Aerosol delivery system

Abstract

An aerosol delivery system configured to generate an aerosol from an aerosol-generating material is described, wherein the aerosol delivery system comprises: a heater element configured to generate heat for aerosolizing the aerosol-generating material; a monitoring circuit configured to monitor electrical parameters of the heater element during activation of the heater element; and a defect detection circuit configured to detect a defect in the heater element based on the monitored electrical parameters of the heater element. The defect detection circuit is configured to determine that a defect in the heater element has been detected based on identifying characteristics indicating a defect condition in the electrical parameters monitored during activation of the heater element. An aerosol delivery device and a method of operation are also described.

Description

Technology Field

[0001] The present disclosure generally relates to non-flammable aerosol delivery systems. In particular, the present disclosure relates to the selective energyization of aerosol generators for use in non-flammable aerosol delivery systems. Background Technology

[0002] Non-flammable aerosol delivery systems for generating aerosols for inhalation by a user are known in the art. Such systems typically include an aerosol generator capable of converting an aerosol-generating material into an aerosol. In some cases, the generated aerosol is a condensed aerosol, thereby allowing the aerosol-generating material to evaporate first and then adhere to the aerosol. In other cases, the generated aerosol is an aerosol resulting from the atomization of the aerosol-generating material. Such atomization can be induced mechanically, for example, by applying vibrations to the aerosol-generating material to form small particles of material that are entrained in the airflow. Alternatively, such atomization can be induced electrostatically or in other ways, such as by using pressure.

[0003] Aerosol generators, particularly heating elements, are the primary components responsible for aerosol generation in aerosol delivery systems. Successful delivery of aerosols depends on the aerosol generator functioning correctly. Additionally, if the aerosol generator does not function correctly, the overall safety of the aerosol delivery system can be severely affected, especially in the case of heating elements that can reach temperatures of 200°C or higher in some instances.

[0004] Various approaches intended to help solve some of these problems are described.

[0005] According to a first aspect of the present disclosure, an aerosol providing system configured to generate an aerosol from an aerosol generating material is provided. The aerosol providing system comprises: a heater element configured to generate heat for aerosolizing the aerosol generating material; a monitoring circuit configured to monitor electrical parameters of the heater element during activation of the heater element; and a defect detection circuit configured to detect a defect in the heater element based on the monitored electrical parameters of the heater element. The defect detection circuit is configured to determine that a defect in the heater element has been detected based on identifying characteristics indicating a defect condition in the electrical parameters monitored during activation of the heater element.

[0006] In some examples, the characteristic indicating a fault condition includes a non-zero rate of change of an electrical parameter that is greater or less than a predetermined threshold over a predetermined time period.

[0007] In some examples, the characteristics indicating a fault condition include a first part and a second part, and the first part has a larger or smaller rate of change of electrical parameters than the second part.

[0008] In some examples, the first part starts from the initial activation of the heater element, and the second part is a subsequent part in time.

[0009] In some examples, activation of the heater element involves supplying power from the power source of the aerosol supply system to cause the heater element to heat the aerosol-generating material to an operating temperature for aerosolizing.

[0010] In some examples, the electrical parameter includes at least one of electrical resistance and inductance.

[0011] In some examples, the fault detection circuit is configured to identify characteristics indicating a fault condition by comparing the monitored electrical parameters during the activation of the heater element with the expected values ​​or values ​​of the electrical parameters during the activation of the heater element that are set in advance.

[0012] In some examples, a characteristic is identified when a monitored electrical parameter deviates from an expected value or a predetermined amount from the values. In some examples, the heater element is carbon foam or contains carbon foam.

[0013] In some examples, the expected or values ​​of the electrical parameters are determined from one or more activations of the heater element performed in time prior to the current activation of the heater element.

[0014] In some examples, the expected values ​​or values ​​of the electrical parameters are determined from the initial part of the current activation of the heater element.

[0015] In some examples, in response to determining the fault condition, the control circuit is configured to prevent further activation of the heater element.

[0016] In some examples, in response to determining a fault condition, the control circuit is configured to provide an alert to the user.

[0017] In some examples, carbon allotropes include disordered graphite and / or amorphous carbon.

[0018] In some examples, the Raman spectrum of carbon allotropes includes G and D bands, where the G band peak is at approximately 1500 cm⁻¹. -1 to about 1650 cm -1 It is within the Raman shift range, and the D-band peak is approximately 1250 cm⁻¹. -1 to about 1400 cm -1It is within the Raman shift range, and the intensity of the D-band peak I D Strength of the G-band peak I G Of I D / I G is about 0.8 to about 2, preferably about 1 to about 1.8.

[0019] In some examples, carbon allotropes include disordered graphite and / or amorphous carbon and / or nanocrystalline graphite.

[0020] According to a second aspect of the present disclosure, an aerosol providing device configured to generate an aerosol from an aerosol generating material is provided. The aerosol providing device comprises: a monitoring circuit configured to monitor electrical parameters of a heater element during activation of a heater element—the heater element is configured to generate heat for aerosolizing an aerosol generating material—; and a defect detection circuit configured to detect a defect in the heater element based on the monitored electrical parameters of the heater element. The defect detection circuit is configured to determine that a defect in the heater element has been detected based on identifying characteristics indicating a defect condition in the electrical parameters monitored during activation of the heater element.

[0021] In some examples, the aerosol delivery device is configured to accommodate a consumable containing an aerosol-generating material.

[0022] In some examples, the consumable includes a heater element.

[0023] According to a third aspect of the present disclosure, a method for detecting a defect in a heater element for an aerosol delivery system is provided. The method comprises the steps of: providing a heater element; activating a heater element by applying power to the heater element to cause heating of the heater element; monitoring electrical parameters of the heater element during activation of the heater element; and determining a defect in the heater element based on identifying characteristics indicating a defect condition in the electrical parameters monitored during activation of the heater element.

[0024] According to a fourth aspect of the present disclosure, an aerosol providing means configured to generate an aerosol from an aerosol generating material is provided. The aerosol providing means comprises: a heater means configured to generate heat for aerosolizing the aerosol generating material; a monitoring means configured to monitor electrical parameters of the heater means during activation of the heater means; and a defect detection means configured to detect a defect in the heater means based on the monitored electrical parameters of the heater means. The defect detection means is configured to determine that a defect in the heater means has been detected based on identifying characteristics indicating a defect condition in the electrical parameters monitored during activation of the heater means. Brief explanation of the drawing

[0025] Now, various examples will be described in detail merely as examples, with reference to the attached drawings. FIG. 1 is a schematic diagram (not to scale or proportion) of a non-flammable aerosol providing system according to the present disclosure. FIG. 2 is a schematic cross-sectional view of an article to be used as part of a non-flammable aerosol providing system according to the present disclosure. FIG. 3 is a schematic cross-sectional view of a part of an article to be used as part of a non-flammable aerosol providing system according to the present disclosure. FIG. 4 is a schematic cross-sectional view of a part of an article to be used as part of a non-flammable aerosol providing system according to the present disclosure. FIG. 5 is a schematic cross-sectional view of a part of an article to be used as part of a non-flammable aerosol providing system according to the present disclosure. FIG. 6 is a schematic cross-sectional view of an article to be used as part of a non-flammable aerosol providing system according to the present disclosure. FIG. 7 is a schematic circuit diagram illustrating the arrangement of circuit sections for determining defects in a carbon allotrope as an aerosol generator according to the present disclosure. Figure 8 is a graph showing the variation in resistance over time for a first normal or non-defective carbon allotrope and a second defective carbon allotrope. Figure 9 is another graph showing the variation in resistance over time for the first normal or non-defective carbon allotrope and the third defective carbon allotrope. FIGS. 10a to 10c are graphs representing experimental data obtained for a sample carbon allotrope, wherein the graphs each show the measured resistance as a function of time for a plurality of activations of the carbon allotrope, and FIGS. 10b and 10c illustrate the two parts or regions of FIG. 10a in more detail. FIG. 11 is a flowchart illustrating an exemplary method for determining a defect in a heating element according to the present disclosure. Figure 12 plots the Raman spectra of carbon allotrope samples, where the x-axis is the Raman shift (cm²). -1 It corresponds to ), and the y-axis corresponds to intensity (counts), and has a D-band peak, a G-band peak, and a 2D-band peak. Specific details for implementing the invention

[0026] Aspects and features of specific examples are discussed and described herein. Some aspects and features of specific examples may be implemented conventionally and are not discussed or described in detail for the sake of simplification. Accordingly, it will be recognized that aspects and features of assemblies, articles, and non-flammable aerosol delivery systems discussed herein that are not described in detail may be implemented according to any conventional techniques for implementing such aspects and features.

[0027] As described above, the present disclosure relates to non-flammable aerosol providing systems and articles that generate aerosols from aerosol generating materials, but is not limited thereto.

[0028] According to the present disclosure, a "non-combustible" aerosol delivery system is a system in which a component aerosol generating material of the aerosol delivery system (or its component) does not burn or combust in order to facilitate the delivery of at least one material to a user.

[0029] In some examples, the non-flammable aerosol delivery system is a powered non-flammable aerosol delivery system.

[0030] In some examples, the non-flammable aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), but note that the presence of nicotine in the aerosol-generating material is not a requirement.

[0031] In some examples, a non-combustible aerosol delivery system is an aerosol-generating material heating system also known as a heat-not-burn system. One example of such a system is a cigarette heating system.

[0032] In some examples, a non-flammable aerosol providing system is a hybrid system for generating an aerosol using a combination of aerosol generating materials, one or more of which may be heated. Each of the aerosol generating materials may be in the form of, for example, a solid, liquid, or gel, and may or may not contain nicotine. In some examples, the hybrid system comprises a liquid or gel aerosol generating material and a solid aerosol generating material. The solid aerosol generating material may include, for example, tobacco or non-tobacco products.

[0033] Typically, a non-flammable aerosol delivery system may include a non-flammable aerosol delivery device and consumables for use with the non-flammable aerosol delivery device.

[0034] In some examples, the present disclosure relates to consumables comprising an aerosol-generating material and configured to be used with non-flammable aerosol-providing devices. These consumables are sometimes referred to as articles throughout the present disclosure.

[0035] In some examples, a non-flammable aerosol delivery system, such as its non-flammable aerosol delivery device, may include a power source and a controller. The power source may be, for example, an electric power source. The power source may be for supplying electric power to an article (e.g., an aerosol generator). The controller may be for controlling the article (e.g., for controlling the supply of power to the article, such as to the aerosol generator).

[0036] In some examples, the non-flammable aerosol delivery system may include an area for receiving consumables, an aerosol generator, an aerosol generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0037] In some examples, consumables for use with a non-flammable aerosol providing device may include an aerosol generating material, an aerosol generating material storage area (which may be referred to herein as a storage for the aerosol generating material), an aerosol generating material delivery component (also referred to herein as an aerosol generating material delivery component or an aerosol generating material delivery component), an aerosol generator (also referred to herein as an aerosol generating component), an aerosol generating area (also referred to herein as an aerosol generating chamber), a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0038] Throughout the following description, the terms "c-cigarette" and "electronic cigarette" may be used from time to time. However, it will be recognized that these terms may be used interchangeably with non-flammable aerosol (vapor) delivery systems as described above.

[0039] The systems described in this specification typically generate inhalable aerosols by the evaporation of an aerosol-generating material.

[0040] In some examples, the material to be delivered may be an aerosol-generating material. The aerosol-generating material may include one or more active ingredients, flavors, one or more aerosol-forming materials, and / or one or more other functional materials.

[0041] As used herein, the active substance may be a physiologically active material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, functional foods, nootropics, and psychoactive drugs. The active substance may occur naturally or be obtained by synthesis. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or other botanicals.

[0042] In some examples, the active substance comprises nicotine. In some examples, the active substance comprises caffeine, melatonin, or vitamin B12. As mentioned herein, the active substance may comprise one or more components, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0043] As mentioned herein, the active substance may comprise or be derived from one or more botanicals or their constituents, derivatives, or extracts. As used herein, the term “botanical” includes any material derived from plants, including (but not limited to) extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, shells, etc. Alternatively, the material may comprise an active compound naturally present in the botanical that is obtained by synthesis. The material may be in the form of liquid, gas, solid, powder, granules, crushed particles, granules, pellets, shreds, strips, sheets, etc. Examples of herbal medicines include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice, matcha, mate, orange peel, papaya, rose, sage, tea (e.g., green or black tea), thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, and nutmeg. Oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric,Sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. Mint may be selected from the following mint varieties: Mentha arvensis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cordifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens.

[0044] In some examples, the active substance comprises or is derived from one or more plant medicinal substances or their constituents, derivatives, or extracts, and the plant medicinal substance is tobacco.

[0045] In some examples, the active substance comprises or is derived from one or more herbal medicines or their constituents, derivatives, or extracts, and the herbal medicine is selected from eucalyptus, star anise, cocoa, and hemp.

[0046] In some examples, the active substance comprises or is derived from one or more herbal medicines or their constituents, derivatives, or extracts, and the herbal medicine is selected from rooibos and fennel.

[0047] In some examples, the substance to be delivered includes flavor.

[0048] As used herein, the terms “flavor” and “flavoring agent” refer to materials that may be used to produce a desired taste, aroma, or other somatosensorial sensation in products for adult consumers, where permitted by local regulations. These include naturally occurring flavoring ingredients, medicinal plants, extracts of medicinal plants, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (licorice candy), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, anise, cinnamon, turmeric, Indian spices, Asian spices, herbs, *Lysimachia vulgaris*, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruits, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia,Caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay leaf, mate, orange peel, rose, tea (e.g., green or black tea), thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, perilla, turmeric, coriander, myrtle, cassis, valerian, pimento, mace, demian, marjoram, olive, lemon balm, lemon basil, chives, carvi, It may include verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamates, lactose, sucrose, glucose, fructose, sorbitol or mannitol), and other additives, such as charcoal, chlorophyll, minerals, herbal medicines or breath freshening agents. These may be artificial, synthetic, or natural ingredients or blends thereof. They may be in any suitable form, e.g., liquids such as oils,It can be a solid, such as powder, or a gas.

[0049] In some examples, the flavor includes menthol, spearmint, and / or peppermint. In some examples, the flavor includes flavor components of cucumber, blueberry, citrus, and / or red berry. In some examples, the flavor includes eugenol. In some examples, the flavor includes flavor components extracted from tobacco. In some examples, the flavor includes flavor components extracted from cannabis.

[0050] In some examples, the flavor may include a sensate intended to achieve a somatosensorial sensation that is generally chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the aroma or taste nerve, and these may include agents that provide heating, cooling, tingling, or numbing effects. A suitable pyrogenic agent may be vanillyl ethyl ether, but is not limited thereto, and a suitable coolant may be eucalyptol, WS-3, but is not limited thereto.

[0051] An aerosol-generating material is a material capable of generating an aerosol when heated, irradiated, or energized in any other way, for example. The aerosol-generating material may be in the form of a liquid or gel that may or may not contain, for example, active substances and / or flavoring agents.

[0052] The aerosol-generating material may include one or more active substances and / or flavors, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0053] The aerosol-forming material may include one or more components capable of forming an aerosol. In some examples, the aerosol-forming material is glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene It may contain one or more carbonates (propylene carbonate).

[0054] One or more other functional materials may include one or more of pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0055] As used herein, the term “consumable” may refer to an article comprising or constituting an aerosol-generating material, in whole or in part intended to be consumed during use by a user. The consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material delivery component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. The consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate an aerosol upon use. The heater may comprise, for example, a combustible material, a material heatable by electrical conduction, or a susceptor. The consumable may be suitable for holding (or retaining) the aerosol-generating material. In this way, the consumable may hold (or retain) the aerosol-generating material, but is not required to do so.

[0056] As used herein, the term “susceptor” is a material that can be heated by penetration using a varying magnetic field, such as an alternating magnetic field. Since the susceptor may be an electrically conductive material, its penetration using a varying magnetic field causes induction heating of the heating material. Since the heating material may be a magnetic material, its penetration using a varying magnetic field causes magnetic hysteresis heating of the heating material. Since the susceptor may possess both electrical conductivity and magnetism, the susceptor may be heated by both heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0057] As used herein, the term “component” is used to refer to a part, section, unit, module, assembly, or similar device of an electronic cigarette or similar device that incorporates several smaller parts or elements, possibly within an external housing or wall. An electronic cigarette may be formed or constructed from one or more such components, and the components may be removable and detachably connected to one another, or may be permanently joined together during manufacturing to define the entire electronic cigarette. The present disclosure is applicable to (but is not limited to) systems comprising two components detachably connected to one another, the two components comprising, for example, a consumable / article component (also referred to herein as a cartridge or cartomizer) capable of holding an aerosol-generating material, and a device / control unit having a battery for providing electrical power to operate an element for generating vapor from the aerosol-generating material.

[0058] An aerosol modifier is a substance typically located downstream of an aerosol generation region configured to modify a generated aerosol, for example, by altering the taste, flavor, acidity, or other properties of the aerosol. The aerosol modifier may be provided to an aerosol modifier release component operable to selectively release the aerosol modifier.

[0059] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include one or more of, for example, flavoring agents, coloring agents, water, and carbon adsorbents. The aerosol modifier may be, for example, a solid, a liquid, or a gel. The aerosol modifier may be in the form of a powder, thread, or granules. The aerosol modifier may not contain a filter material.

[0060] An aerosol generator (or aerosol generating component) is a device configured to generate an aerosol from an aerosol generating material. In some examples, the aerosol generator is a heater configured to apply thermal energy to an aerosol generating material to release one or more volatile substances from the aerosol generating material to form an aerosol.

[0061] FIG. 1 is a very schematic drawing (not scaled or proportioned) of an exemplary non-flammable aerosol delivery system (10), such as an e-cigarette. The aerosol delivery system (10) has a generally cylindrical shape extending along a longitudinal axis indicated by a dashed line and comprises two main components: a control or power component or section (20) (which may be referred to herein as “device”) and a cartridge assembly or section (30) that operates as a vapor or aerosol generating component (which may be referred to herein as “article,” “consumable,” “cartomizer,” or “cartridge”).

[0062] The article (30) comprises a storage compartment (also referred to herein as “aerosol-generating material storage area” or “storage”) (3) that holds an aerosol-generating material comprising (e.g.) a liquid formulation (from which an aerosol is generated). The liquid formulation may or may not contain nicotine. As an example, the aerosol-generating material may contain about 1 to 3% nicotine and 50% glycerol, with the remainder being approximately propylene glycol, and possibly also include other components such as water or flavorings. The storage compartment (3) takes the form of a storage tank, that is, a container or receptacle in which the aerosol-generating material can be stored so that the aerosol-generating material (if liquid) moves and flows freely within the limits of the container or receptacle. Alternatively, the storage compartment (3) may hold a certain amount of absorbent material, such as cotton wadding or glass fiber, that holds the aerosol-generating material within a porous structure. The storage compartment (3) may be sealed after filling during manufacturing so that it can be disposed of after the aerosol generating material is consumed, or may have an inlet port or other opening that allows new aerosol generating material to be added.

[0063] In this example, the article (30) also includes an electric aerosol generator (4) located outside the storage compartment (3) to generate an aerosol by the evaporation of an aerosol generating material. In many examples, the aerosol generator is a heating element (heater) that is heated by the passage of an electric current (through resistance or induction heating) to raise the temperature of the aerosol generating material until the aerosol generating material evaporates. An aerosol generating material transfer component (not shown in FIG. 1), such as a wick or other porous element, may be provided to transfer the aerosol generating material from the storage compartment (3) to the aerosol generator (4). The aerosol generating material transfer component may have one or more parts located inside the storage compartment (3) so as to absorb the aerosol generating material and transfer it to other parts of the aerosol generating material transfer component in contact with the aerosol generator (4) by wick action or capillary action. By doing so, this aerosol generating material will be evaporated and replaced with a new aerosol generating material delivered to the aerosol generator (4) by the aerosol generating material delivery component.

[0064] A combination of a heater and a wick, or other arrangements of parts performing the same or similar functions, is sometimes referred to as an atomizer or an atomizer assembly. Various designs are possible in which the parts can be arranged differently from the very schematic representation in FIG. 1. For example, the wick may be an element completely separate from the aerosol generator.

[0065] In some examples, the aerosol generating material delivery component (4) may be formed at least partially from one or more slots, tubes, or channels that are narrow enough to support capillary action to draw source liquid from the storage compartment and deliver the source liquid for evaporation between the storage compartment (3) and the aerosol generator (4). Generally, the atomizer may be considered as an aerosol generator (4) capable of generating vapor from the aerosol generating material delivered to the aerosol generator (4), and an aerosol generating material delivery component capable of delivering or transporting liquid from the storage compartment (3) or a similar liquid reservoir to the aerosol generator by capillary force.

[0066] In some examples, the aerosol generator is at least partially located within an aerosol generating chamber that forms part of or is fluidically coupled to an air flow channel through an electronic cigarette / system. Vapor generated by the aerosol generator is released into this chamber, and as air passes through the chamber and flows over and around the aerosol generator, the air collects the generated vapor, thereby condensing the vapor to form the required aerosol.

[0067] Returning to FIG. 1, the article (30) also includes a mouthpiece (35) having an opening or an air outlet, through which the user can inhale an aerosol generated by an aerosol generator (4) and delivered through an air flow channel.

[0068] The power component (or device) (20) includes a rechargeable power source or cell (5) (e.g., "battery") for providing power for the electrical components of the e-cigarette (10), particularly the aerosol generator (4). Additionally, there is a printed circuit board (28) and / or other electronic devices or circuits for generally controlling the aerosol supply system (10). The control electronic device / circuits enable power to be supplied to the aerosol generating element (4) by the battery (5) in response to a signal from an air pressure sensor or air flow sensor (not shown) that detects inhalation to the system (10) through one or more air inlets (not shown) within the wall of the device (20) and flowing along an air flow channel, for example, when vapor is required. When the aerosol generator (4) receives power from the cell (5), the aerosol generator (4) evaporates the aerosol generating material delivered from the storage compartment (3) to generate an aerosol, which is then inhaled by the user through an opening in the mouthpiece (35). The aerosol is transported to the mouthpiece (35) along an air flow channel (not shown) that connects the air inlet to the air outlet when the user inhales the mouthpiece (35). Thus, the air flow path through the aerosol supply system (10) is defined from the air inlet(s) (which may or may not be provided by the device (20)) through the atomizer to the air outlet of the mouthpiece (35). In use, the direction of air flow along this air flow path is directed from the air inlet to the air outlet, and the atomizer can be described as being positioned downstream of the air inlet and upstream of the air outlet.

[0069] In this particular example, the device (20) and the article (30) are separate parts that are detachable from each other by separation in a direction parallel to the longitudinal axis. The components (20, 30) are joined together by cooperative interlocking elements (21, 31) (e.g., screws, magnets, or bayonet fittings) that provide a mechanical and / or electrical connection between the device (20) and the article (30) when the device (10) is in use. However, this is merely an exemplary arrangement, and various components may be distributed differently between the device (20) and the article (30), and other components and elements may be included. The two components (20, 30) may be connected end-to-end in a longitudinal configuration as in FIG. 1, or connected in a different configuration such as a parallel arrangement. Any one or both of the components (20, 30) may be intended to be discarded and replaced when depleted (e.g., when the reservoir is empty or the battery is discharged), or may be intended for multiple uses made possible by actions such as recharging the reservoir, recharging the battery, or replacing the atomizer. Alternatively, the aerosol delivery system (10) may be an integral device (disposable or rechargeable / rechargeable) that cannot be separated into two or more parts, in which case all components are contained within a single body or housing. Examples of the present disclosure are applicable to any of these and other configurations recognized by those skilled in the art.

[0070] According to one embodiment, the type of aerosol generator that can be used in the atomizing part (i.e., the part configured to generate vapor from the source liquid) of the aerosol supply system (10) is electrically conductive (resistive) and porous, thereby combining the functions of heating and liquid delivery. That is, in some embodiments, the aerosol generator (4) is capable of both heating the liquid aerosol generating material and delivering the liquid aerosol generating material (e.g., via capillary action to wick action). Such an aerosol generator (4) may exist in combination with a separate aerosol generating material delivery component (e.g., wick material), or such an aerosol generator (4) may replace such an aerosol generating material delivery component. Here, it should be noted that the reference to electrically conductive (resistive) refers to components that have the ability to generate heat in response to the flow of an electric current within them. Such a flow may be imparted through so-called resistance heating or induction heating. In some implementations, the aerosol generator (4) may be in a sheet form, that is, a flat shape having a thickness several times smaller than its length or width. It is possible for the flat aerosol generator to define a curved surface, and in these cases, the reference that the flat aerosol generator forms a plane means a virtual flat plane forming the plane of the best fit passing through the component.

[0071] In some embodiments, the aerosol generator (4) may be formed of or contain a carbon allotrope. The aerosol generator (4) (e.g., its carbon allotrope) may contain appropriately sized voids and / or interstices to provide capillary force to wick the aerosol generating material (e.g., liquid). Thus, the aerosol generator (4) (e.g., its carbon allotrope) may also be considered porous to provide absorption and distribution of the aerosol generating material (e.g., liquid). Furthermore, the presence of the voids and / or interstices may mean that air can penetrate the aerosol generator (4) (as long as they are not blocked or saturated with liquid). Additionally, the carbon allotrope of the aerosol generator may be electrically conductive and thus configured to be suitable for resistance heating.

[0072] An aerosol generator (e.g., planar and / or sheet-type) may be arranged within a non-flammable aerosol supply system (e.g., electronic cigarettes), so that the aerosol generator is placed within an aerosol generating chamber that forms part of an air flow channel. The aerosol generator may be oriented within the chamber such that the air flow passing through the chamber flows toward the surface, that is, substantially parallel to the plane of the aerosol generator. An example of such a configuration may be found in WO2010 / 045670 and WO2010 / 045671, the contents of which are incorporated herein by reference in their entirety. Thus, air flows over the aerosol generator (e.g., its carbon allotrope) and can collect vapor. By doing so, aerosol generation is effectively achieved. In alternative examples, the aerosol generator may be oriented within the chamber such that the airflow passing through the chamber can flow in a direction substantially transverse to the surface direction, that is, substantially orthogonal to the plane of the aerosol generator. An example of such a configuration may be found in WO2018 / 211252, the contents of which are incorporated herein by reference in their entirety.

[0073] An aerosol generator (e.g., its carbon allotrope) can have a high degree of porosity. A high degree of porosity can ensure that the heat generated by the aerosol generator is primarily used to evaporate the liquid, and that high efficiency can be achieved. Porosity exceeding 50% can be expected. In one example, the porosity of the aerosol generator is 50% or more, 60% or more, or 70% or more.

[0074] The aerosol generator can form a generally flat structure comprising first and second surfaces. The generally flat structure can take the form of any two-dimensional shape, such as a circle, semicircle, triangle, square, rectangle, and / or polygon. The aerosol generator can have a uniform thickness.

[0075] When an aerosol generator (e.g., its carbon allotrope) is formed from an electrically resistive material, an electric current is allowed to flow through the aerosol generator (e.g., its carbon allotrope) to generate heat (so-called Joule heating). In this regard, the electrical resistance of the aerosol generator (e.g., its carbon allotrope) can be appropriately selected. For example, an aerosol generator (e.g., its carbon allotrope) may have an electrical resistance of 2 ohms or less, e.g., 1.8 ohms or less, e.g., 1.7 ohms or less, e.g., 1.6 ohms or less, e.g., 1.5 ohms or less, e.g., 1.4 ohms or less, e.g., 1.3 ohms or less, e.g., 1.2 ohms or less, e.g., 1.1 ohms or less, e.g., 1.0 ohm or less, e.g., 0.9 ohms or less, e.g., 0.8 ohms or less, e.g., 0.7 ohms or less, e.g., 0.6 ohms or less, e.g., 0.5 ohms or less. Parameters of the aerosol generator (e.g., its carbon allotrope), such as material, thickness, width, length, porosity, etc., may be selected to provide the desired resistance. In this regard, a relatively lower resistance will facilitate higher power draw from the power source, which may be advantageous for generating a high rate of aerosolization. On the other hand, the resistance must be low enough not to compromise the integrity of the aerosol generator (e.g., its carbon allotrope). For example, the resistance may not be lower than 0.5 ohms.

[0076] For example, an aerosol generator (e.g., its carbon allotrope) may have an electrical resistance of 1 ohm to 1000 ohm. For example, an aerosol generator (e.g., its carbon allotrope) may have an electrical resistance of 1 ohm to 200 ohm. For example, an aerosol generator (e.g., its carbon allotrope) may have an electrical resistance of 10 ohm to 150 ohm. For example, an aerosol generator (e.g., its carbon allotrope) may have an electrical resistance of 20 ohm to 100 ohm. For example, an aerosol generator (e.g., its carbon allotrope) may have an electrical resistance of 30 ohm to 70 ohm. For example, an aerosol generator (e.g., its carbon allotrope) may have an electrical resistance of 40 ohm to 60 ohm. For example, an aerosol generator (e.g., its carbon allotrope) may have an electrical resistance of 45 ohms to 55 ohms. In this regard, a relatively lower resistance may facilitate higher power draw from the power source, which may be advantageous for generating a high rate of aerosolization. On the other hand, the resistance must be low enough not to compromise the integrity of the aerosol generator (e.g., its carbon allotrope). For example, the resistance may not be lower than 0.5 ohms.

[0077] In one embodiment, the aerosol generator (e.g., its carbon allotrope) has a resistance of 1 Ohm to 100 Ohms. In one embodiment, the laser-induced substrate has a resistance of 1 Ohm to 25 Ohms. In one embodiment, the laser-induced substrate has a resistance of 1 Ohm to 15 Ohms.

[0078] Sheet resistance (Rs) is measured in units of Ohm.sq and is typically used to describe the resistance of essentially two-dimensional (2D) surfaces. In some examples, the Rs of carbon allotropes is about 10 Ohm.sq to about 750 Ohm.sq. In some examples, the Rs of carbon allotropes is about 10 Ohm.sq to about 500 Ohm.sq. In some examples, the Rs of carbon allotropes is about 10 Ohm.sq to about 250 Ohm.sq. In some examples, the Rs of carbon allotropes is about 10 Ohm.sq to about 100 Ohm.sq. In some examples, the Rs of carbon allotropes is about 10 Ohm.sq to about 75 Ohm.sq. In some examples, the Rs of carbon allotropes is about 10 Ohm.sq to about 50 Ohm.sq. In some examples, the Rs of the carbon allotrope is about 10 Ohm.sq to about 25 Ohm.sq. In some embodiments, the sheet resistance of the carbon allotrope is within ±10%, ±9%, ±8%, ±7%, ±6%, ±5%, or ±4% of the Ohm.sq values ​​listed above.

[0079] FIG. 2 illustrates in more detail an exemplary arrangement of articles (100) for use with, for example, the aerosol providing device (20) of FIG. 1. In particular, the article (100) comprises a storage unit (101), a housing (109), and an optional aerosol generator support (129) (including a conduit (130)), which together form an internal volume (104) in which an aerosol generating material (200) can be stored, an aerosol generator (102) which is, in this example, a carbon allotrope (103), an optional seal (125) (including an opening (126)) between the aerosol generator support (129) and the carbon allotrope (103), an optional electrical insulating material (108) (including apertures (135)) provided between the seal (125) and the carbon allotrope (103), and electrical contacts (123) that are maintained in a position and electrically in contact with the carbon allotrope (103) through retaining members (124).

[0080] Overall, the general operating principle of the article (100) is as follows. An aerosol generating material (200) stored in an internal volume (104) can flow from the volume (104) of the storage (101) to an aerosol generator (102) / carbon allotrope (103) provided to be in fluid communication with the storage (101). In some embodiments, such as those in FIG. 2, this may involve the aerosol generating material (200) flowing from the volume (104) of the storage (101) to the carbon allotrope (103) through at least one conduit (130) in the aerosol generator support (129), and / or at least one opening (126) in the seal (125), and / or at least one aperture (132) in the electrical insulating substrate (108). A power source, such as the battery (5) of the device (20), can power the aerosol generator (102) to energize (e.g., heat) the aerosol generator (102) so that the aerosol generator (102) can generate an aerosol from the aerosol generating material (200). The generated aerosol can be released into an environment (105) outside the storage (101), where it can be entrained in the airflow passing through / around the aerosol generator (102).

[0081] FIGS. 3 and 4 schematically illustrate two different arrangements of a reservoir (101) containing a carbon allotrope (103). These figures will be described in more detail below in the relevant sections.

[0082] It will be understood that the aerosol generator (102) is intended to generate an aerosol from an aerosol generating material (200), and any suitable component capable of generating an aerosol from the aerosol generating material (200) may be used as the aerosol generator (102). The aerosol generator (102) may be configured to aerosolize the aerosol generating material (200) in any suitable manner. For example, the aerosol generator (102) may be configured to raise its temperature (or the temperature of a part thereof) to evaporate the aerosol generating material (200).

[0083] In the described embodiment, the aerosol generator (102) comprises a carbon allotrope (103). At least a portion of the carbon allotrope (103) can generate an aerosol from the aerosol generating material (200) by heating. In some examples, heating of the carbon allotrope (103) can be achieved by delivering an electric current through the carbon allotrope (103) with an amperage sufficient to cause evaporation of the aerosol generating material (200). For example, a pair of electric contacts (123) may be provided to make electrical contact with regions of the carbon allotrope (103) so that when current is applied to the electric contacts, electric current may be delivered through the carbon allotrope (103) between the electric contacts (123). In other examples, the carbon allotrope (103) may be a susceptor and configured to be inductively heated (e.g., by being in close proximity to a magnetic field generator, such as a driving coil that generates a changing magnetic field penetrating the carbon allotrope (103) to cause inductive heating of the carbon allotrope (103) when an AC current is applied to the magnetic field generator). Either the article (100) or the aerosol providing device may include a magnetic field generator.

[0084] The carbon allotrope (103) may be porous or otherwise may contain a plurality of interconnected pores, cells, or gaps. The carbon allotrope (103) may contain pores. For example, the carbon allotrope (103) may be porous. The carbon allotrope (103) may be permeable, for example, liquid and / or gas permeable. The pores or gaps allow for the transport of aerosol-generating material through the carbon allotrope (103). For example, the pores or gaps may allow the aerosol-generating material to flow from a surface of the carbon allotrope (103) facing the volume (104) inside the reservoir (101) to an opposing surface facing the environment (105) outside the reservoir (101) through the carbon allotrope (103). In some embodiments, the aerosol-generating material may also be moved laterally within the carbon allotrope (103).

[0085] The carbon allotrope (103) can be a single material.

[0086] The carbon allotrope (103) may have a heating surface. The heating surface may be partially or completely exposed. When in use, an aerosol may be released from the heating surface.

[0087] The carbon allotrope (103) may include one or more parts (106, 107). For example, FIG. 4 illustrates an embodiment in which the carbon allotrope (103) includes a plurality of parts (106, 107). A part (106) of the carbon allotrope (103) may be referred to as an aerosol generating part (106). The aerosol generating part (106) may include a heating surface. The aerosol generating part (106) may be configured to reach temperatures for generating an aerosol from the aerosol generating material (200). That is, the aerosol generating part (106) is a part of the carbon allotrope (103) configured to be energized (e.g., heated to a sufficient temperature) to cause the generation of an aerosol from the aerosol generating material (200) when in use. The aerosol generating portion (106) (e.g., its surface) is exposed to the environment (105) outside the storage (101), and thus aerosols can be generated in the environment (105) outside the storage (101), particularly near the exposed surface of the aerosol generating portion (106). A portion (107) of the carbon allotrope (103) may be referred to as a transport portion (107). The transport portion (107) is configured to transport an aerosol generating material (200) (e.g., within the storage (101)) to the aerosol generating portion (106) of the carbon allotrope (103). The transport portion (107) may be exposed to the volume (104) of the storage (101). The transport portion (107) may extend from the volume (104) inside the storage (101) to the aerosol generating portion (106). When in use, the transport portion (107) of the carbon allotrope (103) may not reach temperatures sufficient to cause evaporation of the aerosol generating material (200). Therefore, aerosol generation may be largely limited to the aerosol generating portion (106).

[0088] The surface area of ​​the aerosol generating portion (106) exposed to the environment (105) outside the storage (101) may be larger than the surface area of ​​the transport portion (107) exposed inside the storage (101).

[0089] The carbon allotrope (103) can be formed as a single unit. That is, the carbon allotrope (103) can be formed as a single piece (which may include multiple parts as discussed above). When the carbon allotrope (103) is formed as a single unit, it has been found that the carbon allotrope (103) is more rigid and easier to manufacture and assemble compared to a carbon allotrope formed from separate pieces.

[0090] The carbon allotrope (103) provides an aerosol generator (102) that is particularly effective in non-flammable aerosol supply systems. The carbon allotrope (103) can be considered to provide a carbonaceous surface (e.g., an aerosol generating portion (106)) that distributes and generates aerosol from an aerosol generating material (200) when in use. Without being bound by theory, it is believed that when the carbon allotrope (103) is heated to temperatures for generating aerosol from the aerosol generating material, the carbonaceous surface may have high surface free energy and, consequently, high wettability (and a low contact angle). In this way, when the carbon allotrope (103) is heated to temperatures for generating aerosol from the aerosol generating material, a thin layer of the aerosol generating material can be evenly distributed across the carbonaceous surface of the carbon allotrope (103) and efficiently aerosolized. Furthermore, the carbon allotrope (103) has a high power density and low thermal mass, and compared to materials having a surface where the aerosol generating material cannot be formed as thinly, a small volume of the aerosol generating material can be formed thinly over a given surface area of ​​the carbon allotrope (103). This provides efficient transfer of energy to the aerosol generating material (200) during use.

[0091] The carbon allotrope (103) may be formed into a foam. It will be understood that "carbon allotrope formed into a foam" means that the carbon allotrope (103) itself is the foam. The foam may include a foam structure and a plurality of cells. It will be understood that the carbon allotrope forms a foam structure, and the foam structure defines a plurality of cells. The foam structure may define a plurality of cells. The plurality of cells may be interconnected. The foam may be an open-cell foam, such as a reticulated foam. It will be understood that the foam is a solid foam (e.g., at least 20°C to 350°C and 101325 Pa). The carbon allotrope (103) may include a capillary structure. For example, the foam may include a capillary structure.

[0092] A carbon allotrope (103) formed from foam has been found to provide a particularly effective aerosol generator (102). Without being bound by theory, it is believed that the foam (which may have high thermal conductivity and high electrical conductivity) can effectively dissipate heat, reduce temperature fluctuations, and reduce the severity of hot spots when hot spots (localized areas of increased temperature that may occur when a portion of a heated aerosol generator dries out during use) are formed. Consequently, the aerosol generator can operate at high power levels with a reduced risk of hot spots causing damage to the aerosol generator. Furthermore, the foam can adapt to thermal expansion during use. Therefore, the foam may be resistant to heat-induced degradation during use. Additionally, the foam has been found to facilitate reduced battery throughput and / or extended battery life. Additionally, the foam has been found to provide reduced battery size requirements and consequently improved packaging efficiency, for example, in terms of cost and space requirements. Furthermore, the foam can facilitate the rapid evaporation of the aerosol-generating material (200), which can improve the user experience by reducing the time required to generate an aerosol in response to a first inhalation ("first puff") by the user. Moreover, the foam can facilitate consistency between individual inhalations ("puff-to-puff consistency") by the user. The use of foam can also provide certain user experience advantages associated with conventional factory-made cigarettes.

[0093] When the carbon allotrope (103) is formed into a foam, the carbon allotrope (103) may be referred to as "carbon foam." It will be understood that carbon foam includes, for example, graphite foam, graphene foam, or any other carbon-based foam. It will be understood that various methods, including (but not limited to) arc discharge, laser ablation, laser induction, laser induction pyrolysis, high-pressure carbon monoxide disproportionation, and chemical vapor deposition, may be used to form the foam. In the examples of the drawings, laser induction was used to form the foam (103). When the carbon allotrope (103) is formed into a foam, the foam may include a plurality of layers. Each layer may include or be composed of carbon atoms arranged in a hexagonal lattice structure, such as a honeycomb lattice structure.

[0094] A carbon allotrope (103) may comprise carbon structured to possess multiple carbon-carbon bonds lying in the same plane. For example, the carbon allotrope (103) may comprise graphite. When the carbon allotrope (103) comprises graphite, the carbon allotrope (103) comprises multiple stacked layers of carbon atoms, wherein the carbon atoms in each layer are bonded to three adjacent carbon atoms within the layer, and each bond lies in the same plane to form a hexagonal lattice structure. Non-covalent bonds exist between the stacked layers. Thus, graphite comprises multiple stacked layers of carbon, wherein the layers of carbon are parallel to each other. Two forms of graphite exist: alpha graphite, in which the layers are stacked ABA; and beta graphite, in which the layers are stacked ABC.

[0095] It is also possible for the carbon allotrope (103) to include graphene. For example, the carbon allotrope (103) may be graphene. When the carbon allotrope (103) is graphene (or includes it), a single layer of carbon atoms, i.e., a one-atom-thick layer of carbon, is formed such that the carbon atoms are arranged to form a hexagonal lattice structure. It has been found that graphene provides an effective aerosol generator (102). Advantageously, when hot spots (localized areas of increased temperature that may occur when a portion of the heated aerosol generator dries out during use) are formed, the high thermal and electrical conductivity of graphene allows the graphene to effectively dissipate heat, reduce temperature fluctuations, and reduce the severity of the hot spots. Consequently, the aerosol generator (102) can be operated at high power levels with a reduced risk of hot spots causing damage to the aerosol generator (102). Furthermore, graphene can be elastic and thus adapt to thermal expansion during use (e.g., of the electrical insulating substrate (108) discussed below). Thus, the aerosol generator (102) can be resistant to degradation due to the difference in thermal expansion coefficients between the graphene and the electrical insulating substrate (e.g.). Additionally, the use of graphene has been shown to provide reduced battery throughput and consequently extended battery life. Furthermore, the use of graphene can provide reduced battery size requirements and consequently improved packaging efficiency, for example, in terms of cost and space requirements. Additionally, the use of graphene can facilitate the rapid evaporation of the aerosol generating material, which can improve the user experience by reducing the time required to generate an aerosol in response to a first inhalation ("first puff") by the user. Moreover, the use of graphene can facilitate consistency between individual inhalations ("puff-to-puff consistency") by the user.The use of graphene can also provide certain user experience advantages associated with conventional factory-made cigarettes.

[0096] If the carbon allotrope (103) comprises graphene, more than one layer of graphene may exist. If more than one layer of graphene (103) exists, at least two of the layers of graphene (103) may be non-parallel to each other. “Non-parallel” means that an imaginary plane penetrating one layer of graphene (103) (or an imaginary plane of best-fit penetrating a non-plane layer of graphene (103)) is non-parallel to an imaginary plane penetrating another layer of graphene (103) (or an imaginary plane of best-fit penetrating another non-plane layer of graphene (103)). In use, the layers of graphene (103) are electrically connected to form a current path. By providing non-parallel layers of graphene, a porous graphene structure may be provided. The combination of porosity at typical aerosolization temperatures and the low surface energy of graphene allows the aerosol-generating material to be effectively distributed across the bulk structure of graphene as well as the outermost surface of graphene. In fact, the aerosol-generating material can be provided in close contact with the increased surface area of ​​the heated material provided by the graphene layers. This provides efficient and effective aerosolization performance. For example, at least 3, at least 4, at least 5, at least 6, at least 8, or at least 10 of the layers of graphene (103) may be non-parallel to each other. If more than one layer of graphene (103) is present, at least 2 of the layers of graphene (103) may be parallel to each other. For example, the carbon allotrope (103) may be double-layered graphene.

[0097] Where the carbon allotrope (103) comprises graphene, the carbon allotrope (e.g., one or more layers of graphene) may comprise three-dimensional graphene (which may be referred to as porous graphene or laser-induced graphene (LIG)) or be in the form of three-dimensional graphene. Three-dimensional graphene can be considered as one or more graphene sheets (or layers) folded backward (e.g., relative to each other) to form a three-dimensional structure. Without being bound by theory, it is believed that interatomic bonds in three-dimensional graphene are formed mainly between sp2-hybridized orbitals, and the dominant local coordination of carbon atoms in three-dimensional graphene is similar to the coordination in two-dimensional graphene, so that two-dimensional and three-dimensional graphene may have similar electronic properties. A graphene foam (described below) can be considered as an example of three-dimensional graphene.

[0098] In examples comprising one or more layers of graphene (103), the layers or layers may be provided in various forms. For example, one or more layers of graphene (103) may be formed into a plurality of three-dimensional structures. The three-dimensional graphene structures may be selected from cubes, cuboids, cones, cylinders (e.g., tubes), spheres, pyramids, and / or prisms. It will be understood that various methods, including (but not limited to) arc discharge, laser ablation, high-pressure carbon monoxide disproportionation, and chemical vapor deposition, may be used to create three-dimensional graphene structures.

[0099] In some embodiments, the carbon allotrope (103) comprises disordered graphite and / or amorphous carbon. In some preferred embodiments, the carbon allotrope (103) is selected from the group comprising disordered graphite, amorphous carbon, or a combination thereof. In some embodiments, the carbon allotrope (103) comprises disordered graphite and / or amorphous carbon and / or nanocrystalline graphite. In some preferred embodiments, the carbon allotrope (103) is selected from the group comprising disordered graphite, amorphous carbon, nanocrystalline graphite, or a combination thereof. The Raman spectrum of the carbon allotrope (103) includes a G band and a D band. The Raman spectrum of the carbon allotrope (103) also includes a 2D band.

[0100] In some embodiments, the Raman spectrum of the carbon allotrope (103) is about 1500 cm⁻¹ -1 to about 1650 cm -1 It includes a G band peak within the Raman shift range. In such examples, the Raman spectrum of the carbon allotrope (103) is about 1250 cm⁻¹. -1 to about 1400 cm -1 It may include a D-band peak within the Raman shift range. In such examples, the Raman spectrum of the carbon allotrope (103) is about 2600 cm⁻¹ -1 to about 2750 cm -1 It may include 2D band peaks within the Raman shift range.

[0101] For example, in some examples, the Raman spectrum of the carbon allotrope (103) is about 1550 cm⁻¹ -1 to about 1590 cm -1 It includes a G band peak within the Raman shift range. In such examples, the Raman spectrum of the carbon allotrope (103) is about 1310 cm⁻¹. -1 to about 1340 cm -1It may include a D-band peak within the Raman shift range. In such examples, the Raman spectrum of the carbon allotrope (103) is about 2620 cm⁻¹. -1 to about 2680 cm -1 It may include 2D band peaks within the Raman shift range.

[0102] D-band peak intensity I D Strength of the G-band peak I G Of I D / I G It can be about 0.8 to about 2. Non-I D / I G It can be about 0.9 to about 1.9. Non-I D / I G It can be about 1 to about 1.8.

[0103] The G band peak is about 30 cm -1 to about 100 cm -1 It can have a full width at half maximum (FWHM). The G band peak is approximately 30 cm. -1 to about 70 cm -1 It can have an FWHM. The 2D band can follow a Gaussian curve model or a Lorentz curve model.

[0104] Any of the above features related to the Raman spectrum may be combined. For example, in some examples, the Raman spectrum of a carbon allotrope (103) includes a G band and a D band, where the G band peak is about 1500 cm⁻¹. -1 to about 1650 cm -1 It is within the Raman shift range, and the D-band peak is approximately 1250 cm⁻¹. -1 to about 1400 cm -1 It is within the Raman shift range, and the intensity of the D-band peak I D Strength of the G-band peak I G Of I D / I Gis about 0.8 to about 2. For example, in some examples, the Raman spectrum of the carbon allotrope (103) includes a G band and a D band, where the G band peak is about 1550 cm⁻¹. -1 to about 1590 cm -1 It is within the Raman shift range, and the D-band peak is approximately 1310 cm⁻¹. -1 to about 1340 cm -1 It is within the Raman shift range, and the intensity of the D-band peak I D Strength of the G-band peak I G Of I D / I G It is about 1 to about 1.8.

[0105] For example, in some examples, the carbon allotrope (103) is porous. For example, in some examples, the carbon allotrope (103) is formed as foam. The carbon allotrope (103) is electrically conductive.

[0106] In this specification, Raman spectra may be measured using Raman microspectroscopy. In this specification, Raman microspectroscopy may be performed using a laser wavelength of 638 nm. In this specification, Raman microspectroscopy may be performed using a grating having 1800 grooves / mm. In this specification, Raman microspectroscopy may be performed using a laser power of 10.9 mW. In this specification, Raman microspectroscopy may be performed using an acquisition time of 5 seconds. In this specification, Raman microspectroscopy may be performed using 20 accumulations. In this specification, Raman microspectroscopy may be performed using a confocal pinhole of 300 μm. In this specification, Raman microspectroscopy may be performed at approximately 1000 cm⁻¹ -1 to about 3000 cm -1It can be performed in the wavelength range. In this specification, Raman microspectroscopy can be performed using a microscope objective lens of 50x LWD (long working distance) and 0.8 NA (numerical aperture). In this specification, Raman microspectroscopy can be performed using a Horiba Xplora Plus Raman microspectroscopy. In this specification, Raman microspectroscopy can be performed at 21°C. In this specification, the carbon allotrope (103) that has undergone Raman microspectroscopy may be unused. That is, the carbon allotrope (103) was not used to generate an aerosol and / or was not heated to conventional aerosolization temperatures (after the preparation of the carbon allotrope (103)).

[0107] It will be understood that the carbon allotrope (103) is thermally conductive. The carbon allotrope (103) is 100 Wm -1 K -1 Up to 5500 Wm -1 K -1 It can have a thermal conductivity of 100 Wm. The carbon allotrope (103) has a thermal conductivity of 100 Wm -1 K -1 to 4000 Wm -1 K -1 It can have a thermal conductivity of 100 Wm. The carbon allotrope (103) has a thermal conductivity of 100 Wm -1 K -1 to 2000 Wm -1 K -1 It can have a thermal conductivity of 150 Wm. The carbon allotrope (103) has a thermal conductivity of 150 Wm -1 K -1 to 1000 Wm -1 K -1 It can have a thermal conductivity of 180 Wm. The carbon allotrope (103) has a thermal conductivity of 180 Wm -1 K -1 Up to 700 Wm -1 K -1 It can have a thermal conductivity of 200 Wm. The carbon allotrope (103) has a thermal conductivity of 200 Wm -1 K -1 up to 500 Wm -1 K -1 It can have a thermal conductivity of

[0108] It will be understood that the carbon allotrope (103) is electrically conductive. The carbon allotrope (103) is 1 Sm -1 Up to 2.5×10 6 Sm -1 It can have an electrical conductivity of . The carbon allotrope (103) is 100 Sm -1 Up to 1.0×10 6 Sm -1 It can have an electrical conductivity of 200 Sm. The carbon allotrope (103) is 200 Sm -1 to 100,000 Sm -1 It can have an electrical conductivity of 400 Sm. The carbon allotrope (103) is 400 Sm -1 to 50,000 Sm -1 It can have an electrical conductivity of 500 Sm. The carbon allotrope (103) is 500 Sm -1 to 10,000 Sm -1 It can have an electrical conductivity of 600 Sm. The carbon allotrope (103) is 600 Sm -1 to 5000 Sm -1 It can have an electrical conductivity of 800 Sm. The carbon allotrope (103) is 800 Sm -1 to 3000 Sm -1 It can have an electrical conductivity of 900 Sm. The carbon allotrope (103) is 900 Sm -1 to 1300 Sm -1 It can have electrical conductivity.

[0109] In examples, the carbon allotrope (103) is 200 Wm -1 K -1 up to 500 Wm -1 K -1 thermal conductivity of and 900 Sm -1 to 1300 Sm -1 It can have an electrical conductivity of 200 Wm -1 K -1 up to 500 Wm -1 K -1 thermal conductivity of and 900 Sm -1 to 1300 Sm-1 It can have electrical conductivity.

[0110] The carbon allotrope (103) may be elastically deformable. The carbon allotrope (103) may have non-linear elasticity.

[0111] The carbon allotrope (103), or a portion of the carbon allotrope (103), may be in a sheet-like form. For example, the aerosol-generating portion (106) may be in a sheet-like form. The carbon allotrope (103), or a portion of the carbon allotrope (103), may be substantially planar. For example, the aerosol-generating portion (106) may be substantially planar.

[0112] The thickness of the carbon allotrope (103) may be understood to refer to the range of the carbon allotrope (103) measured orthogonally between the outer surface of the carbon allotrope (103) facing the environment (105) outside the reservoir (101) and the opposing outer surface of the carbon allotrope (103). Alternatively, the thickness of the carbon allotrope (103) may be understood to refer to the range of the carbon allotrope (103) measured orthogonally to the planar or lateral range of the carbon allotrope (103) between the outer surfaces of the carbon allotrope (103). If the carbon allotrope (103) (or the aerosol generating portion (106)) contains internal cells or pores, these are substantially ignored in the measurement of thickness. Those skilled in the art will recognize suitable methods for measuring the thickness of the carbon allotrope (103), such as electron microscopy.

[0113] The carbon allotrope (103) (or aerosol generating portion (106)) may have a thickness of 0.345 nm to 500 μm, 0.345 nm to 400 μm, 0.345 nm to 300 μm, 0.345 nm to 200 μm, 0.345 nm to 100 μm, 0.345 nm to 80 μm, or 0.345 nm to 60 μm.

[0114] The carbon allotrope (103) (or aerosol generating portion (106)) may have a thickness of 1 μm to 500 μm, 1 μm to 400 μm, 1 μm to 300 μm, 1 μm to 200 μm, 1 μm to 100 μm, 1 μm to 80 μm, or 1 μm to 60 μm.

[0115] The carbon allotrope (103) (or aerosol generating portion (106)) may have a thickness of 10 μm to 500 μm, 10 μm to 400 μm, 10 μm to 300 μm, 10 μm to 200 μm, 10 μm to 100 μm, 10 μm to 80 μm, or 10 μm to 60 μm.

[0116] The carbon allotrope (103) (or aerosol generating portion (106)) may have a thickness of 20 μm to 500 μm, 20 μm to 400 μm, 20 μm to 300 μm, 20 μm to 200 μm, 20 μm to 100 μm, 20 μm to 80 μm, or 20 μm to 60 μm.

[0117] The carbon allotrope (103) (or aerosol generating portion (106)) may have a thickness of 30 μm to 500 μm, 30 μm to 400 μm, 30 μm to 300 μm, 30 μm to 200 μm, 30 μm to 100 μm, 30 μm to 80 μm, 30 μm to 60 μm, or 30 μm to 50 μm.

[0118] The carbon allotrope (103) (or aerosol generating portion (106)) may have a thickness of 50 μm to 500 μm, 50 μm to 300 μm, 80 μm to 300 μm, 90 μm to 200 μm, 100 μm to 150 μm, or 120 μm to 130 μm.

[0119] The carbon allotrope (103) (or aerosol-generating portion (106)) may have a thickness of 20 μm to 150 μm, 30 μm to 120 μm, 40 μm to 110 μm, or 50 μm to 100 μm.

[0120] The carbon allotrope (103) (or aerosol generating portion (106)) may have a thickness of 1 μm to 50 μm, 1 μm to 20 μm, 1 μm to 10 μm, or 1 μm to 5 μm.

[0121] In some examples, the carbon allotrope (103) has a thickness of up to about 50 μm. In some examples, the carbon allotrope (103) has a thickness of up to about 40 μm. In some examples, the carbon allotrope (103) has a thickness of up to about 30 μm. In some examples, the carbon allotrope (103) has a thickness of up to about 20 μm. In some examples, the carbon allotrope (103) has a thickness of up to about 5 μm.

[0122] The carbon allotrope (103) (or aerosol-generating portion (106)) may have a length of 6 mm or less, 5 mm or less, 4 mm or less, 3 mm or less, or 2 mm or less.

[0123] The carbon allotrope (103) (or aerosol-generating portion (106)) may have a length of at least 0.5 mm, at least 1 mm, or at least 1.3 mm.

[0124] The carbon allotrope (103) (or aerosol-generating portion (106)) may have a length of 0.5 mm to 6 mm, 0.5 mm to 5 mm, 1 mm to 4 mm, 1 mm to 3 mm, or 1.3 mm to 2 mm.

[0125] The carbon allotrope (103) (or aerosol-generating portion (106)) may have a width of 6 mm or less, 5 mm or less, 4 mm or less, 3 mm or less, 2.5 mm or less, or 2.3 mm or less.

[0126] The carbon allotrope (103) (or aerosol-generating portion (106)) may have a width of at least 0.5 mm, at least 1 mm, at least 1.5 mm, or at least 1.7 mm.

[0127] The carbon allotrope (103) (or aerosol-generating portion (106)) may have a width of 0.5 mm to 6 mm, 0.5 mm to 5 mm, 1 mm to 4 mm, 1 mm to 3 mm, 1.5 mm to 2.5 mm, or 1.7 mm to 2.3 mm.

[0128] In some examples, the carbon allotrope (103) (or aerosol-generating part (106)) takes on a substantially rectangular shape (e.g., when viewed from above).

[0129] In some examples, the carbon allotrope (103) (or aerosol-generating portion (106)) has a length of about 0.5 mm to about 6 mm. In some examples, the carbon allotrope (103) (or aerosol-generating portion (106)) has a length of about 1 mm to about 4 mm. In some examples, the carbon allotrope (103) (or aerosol-generating portion (106)) has a length of about 2 mm to about 3.2 mm. In some examples, the carbon allotrope (103) (or aerosol-generating portion (106)) has a length of about 2.2 mm to about 3 mm. In some examples, the carbon allotrope (103) (or aerosol-generating portion (106)) has a length of about 2.4 mm to about 2.8 mm.

[0130] In some examples, the carbon allotrope (103) (or aerosol generating portion (106)) has a width of about 0.5 mm to about 6 mm. In some examples, the carbon allotrope (103) (or aerosol generating portion (106)) has a width of about 1 mm to about 4 mm. In some examples, the carbon allotrope (103) (or aerosol generating portion (106)) has a width of about 1.4 mm to about 2.6 mm. In some examples, the carbon allotrope (103) (or aerosol generating portion (106)) has a width of about 1.6 mm to about 2.2 mm. In some examples, the carbon allotrope (103) (or aerosol generating portion (106)) has a width of about 1.7 mm to about 2.1 mm.

[0131] In some examples, the carbon allotrope (103) (or aerosol generating portion (106)) has a length of about 0.5 mm to about 6 mm and a width of about 0.5 mm to about 6 mm. In some examples, the carbon allotrope (103) (or aerosol generating portion (106)) has a length of about 1 mm to about 4 mm and a width of about 0.5 mm to about 5 mm. In some examples, the carbon allotrope (103) (or aerosol generating portion (106)) has a length of about 2 mm to about 3.2 mm and a width of about 1.4 mm to about 2.6 mm. In some examples, the carbon allotrope (103) (or aerosol generating portion (106)) has a length of about 2.2 mm to about 3 mm and a width of about 1.6 mm to about 2.2 mm. In some examples, the carbon allotrope (103) (or aerosol-generating portion (106)) has a length of about 2.4 mm to about 2.8 mm and a width of about 1.7 mm to about 2.1 mm.

[0132] The carbon allotrope (103) may not contain metal. Furthermore, the aerosol generator (102) may not contain metal. For example, the aerosol generator (102) may not contain metal-retaining electrical contacts. Thus, the carbon allotrope (103) and / or the aerosol generator (102) may not contain metal. The carbon allotrope (103) may be directly connected to a power source without requiring metal-retaining electrical contacts as part of the carbon allotrope (103). In this way, metal emissions from the aerosol generator (102) may be reduced during use.

[0133] In some embodiments, the aerosol generator (102) may be configured to generate an aerosol so that the aerosol collection mass (ACM) is at least 2 mg. The aerosol generator (102) may be configured to generate an aerosol so that the aerosol collection mass (ACM) is at least 4 mg. The aerosol generator (102) may be configured to generate an aerosol so that the aerosol collection mass (ACM) is 20 mg or less. The aerosol generator (102) may be configured to generate an aerosol so that the aerosol collection mass (ACM) is 10 mg or less. The aerosol generator (102) may be configured to generate an aerosol so that the aerosol collection mass (ACM) is 2 mg to 10 mg. The aerosol generator (102) may be configured to generate an aerosol so that the aerosol collection mass (ACM) is 4 mg to 8 mg. In this specification, the aerosol collection mass (ACM) corresponds to the amount of aerosol collected per puff based on a puff regimen of 25 puffs, each puff having a puff volume of 55 mL, a puff duration of 3 seconds, and a puff interval of 30 seconds.

[0134] A carbon allotrope (103) may be formed on an electrical insulating substrate (108) by laser irradiation of the electrical insulating substrate (108). In embodiments where the carbon allotrope (103) is formed as a foam, the foam may be formed on the electrical insulating substrate (108) by laser irradiation of the electrical insulating substrate (108). Laser irradiation may include irradiating the electrical insulating substrate (108) using a laser beam, wherein the electrical insulating substrate (108) is a carbon-containing material. In examples involving laser irradiation, the electrical insulating substrate (108) may be formed of polyimide (PI). Laser irradiation may be performed in an inert environment. Laser irradiation may be performed in an ambient environment. Laser irradiation may be performed in atmospheric air (air from the Earth's atmosphere).

[0135] Accordingly, a method for forming an aerosol generator (102) may include the step of forming a carbon allotrope (103) on an electrical insulating substrate (108) by laser irradiation, which includes irradiating the electrical insulating substrate (108) using a laser beam, wherein the electrical insulating substrate (108) is a carbon-containing material (optionally formed of polyimide (PI)) and optionally the carbon allotrope (103) is formed of foam. Optionally, the carbon allotrope (103) comprises disordered graphite and / or amorphous carbon.

[0136] A method for forming an aerosol generator (102) may include the step of forming at least one aperture (132) that extends through an electrically insulating substrate (108). The at least one aperture (132) may be as defined herein. The at least one aperture (132) may be formed by laser irradiation of the electrically insulating substrate (108).

[0137] In some examples, the step of forming at least one aperture (132) that extends through the electrical insulating substrate (108) occurs prior to the step of forming a carbon allotrope (103) on the electrical insulating substrate (108). The carbon allotrope (103) may be formed on a portion of the electrical insulating substrate (108) and at least one aperture (132) extends through the electrical insulating substrate (108). The at least one aperture (132) may extend through the carbon allotrope (103) and / or be covered (partially or completely) by the carbon allotrope (103).

[0138] In some examples, a method of forming an aerosol generator (102) is,

[0139] (A) forming at least one aperture (132) by penetrating the electrical insulating substrate (108) through laser irradiation of the electrical insulating substrate (108); and

[0140] (B) A step of forming a carbon allotrope (103) on an electrical insulating substrate (108) by laser irradiation of the electrical insulating substrate (108).

[0141] The method comprises, wherein the electrical insulating substrate (108) is a carbon-retaining material (optionally formed of polyimide (PI)), step (A) occurs prior to step (B), and at least one aperture (132) extends through the carbon allotrope (103) and / or is covered (partially or completely) by the carbon allotrope (103). Optionally, the carbon allotrope (103) is formed of foam. Optionally, the carbon allotrope (103) comprises disordered graphite and / or amorphous carbon.

[0142] In some examples, the step of forming at least one aperture (132) extending through the electrical insulating substrate (108) occurs after the step of forming a carbon allotrope (103) on the electrical insulating substrate (108). The carbon allotrope (103) may cover at least one aperture (132) (partially or completely).

[0143] In some examples, a method of forming an aerosol generator (102) is,

[0144] (A) A step of forming a carbon allotrope (103) on an electrical insulating substrate (108) by laser irradiation of the electrical insulating substrate (108); and

[0145] (B) A step of forming at least one aperture (132) by penetrating the electrical insulating substrate (108) through laser irradiation of the electrical insulating substrate (108).

[0146] It includes, wherein the electrical insulating substrate (108) is a carbon-retaining material (optionally formed of polyimide (PI)), step (A) occurs prior to step (B), and the carbon allotrope (103) covers at least one aperture (132) (partially or completely). Optionally, the carbon allotrope (103) is formed of foam. Optionally, the carbon allotrope (103) comprises disordered graphite and / or amorphous carbon.

[0147] Without being bound by theory, it is believed that energy from a laser beam can form a porous conductive carbon-retaining material (103) having a porous (e.g., foam) structure from an electrically insulating substrate (108) (e.g., PI). It should be understood that various properties of the carbon allotrope (103) and / or at least one aperture (132) can be controlled by adjusting laser beam parameters such as pulse duration, power, focal length, frequency, wavelength, and / or scanning speed.

[0148] The carbon allotrope (103) can be formed on an electrical insulating substrate (108) by laser-induced deposition.

[0149] The inventors analyzed various carbon allotropes (103) samples using Raman microspectroscopy.

[0150] Each carbon allotrope (103) sample was prepared by laser irradiation of a polyimide (poly(4,4'-oxydiphenylene-pyromellitimide), Kapton® HN, DuPont) substrate (102) (electrical insulating substrate). Each polyimide substrate had a length of about 4.5 mm, a width of about 4.5 mm, and a thickness of about 125 μm, and was shaped into a rectangular prism. This was done by using a laser beam to form the carbon allotrope (103) on each polyimide substrate, approximately 4.5 mm multiplied by about 2 mm (i.e., about 9 mm 2 It involved investigating the area of ​​; and rectangle). Each of the carbon allotrope (103) samples underwent Raman microspectroscopy. Each of the carbon allotrope (103) samples was porous and electrically conductive.

[0151] Without being bound by theory, Raman spectroscopy is considered a non-destructive vibrational spectroscopic technique that uses a laser to excite bonds within a sample (e.g., carbon) and interprets the inelastic scattering of bond vibrations as relative Raman shifts. Inelastic scattering from interactions with the sample generates relative Raman shifts, thereby producing a spectrum that can be used to interpret the characteristics and / or identity of the sample. For the characterization of carbon allotrope (103) samples, the present invention typically uses about 1329 cm⁻¹ -1 D band observed at, typically about 1579 cm⁻¹ -1 The G band observed at, and typically around 2630 cm⁻¹ -1The peak positions of the 2D bands observed in can be investigated. The D band may be referred to as the "disorder band" and is an indication of sp3 hybridization of carbon within the sample. The G band may be referred to as the "graphene band" and is used to determine the sp2 hybridization of the carbon structure within the sample. For example, the Raman spectrum of a pristine graphene sample typically includes a narrow G band of high intensity and will not include a D band. The Raman spectrum of a graphite sample typically includes both a G band and a D band, with the D band having a lower intensity than the G band. I D / I G The ratio is the counts (I) of the intensity (au) of the D-band peak. D ) Counts of G-band peak intensity (I G It can be used by determining ) and can be used to determine the carbon allotropes present in the sample. 2D bands can also be used by interpreting the area of ​​the curve and the peak position to determine the morphology of the allotropes. For example, crystalline graphite will typically exhibit a sharp, narrow peak curve following a Lorentz curve fitting model, whereas the 2D bands of a sample containing amorphous carbon will typically exhibit a wider, flatter band following a Gaussian curve fitting model. The full width at half maximum (FWHM) of the peak can also be used to determine the crystallinity within the sample. FWHM is measured by determining the width of the peak in question at half the total intensity of the sample.

[0152] Raman microspectroscopy involved measuring the Raman spectrum of each sample using a Horiba Xplora Plus Raman microspectroscopy instrument and the following parameters:

[0153] Laser wavelength of 638 nm;

[0154] Grid having 1800 grooves / mm;

[0155] 5 seconds acquisition time;

[0156] 20 accumulations (20 spectra);

[0157] Laser power of 10.9 mW;

[0158] 300 μm confocal pinhole; and

[0159] Approximately 1000 cm -1 to about 3000 cm -1 Wavelength range of.

[0160] Raman microspectroscopy was performed at 21°C.

[0161] The carbon allotrope (103) samples that underwent Raman microspectroscopy were unused.

[0162] The Raman spectrum of each carbon allotrope (103) sample included a G band and a D band, where the G band peak was at approximately 1550 cm⁻¹. -1 to about 1590 cm -1 It was within the Raman shift range, and the D-band peak was approximately 1310 cm⁻¹ -1 to about 1340 cm -1 It was within the Raman shift range, and the intensity of the D-band peak I D Strength of the G-band peak I G Of I D / I G The value was 1 to 1.8. The Raman spectrum of each carbon allotrope (103) sample was approximately 2620 cm⁻¹. -1 to about 2680 cm -1 It included a 2D band peak within the Raman shift range. In the Raman spectrum of each carbon allotrope (103) sample, the G band peak is approximately 45 cm⁻¹. -1 to about 62 cm -1 It had a full width at half maximum (FWHM). In the Raman spectra of each carbon allotrope (103) sample, the 2D band typically followed a Lorentz curve fitting model.

[0163] The Raman spectra of each of the carbon allotrope (103) samples indicated that the samples contained disordered graphite, amorphous carbon, or a combination thereof.

[0164] FIG. 12 shows the Raman spectrum of one of the carbon allotrope (103) samples. The sample was unused. As shown in FIG. 12, the G band peak is at approximately 1573 cm⁻¹. -1 It was observed at, and the D band peak is approximately 1320 cm⁻¹. -1 It was observed at, and the 2D band peak is approximately 2630 cm⁻¹. -1 It was observed at. Intensity of the G band peak I G vs D-band peak intensity I D Of I G / I D It was approximately 1.6. The G band peak was approximately 62 cm. -1 It had an FWHM. The 2D band followed the Lorentz curve fitting model.

[0165] The inventors have discovered that carbon allotropes (103), comprising disordered graphite, amorphous carbon, nanocrystalline graphite, or a combination thereof, provide particularly effective aerosol generating components. Such carbon allotropes (103) have been found to effectively dissipate heat, reduce temperature fluctuations, and reduce the severity of any hot spots. Such carbon allotropes (103) exhibited low electrical resistance (and high electrical conductivity), which were particularly suitable for use in non-flammable aerosol supply systems. Such carbon allotropes (103) also facilitated effective liquid distribution, for example, across the surface of the carbon allotropes and / or within the carbon allotropes.

[0166] Although the focus above has been on describing a carbon allotrope (103) as an aerosol generator (102), it should be understood that the principles of the present disclosure are applicable to any aerosol generator (102) that can be used in the article (100).

[0167] The storage (101) is suitable for storing the aerosol generating material (200). The storage (101) can take various forms. As illustrated in FIG. 2, the storage (101) may have at least one wall (109) defining an internal volume (104) in which the aerosol generating material (200) can be stored.

[0168] FIG. 2 schematically illustrates a reservoir (101) formed by outer walls (109) and (optional) aerosol generator supports (129). The outer walls (109) and the aerosol generator supports (129) define an internal volume (104) of the reservoir (101) where an aerosol generating material (200) can be placed. In implementations where the aerosol generator supports (129) are not present, the aerosol generator supports (129) are replaced by additional outer walls (109).

[0169] The aerosol generator (102) / carbon allotrope (103) is arranged so that an aerosol generating material (200) can be supplied to them. For example, the reservoir (101) may include an opening or channel (particularly, see flow conduit (130) in FIG. 2) penetrating the outer wall (109) or the aerosol generator support (129) that allows the aerosol generating material (200) to be transferred from the inner volume (104) of the reservoir (101) to the carbon allotrope (103). In some embodiments, the carbon allotrope (103) may extend through the wall (109) and / or be formed as part of the wall (109).

[0170] FIG. 3 schematically illustrates an enlarged cross-section of a reservoir (101) and a carbon allotrope (103) of an article (100) according to another example. In the example of FIG. 3, the reservoir (101) converges toward the carbon allotrope (103). That is, the inner surface of the reservoir (101) may converge toward the carbon allotrope (103). Such arrangements help to orient the aerosol-generating material (200) toward or toward the carbon allotrope (103) when in use. This is particularly beneficial when the surface area of ​​the carbon allotrope (103) exposed inside the reservoir (101) is significantly smaller than the total surface area of ​​the inner surface of the reservoir (101).

[0171] In FIG. 3, it is also seen that the carbon allotrope (103) is positioned to extend between the outer walls (109). The carbon allotrope (103) and the reservoir (101) may be formed integrally. For example, the carbon allotrope (103) and the wall (109)—through which the carbon allotrope (103) extends at least partially—may be formed integrally. In this way, the article (100) can be manufactured efficiently without the need to assemble the reservoir (101) and the carbon allotrope (103) as separate components. Furthermore, the article (100) may be more rigid than an article in which the carbon allotrope (103) and the reservoir (101) are formed as separate components.

[0172] As discussed above, the carbon allotrope (103) may comprise a plurality of portions, such as an aerosol generating portion (106) and / or a transport portion (107). The cross-sectional area of ​​the transport portion (107) may be smaller than the cross-sectional area of ​​the aerosol generating portion (106), wherein each cross-sectional area is measured orthogonally to the thickness direction of the wall (109). This arrangement may facilitate the delivery of the aerosol generating material (200) at a controlled rate (e.g., with reduced risk of leakage) and a desirable aerosol generating profile. Referring to FIG. 4, the transport portion (107) may comprise a first portion (112) and a second portion (113). The first portion (112) may be exposed to the internal volume (104) of the storage (101). The second portion (113) may extend from the first portion (112) to the aerosol generating portion (106). The transport portion (113) may or may not be exposed to the interior (104) of the storage (101).

[0173] The reservoir (101) may be formed at least partially from an electrical insulating material. For example, a wall (109)—through which the carbon allotrope (103) extends at least partially—may be formed from an electrical insulating material. For example, a portion of the wall (109)—through which the carbon allotrope (103) extends at least partially—may be formed from an electrical insulating material. For example, a portion of the wall (109) adjacent to the carbon allotrope (103) may be formed from an electrical insulating material.

[0174] It will be understood that various electrical insulation materials may be used. Electrical insulation materials may include or be formed from plastics, glass, paper, and / or ceramics. Plastics may be selected from polysulfone (PSU), poly(ethersulfone) (PES), polyimide (PI), poly(phenylene sulfide) (PPS), polyetheretherketone (PEEK), and polyetherketone (PEK). In some examples, polyimide (PI) is selected from polyetherimide (PEI) and polyamide-imide (PAI). Glass may be selected from the group consisting of silicate glass and non-silicate glass. In some examples, silicate glass is borosilicate glass or quartz glass (fused quartz). Glass may be flexible. Glass may be non-porous.

[0175] It should be understood that the form and structure of the storage (101) are not particularly limited, and that the principles of the present disclosure may be applied to any specific form or structure of the storage (101).

[0176] Referring to FIG. 2, the aerosol generator (102) may include an (optional) electrical insulating substrate (108). A carbon allotrope (103) may be arranged on the electrical insulating substrate (108) (or deposited on it or supported on it). It has been found that the electrical insulating substrate (108) can provide useful structural support to the carbon allotrope (103), thereby improving the rigidity of the aerosol generator (102). The electrical insulating substrate (108) may be non-porous or porous.

[0177] The electrical insulating substrate (108) may also be made of any suitable electrical insulating material that may be thermally insulating. The electrical insulating substrate (108) may comprise or be formed from plastic (e.g., polyetheretherketone (PEEK)), glass (e.g., quartz glass), paper, and / or ceramic. In some embodiments, the electrical insulating substrate (108) has a thickness of 100 μm to 4 mm, but the thickness of the electrical insulating substrate (108) is not limited to these thicknesses.

[0178] In FIG. 2, at least one aperture (132) is shown extending through the electrically insulating substrate (108). The at least one aperture (132) is found to facilitate the effective delivery of the aerosol generating material (200) to the carbon allotrope (103). In particular, the aerosol generating material (200) can be delivered to the carbon allotrope (103) through the at least one aperture (132) from the surface of the substrate (108) facing the surface on which the carbon allotrope (103) is supported. In this way, the aerosol generating material (200) delivered through the at least one aperture (132) can spread across the carbon allotrope (103) in a controlled manner, while the carbon allotrope (103) is shielded from the bulk volume of the aerosol generating material (200) by the substrate (108). In this way, heat losses are reduced and aerosol generation efficiency is improved. In addition, at least one aperture (132) allows for controlled delivery of the aerosol generating material (200) to the carbon allotrope (103) (e.g., dimensions of the cross-section of at least one aperture (132) and / or the number of apertures (132)), while the structure of the substrate (108) is found to prevent the aerosol from flowing inadvertently into the reservoir (101).

[0179] In other embodiments, at least one aperture (132) may include a plurality of apertures (132). That is, the aerosol generator (102) may include a plurality of apertures (132) each extending through the electrical insulating substrate (108). Each of the plurality of apertures (132) may extend from a first surface of the electrical insulating substrate (108) to a second (e.g., opposite) surface of the electrical insulating substrate (108). The plurality of apertures (132) may be spaced apart from each other. The plurality of apertures (132) may include at least three apertures. The plurality of apertures (132) may form an array or a two-dimensional pattern. For example, the plurality of apertures (132) may form an array or a two-dimensional pattern across the first surface and / or the second surface.

[0180] In the example of FIG. 2, the electrical insulating substrate (108) is provided together with an aerosol generator support (129). Accordingly, the conduit (130) of the aerosol generator support (129) is provided to be fluidly connected to one or more apertures (132) of the electrical insulating substrate (108). However, it should be understood that the electrical insulating substrate (108) may also be provided in implementations where the aerosol generator support (129) is omitted.

[0181] Referring to FIG. 2, in some embodiments, the article (100) (e.g., storage (101)) may include an aerosol generator support (129). It will be understood that the aerosol generator support (129) supports an aerosol generator (102). For example, the aerosol generator (102) may be mounted on the aerosol generator support (129). The aerosol generator support (129) has been found to help maintain the structural integrity of the aerosol generator (102), particularly when the carbon allotrope (103) and / or electrical insulating substrate (108) are vulnerable. In use, the aerosol generator support (129) may restrict and / or reduce the flow of the aerosol generating material (200) inside the storage (101) to the aerosol generator (102).

[0182] The aerosol generator support (129) may include at least one conduit (130). The inner diameter of the or each conduit (130) may be smaller than the inner diameter of the reservoir (101). The or each conduit (130) may extend toward (or to) the aerosol generator (102). For example, the or each conduit (130) may be aligned with the aerosol generator (102). The aerosol generator support (129) may include a solid structure (131) — through which at least one conduit (130) extends.

[0183] When in use, the aerosol generating material may preferentially (or only) cross the aerosol generator support (129) through the or each conduit (130). It has been found that the aerosol generator support (129) can help control the flow of the aerosol generating material (200) to the aerosol generator (102), while also helping to shield the aerosol generator (1020) from the bulk volume of the aerosol generating material (200). In this way, the aerosol generator support (129) can be considered a thermal break. Additionally, it has been found that the conduit(s) (130) can help channel the liquid toward the aerosol generator (102) and / or reduce or prevent the formation of air bubbles (which may be formed by the movement of the article (100).

[0184] The aerosol generator support (129) may be made of a thermal insulating material. Various thermal insulating materials may be used. The thermal insulating material may include or be formed from plastic, glass, paper, and / or ceramic.

[0185] The aerosol generator support (129) may be arranged so that the aerosol generating material (200) inside the reservoir (101) to be delivered to the aerosol generator (102) passes through at least one channel (130). The aerosol generator support (129) may be a part formed integrally with the reservoir (101). Alternatively, the aerosol generator support (129) may be a detachable or separate part of the reservoir (101). For example, the wall (109) of the reservoir (101) may include the aerosol generator support (129). For example, the wall (109) (or part thereof)—through which, at least partially, a carbon allotrope is extended—may include the aerosol generator support (129).

[0186] In some examples, the carbon allotrope (103) may extend at least partially through the aerosol generator support (129). For example, the carbon allotrope (103) may be formed integrally with the aerosol generator support (129).

[0187] Referring to FIGS. 2 and 3, the article (100) may include an optional seal (125). The seal (125) may be arranged between the storage (101) and the aerosol generator (102). The seal (125) may be arranged between the wall (109) and the aerosol generator (102). The seal (125) may be arranged between the aerosol generator support (129) and the aerosol generator (102). The seal (125) may be arranged between the storage (101) and the carbon allotrope (103). The seal (125) may be arranged between the wall (109) and the carbon allotrope (103). The seal (125) may be arranged between the aerosol generator support (129) and the carbon allotrope (103).

[0188] Referring to FIGS. 2 and FIGS. 3, the seal (125) may be a gasket. For example, the seal (125) may be a mechanical seal.

[0189] It will be understood that the seal (125) can be formed from various materials. For example, the seal (125) can be formed from a flexible and / or deformable material. The seal (125) may include or be formed from polymer materials, fibrous materials, metallic materials, and / or glass materials. The polymer material may be (e.g.) silicon or polyimide.

[0190] In some embodiments, the seal (125) may include or be formed from an adhesive. Such a seal (125) may be referred to as an adhesive seal (125). The adhesive seal (125) may adhere the aerosol generator (102) to the reservoir (101), for example, in embodiments where the aerosol generator (102) is not formed as part of the wall (109) of the reservoir (101). For example, the adhesive seal (125) may adhere the aerosol generator (102) to the wall (109) of the reservoir (101) (e.g., an aerosol generator support (129)).

[0191] The seal (125) may be intended to reduce or prevent unintended leakage of the aerosol generating material (200) between the reservoir (101) (e.g., its wall (109); e.g., aerosol generator support (129)) and the aerosol generator (102). The seal (125) may be intended to reduce or prevent unintended leakage of the aerosol generating material (200) between the reservoir (101) (e.g., its wall (109); e.g., aerosol generator support (129)) and the carbon allotrope (103).

[0192] At least one opening (126) (e.g., illustrated in FIG. 2) may be provided in the seal (125). At least one opening (126) may overlap or overlay with the aerosol generator (102). In use, the aerosol generating material (200) in the reservoir (101) may flow into the aerosol generator (102) (e.g., carbon allotrope (103)) through at least one opening (126).

[0193] Referring to FIG. 2, the article (100) may include at least one electrical contact portion (123). For example, the article (100) may include at least two (e.g., a pair) electrical contact portions (123). It will be understood that each of the electrical contact portions (123) is electrically conductive.

[0194] At least one electrical contact (123) may be connected to a power source such as a cell (5) provided to the device (20) of the aerosol supply system (10). The power source may be for supplying electrical power to the aerosol generator (102) so that the aerosol generator (102) generates an aerosol from the aerosol generating material (200) (e.g., through heating).

[0195] FIGS. 3 and 4 illustrate at least one electrical contact (123) arranged on or in contact with an aerosol generating component (102) (e.g., a carbon allotrope (103)). The at least one electrical contact (123) is provided to contact an electrical conductor (e.g., a pogo pin, etc.) of the device (20) when the article (100) is coupled to the device (20). Thus, electric power can be supplied to the carbon allotrope (103) to heat the aerosol generating material (200).

[0196] At least one electrical contact (123) may be provided in various forms. The or each electrical contact (123) may be joined to or in contact with a carbon allotrope (103). The or each electrical contact may comprise or be formed from a metallic material. The metallic material may be a metal alloy such as solder. The metallic material may be silver, copper, gold, platinum, palladium, tungsten, or nickel. For example, the metallic material may be silver chloride.

[0197] Referring to FIG. 4, at least two of the electrical contacts (123) may be arranged in contact with the carbon allotrope (103) such that a path of minimum electrical resistance extends through the aerosol generating portion (106) while bypassing the transport portion (107). In this way, the aerosol generating portion (106) may reach temperatures for generating an aerosol from the aerosol generating material, whereas the transport portion (107) may not. Such an arrangement may result in improved efficiency and performance (compared to the case where the entire carbon allotrope (103) reaches the aerosolization temperatures).

[0198] Additionally, it has been found that impact between the electrical contact(s) (123) and the carbon allotrope (103) can cause damage to the carbon allotrope (103). This may occur during the manufacture of the article (100) or once the article (100) has been manufactured. Damage to the carbon allotrope (103) may manifest as cracks and / or chips within the carbon allotrope and may negatively affect the performance of the aerosol generator (102). Therefore, it is desirable to reduce the risk of damage to the carbon allotrope (103). In this regard, the or each electrical contact(s) (123) may have a substantially flat contact surface. For example, the or each electrical contact(s) (123) may be formed as a plate. The plate may have a substantially flat contact surface. The substantially flat contact surface may be arranged in contact with the carbon allotrope (103). Without being bound by theory, such arrangements are believed to reduce the pressure applied to the carbon allotrope (103) by the electric contact(s).

[0199] FIG. 5 schematically illustrates in more detail an exemplary arrangement of parts of the reservoir (101) and aerosol generator (102) of FIG. 2, in particular schematically illustrating an arrangement in which a retaining element (124) is provided to hold the aerosol generator (102) and / or electrical contacts (123) in a suitable position.

[0200] In this example, the aerosol generator support (129) is shown having recesses (128). A seal (125) is shown between the aerosol generator (102) and the aerosol generator support (129). The seal (125) similarly has recess / channel portions that extend through the seal (125) (not labeled in FIG. 5). A pair of electrical contacts (123) are shown on both sides of the carbon allotrope (103) (which also includes an electrical insulating substrate (108)). In particular, each electrical contact (123) is positioned on either the side or the end of the carbon allotrope (103). Each of the electrical contacts (123) has a through hole (not labeled in FIG. 5). As can be seen in FIG. 5, when the article (100) is assembled with the seal (125) positioned on the base of the reservoir (101) and the carbon allotrope (103) positioned between the seal (125) and the electrical contacts (123), in this embodiment, a retaining element (124), which is a screw or pin, is positioned in the individual through holes of the electrical contacts (123) and the seal (125) and is secured within the recesses (128). In this way, the retaining element (124) holds the electrical contacts (123) in a position relative to the reservoir (101) and additionally helps to keep the electrical contacts (123) in contact with the carbon allotrope (103). Thus, by the screw / pin as the retaining element (124), the carbon allotrope (103) and the electrical contacts (123) can be held in a position.

[0201] FIG. 5 depicts an exemplary arrangement of the retaining element (124), and it should be recognized that in other embodiments, the retaining element (124) may take different forms. For example, in some embodiments, the retaining element (124) may be an adhesive (e.g., provided between the electrical contact (123) and the seal (125) / aerosol generator support (129)). In other embodiments, the retaining element (124) may be a deflection element, such as an elastic deflection element, such as a clamp or a clip.

[0202] It will be understood that in some embodiments, the retaining element(s) (124) may be separate from or integrally formed with the electrical contact(s) (123). For example, in some embodiments, the or each electrical contact (123) may include a retaining element (124) integrally formed therewith.

[0203] As described above, the aerosol delivery system (10) defines an air flow path through the system (10) from an air inlet to an air outlet (located in the mouthpiece (35) of the aerosol delivery system (10). The article (100) is coupled to the device (20) upon use, and thus the article (100) comprises a housing (134) including an air inlet (135), an air outlet (136), and an air passage (137) extending between the air inlet (135) and the air outlet (136). An aerosol generator (102) / carbon allotrope (103) is arranged to be in fluid communication with the air passage (137) so that when a user inhales the aerosol delivery system (10), the aerosol can be delivered into the air passage (137).

[0204] FIG. 6 schematically illustrates an article (100) comprising a housing (134) and an air passage (137). The housing (134) includes an air inlet (135) and an air outlet (136) provided on the outer surfaces of the housing (134). The air inlet (135) may be provided at various positions, such as at the base of the housing (134). The air outlet (136) may be provided at various positions, such as at the top of the housing (134). Generally, the air inlet (134) and the air outlet (136) are provided at different positions relative to the housing (134) and at positions that define or facilitate air flow around the aerosol generator (102). For example, the article (100) may include a mouthpiece (not shown in the drawings), and an air outlet (136) may be formed in or by the mouthpiece, while an air inlet (135) is provided at the opposite end of the article (100).

[0205] In the example of FIG. 6, the air passage (137) is provided to surround the outer wall (109) (or at least part thereof) of the storage (101). That is, the air passage (137) includes an upstream portion (upstream from the aerosol generator (102)), the upstream portion is divided into a plurality of midstream portions passing through both sides of the storage (101) before being combined into a downstream portion, and the downstream portion extends to an air outlet (136). However, the principles of the present disclosure are not limited to this specific configuration of the air passage (137), and different designs of the article (100) and the storage (101) may result in other configurations of the air passage (137) as needed. For example, in some embodiments, the air passage (137) may be provided in the center of the housing (134) with the reservoir (101) positioned around the air passage (137) (e.g., as an annular cylinder having inner and outer walls defining the volume (104), while the air passage (137) continues through a tubular portion defined by an inner wall). Various forms of the air passage (137) are anticipated.

[0206] When in use, air flow through the air passage (137) enters the housing (134) at the air inlet (135) and can flow toward the aerosol generator (102) / carbon allotrope (103). The air flowing through the aerosol generator (102) carries aerosols generated by the aerosol generator (102) as droplets, and the resulting air-aerosol mixture flows through the remainder of the air passage (137), exits the housing (134) at the air outlet (136), and enters the user's mouth.

[0207] FIG. 6 does not illustrate the electric contacts (123) and the corresponding electric contacts of the control portion (20) that are coupled to the article (100) when used to form the aerosol supply system (10). Depending on the embodiment at hand, the electric contacts of the control portion (20) may protrude through the housing (134), for example, through openings within the housing (134), to make electrical contact with the electric contacts (123).

[0208] According to the present disclosure, an aerosol supply system (10) is provided with a circuit section (300) including a monitoring circuit section (310) and a defect detection circuit section (320).

[0209] FIG. 7 illustrates an example of such a circuit section (300) according to the principles of the present disclosure. The circuit section (300) is schematically depicted and illustrates the main components involved in explaining the principles of fault detection according to the present disclosure. However, it will be recognized that in actual implementations certain components may be omitted and / or certain other components may be added to the circuit section (300).

[0210] The circuit section (300) includes a power source (5) (e.g., battery (5)) electrically connected to a carbon allotrope (103) (acting as an aerosol generator (102)). Electrical power can be supplied from the power source to the carbon allotrope (103) by means of electrical connections. FIG. 7 does not show any control circuit section, such as a PCB (26), capable of controlling the power supply to the carbon allotrope (103) through, for example, a switch or similar component.

[0211] The circuit section (300) also includes a monitoring circuit section (310). The monitoring circuit section (310) is connected to the power source (5) in parallel with the carbon allotrope (103). In particular, FIG. 7 illustrates two wires extending from the power source (5) to the carbon allotrope (103) and two branched wires connected to the monitoring circuit section (310). In FIG. 7, the branches are represented by black circles on each of the wires.

[0212] The monitoring circuit (310) is configured to monitor the electrical parameters of the carbon allotrope (103) during the activation of the carbon allotrope (103). In this case, the activation of the carbon allotrope (103) means the activation of the carbon allotrope (103) to generate an aerosol from the aerosol generating material (200). In other words, the activation of the carbon allotrope (103) involves supplying power from the power source (5) sufficient to cause the carbon allotrope (103) to heat the aerosol generating material (200) to a temperature at which it can aerosolize.

[0213] In the use of the aerosol delivery system (10), power is supplied to the carbon allotrope (103) upon detection of the user's intention to generate aerosol. For example, in some implementations, the aerosol delivery system (10) includes a pressure or air flow sensor capable of determining a change in air pressure or flow when the user inhales from the mouthpiece of the aerosol delivery system (10). A change in pressure or air flow indicates that the user is inhaling the aerosol delivery system (10) and thus indicates the user's intention to generate aerosol. Alternatively or additionally, the aerosol delivery system (10) may include a user input mechanism, such as a button, that indicates the user's intention to generate aerosol when operated by the user. In any scenario, in response to determining the user's intention to generate aerosol, a control circuit, such as a PCB (26), controls the power supply from the power source (5) to the carbon allotrope (103) to activate the carbon allotrope (103). During such activation, the monitoring circuit (310) monitors the electrical parameters of the carbon allotrope (103).

[0214] The monitored electrical parameter may be any suitable electrical parameter that can be monitored, and the specific parameter selected may depend on the type of aerosol generator (102) used and / or the configuration of the circuit (300). In the described example, the monitored electrical parameter of the carbon allotrope (103) is the electrical resistance of the carbon allotrope (103). The electrical resistance of the carbon allotrope (103) may be measured directly, for example, through a resistance meter or a similar circuit, or the electrical resistance may be derived from one or more other measurements (e.g., voltage and / or current measurements). In some implementations, the power source (5) may be controlled to output power at a constant voltage or current, and thus, the monitoring circuit (310) may be configured to monitor the other of the voltage or current and determine the resistance based on a constant voltage or current value that can be communicated to the monitoring circuit (310). In other implementations, the monitored electrical parameter may be an inductance.

[0215] The monitoring circuit (310) is configured to monitor electrical parameters over time. For example, the monitoring circuit (310) may be configured to periodically acquire measurements of electrical parameters (e.g., every 1 millisecond, every 10 milliseconds, etc.) during the activation of the carbon allotrope (103). The rate at which the monitoring circuit (310) acquires measurements of electrical parameters will be shorter than the expected duration for a given activation of the carbon allotrope (103) (which may be approximately 2 seconds if the carbon allotrope (103) is activated during a normal inhalation duration). In this way, the monitoring circuit (310) can monitor the electrical parameters of the carbon allotrope (103) during a given activation of the carbon allotrope (103), or even during part of the activation of the carbon allotrope (103).

[0216] Although FIG. 7 illustrates a monitoring circuit section (310) coupled in parallel with a carbon allotrope (103), it should be recognized that the monitoring circuit section (310) may instead be coupled in series, for example, depending on the electrical parameters to be monitored. Additionally, it should be recognized that any other electronic components may also be provided to the circuit section (300), for example, between the branching points and the monitoring circuit section (310).

[0217] FIG. 7 also illustrates a defect detection circuit (320) coupled to a monitoring circuit (310). The defect detection circuit (320) receives the output of monitored electrical parameters from the monitoring circuit (310) and can perform a defect detection process to detect defect conditions of the aerosol generator (102) / carbon allotrope (103) based on the monitored electrical parameters of the heater element.

[0218] FIG. 8 is a graph depicting two traces of electrical parameters (resistance) over time for two different carbon allotropes (103). The graph depicts time (t) in any unit on the x-axis and resistance (R) in any unit on the y-axis. The first trace, shown by a dashed line in FIG. 8 and labeled N, represents the monitored resistance of the non-defective carbon allotrop (103) over the activation of the carbon allotrop (103). The second trace, shown by a solid line in FIG. 8 and labeled D, represents the monitored resistance of the defective carbon allotrop (103) over the activation of the carbon allotrop (103). It should be recognized that the two traces shown in FIG. 8 are merely examples and do not necessarily represent actual values ​​obtained during actual experiments; rather, these traces serve to highlight the principles of defect detection according to the present disclosure.

[0219] Before describing the first and second traces N and D in more detail, the following conditions are assumed. Carbon allotropes (103) generally have a zero or negative temperature coefficient of (electrical) resistance. A material having a zero temperature coefficient of resistance does not experience a change in electrical resistance with a change in temperature. That is, the electrical resistance is approximately constant with temperature. A material having a negative temperature coefficient of resistance experiences a decrease in electrical resistance with an increase in temperature. That is, the electrical resistance decreases as the temperature of the material increases. Carbon allotropes (103) may generally exhibit any one of these characteristics depending on the formation / structure of the carbon allotropes (103) used. Additionally, it should be recognized that carbon allotropes (103) may exhibit any one of these characteristics over a given temperature range. That is, just as an example, at temperatures below 150°C, the carbon allotrope (103) may have a negative temperature coefficient of resistance, and at temperatures above 150°C, the carbon allotrope (103) may have a zero temperature coefficient of resistance.

[0220] A first trace N corresponding to monitored electrical parameters for the activation of a normal or non-defective carbon allotrope (103) is now considered. In FIG. 8, at time t0, the activation of the normal or non-defective carbon allotrope (103) begins. As mentioned above, this corresponds to the application of electric power to the carbon allotrope (103) following the detection of the user's intention to generate an aerosol. At time t0, the temperature of the carbon allotrope (103) is at ambient temperature, which corresponds to an initial resistance value. As time progresses, the application of electric power causes the temperature of the carbon allotrope (103) to increase. FIG. 8 illustrates the initial period between t0 and t1 of the negative coefficient of resistance (thereby, as the temperature increases through the application of electric power, the resistance of the carbon allotrope (103) decreases slightly). FIG. 8 illustrates this initial decrease as a linear decrease, for example, up to time t1, before it flattens out and becomes a constant (or approximately constant) value during the activation duration, for example, the period during which the carbon allotrope (103) has a zero temperature coefficient. At time t2, activation is stopped (e.g., because a predetermined time period from time t0 has elapsed as described above, or because the user has stopped inhaling). The first trace N is stopped at time t2 because the monitored electrical parameters are no longer being monitored in this implementation; however, the resistance (and consequently the temperature) can be expected to return to a resistance value corresponding to the resistance value observed at time t0 at ambient temperature.

[0221] The first trace N can generally be thought of as comprising two zones. The first zone corresponds to the initial heating of the carbon allotrope (103) as electric power is supplied to the carbon allotrope (103) (e.g., corresponding to time periods t0 to t1). The temperature reached at the end of the first zone may be referred to as the operating temperature, which is a temperature sufficient to generate an aerosol from the aerosol generating material (200). The second zone corresponds to the maintenance of the temperature of the carbon allotrope (103) at the operating temperature (e.g., corresponding to time periods t1 to t2). During this zone, the temperature of the carbon allotrope (103) is maintained at the operating temperature, and thus, it should be recognized that the second zone is the zone that contributes most to the generation of the aerosol.

[0222] Specific time periods for the first and second zones may depend on the power supplied to the carbon allotrope (103). For example, if the magnitude of the power supplied to the carbon allotrope (103) is relatively larger, it is possible to bring the temperature of the carbon allotrope (103) to the operating temperature more quickly, so the duration of the first zone (time between t0 and t1) may be reduced. Consequently, for a given length of activation, the duration of the second zone (time between t1 and t2) may be relatively longer.

[0223] The first trace N represents the expected change in monitored electrical parameters over time for a normal or defect-free carbon allotrope (103). That is, when a given carbon allotrope (103) is activated, this is the expected shape / form of the trace expected to be observed when the carbon allotrope (103) is properly formed / manufactured.

[0224] However, the inventors recognized that defective carbon allotropes (103) exhibit characteristics different from the expected electrical parameters monitored over time (i.e., represented by the first trace N) in the electrical parameters monitored over time. By identifying such differences in the electrical parameters monitored over time for the activation of the carbon allotrop (103), it is possible to determine whether the carbon allotrop (103) is defective. It is thought that variations or errors in the manufacturing process of the carbon allotrop (103) may result in defective carbon allotropes (103). For example, the carbon allotrop (103) may be formed as a foam comprising a foam structure and a plurality of cells, as described above. During the formation of the foam structure, the extent to which cells are formed and / or their shape and interconnectivity may be affected by manufacturing variables. For example, in defective foam carbon allotropes (103), some regions of the foam carbon allotrop (103) may have a non-uniform cell density compared to other regions (e.g., having relatively more or fewer open cells), which may affect the overall electrical resistance of the carbon allotrop (103).

[0225] A second trace D corresponding to the monitored electrical parameters for the activation of the defective carbon allotrope (103) is now considered. As with the first trace N, in FIG. 8, at time t0, the activation of the defective carbon allotrope (103) begins (through the application of electric power). The temperature of the carbon allotrope (103) at t0 is similarly around in this example and is depicted as having the same starting resistance value as the non-defective carbon allotrope (103) (however, this may not necessarily be the case, and the initial resistance value may vary depending on, for example, the influence of the local zones discussed above).

[0226] As described above, electric power is applied to the defective carbon allotrope (103) at time t0. The defective zones were initially observed to contribute to an increase in the total resistance of the defective carbon allotrope (103). As shown in FIG. 8, the second trace D rises from an initial resistance value to a higher resistance value from time t0 to t3.

[0227] As the defective zones are subsequently heated (i.e., their temperature increases) due to the continued application of electric power, the total resistance of the carbon allotrope (103) is observed to decrease over time. In FIG. 8, between t3 and t4, it can be seen that the total resistance value of the carbon allotrope (103) decreases linearly over time. It should be recognized that the total resistance of the carbon allotrope (103) may decrease in a different way (e.g., non-linearly, such as quadratically). At time t4, it can be seen that the total resistance value for the defective carbon allotrope (103) is the same (or approximately the same) as the resistance value observed at the first trace N (however, it should be recognized that in other examples, this may not necessarily be the case). In the example of FIG. 8, during the period t4 to t2, the electrical resistance of the defective carbon allotrope (103) is constant.

[0228] Accordingly, from FIG. 8, it can be seen that the two traces, namely the first trace N and the second trace D, are different from each other in at least one aspect. In this regard, the defect or failure of the carbon allotrope (103) can be determined by identifying specific characteristics indicating the defect or failure of the carbon allotrope (103) in the electrical parameters monitored during the activation of the carbon allotrope (103).

[0229] FIG. 9 is another graph depicting two traces of electrical parameters (resistance) over time for two different carbon allotropes (103). As with FIG. 8, the graph in FIG. 9 depicts time (t) in arbitrary units on the x-axis and resistance (R) in arbitrary units on the y-axis. The first trace, shown by a dashed line and labeled N in FIG. 9, represents the monitored resistance of the non-defective carbon allotrop (103) over the activation of the carbon allotrop (103). The first trace N is identical to the trace described in FIG. 8, and a description thereof will not be repeated. The third trace, shown by a solid line and labeled D1 in FIG. 9, represents the monitored resistance of the second example of the defective carbon allotrop (103) over the activation of the carbon allotrop (103). The two traces shown in FIG. 9 are merely examples and do not necessarily represent actual values ​​obtained during actual experiments; rather, it should be recognized that these traces serve to highlight the principles of defect detection according to the present disclosure.

[0230] A third trace D1 corresponding to the monitored electrical parameters for the activation of the second example of the defective carbon allotrope (103) is now considered. As with the first trace N, in FIG. 8 or FIG. 9, the activation of the second example of the defective carbon allotrope (103) is initiated at time t0 (through the application of electric power). The temperature of the carbon allotrope (103) at t0 is similarly around in this example and is depicted as having the same starting resistance value as the non-defective carbon allotrope (103) (however, this may not necessarily be the case, and the initial resistance value may vary depending on, for example, the influence of the local zones discussed above).

[0231] As described above, electric power is applied to the defective carbon allotrope (103) at time t0. In this example, the defective carbon allotrope (103) responds in a manner similar to that of the non-defective carbon allotrope (103). That is, after the application of power at time t0, as the temperature of the carbon allotrope (103) increases (due to the negative coefficient of resistance), the resistance of the defective carbon allotrope (103) decreases slightly. The resistance decreases linearly until time t1, and then begins to follow the profile / trace of the normal carbon allotrope (103), where the resistance flattens out and begins to reach a constant (or approximately constant) value (corresponding to the period when the carbon allotrope (103) has a zero temperature coefficient). However, in this example, at time t5, the resistance of the defective carbon allotrope (103) begins to decrease abruptly from the expected values ​​of the normal or non-defective carbon allotrope (103). As shown in the third trace D1, the resistance of the defective carbon allotrope (103) continues to decrease from the (expected) resistance value at the equivalent point in time for the first trace N until time t6, where in this example, the resistance flattens out and begins to become a constant (or approximately constant) value until time t2, when the activation of the carbon allotrope (103) is stopped and the monitored electrical parameter is no longer being monitored.

[0232] Accordingly, in this example and as illustrated by the third trace D1, the defective carbon allotrope (103) experiences a sudden and potentially significant drop in resistance compared to the non-defective carbon allotrope (103). For example, as merely an example, the resistance value at time t6 for the third trace D1 may be found to be approximately 5Ω to 10Ω or higher, or alternatively, approximately 10% to 50% of the resistance value at the equivalent time for the non-defective carbon allotrope (103) illustrated by the first trace N in FIG. 9. Without being bound by theory, this sudden change in resistance is thought to be caused as a result of defects within the carbon allotrope (103) that cause a sudden change in the physical structure of the carbon allotrope (103) affecting the resistance of the carbon allotrope (103) when exposed to electric power or temperature, such as graphitization. Although the resistance of the defective carbon allotrope is shown in FIG. 9 as starting to decrease at time t5, it should be recognized that the decrease in resistance may occur at any time during the activation of the carbon allotrope (103), that is, at any time between t0 and t2.

[0233] Accordingly, from FIG. 9, it can be seen that the two traces, namely the first trace N and the third trace D1, are different from each other in at least one aspect. In this regard, the defect or failure of the carbon allotrope (103) can be determined by identifying specific characteristics indicating the defect or failure of the carbon allotrope (103) in the electrical parameters monitored during the activation of the carbon allotrope (103).

[0234] Referring to FIGS. 8 and 9, the characteristic indicating a defect or disorder of the carbon allotrope (103) in the electrical parameters monitored during the activation of the carbon allotrope (103) is at least one of an increase in electrical resistance from an initial value during the activation of the carbon allotrope (103) (e.g., an increase in the second trace D of FIG. 8 observed during periods t0 to t3) and a significant decrease in electrical resistance of the carbon allotrope (103) during continued activation of the carbon allotrope (103) (e.g., a decrease in the second trace D of FIG. 8 observed during periods t3 to t4 or a decrease in the third trace D1 of FIG. 9 observed during periods t5 to t6).

[0235] The defect detection circuit (320) is configured to identify one or more of these characteristics indicating a defect or failure of the carbon allotrope (103) in electrical parameters monitored during the activation of the carbon allotrope (103), and to determine that the carbon allotrope (103) is defective / failure when one of these characteristics is identified.

[0236] In some embodiments, the characteristic indicating a fault condition includes a non-zero rate of change of a monitored electrical parameter that is greater than a predetermined threshold during a predetermined time period. For example, referring to FIG. 8, the rate of change of electrical resistance (as a monitored electrical parameter) for the second trace D during the time period t0 to t3 is positive, whereas the rate of change of electrical resistance for the first trace N during the time period t0 to t3 is negative. Thus, in this example, the predetermined threshold may be set to a zero or positive value to distinguish between a positive rate of change and a negative rate of change of the electrical parameter. Thus, when it is determined that the rate of change of the monitored electrical parameter exceeds the threshold, the fault detection circuit (320) may determine that the carbon allotrope is defective / faulty. However, in other embodiments, for example, for different carbon allotropes (103) and / or different heating elements, the rates of change for a non-defective heating element and a defective heating element may both be positive. In such implementations, the threshold can be set to a positive value capable of distinguishing between a non-defective heating element and a defective heating element. The exact value can be determined empirically or through computer modeling. In other implementations, the predetermined threshold can be set to the magnitude or absolute value of the rate of change. For example, referring to FIG. 9, the rate of change of electrical resistance (as a monitored electrical parameter) for the third trace D1 during the time period t5 to t6 is negative, and is negative by an amount greater than any rate of change of electrical resistance during the time period t0 to t1.In such examples, a predetermined threshold can be set to an absolute value of a size that allows for a distinction between any small reductions in electrical resistance that may manifest during the initial warming of the carbon allotrope (103) (e.g., during the period t0 to t1 in the first and third traces N, D1 of FIG. 9) and more significant reductions in resistance caused by a defective zone that causes structural or physical changes in the carbon allotrope (103) (e.g., during the period t5 to t6 in the third trace D1 of FIG. 9). Additionally, by requiring the rate of change to exist over a predetermined time period, this can help distinguish minor fluctuations in the measured resistance caused, for example, by environmental influences or measurement errors. Thus, when the absolute value of the rate of change of the monitored electrical parameter (e.g., resistance) exceeds the threshold, the carbon allotrope (103) may be determined to be defective.

[0237] The predetermined time period used above is any predetermined time period sufficient to minimize errors and provide a reliable measurement of the rate of change of electrical parameters. The exact length of this time period will depend on details of the circuit (300), such as the measurement resolution of the monitoring circuit (310). For example, this may be approximately tens of ms to hundreds of ms.

[0238] In some embodiments, the characteristic indicating a fault condition includes a non-zero rate of change of a monitored electrical parameter that is less than a predetermined threshold during a predetermined time period. For example, referring to FIG. 8, the rate of change of electrical resistance (as a monitored electrical parameter) for the second trace D during the time period t3 to t4 is negative, whereas the rate of change of electrical resistance for the first trace N during the time period t3 to t4 is zero or slightly positive. Thus, in this example, the predetermined threshold may be set to a zero or positive value to distinguish between a negative rate of change and a positive / zero rate of change of the monitored electrical parameter. Thus, when it is determined that the rate of change of the monitored electrical parameter is less than the threshold, the fault detection circuit (320) may determine that the carbon allotrope is defective / faulty. However, in other embodiments, for example, for different carbon allotropes (103) and / or different heating elements, the rates of change for both the non-defective heating element and the defective heating element may be negative. In such implementations, the threshold can be set to a negative value capable of distinguishing between a non-defective heating element and a defective heating element. The exact value can be determined empirically or through computer modeling. Correspondingly, referring to FIG. 9, the rate of change of electrical resistance (as a monitored electrical parameter) for the third trace D1 during the time period t5 to t6 is negative, and is negative by an amount greater than any rate of change of electrical resistance during the time period t0 to t1.In such examples, a predetermined threshold may be set to a negative value and is set to a size that allows for a distinction between any small reductions in electrical resistance that may manifest themselves during the initial heating of the carbon allotrope (103) (e.g., during the period t0 to t1 in the first and third traces N, D1 of FIG. 9) compared to more significant reductions in resistance caused by a defective zone that causes structural or physical changes in the carbon allotrope (103) (e.g., during the period t5 to t6 in the third trace D1 of FIG. 9). By setting the predetermined threshold of the rate of change of the electrical parameter to a negative value, the carbon allotrope (103) may be determined to be defective when the monitored electrical parameter drops below that negative value.

[0239] Similarly, the predetermined time period used above is any predetermined time period sufficient to minimize errors and provide a reliable measurement of the rate of change of electrical parameters. The exact length of this time period will depend on details of the circuit (300), such as the measurement resolution of the monitoring circuit (310). For example, this may be approximately tens of ms to hundreds of ms.

[0240] In some implementations, a characteristic indicating a defect condition is based on a comparison of the rates of change of monitored electrical parameters in different parts of the activation of the carbon allotrope (103). For example, in FIG. 8, the characteristic may be considered to include a first part (e.g., the initial activation of the carbon allotrope, e.g., corresponding to time periods t0 to t3) and a second part (e.g., a subsequent period of the activation of the carbon allotrope, e.g., corresponding to time periods t3 to t4). In this example, the rate of change of the monitored electrical parameter in the first part (t0 to t3) is greater than the rate of change of the monitored electrical parameter in the second part (t3 to t4). Thus, when it is determined that the rate of change of the monitored electrical parameter in the first period is greater than the rate of change of the monitored electrical parameter in the second period, the defect detection circuit (320) may determine that the carbon allotrope is defective / failure. Similarly, in FIG. 9, the characteristics may be considered to include a first part (e.g., initial activation of the carbon allotrope, e.g., corresponding to time periods t0 to t1) and a second part (e.g., subsequent period of activation of the carbon allotrope, e.g., corresponding to time periods t1 or t5 to t6). In this example, the rate of change of the monitored electrical parameter in the first part (t0 to t1) is smaller (in magnitude or as an absolute value) than the rate of change of the monitored electrical parameter in the second part (t1 or t5 to t6). Thus, when it is determined that the rate of change of the monitored electrical parameter in the first period is smaller (in terms of magnitude or absolute value) than the rate of change of the monitored electrical parameter in the second period, the defect detection circuit (320) may determine that the carbon allotrope is defective / faulty.

[0241] In other implementations, rather than simply comparing the monitored electrical parameters with different thresholds, the fault detection circuit (320) may be pre-programmed with expected values ​​or values ​​for the monitored electrical parameters. For example, referring to FIG. 8, the fault detection circuit (320) may be programmed with values ​​corresponding to a first trace N, where the first trace N is a trace representing the monitored electrical parameters for a normal or non-defective carbon allotrope during the activation of the normal or non-defective carbon allotrope as described above. Alternatively, an average resistance value may be calculated for the first trace N and stored in advance. The fault detection circuit (320) is configured to identify characteristics indicating a fault condition by comparing the monitored electrical parameters during the activation of the carbon allotrope with expected values ​​or values ​​of the pre-set electrical parameters. Expected values ​​or expected values ​​can be programmed in the defect detection circuit (320) from computer modeling or through empirical testing, for example, through a calibration or test procedure in which one or more activations of a normal or defect-free carbon allotrope (103) are activated and monitored electrical parameters are recorded.

[0242] In some implementations, the defect detection circuit (320) is configured to identify a characteristic when a monitored electrical parameter deviates from an expected value or a predetermined amount from the values. For example, in FIG. 8, at time t3 (used purely as an exemplary reference point), we can consider the difference between the expected value (i.e., the resistance value at the first trace N) and the monitored electrical parameter (i.e., the resistance value at the second trace D). Setting the predetermined amount to be smaller than the difference between the expected value and the monitored electrical parameter at time t3 means that the defect detection circuit (320) will determine that the second trace D corresponds to a defective or faulty carbon allotrope (103). The predetermined amount may take any suitable value that allows the non-defective and faulty carbon allotropes (103) to be distinguished from each other. This may be determined empirically or through computer modeling. Correspondingly, in FIG. 9, at time t6, we can consider the difference between the expected value (i.e., the resistance value at the first trace N) and the monitored electrical parameter (i.e., the resistance value at the third trace D1 at time t6). Setting a predetermined amount to a value smaller than the difference between the expected value and the monitored electrical parameter at time t6 means that the defect detection circuit (320) will determine that the third trace D1 corresponds to a defective or defective carbon allotrope (103) (by the fact that the difference between the value at time t6, i.e., the monitored resistance and the expected resistance, will be greater than the predetermined amount). The predetermined amount may take any suitable value that allows the non-defective and defective carbon allotropes (103) to be distinguished from each other.For example, a predetermined amount may be set between 5Ω and 10Ω (or greater than that), or alternatively, to 10% to 50% of the resistance value during a second period, i.e., t1 to t2, for the non-defective carbon allotrope (103) (or, more generally, 10% to 50% of the resistance value of the non-defective carbon allotrope (103) when the resistance value is approximately constant). Thus, when the monitored resistance value deviates from the expected resistance value by 5Ω to 10Ω (or greater than that), or by 10% to 50%, or by a value equal to, for example, 20%, the defect detection circuit (320) may determine that the carbon allotrope (103) is defective. These expected values ​​may be determined empirically or through computer modeling.

[0243] Accordingly, it should be recognized that the circuit unit (300) can determine whether the carbon allotrope (103) (or more generally the aerosol generator (102)) is defective or defective. In particular, by monitoring the electrical parameters of the carbon allotrope (103) during the activation of the carbon allotrope (103), characteristics indicating a defective or defective carbon allotrope (103) can be identified based on characteristics identifiable in the monitored electrical parameters themselves or by comparison with expected values ​​or values. The defect detection circuit unit (320) can determine whether the carbon allotrope (103) is defective or defective based on identifying any one or more of the characteristics.

[0244] In some embodiments, the defective carbon allotrope (103) may be identified at or during the first activation of the carbon allotrope (103). That is, as soon as power is applied to the carbon allotrope (103), the monitored electrical parameters exhibit characteristics indicating the defective carbon allotrope (103). However, in some cases, the defective carbon allotrope (103) may only begin to exhibit characteristics indicating the defect after some time has elapsed since the application of power to the defective carbon allotrope (103). For example, in FIG. 9, the characteristics indicating the defective or impaired carbon allotrope (103) begin to exhibit only after some time has elapsed since the initial application of power to the carbon allotrope (103), for example, at time t5. The point at which the defective carbon allotrope (103) begins to exhibit defect-indicating characteristics may vary depending on the nature of the defect region of the carbon allotrope (103) and / or the operating conditions to which the carbon allotrope (103) is exposed. In some cases, defect-indicating characteristics may be identifiable only after a number of distinct activations of the carbon allotrope (103). That is, the carbon allotrope (103) containing the defect region may have the electrical characteristics of a normal or non-defective carbon allotrope (103) for, for example, a number of distinct activations, i.e., 10 or 100 distinct activations, and upon subsequent activation, the defect region affects the electrical properties of the carbon allotrope (103) thereby exhibiting defect-indicating characteristics.

[0245] In some implementations, the expected value or values ​​may be determined from one or more previous activation(s) of the carbon allotrope (103). For example, if the immediate previous activation of the carbon allotrope (103) is as illustrated, for example, by the first trace N of FIG. 9, the fault detection circuit (320) may be configured to set the expected value(s) according to the monitored electrical parameters of that activation of the carbon allotrope (103). To be simpler, the fault detection circuit (320) may compare the values ​​of the previous activation (or the average of the values ​​of the previous activations) with the monitored electrical parameters for the current activation and determine whether the difference between the expected value(s) and the current values ​​exceeds or is greater than a predetermined amount. In this way, by using the previous activation(s) to calculate or determine the expected values, minor changes—such as environmental or ambient temperature—can be taken into account when determining whether the currently monitored parameters deviate from the expected value by a predetermined amount. Alternatively or additionally, one or more expected values ​​may be determined based on initial values ​​of the activation of the carbon allotrope (103). For example, referring to FIG. 9, the expected values ​​may be set based on the average of resistance values ​​measured, for example, during a time period t0 to t1, and thus, when the measured resistance value deviates by more than a predetermined amount from the expected values ​​determined in an earlier part of the activation, the defect detection circuit (320) may determine that the carbon allotrope (103) is defective.

[0246] It should be recognized that the characteristics described above do not limit the possible characteristics that can be identified for any given aerosol delivery system (10). In other words, the carbon allotrope (103) may have an electrical parameter (e.g., resistance) profile different from that shown in FIG. 8 or FIG. 9 in relation to either a normal or non-defective carbon allotrope and / or a defective carbon allotrope (103). The above description is presented only to highlight the principles of how defect detection can be achieved in an aerosol delivery system (10), particularly in a system where a carbon allotrope (103) (e.g., carbon foam) is used as an aerosol generator (102). For a given system, it may be possible to determine the defective carbon allotrope (103) by testing a large number of carbon allotropes (103) to potentially identify the characteristics of electrical parameter profiles indicating the defective or defective carbon allotrope (103).

[0247] FIG. 10a is a graph of experimental data showing the measured resistance (in ohms) for an exemplary carbon allotrope (103) activated over a time period (t). The experimental data is for a carbon allotrope (103) used, for example, as a heating element in an aerosol delivery system (10). The graph in FIG. 10a shows multiple distinct activations of the carbon allotrope (103). Resistance was sampled every 0.1 ms.

[0248] FIG. 10a shows the resistance of an exemplary carbon allotrope (103) of approximately 80 Ohms at 330 seconds. FIG. 10b shows the portion labeled B of the graph in FIG. 10a in more detail (i.e., with finer resolution on both the resistance axis and the time axis). FIG. 10b shows data corresponding to two distinct individual activations labeled A1 and A2 in the graph, mostly indicated by vertical dashed lines. The duration of the activations is approximately 2 to 3 seconds, which was chosen because this corresponds to the typical duration of user inhalation for aerosol delivery systems.

[0249] In the first activation of Fig. 10b, i.e., activation A1, it can be seen that the resistance remains approximately constant over the duration of the activation. Specifically, the resistance is approximately 86Ω ± 5Ω. However, any changes in resistance are quite gradual; that is, the rate of change of resistance is relatively low. An exception to this can be seen in the change in resistance at times 331.2 to 331.3, where the resistance is between 83Ω and 86Ω, i.e., 30Ωs -1 It increases at a rate of . However, such more significant changes are limited to one or two consecutive samples, i.e., 0.1 to 0.2 ms. By imposing conditions that the rate of change is consistent over a predetermined time period, for example, 0.5 m, or exceeds / falls below a threshold, such changes, which may be due to measurement errors or ambient influences, can be ignored by the defect detection circuit (320) as indicating a defect condition of the carbon allotrope (103). Thus, in the case of activation A1, a threshold for the rate of change of resistance (based on absolute value), for example, 10 Ωs -1 By setting it larger and requiring it to be observed over a predetermined time period, or by setting the rate of change of resistance, e.g. -6Ωs -1By setting it to this, the defect detection circuit (320) can determine that the carbon allotrope (103) is a normal or non-defective carbon allotrope (103) (at least at this point in time).

[0250] In the second activation of Fig. 10b, namely activation A2, it can be seen that the resistance changes over the duration of the activation, and more specifically, that the resistance decreases at certain points during the activation. In this example, the change in resistance, indicated by the quantity ΔR1 and the horizontal dashed lines in Fig. 10b, changes by approximately 14Ω. It should be noted that the manner in which the resistance drops is similar to the third trace D1 shown in Fig. 9. Additionally, it can be seen that the rate of change of resistance is approximately constant across multiple samples. For example, it can be seen that over a period of approximately 333.3 to 334.4 seconds, the resistance decreases from approximately 91Ω to 77Ω, which is approximately -12.7Ω over a time period of 1.1 seconds. -1 It corresponds to the rate of change. Therefore, in the case of activation A2, as above, the threshold for the rate of change of resistance (based on absolute value) is, for example, 10Ωs -1 By setting it larger and requiring it to be observed over a predetermined time period, or by setting the rate of change of resistance, e.g. -6Ωs -1 By setting it as such, the defect detection circuit (320) can determine that the carbon allotrope (103) is a defective carbon allotrope (103) as a result of the reduction in resistance.

[0251] As mentioned above, the defect detection circuit (320) may instead determine whether the carbon allotrope (103) is defective by determining the deviation of the measured resistance from one or more expected values. For example, by overlapping the trace corresponding to the first activation A1, or by setting the expected value to the average resistance of the trace corresponding to the first activation, which is 86Ω, it can be seen that at time 334.4 seconds of the second activation A2, the measured resistance deviates by approximately 10Ω from the expected value. Thus, by setting a predetermined amount, i.e., 8Ω, the defect detection circuit (320) can determine that the difference between the measured value and the expected value of the resistance of the second activation A2 at time 334.4 seconds exceeds the predetermined amount, and thus the defect detection circuit (320) can determine that the carbon allotrope (103) is (now) a defective or faulty carbon allotrope (103).

[0252] Returning to FIG. 10a, it can be seen that distinct activations of the carbon allotrope (103) may exhibit some variation with each activation, while having a measured resistance that is approximately constant during activation. For example, during a time period of 330 to 356 seconds, the measured resistance for each activation of the carbon allotrope (103) decreases by a small amount. However, as shown in the graph portion labeled C in FIG. 10a, between two specific activations, the resistance decreases by a significant amount.

[0253] Figure 10c shows the portion labeled C of the graph in Figure 10a in more detail (i.e., with finer resolution on both the resistance axis and the time axis). Figure 10c shows data corresponding to three distinct individual activations labeled A3, A4, and A5 in the graph, generally depicted by vertical dashed lines. Similarly, the duration of the activations is approximately 2 to 3 seconds.

[0254] As can be seen in FIG. 10c, there is a small decrease in the average resistance values ​​of the third activation A3 compared to the fourth activation A4; for example, this is approximately 3Ω to 4Ω. This corresponds to a percentage decrease of approximately 7% to 8% of the measured resistance. Such a decrease between activations can be considered normal, and thus the fault detection circuit (320) can determine that, at the beginning of the fourth activation A4, such a decrease is within the normal operating tolerance, despite the drop in resistance compared to the third activation A3.

[0255] However, there is a more significant decrease in the measured resistance values ​​between the fourth activation A4 and the fifth activation A5. This decrease is illustrated in FIG. 10c by the quantity △R2 and horizontal dashed lines. In this example, the decrease is approximately 20Ω, which represents a percentage decrease of approximately 40%. Such a significant decrease between activations was found to indicate a defect condition, namely a defective carbon allotrope (103). Thus, by setting the defect detection circuit (320) to identify the characteristics of the monitored electrical parameter that deviate from the measured resistance by a percentage exceeding 25% of the expected value(s) corresponding to the resistance values ​​obtained during one or more previous activations of the carbon allotrope (103), even if this is during the initial part of the activation, or by a quantity greater than, for example, 10Ω, this means that the defect detection circuit (320) determines that the carbon allotrope (103) is defective. In this example, such a defect detection circuit (320) will determine that the carbon allotrope (103) in the fifth activation A5 is defective.

[0256] It should be recognized that the above description describes examples of how a carbon allotrope (103) can be determined to be defective or non-defective based on identifying characteristics of monitored electrical parameters that indicate a defective carbon allotrope (103). Depending on the structure, composition and / or formation of the carbon allotrope (103) and how it is used, characteristics other than those identified above may be found to indicate a defective carbon allotrope (103). That is, the examples described above should not be considered as limiting examples of what constitutes monitored electrical parameters that are considered to indicate a defective carbon allotrope (103).

[0257] Additionally, it should be recognized that any combination of characteristics may be used to indicate a defective carbon allotrope (103). For example, both the techniques of FIG. 10b related to identifying changes in resistance during activation and the techniques of FIG. 10c related to identifying changes in resistance between activations may be used (however, note that in the latter case, such determination still requires activation of the carbon allotrope (103)). In the example of FIG. 10a, the characteristic at part B of the graph may indicate the onset of the effect of the defective part of the carbon allotrope, and continued use of the carbon allotrope (103) causes the defect to have an increasingly greater effect on the measured resistance of the carbon allotrope (103) until a significant effect is observed at activation A5. The defect detection circuit (320) may be configured to determine that the carbon allotrope (103) is defective at activation A2 and / or defective at activation A5.

[0258] Furthermore, in some cases, as illustrated in FIGS. 10a through 10c, the reduction in resistance typically indicates a defective or defective carbon allotrope (103), but continued use of the defective carbon allotrope (103) can cause significant damage to the carbon allotrope (103), such as breakage within the carbon allotrope (103), which has been found to result in significantly larger measured resistances than those observed in the second activation A2 of FIG. 10b or the fifth activation A5 of FIG. 10c (e.g., approximately 5 to 10 times the measured resistance in the second activation A2 of FIG. 10b or the fifth activation A5 of FIG. 10c). While it may be advantageous to determine whether the carbon allotrope (103) is defective before significant damage is observed, in other implementations, the defect detection circuit (320) may be configured to determine that the carbon allotrope (103) is defective when the resistance exceeds a high value such as 800Ω or when the change in resistance exceeds a high value such as 500% of the resistance of the previous activation or 700Ω.

[0259] Once the defect detection circuit (320) determines that the carbon allotrope (103) is defective or has a defect, the defect detection circuit (320) can signal to a suitable control circuit (e.g., PCB (26)) that the carbon allotrope (103) has a defect. In response to this, the control circuit (e.g., PCB (26)) can cause an action intended to improve the operational safety of the aerosol supply system (10) to be performed.

[0260] In some implementations, in response to determining a fault condition, the control circuit is configured to prevent further activation of the carbon allotrope (103). For example, in such an implementation, when the control circuit receives an indication of the user's intention to generate an aerosol (e.g., from a pressure or airflow sensor), the control circuit is configured to determine whether the carbon allotrope (103) has been identified as faulty / defective, and if so, to prevent power from the power source (5) from being supplied to the carbon allotrope (103). Additionally, or alternatively, the control circuit may be configured to provide a warning to the user. In some implementations, the aerosol delivery system (10) may include an LED or other feedback mechanism that can be actuated by the control circuit when the control circuit is notified that the carbon allotrope (103) has a fault / defective condition (e.g., from the fault detection circuit (320)). In some implementations, the feedback mechanism may additionally or alternatively be remote from the aerosol delivery system (10) and may be, for example, on a smartphone or other remote device communicateably coupled to the aerosol delivery system (10). In such implementations, the control circuit is configured to transmit a control signal to the remote device so that the feedback mechanism generates a warning to the user (for example, displaying a message or notification on the user's smartphone). The type and / or location of the feedback mechanism is not particularly limited.

[0261] Although the principles of the present disclosure may be extended to any suitable heating element acting as an aerosol generator (102), it should be recognized that such an approach has been found to have particular applicability in aerosol supply systems (10) utilizing a carbon allotrope (103) as an aerosol generator (102).

[0262] Referring again to FIG. 7, although FIG. 7 illustrates the monitoring circuit (310) and the fault detection circuit (320) as separate circuit arrays, it should be recognized that in certain implementations, the monitoring circuit (310) and the fault detection circuit (320) may be implemented as a combined circuit (e.g., a single integrated circuit). In other implementations, the monitoring circuit (310) and the fault detection circuit (320) may be integrated into any control circuit (e.g., a PCB (26)) of the aerosol supply system (10).

[0263] Additionally, FIG. 7 also includes a dashed line A provided between the power source (5) and the carbon allotrope (103). The dashed line A represents an interface between the aerosol providing device (20) and the detachable article (30 / 100). In this regard, FIG. 7 can be understood as depicting everything to the left of the dashed line A as being included in the aerosol providing device (20) and everything to the right of the dashed line A as being included in the article (30 / 100). In particular, in this implementation, the monitoring circuit (310) and the fault detection circuit (320) are part of the aerosol providing device (20), and thus, when the article is coupled to the aerosol providing device (20), electrical parameters can be monitored and the faulty carbon allotrope (103) can be detected. However, in other implementations, it should be understood that the aerosol providing device (20) may be formed integrally with the article (30 / 100).

[0264] FIG. 11 is an exemplary method for detecting defects in a heater element (e.g., the carbon allotrope (103) above) for an aerosol delivery system.

[0265] The method begins at step S1, where a heating element (e.g., a carbon allotrope (103)) is provided. In some embodiments, this involves coupling an article (30 / 100) (which includes the carbon allotrope (103)) to an aerosol providing device (20).

[0266] In step S2, the method proceeds to activate a heating element (e.g., a carbon allotrope (103)). As described above, power can be controlled to be output from the power source (5) to the carbon allotrope (103) in response to detecting a user's intention to activate aerosol generation (e.g., detected inhalation of the aerosol supply system (10) or pressing of a button or other user input mechanism).

[0267] In step S3, the method proceeds to monitor electrical parameters of a heater element (e.g., a carbon allotrope (103)) during the activation of the heater element in step S2. During step S3, the monitoring circuit (310) monitors electrical parameters, such as resistance, during the activation of the heater element as described above. In some implementations, monitoring may be performed for the entire duration of the activation of the heater element, but in other implementations, monitoring may be performed only for a portion of the activation of the heater element (e.g., the first second of the activation). The monitoring circuit (310) monitors electrical parameters over time.

[0268] In step S4, the method proceeds to determine a defect in the heater element based on identifying characteristics indicating a defect condition from the electrical parameters monitored in step S3. As discussed above, this step may be performed by the defect detection circuit (320) after receiving the electrical parameters monitored from the monitoring circuit (310). Step S4 may use any of the techniques described above to identify characteristics indicating a defect in the heater element.

[0269] In step S5, optionally, in response to determining the fault condition in step S4, the method prevents further activation of the heater element (e.g., by preventing power from the power source (5) from being supplied to the carbon allotrope (103)) and / or generates a warning provided to the user, wherein the warning indicates to the user that the heater element is faulty.

[0270] Although not illustrated in FIG. 11, once the aerosol is generated (e.g., after a predetermined time from the detected start of user inhalation and / or when the user stops inhaling the aerosol supply system (10)), the power supply to the heater element may be stopped. Subsequently, the method may proceed backward to step S2 to wait for the next detection of the user's intention to activate aerosol generation.

[0271] In an aspect of the present disclosure, a non-flammable aerosol providing system (10) comprising an article (30 / 100) and an aerosol providing device (20) comprising a power source are provided. As in the examples above, the aerosol providing device (20) and the article (30 / 100) are separable from each other, and one (e.g., article (30 / 100)) can be replaced independently of the aerosol providing device (20).

[0272] More generally, the device may be intended to accommodate an article (30 / 100). In some embodiments, the device may surround the article (30 / 100). In some embodiments, the device (20) may include a mouthpiece (e.g., surrounding the article (30 / 100)), or alternatively, the mouthpiece may form part of the article (30 / 100).

[0273] In some implementations, the aerosol providing device (20) includes a monitoring circuit (310) and a fault detection circuit (320).

[0274] In other embodiments, the device (20) and the article (30 / 100) may be formed as an integral structure (i.e., the device (20) and the article (30 / 100) are formed integrally as an aerosol providing system (10)). The system may include any feature or feature of the system described herein.

[0275] In another aspect of the present disclosure, an aerosol providing means configured to generate an aerosol from an aerosol generating material (these include an aerosol providing system (10)). The aerosol providing means comprises: a heater means configured to generate heat for aerosolizing the aerosol generating material (these include an aerosol generator (102) / carbon allotrope (103); a monitoring means configured to monitor electrical parameters of the heater means during activation of the heater means (these include a monitoring circuit section (310); and a defect detection means configured to detect a defect in the heater means based on the monitored electrical parameters of the heater means (these include a defect detection circuit section (320)). The defect detection means is configured to determine that a defect in the heater means has been detected based on identifying characteristics indicating a defect condition in the electrical parameters monitored during activation of the heater means.

[0276] Accordingly, an aerosol delivery system configured to generate an aerosol from an aerosol-generating material is described, wherein the aerosol delivery system comprises: a heater element configured to generate heat for aerosolizing the aerosol-generating material; a monitoring circuit configured to monitor electrical parameters of the heater element during activation of the heater element; and a defect detection circuit configured to detect a defect in the heater element based on the monitored electrical parameters of the heater element. The defect detection circuit is configured to determine that a defect in the heater element has been detected based on identifying characteristics indicating a defect condition in the electrical parameters monitored during activation of the heater element. An aerosol delivery device and a method of operation are also described.

[0277] Any aspect of the present disclosure may be defined in relation to any aspect of other aspects of the present disclosure. For example, one aspect of the present disclosure may include any feature of any other aspect of the present disclosure and / or the features of one aspect of the present disclosure may be as defined in relation to the features of any other aspect of the present disclosure.

[0278] The various examples described herein are presented merely to aid understanding and to teach the claimed features. These examples are provided only as representative samples of examples and are not comprehensive and / or exclusive. It should be understood that the advantages, examples, functions, features, structures, and / or other aspects described herein are not to be considered as limitations on the scope of the invention as defined by the claims or limitations on equivalents thereof, and that other examples may be utilized and modifications may be made without departing from the scope of the claimed invention. Various examples of the invention may suitably include, be composed of, or constitute essentially of other disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Additionally, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

Claim 1 An aerosol providing system configured to generate an aerosol from an aerosol generating material, comprising: a heater element configured to generate heat for aerosolizing the aerosol generating material; a monitoring circuit unit configured to monitor electrical parameters of the heater element during activation of the heater element; and a defect detection circuit unit configured to detect a defect in the heater element based on the monitored electrical parameters of the heater element, wherein the defect detection circuit unit is configured to determine that a defect in the heater element has been detected based on identifying characteristics indicating a defect condition in the monitored electrical parameters during activation of the heater element. Claim 2 An aerosol providing system according to claim 1, wherein the characteristic indicating the defect condition comprises a non-zero rate of change of the electrical parameter, which is greater than or less than a predetermined threshold during a predetermined time period. Claim 3 An aerosol providing system according to claim 1 or 2, wherein the characteristic indicating the defect condition comprises a first part and a second part, and the first part has a larger rate of change or a smaller rate of change of the electrical parameter than the second part. Claim 4 An aerosol providing system according to paragraph 3, wherein the first part is a part starting from the initial activation of the heater element, and the second part is a part that follows in time. Claim 5 An aerosol providing system according to any one of claims 1 to 4, wherein the activation of the heater element comprises supplying power from the power source of the aerosol providing system to cause the heater element to heat to an operating temperature for aerosolizing an aerosol generating material. Claim 6 An aerosol providing system according to any one of claims 1 to 5, wherein the electrical parameter comprises at least one of electrical resistance and inductance. Claim 7 An aerosol delivery system according to any one of claims 1 to 6, wherein the defect detection circuit is configured to identify characteristics indicating a defect condition by comparing the monitored electrical parameter during the activation of the heater element with the expected value or value of the electrical parameter during the activation of the heater element set in advance. Claim 8 In claim 7, the above characteristic is identified when the monitored electrical parameter deviates from the above expected value or values ​​by a predetermined amount, and optionally, the heater element is carbon foam or comprises carbon foam, an aerosol delivery system. Claim 9 An aerosol delivery system according to claim 7 or 8, wherein the expected values ​​or values ​​of the electrical parameters are determined from one or more activations of the heater element performed in time prior to the current activation of the heater element. Claim 10 An aerosol providing system according to claim 7 or 8, wherein the expected values ​​or values ​​of the electrical parameters are determined from the initial part of the current activation of the heater element. Claim 11 An aerosol providing system, wherein, in response to determining a defect condition in any one of claims 1 to 10, the control circuit is configured to prevent further activation of the heater element. Claim 12 An aerosol providing system according to any one of claims 1 to 11, wherein, in response to determining a defect condition, the control circuit is configured to provide an alert to the user. Claim 13 An aerosol providing system according to any one of claims 1 to 12, wherein a plurality of aerosol generators comprise a carbon allotrope. Claim 14 In paragraph 13, the carbon allotrope comprises disordered graphite and / or amorphous carbon, an aerosol providing system. Claim 15 In claim 13 or 14, the Raman spectrum of the carbon allotrope comprises a G band and a D band, and the G band peak is approximately 1500 cm⁻¹ -1 to about 1650 cm -1 It is within the Raman shift range, and the D-band peak is approximately 1250 cm⁻¹. -1 to about 1400 cm -1 It is within the Raman shift range of, and the intensity of the D-band peak I D The intensity of the above G-band peak I G Of I D / I G An aerosol providing system, wherein the amount is about 0.8 to about 2, preferably about 1 to about 1.

8. Claim 16 An aerosol providing system according to any one of claims 1 to 15, wherein the carbon allotrope comprises disordered graphite and / or amorphous carbon and / or nanocrystalline graphite. Claim 17 An aerosol providing device configured to generate an aerosol from an aerosol generating material, comprising: a monitoring circuit configured to monitor electrical parameters of a heater element during activation of the heater element — said heater element is configured to generate heat for aerosolizing the aerosol generating material —; and a defect detection circuit configured to detect a defect in the heater element based on the monitored electrical parameters of the heater element, wherein the defect detection circuit is configured to determine that a defect in the heater element has been detected based on identifying characteristics indicating a defect condition in the monitored electrical parameters during activation of the heater element. Claim 18 In claim 17, the aerosol providing device is configured to receive a consumable comprising an aerosol generating material. Claim 19 In paragraph 18, the above consumable is an aerosol providing device comprising the above heater element. Claim 20 A method for detecting a defect in a heater element for an aerosol delivery system, comprising: providing a heater element; activating the heater element by applying power to the heater element to cause heating of the heater element; monitoring electrical parameters of the heater element during activation of the heater element; and determining a defect in the heater element based on identifying characteristics indicating a defect condition in the electrical parameters monitored during activation of the heater element. Claim 21 An aerosol providing means configured to generate an aerosol from an aerosol generating material, comprising: a heater means configured to generate heat for aerosolizing the aerosol generating material; a monitoring means configured to monitor electrical parameters of the heater means during activation of the heater means; and a defect detection means configured to detect a defect in the heater means based on the monitored electrical parameters of the heater means, wherein the defect detection means is configured to determine that a defect in the heater means has been detected based on identifying characteristics indicating a defect condition in the monitored electrical parameters during activation of the heater means.

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