonwoven sheet. In other words, the vertical channels 759 of FIG. 7C extend entirely through the nonwoven sheet from the first surface to the second surface. The horizontal channels 757, as in FIG. 7A, extend only partially from the first surface to the second surface of the susceptor element. Thus, all portions of the susceptor element are connected by at least some material.

[0109] FIG. 7D shows a schematic diagram of a further susceptor element according to the present disclosure. The susceptor element 1016 of FIG. 7D is similar to the susceptor element 716 shown in FIG. 7A and will therefore be described only with respect to its differences. The susceptor element includes a plurality of channels 1057. Each channel of the plurality of channels does not extend between or contact any of the openings 1050 of the plurality of openings. Each channel of the plurality of channels extends either vertically or horizontally on the susceptor element to form a grid pattern. Each opening of the plurality of openings is positioned in a square or rectangular portion of the susceptor element formed by the grid of channels. A horizontal channel of the plurality of channels extends between two peripheral edges of the susceptor element. Advantageously, this arrangement of channels facilitates transport of the liquid aerosol-forming substrate from the peripheral edges of the susceptor element, which may contact a reservoir of liquid aerosol-forming substrate as in FIGS. 1A, 1B, and 2, toward the center of the susceptor element. The susceptor is described as including multiple channels, all of which overlap one another to form a network of interconnected channels.

[0110] FIG. 8 shows a schematic diagram of a susceptor element according to the present disclosure. The susceptor element 816 of FIG. 8 is similar to the susceptor element 616 shown in FIG. 4 and will be described only with respect to the differences. The susceptor element 816 of FIG. 8 is configured to be folded around the wicking element 20 of FIGS. 1A, 1B, and 2. To facilitate this folding, an elongated opening 880 is positioned in the center of the susceptor element 816. The elongated opening 880 divides the susceptor element into two approximately equal portions, each of which includes a plurality of openings 850 arranged in a square array as described with respect to FIG. 3. The elongated opening 880 extends the majority of the distance across the susceptor element 816, leaving two connecting portions 881 between the two approximately equal portions of the susceptor element 816. Thus, when the susceptor element 816 is folded around the wicking element 20, the connecting portion 881 may easily deform, allowing for ease of manufacturing. The elongated opening 880 is formed by either laser cutting, chemical etching, stamping, or wire discharge.

[0111] FIG. 9 shows a schematic diagram of a susceptor element according to the present disclosure. The susceptor element 916 of FIG. 9 is similar to the susceptor element 616 shown in FIG. 4 and will be described only with respect to the differences. The susceptor element 916 of FIG. 9 further includes four outward protrusions 982 positioned at the four corners of the peripheral edge of the nonwoven fabric sheet of the susceptor element 916. The outward protrusions 982 are configured to engage with corresponding slots in the susceptor holder 14 of the cartridge. Thus, the susceptor element 916 can be secured to the susceptor holder 14 to enhance the security of the susceptor assembly relative to the susceptor holder 14. The outward protrusions 982 occupy between 2 percent and 10 percent of the peripheral edge of the susceptor element 916 to minimize heat transfer from the susceptor element 916 to the susceptor holder 14. Such an arrangement is not possible with woven susceptor elements due to fraying of the woven filaments. The outward protrusions 982 are formed by removing excess nonwoven sheet. The excess nonwoven sheet is removed either by laser cutting, chemical etching, stamping, or wire discharge. The outline of the removed nonwoven sheet is shown by dashed line 983.

[0112] FIG. 10A shows a cross-sectional schematic view of an aerosol generation system 100 according to the present disclosure, with the cartridge 10 separated from the aerosol generation device 60.

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

[0114] The aerosol generating device 60 includes a generally cylindrical device 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 device outer housing 62 at the base of the cavity 64 to allow ambient air to be drawn into the cavity 64.

[0115] Device 60 further comprises an induction heating arrangement disposed within device outer housing 62. The induction heating arrangement includes an inductor coil 90, control circuitry 70, and a power source 72. Power source 72 comprises a rechargeable 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.

[0116] A single inductor coil 90 is positioned around the susceptor assembly 12 when the cartridge 10 is received in the cavity 64. The inductor coil 90 has a size and shape that matches the size and shape of the heating area of ​​the susceptor element. The inductor coil 90 is made of copper wire with a circular cross-section and disposed on a coil former element (not shown). The inductor coil 90 is a helical coil and has a circular cross-section when viewed parallel to the longitudinal axis of the aerosol generating device.

[0117] The inductor coil 90 is configured such that when an alternating current is supplied to the inductor coil, the inductor coil generates an alternating magnetic field in the region of the susceptor assembly 12 when the cartridge 10 is received in the cavity 64 .

[0118] The induction heating arrangement further includes a 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.

[0119] FIG. 10B shows a schematic cross-sectional view of the aerosol generation system 100 of FIG. 10A, but with the cartridge 10 coupled to an aerosol generation device 60.

[0120] In operation, when a user draws on mouth-end opening 38 of cartridge 10, ambient air is drawn into the base of cavity 64 through air inlet 65 and into cartridge 10 through air inlet 32 ​​in base 30 of cartridge 10, as shown by the arrows in Figure 7a. Ambient air flows through cartridge 10 from base 30 to mouth-end opening 38 through the air passages and across susceptor assembly 12.

[0121] The control circuit 70 controls the supply of power from the power supply 72 to the inductor coil 90 when the system is powered up.

[0122] The control circuit 72 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 66 when the airflow sensor 63 detects a puff by the user of the cartridge 10.

[0123] When the system is activated, an alternating current is established in the inductor coil 90, which generates an alternating magnetic field in the cavity 64 that penetrates the susceptor assembly 12, heating the susceptor element. The liquid aerosol-forming substrate in the channel 45 is drawn through the wicking element 20 into the susceptor assembly 12 and onto the susceptor element. The liquid aerosol-forming substrate 42 in the susceptor element is heated, 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 mouth-end opening 38 for inhalation by the user.

[0124] Figure 11 shows a schematic cross-sectional view of an aerosol generation device 300 according to the present disclosure. The aerosol generation device 300 according to the present disclosure includes most of the components of the aerosol generation system 100 shown in Figures 10A and 10B and operates in a similar manner. Therefore, unless otherwise stated, a description of any element of the aerosol generation device 300 is the same as the description of the corresponding element of the cartridge of Figures 1A, 1B, and 2 or the aerosol generation system of Figures 10A and 10B.

[0125] One difference is that the aerosol generating device 300 according to the present disclosure does not have a separate cartridge; instead, most of the features of the cartridge 10 according to Figures 1A, 1B, and 2 are incorporated into the aerosol generating device 300.

[0126] As previously mentioned, the aerosol generating device 300 includes a generally cylindrical device outer housing 362 having an oral end and a distal end opposite the oral end. An air inlet 365 is provided through the device outer housing 362 into the device 300.

[0127] Device 300 further comprises an induction heating arrangement disposed within device outer housing 362. The induction heating arrangement includes an inductor coil 390, control circuitry 370, and a power source 372. Power source 372 comprises a rechargeable lithium-ion battery that is rechargeable via an electrical connector (not shown) at the distal end of the device. Control circuitry 370 is connected to power source 372 and inductor coil 390 such that control circuitry 370 controls the supply of power to inductor coil 390. Control circuitry 370 is configured to supply alternating current to inductor coil 390.

[0128] A single inductor coil 390 is positioned around the susceptor assembly 312. The inductor coil 390 has a size and shape that matches the size and shape of the heating area of ​​the susceptor element. The inductor coil 390 is made of copper wire with a circular cross section and is disposed on a coil former element (not shown). The inductor coil 390 is a helical coil and has a circular cross section when viewed parallel to the longitudinal axis of the aerosol generation device.

[0129] The inductor coil 390 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 312 .

[0130] The induction heating arrangement further includes a flux concentrator element 91 as previously described.

[0131] The susceptor assembly 312 and the susceptor holder 314 are identical to the susceptor assembly 12 and the susceptor holder 314 shown in FIGS. 1A-2. As previously described, the susceptor assembly 312 is planar and thin, having a thickness dimension that is substantially smaller than its length and width dimensions. The susceptor assembly 312 is shaped in a rectangular configuration and includes three layers: a first susceptor element 316, a second susceptor element 318, and a wicking element 320 disposed between the first susceptor element 316 and the second susceptor element 318. The first susceptor element 316, the second susceptor element 318, and the wicking element 320 each form a generally rectangular shape, each susceptor element having the same length and width dimensions, with the width of the susceptor elements 316, 318 being smaller than the width of the wicking element 320. Thus, wicking element 320 includes outer, exposed portions of the wicking element that each protrude into one of two channels 345. First susceptor element 316 and second susceptor element 318 are substantially identical and include stainless steel plates having a plurality of openings formed therethrough.

[0132] As previously mentioned, the susceptor holder 314 also includes a base 330 that partially closes one end of the internal passage 326. The base 330 includes a plurality of air inlets that allow air to be drawn into the internal passage 326 through the partially closed end. As previously mentioned, the susceptor holder 314 includes a tubular body formed from a moldable plastic material, such as polypropylene. The tubular body of the susceptor holder 314 includes a sidewall that defines the internal passage 326, which has an open end. However, those skilled in the art will understand that since the apparatus 300 does not include a removable cartridge, the susceptor holder may instead be integrally formed with the apparatus 300, and in particular the apparatus outer housing 362.

[0133] Similarly, the aerosol-generating device 300 further includes a liquid reservoir 344. The liquid reservoir 344 is defined by a device outer housing 362 for holding a liquid aerosol-forming substrate 342. The liquid reservoir 344 extends from the mouth end of the outer housing 362 to the connecting end of the device outer housing 362 and includes an annular space defined by the device outer housing 362. The annular space has an internal passage 348 extending between the mouth end opening 338 and the open end of the internal passage 326 of the susceptor holder 314. The liquid reservoir 344 further includes two channels 345, which are defined between the outer surface of the susceptor holder 314 and the inner surface of the device. Two channels 345 extend from the annular space defined by the device outer housing 362 at the mouth end of the device 300 to the connecting end of the device 300, whereby the wicking element 320 extends through openings in the sidewall of the susceptor holder 314 and into the two channels 345. The two channels 345 extend from the annular space defined by the device outer housing 362 at the mouth end of the device 300 opposite the interior passage 326 of the susceptor holder 314.

[0134] Similarly, an air passageway is formed through the apparatus 300 by the internal passageway 326 of the susceptor holder 314 and the internal passageway 348 of the liquid reservoir 344. The air passageway extends from the air inlet in the base 330 of the susceptor holder 314, through the internal passageway 326 of the susceptor holder 314, through the internal passageway 348 of the liquid reservoir 344, to the mouth end opening 338. The air passageway allows air to be drawn through the apparatus 300 from the air inlet 365 to the mouth end opening 338.

[0135] Similarly, the control circuit 372 includes an airflow sensor 363 that is in fluid communication with the path of ambient air drawn through the device 300 by the user. The control circuit 372 provides power to the susceptor elements 316, 318 when the airflow sensor 363 detects a puff by the user on the device 300.

[0136] When the device is activated, an alternating current is established in the inductor coil 390, which inductively heats the susceptor elements 316, 318. The liquid aerosol-forming substrate 342 in the channel 345 is drawn through the wicking element 320 into the susceptor assembly 312 and onto the susceptor elements 316, 318. The susceptor elements heat the liquid aerosol-forming substrate 342, and volatile compounds from the heated aerosol-forming substrate are released into the air passages 326, 348 of the device 300, which cool and form an aerosol. The aerosol is entrained in air drawn through the air passages 326, 348 of the device 300 and is withdrawn from the device 300 at the mouth-end opening 338 for inhalation by the user.

[0137] For purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, and the like are understood to be modified in all instances by the term "about." Also, all ranges include the maximum and minimum values ​​disclosed, as well as any intermediate ranges contained therein, whether or not specifically recited herein. Thus, in this context, a numerical value A is understood as A ± 10% relative to A. In this context, a numerical value A can be considered to include numerical values ​​that fall within the typical standard error of measurement for the property that 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 maximum and minimum values ​​disclosed, as well as any intermediate ranges contained therein, whether or not specifically recited herein. Also, for purposes of this specification, the term "identical" refers to features that are designed to be identical within typical standard manufacturing tolerances for the feature in question.

Claims

1. 1. A heating assembly for an aerosol generation system, the heating assembly comprising a susceptor assembly, the susceptor assembly comprising: at least one nonwoven susceptor element, the at least one nonwoven susceptor element being in the form of a sheet and including a plurality of apertures, each aperture extending from a first surface of the sheet to a second surface of the sheet; a wicking element coupled to the at least one nonwoven susceptor element, the wicking element configured to transport an aerosol-forming liquid across a surface of the at least one nonwoven susceptor element; each opening of the plurality of openings extends in a first direction parallel to at least one of the first surface and the second surface of the at least one susceptor element; each opening of the plurality of openings extends in a second direction parallel to at least one of the first surface and the second surface of the at least one susceptor element and perpendicular to the first direction; each opening of the plurality of openings extends a greater distance in the first direction than in the second direction; the at least one susceptor element is planar and defines a first plane such that the first and second directions lie within the first plane; The heating assembly further comprising an inductor at least partially surrounding the susceptor element, the inductor configured to generate a magnetic field that varies in a direction parallel to the first direction.

2. 2. The heating assembly of claim 1, wherein each opening of the plurality of openings extends a first distance in the first direction, and each opening of the plurality of openings extends a second distance in the second direction, the first distance being 1.5 to 10 times the second distance.

3. The heating assembly of claim 1 or 2, wherein the plurality of openings form a regular array of openings in the at least one susceptor element.

4. 4. The heating assembly of claim 3, wherein the plurality of openings are spaced apart in the second direction by a second spacing distance that is 0.2 to 5 times the second distance.

5. 5. The heating assembly of claim 1, wherein the wicking element includes a first planar surface and a second planar surface, the first surface and the second surface defining opposite outwardly facing surfaces of the wicking element.

6. 6. The heating assembly of claim 5, wherein the at least one susceptor element includes first and second planar susceptor elements, and the susceptor assembly is arranged such that the first surface of the wicking element contacts the first susceptor element and the second surface of the wicking element contacts the second susceptor element.

7. 6. The heating assembly of claim 5, wherein the at least one susceptor element is folded around the wicking element such that the first surface of the wicking element contacts a first portion of the at least one susceptor element and the second surface of the wicking element contacts a second portion of the at least one susceptor element, the first portion being substantially parallel to the second portion.

8. 8. The heating assembly of claim 7, wherein the at least one susceptor element further includes a folded portion connected between the first portion and the second portion, the folded portion including an elongated opening, the elongated opening extending in a direction parallel to at least one of the first surface and the second surface of the wicking element.

9. 9. The heating assembly of claim 8, wherein the folded portion includes at least one connecting portion between the first portion and the second portion of the susceptor element, and the first portion of the at least one susceptor element and the second portion of the at least one susceptor element, and the at least one connecting portion are integrally formed.

10. 10. The heating assembly of claim 1, wherein the at least one susceptor element includes at least one outward protrusion, the at least one outward protrusion being positioned on a peripheral edge of the at least one susceptor element.

11. 11. The heating assembly of claim 10, wherein the at least one outward protrusion includes four outward protrusions positioned at four corners of the peripheral edge of the nonwoven sheet of the susceptor element, the outward protrusions configured to engage with a susceptor holder component of a cartridge.

12. 12. The heating assembly of claim 1, wherein the at least one nonwoven susceptor element comprises a first region, the first region comprising openings of a first configuration of the plurality of openings, and the at least one nonwoven susceptor element comprises a second region, the second region comprising openings of a second configuration of the plurality of openings, the openings of the second configuration being different from the openings of the first configuration.

13. 13. The heating assembly of claim 12, wherein the openings in the second configuration are different from the openings in the first configuration such that when the first region is exposed to the same alternating magnetic field as the second region, and when the alternating magnetic field is uniform across the first region and the second region, the temperature of the first region increases more than the temperature of the second region.

14. An aerosol generating device comprising a heating assembly according to any one of claims 1 to 13, the aerosol generating device comprising: an air inlet and an air outlet; an internally positioned airflow passageway extending between the air inlet and the air outlet; a reservoir for a liquid aerosol-forming substrate, said reservoir being in fluid communication with the wicking element of the susceptor assembly; a battery configured to supply an alternating current to the inductor to generate a magnetic field; The aerosol generating device, wherein the susceptor element is positioned within the airflow passage such that the susceptor element is at least partially within the magnetic field generated by the inductor.

15. An aerosol generation system comprising an aerosol generation device and a cartridge, the cartridge being configured to be connectable to the aerosol generation device, The aerosol generation system comprises the heating assembly of any one of claims 1 to 13, wherein the cartridge includes the susceptor assembly, and the aerosol generation device includes the inductor; The cartridge further comprises: an air inlet and an air outlet; an internally positioned cartridge airflow passageway extending between the air inlet and the air outlet; a reservoir for a liquid aerosol-forming substrate; the susceptor element is positioned within the cartridge airflow passage, the reservoir is in fluid communication with the wicking element of the susceptor assembly; The aerosol generating device further comprises: a device airflow inlet and a device airflow outlet; a device airflow passage extending between the device airflow inlet and the device airflow outlet; a battery configured to supply an alternating current to the inductor to generate the magnetic field such that the susceptor element is at least partially within the magnetic field generated by the inductor when the cartridge is coupled to the aerosol generating device; the inductor at least partially surrounds the susceptor element when the cartridge is coupled to the aerosol generating device; An aerosol generation system, wherein the magnetic field generated by the inductor varies in a direction parallel to the first direction.

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