Atomization device with heating element made of laser-induced carbon foam

Abstract

A method of manufacturing a component for an atomization device is disclosed; the component is substantially made of carbon foam. The method includes the step of manufacturing a carbon foam part using a high temperature process generated by a laser beam directed toward a carbon-based precursor material, such as a polymer or polyimide sheet. The component is electrically conductive, non-metallic and porous to electronic liquids. The component may be a carbon foam-based component that functions both as a wicking element and as a heating element.

Description

Technical Field

[0001] This invention relates to an atomizing device having a heating element component made of laser-induced carbon foam, such as multilayer carbon foam with randomized twisting. The heating element is suitable for use in various atomizing devices, including electronic nicotine devices (“END”), such as electronic cigarette devices and heated tobacco sticks, as well as other devices, including medical inhalation devices, where the substance must be rapidly heated to produce a safe inhalable vapor. Background Technology

[0002] Electronic vaping devices heat a liquid (typically containing nicotine, propylene glycol, vegetable glycerin, and flavorings) to produce inhalable vapor; the heater is usually a wire or mesh that uses resistance heating via a 4V to 5V power supply. The wicking mechanism supplies the liquid from a small container (typically 2mL; often filled with fiberglass foam) within the device to the heating element; cotton or semi-synthetic fiber wicks are commonly used; ceramic wicks are also common. A significant drawback of using metal heaters is that the inhaled vapor often contains metals (such as nickel and chromium), which can have undesirable health consequences. For ceramic wicks, the release of silica dust is a potential hazard. While electronic vaping devices are not without risk, their use is widely considered much safer than smoking combustible cigarettes.

[0003] Heated tobacco products are also much safer than combustible cigarettes: the cigarette-shaped "stick" (made from tobacco derivatives and forming a "plug") also contains a thin, stainless steel-coated ferromagnetic metal strip that acts as a sensor. The "stick" is placed in a portable heating device, which inductively heats the metal sensor strip to no more than about 350°C. This, in turn, heats the plug, producing inhalable vapor. As with e-cigarette devices, this vapor may contain very small amounts of metal (but at significantly lower levels than in e-cigarette devices).

[0004] Graphene has garnered significant attention for years due to its applications in biosensors, electrochemical sensing systems, supercapacitors, electrodes, and fuel cells. Known methods for producing 3D graphene include laser-induced graphene production as described in WO 2019 / 038558; 3D graphene forms on the surface of the exposed polyimide film when a suitable carbon precursor material (such as a polyimide film) is positioned on a supporting substrate and irradiated with a CO2 laser. Experience has shown that the thickness of 3D graphene produced by this method is less than 50 μm; furthermore, 3D graphene itself can be brittle and has poor adhesion to the underlying substrate, potentially leading to peeling. Therefore, 3D graphene is unsuitable for many applications. While there has been speculation that graphene could be used as part of the heater in electronic cigarette devices, conventional graphene manufacturing methods (such as chemical vapor deposition) make its large-scale use in this area uneconomical.

[0005] A note on terminology used in the field of carbon nanostructures: If we use only the term "graphene," there are numerous different forms of "graphene"; for example, the literature describes monolayer graphene, bilayer graphene, disordered-layer graphene, graphene superlattices, graphene fibers, 3D graphene, graphene aerogels, wrinkled graphene, and many other forms. This presents a defining challenge, as using a specific term (e.g., "3D graphene") may imply limitation to that specific form of graphene. Furthermore, the IUPAC (International Union for Pure and Applied Chemistry) recommends using the name "graphite" for three-dimensional materials, and "graphene" only when discussing the reactions, structural relationships, or other properties of individual layers.

[0006] Therefore, in this specification, we use the term "carbon foam" as a general term, and this term should be broadly interpreted to cover any carbon nanostructure, such as 3D carbon material foam, including multilayer 3D carbon material foam with disordered layer twisting.

[0007] An example of the term "carbon foam" refers to a material manufactured using the methods described in this specification; such a material has slightly different properties from conventional graphene or conventional graphene foam. For example, graphene foam has several characteristics: it is hydrophobic and has low wettability. Raman analysis of a typical graphene foam reveals the following signature: the absence of a D peak; a 2D peak higher than the G peak; and a D peak:G peak ratio close to zero. As we will describe in more detail below, the carbon foam produced in specific embodiments of the invention does not possess these characteristics; it is hydrophilic with a contact angle less than 20°; it lacks the Raman signature indicative of graphene: it exhibits a prominent D peak; a 2D peak significantly smaller than the G peak; and a D peak:G peak ratio significantly higher than zero. In terms of appearance and Raman signature, it appears to be closer to carbon nanotube onion materials. Therefore, the term "carbon foam" in its scope also includes materials that are carbon nanostructures, such as carbon nanotube onions, carbon nanohorns, carbon nanotubes, carbon nanodots, nanodiamonds, and fullerenes, or any combination thereof. Therefore, "carbon foam" can refer to non-graphene materials. Summary of the Invention

[0008] One aspect of the invention is a method of manufacturing an atomizing device; the atomizing device includes a heating element made substantially of carbon foam. The method includes the step of manufacturing the carbon foam element using a high-temperature process generated by a laser beam directed at a carbon-based precursor material, such as a polymer or polyimide sheet. The element is conductive, non-metallic, and porous for atomizable liquids, or capable of wicking atomizable liquids. The element can be a carbon foam-based component that serves both as a liquid wicking element and as a heating element for atomizing the liquid. As previously mentioned, heating elements are suitable for use in a variety of atomizing devices, including electronic nicotine devices (“END”), such as electronic cigarette devices and heated tobacco sticks, and other devices, including medical inhalation devices, where the substance must be rapidly heated to produce a safe inhalable vapor. Heating elements are also suitable for heating non-liquids; then it need not be porous for atomizable liquids or capable of wicking atomizable liquids. One aspect of the invention is a method of manufacturing a heating element used as an induction-heated carbon foam sensor strip in a tobacco "stick," such as in heated noncombustible (HNU) or THP (heated tobacco products); a related aspect of the invention is a tobacco "stick" comprising a carbon foam sensor strip. Typically, induction-heated sensor strips are metallic, but this carries the risk of introducing metallic contaminants into the inhaled vapor.

[0009] Similar challenges are faced when using drug nebulizers such as metered-dose inhalers and soft-mist inhalers; some of these may be enhanced if the drug in liquid or powder form is heated, for example, to atomize or mist the drug or to sublimate the drug directly into the gas phase. However, the heater is typically metallic, thus posing a risk of introducing metallic contaminants into the inhaled vapor. Another aspect of the invention is a method of manufacturing a carbon foam heating element for a drug nebulizer, and a related aspect is a drug nebulizer including the carbon foam heating element.

[0010] Other aspects and features of the invention are defined in the claims. Attached Figure Description

[0011] The invention will be described with reference to specific embodiments shown in the following figures.

[0012] Figures 1-6 The diagram schematically illustrates a dual-laser process for generating carbon foam when a polyimide (PI) film (which acts as a carbon precursor) is positioned on a substrate.

[0013] Figure 7 It is a scanned electronic image that shows the unique surface morphology (x250) of carbon foam achieved using a dual-laser method.

[0014] Figure 8 It is a scanning electron image that shows the surface of conventional laser-induced graphene.

[0015] Figures 9-14B The diagram schematically illustrates a dual-laser process for generating carbon foam when the PI film (which acts as a carbon precursor) is not positioned on the substrate.

[0016] Figure 15A and Figure 15B This is a Raman analysis of a carbon foam sample prepared using a dual-laser process.

[0017] Figure 15C This is a Raman analysis of carbon nanotube onion material.

[0018] Figure 16 It is a scanning electron image showing dual-laser carbon foam and conventional graphene.

[0019] Figure 17 This is a schematic diagram of a high-speed roll-to-roll or roll-to-sheet manufacturing system for Gii carbon foam.

[0020] Figures 18-22 It displays scanned electronic images of dual-laser carbon foam at different magnifications.

[0021] Figure 23 This is a scanning electron image of carbon nanotube onion material produced using conventional processes.

[0022] Figure 24 The Raman shifts of eight carbon foam sheets fabricated using a dual-laser process are shown.

[0023] Electronic cigarette device illustration Figure 25 This is a schematic cross-section of a conventional electronic cigarette device with a metal mesh heater.

[0024] Figure 26 yes Figure 25 A schematic cross-section of an electronic cigarette device, in which a carbon foam heater replaces a mesh heater.

[0025] Figure 27 This is a schematic cross-section through the carbon foam integrated core and the heater.

[0026] Figure 28 yes Figure 27 A schematic perspective view of the integrated carbon foam core and heater as it is rolled into a cylinder.

[0027] Figure 29 It is a schematic cross-section through a carbon foam structure with parallel, non-planar core and heater sections, wherein internal liquid microchannels are formed in the PI substrate to bind the core and heater sections.

[0028] Figure 30 This is a schematic plan view of a coplanar core and heater of carbon foam, wherein internal liquid microchannels formed in the PI substrate connect the coplanar core and heater.

[0029] Figure 31 yes Figure 30 A schematic cross-section of the structure.

[0030] Figure 32A It is a schematic cross-section through the tip or pod of an electronic cigarette device, which contains carbon foam, a combined coplanar core, and a heater.

[0031] Figure 32B yes Figure 32A A perspective view of the cigarette cartridge.

[0032] Figure 33 It is a schematic cross-section through the mouthpiece or cartridge used in an electronic cigarette device, which contains carbon foam, a combined non-coplanar core, and a heater.

[0033] Figure 34 It is a schematic cross-section through the mouthpiece or cartridge used in an electronic cigarette device, which contains carbon foam, a combined non-coplanar but parallel core, and a heater.

[0034] Please note that Gii is a trademark of the patent owner. "Gii" generally refers to carbon foam manufactured using a dual-laser process.

[0035] Figure Labels Electronic cigarette devices and THP devices 20 Cylindrical metal mesh heating elements 21 Cylindrical Flexible Sleeve 22 Electronic liquid storage device 23. Holes in sleeve 21 24 Steam generation chamber 26 Steam passage 27 Steam outlet in the nozzle 28 Top silicone seal 29 Bottom silicone seal 30 Plastic casing of sealed liquid reservoir 22 40 Carbon Foam Heating Element 50 Carbon Foam Zone 51 Liquid core carbon-absorbing foam section 52 Heated carbon foam section 53 High-temperature polyimide film substrate 54 Screen-printed power electrodes 55. Arrow indicating the direction of liquid movement 56 Liquid Microchannels 57 Electrical Connectors Dual laser process 110 IR laser 120 IR laser beam 125 CO2 laser The interior of a 130 PI film 140 PI film 150 substrate 160 Sub-surface carbon foam region 170 Disordered amorphous non-graphene materials beneath the surface carbon foam region 180. Extended region of disordered, amorphous, non-graphene material above the subsurface carbon foam region. 185. Unique surface morphology of the exposed carbon foam region. Detailed Implementation

[0036] We organize the specific implementation method as follows: Part A: Manufacturing Carbon Foam Part B: Key Features of Carbon Foam Manufacturing Methods AK Part C: Carbon foam for electronic cigarette devices and THP (heated tobacco products) devices In Part A, we explained how carbon foam (and various related types of carbon foam) can be manufactured. See WO 2023 / 118866, the contents of which are incorporated to the maximum permissible extent. One realization of this carbon foam is called… Carbon foam.

[0037] Part A: Manufacturing Carbon Foam We will begin with a simplified, illustrative walkthrough of a specific embodiment of the invention. We present two demonstrations; the first demonstration ( Figure 1-6 The second demonstration will describe at a high level the carbon foam production process in which a carbon precursor (e.g., a polyimide (PI) film, in this case such as a Kapton® film) is mounted on a substrate; Figure 9-1 4) This covers the carbon foam production process without mounting the polyimide film onto the substrate. In each case, we use a dual-laser process; the meaning of the terminology will be explained below.

[0038] In the first stage, (see Figure 1 A laser 110 with a wavelength of Å uses a laser beam 120 to irradiate the interior 130 of a polyimide film 140, which is positioned on a substrate 150 suitable for end applications. This laser may be a pulsed IR laser that delivers IR radiation with a wavelength of 1064 nm.

[0039] like Figure 2 As shown, a laser 110 with wavelength A is tuned such that the subsurface region 160 is transformed into carbon foam. The focus of laser A is gradually moved through the interior 130 of the polyimide film 140 to generate the entire carbon foam region 160. The depth or height of the carbon foam region 160 can be approximately 50 µm or greater, much higher than that achievable by other methods. Note that no carbon foam is generated at any time on the exposed surface of the polyimide film 140 (i.e., the surface on which the laser beam is incident). The region above the carbon foam 160 (i.e., closer to the laser than the carbon foam region 160) is not transformed into carbon foam. The region 170 below the carbon foam region 160 (i.e., the lower surface of the PI film) is also not transformed into carbon foam, but rather into a disordered, amorphous, non-graphene material adhered to the underlying substrate 150.

[0040] Figure 3 The results show that, due to gas trapping, the laser 110 with wavelength λ causes physical expansion in region 180 above (i.e., closer to the laser than the carbon foam region 160) the internal carbon foam region 160. This region 180 is neither 3D graphene nor a polymer; it is a disordered amorphous material.

[0041] In the second stage, a laser with wavelength B is now tuned to the disordered amorphous material region 180 above the carbon foam region 160, such as... Figure 4 As shown. This could be a CO2 laser with a wavelength of 10.6 μm, 125.

[0042] like Figure 5 As shown, a laser 125 with wavelength B ablates some or all of the region 180 above the carbon foam region 160, exposing at least some of the underlying carbon foam region 160.

[0043] A laser with wavelength B 125 also revealed a lower carbon foam region with a unique surface morphology 185, such as Figure 6 As shown.

[0044] we will Figure 1-6 The process described in the text is called the "dual laser process".

[0045] Figure 7 This is a scanning electron image showing a unique surface morphology (x250) achieved using a dual-laser method. In this case, the carbon source was first irradiated with IR radiation at a wavelength of 1064 nm from a pulsed IR laser, the radiation being focused into and gradually penetrating the carbon source. Then, the carbon source was irradiated with a laser beam from a CO2 laser at a wavelength of 10.6 μm. The thickness of the carbon foam layer in this image is approximately 220 μm.

[0046] like Figure 8 As shown, the contrast with the surface morphology (x250) achieved using conventional LIG (laser-induced graphene) methods is striking: it features clear grating lines and less spiral folding. The thickness of this carbon foam layer is less than 50 μm.

[0047] according to Figure 7 Based on the images, we can infer that the material produced using the dual-laser process does not have a surface morphology similar to that of conventional graphene foam; although it appears to be a multilayered 3D carbon-based material with a chaotic twisted foam structure, it is not necessarily a material commonly described as "graphene" in the conventional sense.

[0048] In the aforementioned demonstration ( Figure 1-6 In [the following section], we investigated a dual-laser process for mounting carbon precursor materials (polyimide films) onto a substrate. Figure 9-1In section 4, we will examine a dual-laser process that does not mount the polyimide film onto a substrate. We will later describe in detail two specific implementations of the manufacturing process, referred to as Gii-Cap (supercapacitor) and Gii-Sens (sensor), which use a standard 220 mm × 180 mm sheet of polyimide film, which is not mounted on a substrate; this size can be considered in standard laser scanning equipment, typically used for laser engraving, laser cutting, and laser drawing (which can trace paths defined by standard CAD programs). The manufacturing process also utilizes standard flatbed screen printing equipment and a standard conveyor belt dryer to easily accommodate thin PI films of different sizes. Other sizes of polyimide sheets can be considered.

[0049] As previously described, a laser 110 with wavelength λ (e.g., an IR laser) irradiates the interior 130 of the PI film 140; the film 140 is not currently mounted on the substrate, as... Figure 9 As shown. It can be a sheet whose edges are supported or temporarily rested on a surface, or a sheet that forms part of a PI film roll when using a continuous manufacturing (e.g., roll-to-roll or roll-to-sheet) system (see Feature L).

[0050] Tuning a laser 110 with wavelength A causes the subsurface region 160 to transform into carbon foam, such as... Figure 10 As shown. The focal point gradually moves through the membrane 140 to create the entire carbon foam region 160. The height of the carbon foam region 160 can be about 50 µm or greater, much deeper or higher than could be achieved by other methods.

[0051] At no time does 3D graphene form on the exposed surface of the polymer film. The region above the carbon foam does not transform into 3D graphene.

[0052] like Figure 11 As shown, due to gas retention, region 180 above the internal carbon foam region 160 undergoes physical expansion. This region is neither 3D graphene nor a polymer; it is a disordered amorphous material.

[0053] Now, a laser 125 with wavelength B (e.g., CO2) is tuned in region 180 above the carbon foam, as follows: Figure 12 As shown. A laser with wavelength B ablates region 180 above carbon foam region 160, exposing at least some of the underlying carbon foam 16, such as... Figure 13 As shown.

[0054] Just as with the case where the polyimide film 140 is mounted on the substrate, the laser 125 with wavelength B also imparts a unique surface morphology 185 to the underlying carbon foam 160, as shown in Figure 14.

[0055] Some specific implementation details of this dual-laser method for producing carbon foam are as follows: In one example, the Nd:YAG solid-state laser is a wavelength A-wave laser, and it is positioned such that the IR laser radiation beam (wavelength 1064 nm) generated by the solid-state laser perpendicularly impacts the polyimide layer. Optics focus the IR laser radiation beam to a minimum beam convergence within a certain volume of the polyimide layer.

[0056] In the encapsulation region or subsurface region or location around the minimum beam convergence, the interaction between the laser and the polyimide leads to the carbonization of the carbon source. This carbonization results in the generation of carbon foams, such as twisted or disordered multilayer carbon foams, in the encapsulation region or subsurface region, and causes the formation of a disordered, amorphous, non-graphene material layer on the surface of the polyimide film.

[0057] While maintaining the laser beam focused at a specific depth within the polyimide layer, the laser scans laterally above the polyimide layer. In this way, the path entirely within the polyimide carbon source is traced and transformed into carbon foam. Thus, the polyimide is carbonized into carbon foam with a pattern corresponding to the path traced by the scanning, focused IR laser beam.

[0058] In one setup, the Nd:YAG IR laser pulsed at 80 kHz, and the laser beam scanned the surface at a speed of 9.4 cm / s. Other implementations utilized different parameters. For example, a pulse frequency of 50 kHz and a scanning speed of 35.5 cm / s were also successfully used to generate carbon foam. The laser power was typically in the range of 8–20 watts, with an optimal value of 12 W; the laser focal length was typically in the range of 50 mm–400 mm.

[0059] Once a predetermined area within the polyimide layer is irradiated by a focused IR laser beam in the manner described above, the depth of the encapsulated area or subsurface region or location within the polyimide is altered, and the IR laser beam scans the same predetermined area again. A standard computer-controlled laser scanning system can be used, which controls the XY position of the laser on the polyimide film. It may be necessary to pass the focused IR laser radiation through the same area more than once to generate carbon foam. In this specific implementation, the focused IR laser also irradiates adjacent but not substantially overlapping areas. This process of irradiating the carbon source with focused IR laser radiation at different focal depths is repeated until the desired depth of the polyimide layer is exposed to IR laser radiation and carbon foam is formed in the encapsulated area or subsurface region. However, the surface layer is a disordered, amorphous, non-graphene material.

[0060] In the second step, the polyimide layer is exposed to radiation from a CO2 laser for an ablation process, exposing at least some of the underlying carbon foam and obtaining exposed carbon foam with a specific surface morphology. Radiation from the CO2 laser scans the surface of the treated carbon source at a speed of 19 cm / s to match patterns or areas irradiated using an IR laser. Other embodiments utilize different parameters. For example, a pulse frequency of 50 kHz and a scan speed of 35.5 cm / s have also been used to successfully expose the underlying carbon foam. The laser power is typically in the range of 8–20 watts, with an optimal value of 12 W; the laser focal length is typically in the range of 50 mm–400 mm.

[0061] As described above, CO2 lasers ablate the disordered, amorphous, non-graphene material on the surface layer, thereby exposing the underlying carbon foam and altering the surface morphology of the carbon foam to produce exposed carbon foam with a greater number of defects compared to standard laser-induced graphene; as previously stated, this endows the carbon foam with extremely useful properties superior to those of standard laser-induced graphene.

[0062] Changing the laser parameters of one or two lasers (e.g., IR laser and CO2 laser), such as power, focus, wavelength, and scanning speed, alters the properties of the carbon foam material, enabling the production of carbon foams with properties optimized for different applications.

[0063] One useful property of exposed carbon foam produced using a dual-laser process is its high wettability: the contact angle can be less than 20°, making this carbon foam hydrophilic, compared to the hydrophobic nature of conventional graphene foam, which has a contact angle between 70° and 150°. This hydrophilicity of carbon foam produced via the dual-laser process is significant for e-cigarette applications because it enables the rapid and uniform distribution of e-liquids.

[0064] Another useful property of exposed carbon foam produced by the dual-laser process is its high resistance to contamination: the carbon foam can be used in applications where the accumulation of contaminants or residues may damage the performance or lifespan of components (e.g., heating elements in electronic cigarettes and HNB devices described in Part C below; electrodes); the exposed carbon foam produced by the dual-laser process can be used in said components, resulting in enhanced performance or lifespan.

[0065] The Raman spectrum of carbon foam produced by a dual-laser process is shown in... Figure 15A It has three main peaks. Specifically, at approximately 1344 cm... -1 The D peak is characteristic of the presence of lattice defects, and it is located at approximately 1577 cm⁻¹. -1 The G peak exists as sp 2The carbon hybridization is characterized by the presence of twisted six-fold carbon rings. At approximately 2685 cm⁻¹ -1 The 2D peak is characteristic of the secondary transition in 3D graphene, and the absence of a bimodal structure here indicates a lack of planar AB stacking found in multilayer 2D graphene or graphite. Comparing the 2D peak with a peak at 2685 cm⁻¹... -1 The central single Lorentzian peak (its full width at half maximum is 67 cm) -1 The fitting results indicate that only one or a few carbon foam-like layers exist in the 3D carbon formed using these two methods. Analysis of the D / G peak ratio (0.85) of the dual-laser process indicates a higher defect density compared to the conventional laser-induced graphene process using a single laser step (0.67), as shown in Table 1 below.

[0066] Table 1

[0067] As we previously explained, Raman analysis of typical graphene foam revealed the following characteristic signatures: the absence of a D peak; a 2D peak higher than the G peak; and a D:G peak ratio close to zero. The carbon foam produced in the specific embodiments of this invention does not possess these characteristics; it is highly hydrophilic with a contact angle below 20°; and it lacks the graphene-indicating Raman signatures. Figure 15A The material produced by the dual-laser process shows the presence of a D peak; the 2D peak is lower than the G peak; and the ratio of the D peak to the G peak is higher than zero. Figure 15B Another Raman analysis of carbon foam produced by a dual-laser process again showed the presence of a D peak; the 2D peak was lower than the G peak; and the ratio of the D peak to the G peak was higher than zero. Figure 15C The results show a Raman spectroscopy of polyhedral carbon nano-onions (DOI: 10.1007 / s00339-015-9315-9) for carbon nano-onions, and a clear similarity to the Raman spectroscopy of carbon foam produced by a dual-laser process. A plausible explanation is that the carbon foam produced by the dual-laser process is, or contains, carbon nano-onions.

[0068] Both dual-laser carbon foam and conventional graphene fabricated using a single-laser process exhibit microporous structures, such as... Figure 16 The SEM images are shown. Low-magnification images reveal significant differences in surface morphology. The single-laser surface shows a smoother, more textured surface with rougher edges, while the carbon foam produced using a dual-laser process shows a rougher surface.

[0069] Part B: Key Features of Carbon Foam Manufacturing Methods In this section, we outline the key features AL of a specific embodiment of the invention. These features define the production of carbon fiber foam in the previously described dual-laser manufacturing process; this process offers numerous advantages over conventional CVD: we can compare the production of 1 cm⁻¹ carbon fiber foam onto plastic substrates (or virtually many other types of substrates) as shown in Table 2. 2 Carbon foam approximately 50 µm thick.

[0070] Table 2

[0071] The AL characteristic defines all aspects of the carbon foam manufacturing process, which is highly scalable, high-yield, highly reproducible, and easily adaptable to a wide range of different applications, all using the same process. For example, dual-laser carbon foam is particularly suitable for biosensors and electrochemical capacitors (e.g., supercapacitor and pseudocapacitor applications).

[0072] Compared to conventional graphene foam, dual-laser carbon foam has the following advantages: larger surface area; more porous structure; higher quality; lower sheet resistance; higher wettability; and higher stain resistance.

[0073] The characteristic AL is organized into the following four groups: Group 1: Subsurface carbon foam Group 2: Dual Laser Processing Group 3: Other aspects.

[0074] We can extend this organization as follows: Group 1: Subsurface carbon foam Feature A: Carbon foam generated in the region below the surface of the carbon precursor material. Feature B: Carbon foam generated in the encapsulation region of the carbon precursor material. Feature C: Carbon foam generated in regions of the carbon precursor material, wherein said regions do not have substantial gas escape channels. Feature D: Amorphous non-graphene material that adheres to a substrate.

[0075] Group 2: Dual Laser Processing Feature E: Carbon foam generated by laser ablation of the carbon foam region beneath the surface. Feature F: Non-graphene carbon foam generated by laser ablation of the carbon foam region beneath the surface. Feature G: Dual lasers operating in different frequency bands Feature H: Electrical contacts positioned within carbon foam generated by laser ablation of the carbon foam region beneath the surface. Feature I: Electrical contacts are printed on a polyimide film, and then exposed carbon foam is produced. Feature J: High trajectory formed in carbon foam Feature K: Application of first and second lasers in different manufacturing facilities Group 3: Other Aspects Feature L: Scalable manufacturing of carbon foam: Gii 3 Now let's look at Group 1: Group 1: Subsurface carbon foam Feature A: Carbon foam generated in the region below the surface of the carbon precursor material. Previously, existing techniques for laser-induced graphene conversion transformed the surface layer of a carbon precursor into 3D graphene. However, the resulting 3D graphene can be somewhat brittle, potentially peeling off from the underlying substrate, and is generally unsuitable for many real-world applications; furthermore, 3D graphene is typically relatively thin, with a depth of less than 50 µm.

[0076] In this specification, we describe an alternative method in which the surface of the carbon precursor is not converted into graphene at all; instead, only the subsurface region 140 of the carbon precursor is converted into carbon foam 160 by a focused laser beam 120; in one specific embodiment, the focused IR beam 120 is applied over an extremely short time, between 1 ns and 10 μs (i.e., at a rate of approximately 5 × 10⁻⁶). 7 ℃ / s and 2×10 12 Temperatures exceeding 500°C are generated in the subsurface region or encapsulation region within the polyimide film 140 (between °C / s); this brief but intense heating is sufficient to form carbon foam 160 in this subsurface region or encapsulation region. This subsurface region or encapsulation region 160 lacks a substantial gas escape pathway; confining gaseous products within the subsurface region or encapsulation region advantageously affects the structure of the carbon foam 160 formed in the subsurface region. The formation of carbon foam 160 solely in the subsurface region was an unexpected discovery; this was unexpected due to several factors, including the extremely low absorptivity of the polyimide carbon precursor material to 1064 nm IR radiation, with an absorptivity per centimeter (decimal) of less than 50 or even less than 10.

[0077] Under laser irradiation, the surface (e.g., the interface between the carbon precursor material perpendicular to and facing the laser and the gaseous environment surrounding the carbon precursor material) expands and transforms from the carbon precursor material into disordered amorphous non-graphene material 180. This disordered amorphous non-graphene material 180 forms a layer, which is typically at least 1% of the total thickness of the carbon precursor material; for a 500 µm thick polyimide film, the top 1 µm–10 µm is typically transformed into disordered amorphous non-graphene material 180; below this upper surface layer, within the bulk of the carbon precursor material, we obtain a region transformed into carbon foam 160.

[0078] The thickness of this carbon foam 160 is controlled by gradually moving the focus of the laser beam through the carbon precursor material; exceptionally thick carbon foam structures can be made using this process: carbon foam tracks with thicknesses of 50 µm to 200 µm have been achieved.

[0079] If a laser irradiates a carbon film precursor material, such as... Figure 9-14B The polyimide film shown, suspended in space (i.e., not mounted on a substrate), after irradiation, as we gradually move through the material, we obtain disordered, amorphous, non-graphene material 180 on the upper surface (i.e., the surface facing the laser); then we obtain carbon foam regions 160. The laser beam 120 typically does not approach the lower surface of the carbon precursor material, such that the carbon foam regions 160 are located above the carbon precursor material that has not yet been converted into carbon foam. If the laser approaches the lower surface of the carbon precursor material, the carbon precursor near and located on the lower surface is converted into disordered, amorphous, non-graphene material.

[0080] Similarly, if a laser irradiates a carbon precursor film, such as a polyimide (PI) film mounted on a substrate, as... Figure 1-6 As shown, we obtain the same material order; furthermore, the laser typically targets the lower surface of the carbon precursor material close to the substrate: then the carbon precursor near and located on the lower surface is transformed into disordered amorphous non-graphene material 170. This disordered amorphous non-graphene material 170 adheres to the substrate 150; since the carbon foam region 160 adheres to this disordered amorphous non-graphene material 170, the carbon foam region 160 itself is not directly bonded to the substrate 150, but is firmly attached to the substrate 150 via the intermediate disordered amorphous non-graphene material 170.

[0081] This method achieves carbon foam structures with significantly greater thickness than those achievable using previous methods that confine graphene foam formation to surface regions. Furthermore, this method enables carbon foam structures to adhere more robustly (but not directly) to the underlying substrate. It is important to note that with this method, carbon foam is not generated on any surface of the carbon precursor material; rather, it is generated only in the subsurface region within the carbon precursor material.

[0082] We can summarize it as follows: A method for manufacturing carbon foam material includes the steps of: irradiating a subsurface region of a carbon precursor material, wherein parameters of a laser beam are selected to generate carbon foam in the subsurface region.

[0083] Feature B: Carbon foam generated in the encapsulation region of the carbon precursor material. In Feature A above, we define the region where carbon foam is generated by laser irradiation as the “under-surface” region. Another way to describe this region is to characterize it as “encapsulation”; this reflects the three-dimensional relationship between the carbon foam and its surrounding environment; the carbon foam 160 is “encapsulated” by the original carbon precursor material and by the disordered, amorphous, non-graphene material 180 generated by laser irradiation of the upper surface of the carbon precursor material 140.

[0084] We can summarize it as follows: A method for manufacturing carbon foam material includes the following steps: irradiating an encapsulation region of a carbon precursor material, wherein parameters of a laser beam are selected to generate carbon foam in the encapsulation region.

[0085] Feature C: Carbon foam generated in regions of carbon precursor material, wherein said regions do not have substantial gas escape channels.

[0086] As we have seen above, the subsurface region or encapsulation region of the carbon precursor is transformed into carbon foam, and this subsurface region or encapsulation region has no substantial gas escape channel; confining the gaseous products within the subsurface region or encapsulation region affects the structure of the carbon foam 160 formed in the region.

[0087] We can summarize it as follows: A method for manufacturing carbon foam material includes the steps of: irradiating an encapsulated, subsurface region of a carbon precursor material, wherein parameters of a laser beam are selected to generate carbon foam in the region, and wherein the laser beam does not generate substantial gas escape channels leading to the surface of the precursor material.

[0088] Feature D: Amorphous non-graphene materials adhered to a substrate As we have previously observed, when laser 110 irradiates the carbon film 140 mounted on substrate 150, the laser carbonizes the surface of the carbon film adjacent to substrate 150, forming a disordered amorphous non-graphene material 170 adjacent to substrate 150. This disordered amorphous non-graphene material 170 adheres to substrate 150. Because the internal, subsurface, or encapsulated carbon foam region 160 itself is bonded to this disordered amorphous non-graphene material 170, the carbon foam region 160 itself is not directly attached to substrate 150, but is firmly positioned on substrate 150 via the intermediate disordered amorphous non-graphene material 170. Compared to conventional laser-induced graphene, the carbon foam region 160 adheres more firmly and is less likely to peel off even if the substrate is flexible, thus enabling applications such as biosensor applications where the substrate is typically a thin and flexible structure.

[0089] We can summarize it as follows: A method for manufacturing carbon foam material includes the following steps: irradiating an internal region of a carbon precursor material positioned on a substrate, wherein parameters of a laser beam are selected to generate carbon foam in the region and to generate disordered amorphous non-graphene material between the carbon foam region and the substrate; wherein the disordered amorphous non-graphene material is adhered to or otherwise directly attached to the substrate.

[0090] Group 2: Dual Laser Processing Feature E: Carbon foam generated by laser ablation of the carbon foam region beneath the surface. Previous features covered the generation of carbon foam in the subsurface region or encapsulation region of the carbon precursor material. Because carbon foam does not form on exposed surfaces, and many applications require exposed carbon foam, we can take additional steps to expose at least some of the subsurface or encapsulated carbon foam.

[0091] We have previously seen the formation of a disordered, amorphous, non-graphene material 180 beneath or above the encapsulated carbon foam 160 by laser irradiation with an IR laser 110. We now use a laser (typically a long IR CO2 laser 125) to ablate or otherwise process this disordered, amorphous, non-graphene material 180, thus exposing the underlying carbon foam 160. Unlike the initial laser, this second laser 125 is typically defocused.

[0092] As mentioned earlier, we use standard 220 mm × 180 mm polyimide sheets (but other sizes of polyimide sheets may also be considered); this size is commonly used in standard laser scanning equipment, standard flatbed screen printing equipment, and standard conveyor belt dryers for laser engraving, laser cutting, and laser drawing (which can trace paths defined by standard CAD programs). Other sizes of polyimide sheets may also be considered.

[0093] We have discovered that this secondary laser irradiation step alters the morphology and other characteristics of the underlying carbon foam in a surprising and advantageous manner, resulting in previously unobserved twisted or disordered multilayer carbon foams. Changing the parameters of the CO2 laser 125 can alter the properties of the carbon foam material, enabling the production of carbon foams with properties optimized for different applications.

[0094] This new exposed carbon foam possesses one or more of the following properties: Thickness or depth is easy to control It is more flexible than graphene produced using conventional laser processes, which is highly brittle.

[0095] It has strong adhesion to any underlying flexible substrate. High porosity High conductivity Increase in capacitance or charge storage Rapid absorption of organic solvents and water-based solutions Higher hydrophilicity High EMI shielding Electrode quality enhancement High wettability Anti-fouling.

[0096] It should be noted that by changing the laser parameters of any one or both lasers used in the dual-laser process, one or more of these properties, as well as the size and extent of defects and the magnitude (including relative magnitude) of the Raman D and 2D peaks, can be altered. In this way, carbon foams tuned for or particularly suited to different applications can be produced. Surprisingly, the operation of the second ablation laser enables the creation of usable exposed carbon foam regions, especially those with properties that can be adjusted by changing the parameters of the first and / or second lasers.

[0097] We can summarize it as follows: A method for manufacturing carbon foam material includes the following steps: (a) irradiating an encapsulated region or subsurface region of a carbon precursor material with a laser beam to generate carbon foam in the encapsulated region or subsurface region and generate disordered amorphous non-graphene material above the carbon foam, and then (b) performing laser ablation or treatment to remove the disordered amorphous non-graphene material and expose at least some of it in the carbon foam.

[0098] Feature F: Carbon foam generated by laser ablation of the carbon foam region beneath the surface. In the aforementioned feature E, we describe the formation of carbon foam 160 in the region by irradiating the encapsulated region or subsurface region of the carbon precursor with a laser 110 (e.g., an IR laser); the irradiation causes the upper (in the laser direction) carbon precursor material 140 to expand into a disordered, amorphous, non-graphene material 180; then, we expose or reveal the carbon foam 160 by ablating the upper disordered, amorphous, non-graphene material 180 with a second laser 125 (e.g., a CO2 laser). This second irradiation step not only ablates the upper disordered, amorphous, non-graphene material 180 and thus exposes the lower carbon foam 160, but also gives this lower carbon foam an unexpected and unusual surface morphology 185 with very desirable characteristics; such a carbon foam may be a torsion or disordered multilayer carbon foam.

[0099] However, because such foams may possess characteristics unrelated to graphene foams (such as a wide range of defects, appearance, wettability, and Raman spectra), we explicitly describe such foams as “non-graphene carbon foams” in Feature F. Therefore, the term “non-graphene carbon foam” (as opposed to the term “carbon foam”) explicitly excludes graphene foams, including twisted or disordered multilayer graphene foams, but extends to foams covering any other 3D carbon material.

[0100] We can summarize it as follows: A method for manufacturing non-graphene carbon foam, comprising the following steps: (a) A laser beam irradiates the encapsulation region or subsurface region of the carbon precursor material to generate carbon foam in the encapsulation region or subsurface region and to generate disordered, amorphous, non-graphene material above the carbon foam, then... (b) Perform laser ablation or treatment to remove disordered, amorphous, non-graphene material and expose at least some of the underlying carbon foam, and transform at least some of the underlying carbon foam into non-graphene carbon foam.

[0101] Feature G: Dual lasers in different wavelength bands As we saw in features E and F above, we can use two separate laser irradiation steps. These steps are typically performed using two separate lasers: the first step, to generate subsurface or encapsulated carbon foam, is typically accomplished using a focused IR laser 110; and the second step involves irradiation using a defocused CO2 laser 125 at a longer wavelength, but other wavelengths (e.g., UV and visible light) can also be used.

[0102] The second laser 125 ablates the material 180 (e.g., disordered, amorphous, non-graphene material) located between the carbon foam 160 and the surface, exposing the underlying carbon foam 160. The exposed carbon foam 160 can also be altered by the second laser (e.g., in terms of its surface morphology 185), that is, the term 'exposed' should be broadly interpreted to include not only revealing at least some of the pre-existing carbon foam, but also transforming or altering at least some of the pre-existing carbon foam into a 3D carbon material foam with characteristics different from those of the pre-existing graphene foam.

[0103] We can summarize it as follows: A method for manufacturing carbon foam material, comprising the following steps: (a) Irradiating an encapsulation region or subsurface region of a carbon precursor material below the surface of the material with a laser beam operating in a first band to generate carbon foam in the encapsulation region or subsurface region, and then (b) Using a laser beam operating in the second band to remove or ablate the material located above the carbon foam to expose at least some of the carbon foam.

[0104] Feature H: Electrical contacts positioned within carbon foam generated by laser ablation of the carbon foam region beneath the surface. We have previously seen how we produce carbon foam, which can be twisted or multilayered: because of the special electrical properties of this material (e.g., conductivity, capacitance), we can attach or position one or more electrical contacts (including electrical objects such as flexible electronics, microprocessors, antennas, IoT devices, electrical interfaces, etc.) into the carbon foam. For printed tracks (e.g., screen-printed silver tracks), these tracks are screen-printed onto a polyimide film (or other suitable substrate) and onto and inside a pre-existing 3D carbon material foam, such that the tracks form good electrical contacts with the foam and any structures formed on the foam.

[0105] We can summarize it as follows: A method for manufacturing carbon foam material, comprising the following steps: (a) Irradiating an encapsulation region or subsurface region of a carbon precursor material below the surface of the material with a laser beam operating in a first band to generate carbon foam in the encapsulation region or subsurface region, and then (b) Using a laser beam operating in the second band to remove or ablate the material located above the carbon foam to expose at least some of the carbon foam; and (c) Attaching, printing or positioning one or more electrical contacts into carbon foam.

[0106] Feature I: Electrical contacts are printed on a polyimide film and then exposed carbon foam is produced. In Feature H, we see that once the dual-laser process is complete, electrical contacts or circuitry are added to contact the pre-existing carbon foam; for example, simple silver electrical contacts can be screen-printed onto the carbon foam. In Feature I, we describe a process that begins by first screen-printing electrical contacts onto a polyimide film, and then completes by creating exposed carbon foam through a second laser ablation step in the dual-laser process. This has several advantages because the screen-printing process can interfere with or destroy the carbon foam. We refer to this process as “PPC” (short for “Post-Print Conversion”), where the screen-printing step is completed before the dual-laser process to create the carbon foam.

[0107] Therefore, for screen-printed tracks (e.g., screen-printed silver tracks), these tracks are screen-printed onto a polyimide film (or other suitable substrate), allowing carbon foam to subsequently form around one end of the printed track, thus providing a contact area with a large surface area and therefore very good electrical connectivity. Similar to the alternative processes described in Feature H above, the printed track also forms good electrical contact with any structures formed on the foam.

[0108] An alternative sequence involves using a first laser beam to generate subsurface carbon foam, then screen printing electrical contacts, and then using a second laser beam to generate carbon foam to create good electrical contact with the electrical contacts.

[0109] We can summarize it as follows: A method for manufacturing carbon foam material, comprising the following steps: (a) Screen printing electrical contacts onto or into a carbon precursor material; (b) Irradiating an encapsulation region or subsurface region of a carbon precursor material below the surface of the material with a laser beam operating in a first band to generate carbon foam in the encapsulation region or subsurface region, wherein steps (a) and (b) may be performed in the order of (a) then (b) or (b) then (a); and (c) Using a laser beam operating in the second band to remove or ablate the material located above the carbon foam to expose at least some of the carbon foam that is connected to the electrical contacts.

[0110] Feature J: High trajectory formed in carbon foam We have previously observed that the thickness of the subsurface or encapsulated carbon foam region can far exceed that of conventional graphene foams confined to the surface layer: the laser focus of the first laser beam can be progressively moved downwards through the carbon precursor material to create a deep or thick subsurface or encapsulated carbon foam layer. Then, a second laser irradiation step is employed to ablate the material between the carbon foam and the surface of the carbon precursor material, resulting in an exposed region of the carbon foam. This now exposed carbon foam region has a thickness or depth of at least 50 µm; carbon foams with a thickness of 300 µm have been produced. The increased thickness is beneficial because it leads to better electrical conductivity, greater capacitance, and higher mechanical integrity.

[0111] We can summarize it as follows: A method for manufacturing carbon foam material, comprising the following steps: (a) Irradiating an encapsulation region or subsurface region of a carbon precursor material below the surface of the material with a laser beam operating in a first band to generate carbon foam in the encapsulation region or subsurface region, and then (b) Using a laser beam operating in the second band to remove or ablate the material located above the carbon foam to expose at least some of the carbon foam; Furthermore, the thickness or depth of the carbon foam is at least 50 µm.

[0112] Feature K: Application of first and second lasers in different manufacturing facilities The specific properties or structure of the carbon foam produced by the second laser beam can be considered sensitive information because they define the characteristics of the final product. For the first laser beam process, it is desirable for the carbon foam supplier to perform the process at their manufacturing facility, then supply the carbon foam to the customer, who then uses the second laser beam for the final stage at their own manufacturing facility. As we explained earlier, by changing the parameters of the first and second lasers, it is possible to alter the properties of the carbon foam material, enabling the production of carbon foams with properties optimized for different applications. Typical parameters that can be changed or tuned in this way include: intensity, wavelength, pulse frequency, pulse duration, pulse profile, scan speed, focal length, and heat generated in the subsurface or encapsulation region.

[0113] By segmenting the manufacturing process in this way, suppliers do not need to know the specific manufacturing processes that customers use as part of the second laser ablation process (e.g., how they change the parameters of the second laser beam to give the exposed carbon foam the properties they need); customers can keep the details of how they produce the finished product confidential.

[0114] Therefore, the manufacturing process is a three-stage process involving the following steps: (a) irradiating the area below the surface of the carbon precursor material with the first laser beam at the manufacturing site to produce an unfinished carbon foam product; (b) transferring the unfinished carbon foam product to a customer-controlled manufacturing site; and (c) performing the laser ablation or treatment at the customer-controlled manufacturing site.

[0115] Furthermore, this method enables the large-scale production (see feature L, for example) of carbon foam using only the first laser process, thereby reducing the cost of this material, which can be used in a wide variety of applications and for a large number of customers. The production volume of more specialized products using a second laser beam may be significantly lower than that of carbon foam produced solely through the first laser process. Therefore, this method achieves a more efficient and lower-cost localized production of the base material, namely carbon foam produced solely through the first laser process.

[0116] We can summarize it as follows: A method for manufacturing an apparatus, comprising the following steps: (a) Irradiating an encapsulation region or subsurface region of a carbon precursor material below the surface of the material with a laser beam operating in a first band to generate carbon foam in the encapsulation region or subsurface region, and then (b) Using a laser beam operating in the second band to remove or ablate the material located above the carbon foam to expose at least some of the carbon foam; Step (a) is performed in one manufacturing facility, and step (b) is performed in a different manufacturing facility.

[0117] Group 3 Feature L: Scalable high-speed manufacturing: G-ii 3 Gii-3 is a scalable manufacturing facility for roll-to-roll or roll-to-sheet production of all the Gii-based materials described above. A key commercial advantage is that Gii-3 manufacturing requires no custom equipment; it utilizes off-the-shelf computer-controlled lasers for dual-laser carbon foam fabrication, along with conventional screen printing and drying techniques: these are well-known, easy-to-understand manufacturing processes and equipment that enable reproducibility and reliability.

[0118] We can summarize it as follows: A method for manufacturing an apparatus comprising carbon foam material; The method described therein includes a series of operations required to produce a carbon foam material by means of a continuous roll of carbon precursor film, which is at least partially produced by means of the method defined in any of the features AK above.

[0119] For feature AL, the following optional features are particularly relevant. It should be noted that any one or more of the following optional features can each be combined with one or more other compatible optional features, as well as with one or more of feature AL: We will cover the following areas: Manufacturing process First laser beam parameters and control scheme Properties of the subsurface region or packaged region carbon precursor materials Substrates supporting carbon precursor materials Carbonization at the surface where the laser beam is incident ablation laser beam or second laser beam Carbon foam.

[0120] It should be noted that any one or more of the following optional features may each be combined with one or more other compatible optional features and with any one or more of the other “features” listed in this specification (e.g., feature AL): The laser-based manufacturing process described above has numerous advantages over conventional CVD processes; these can be listed as the following optional features: It is a room temperature process.

[0121] It is an environmental pressure process.

[0122] It can be done on plastic substrates (compatible with any manufacturing process, not just silicon chip manufacturing).

[0123] It can be done without a catalyst.

[0124] It takes about 2 minutes or less to create a 1 cm² carbon foam that is approximately 50 µm thick on a plastic substrate.

[0125] It has been achieved that 3D carbon foam can be formed on flexible substrates.

[0126] No graphene or graphene oxide precursors are required.

[0127] Carbon foam material is generated only in the encapsulation area or subsurface area of ​​the carbon precursor material, and not on any surface of the carbon precursor material.

[0128] It uses a combination of industry-standard, low-cost, and scalable (i) screen printing technology and (ii) computer-controlled laser scanning technology.

[0129] It is suitable for high-speed, high-volume roll-to-roll or roll-to-sheet production.

[0130] The parameters and control scheme of the first laser beam are crucial for the production of carbon foam; we define the relevant optional characteristics here: The parameters of the laser beam irradiating the subsurface region or packaged region include one or more of the following: intensity, wavelength, pulse frequency, pulse duration, pulse profile, scanning speed, focal length, and heat generated in the subsurface region or packaged region.

[0131] Changing the laser parameters alters the properties of carbon foam materials, enabling the production of carbon foams with properties optimized for different applications.

[0132] Changing laser parameters alters one or more of the following properties or parameters of carbon foam materials: defect size, defect distribution, defect degree, defect type, Raman D and 2D peaks, relative size of Raman D and 2D peaks, thickness or depth, flexibility, adhesion, porosity, conductivity, capacitance, absorption by organic solvents and water-based solutions, hydrophilicity, EMI shielding, electrode quality, wettability, contact angle, and antifouling properties.

[0133] The laser beam generates temperatures above 500°C in the subsurface or encapsulated region to form carbon foam.

[0134] The laser beam generates temperatures exceeding approximately 500°C in the subsurface or encapsulated region to form carbon foam.

[0135] The pulse duration of the laser beam is between approximately 1 ns and 10 μs, resulting in approximately 5 × 10⁻⁶ μs. 7 ℃ / s and 2×10 12 Heating rate between ℃ / s.

[0136] The laser power is typically in the range of 8-20 watts, with 12 W being optimal.

[0137] The typical operating range of laser focal length is 50 mm to 400 mm.

[0138] The laser pulse frequency is between approximately 50 kHz and 500 kHz.

[0139] The laser pulse frequency is between approximately 1 kHz and 2 MHz.

[0140] The laser wavelength is between approximately 0.7 μm and 2.5 μm.

[0141] The laser scanned between approximately 9 cm / s and 40 cm / s.

[0142] The parameters of a laser beam include the focal point parameters.

[0143] The parameters of a laser beam include diffraction parameters.

[0144] The parameters of the laser beam include the interference pattern parameters.

[0145] The focal point of the laser beam moves through the depth of the carbon precursor material to generate carbon foam in the region below the surface of the carbon precursor or in the encapsulation region through which the focal point passes.

[0146] The focal point of the laser beam is moved through a depth of at least about 50 μm through the carbon precursor material to generate carbon foam in the region below the surface of the carbon precursor or in the encapsulation region with a thickness of at least 50 μm.

[0147] The focal point of the laser beam is moved through a depth of at least about 100 μm through the carbon precursor material to generate carbon foam in the region below the surface of the carbon precursor or in the encapsulation region where the thickness of the carbon precursor is at least 100 μm.

[0148] The laser beam scans (e.g., raster scanning) or moves laterally on the carbon precursor material to form the desired pattern.

[0149] A laser beam scans or moves laterally across a carbon precursor material to form a desired pattern that includes non-overlapping areas or lines.

[0150] The laser beam is repeatedly scanned (e.g., raster scan) or moved laterally on the carbon precursor material, with its focal point or maximum intensity arranged at multiple different depths within the carbon precursor material until a carbon foam with the desired pattern and depth is produced.

[0151] The laser beam is scanned at a scanning rate between 1.7 mm / s and 3550 m / s, or more typically between 35 mm / s and 350 mm / s, and the scanning can result in a pulses per inch (PPI) between 100 and 10000 (related to the production of individual polyimide sheets approximately 220 mm × 180 mm).

[0152] The wavelength of the laser beam is not absorbed by the carbon precursor material.

[0153] The carbon precursor material has extremely low absorption of the wavelength of the laser beam, with a radiation absorptivity per centimeter (decimal) of less than 50, or less than 20, or less than 10.

[0154] The laser beam is an IR laser.

[0155] The laser beam is an IR laser with a wavelength between approximately 0.7 μm and 2.5 μm.

[0156] The laser beam is an IR laser with a wavelength between approximately 0.75 μm and 1.40 μm.

[0157] The properties of the subsurface region or encapsulation region where carbon foam is generated can be defined using the following optional features: Unlike conventional graphene foam, the thickness of the subsurface region or encapsulated region can exceed approximately 50 μm.

[0158] The desired depth of the subsurface region or encapsulation region in the carbon precursor material is achieved by moving the focus of the first laser beam through the depth.

[0159] The subsurface region or encapsulation region can be positioned at different depths below the surface of the carbon precursor material, oriented towards the incident laser; and the exact depth of the subsurface region or encapsulation region is a function of various factors, such as laser intensity and the choice of the carbon precursor material used. For example, the subsurface region or encapsulation region can be at least about 10 μm, 20 μm, 30 μm, 40 μm, 50 μm or more below the surface of the carbon precursor material.

[0160] The thickness of the subsurface region or encapsulation region can be between approximately 10 μm and 200 μm.

[0161] The subsurface region or encapsulation region is located at a certain distance below the surface of the carbon precursor material. This distance is a function of various factors, such as laser intensity, other laser parameters, and the selection of the carbon precursor material used. For example, the top of the subsurface region or encapsulation region may be at least 1%, 10%, 20%, 30%, or 40% below the total thickness of the surface carbon precursor material.

[0162] The subsurface region or encapsulation region is a space of a certain volume centered on the midpoint of the minimum cross-section of the first laser beam, and the volume is within 500 or 100 micrometers or 1 micrometer of this midpoint.

[0163] Carbon precursor materials can be defined by the following optional characteristics: Carbon precursor materials are primarily made of thermosetting materials.

[0164] Carbon precursor materials are primarily made of non-thermoplastic materials.

[0165] The carbon precursor material is a thermosetting film.

[0166] The thermosetting film is a polyimide film.

[0167] The carbon precursor is a polyimide film.

[0168] The carbon precursor is a polyimide film, and the wavelength of the first laser is in the range of 0.7 μm to 2.5 μm.

[0169] The carbon precursor is at least 50% by mass of carbon, or at least 75% by mass of carbon, or at least 90% by mass of carbon.

[0170] The carbon precursor is a membrane or sheet.

[0171] Carbon precursor materials are flexible.

[0172] Carbon precursor materials are printed layers, such as screen-printed layers.

[0173] The thickness of the carbon precursor material is greater than 5 μm, or between 5 μm and 120 μm, or greater than 120 μm.

[0174] The carbon precursor material is substantially planar or flat and oriented perpendicular to the first laser beam.

[0175] The carbon precursor material is homogeneous.

[0176] Carbon precursor materials are heterogeneous and contain several different materials.

[0177] The carbon precursor is supported on a substrate that is not made of the carbon precursor.

[0178] The carbon precursor material has a low absorption coefficient at the wavelength of the first laser beam.

[0179] The carbon precursor material has an absorption coefficient of less than 50 cm⁻¹ for the first laser beam. -1 or less than 20 cm -1 or less than 10cm -1 .

[0180] The absorption coefficient of the carbon precursor material to the second or ablation laser beam (see Group 3 below) is less than 300 cm⁻¹. -1 .

[0181] The absorption coefficient of the carbon precursor material for the second or ablation laser beam is 300 ± 50 cm⁻¹. -1 .

[0182] The thermal conductivity of the carbon precursor material is less than 1.0 W / mK (using the method according to ASTM D5470).

[0183] The thermal conductivity of the carbon precursor material is less than 0.5 W / mK (using the method according to ASTM D5470).

[0184] A carbon precursor material is mounted on a substrate that is substantially optically transparent at one or more wavelengths of a first and / or second laser beam.

[0185] The carbon source of a carbon precursor material comprises or is formed from one or more polymers.

[0186] Carbon precursor materials include one or more of the following materials: polyimides (e.g., poly(4,4'-oxophenylene-pyromellitic acid diamine), also known as polyimides), polyetherimides (PEI), poly(methyl methacrylate) (PMMA) (e.g., sprayed PMMA), polyurethanes (PU), polyesters, vinyl polymers, carbonized polymers, photoresist polymers, alkyd resins, and urea-formaldehyde.

[0187] The carbon precursor comprises one or more of the following materials: poly(amic acid) (e.g., aryl-containing poly(amic acid)) (e.g., poly(pyromellitic dianhydride-co-4,4'-oxodiphenylamine), amic acid, also known as polyamic acid); dianhydrides (e.g., aryl dianhydrides) (e.g., pyromellitic dianhydride); derivatives of said poly(amic acid); and derivatives of said dianhydrides (e.g., derivatives of pyromellitic dianhydride).

[0188] The carbon precursor comprises one or more of the following materials: aromatic materials (e.g., aromatic polymers); heteroaromatic materials (e.g., heteroaromatic polymers); polymers containing aromatic moieties; cyclic materials (e.g., polymers containing cyclic moieties); heterocyclic materials (e.g., polymers containing heterocyclic moieties); and heteroaromatic materials (e.g., polymers containing heteroaromatic moieties).

[0189] Carbon precursors comprise materials containing one or more of aromatic bonds, heteroaromatic bonds, or heterobonded bonds (e.g., imide bonds).

[0190] The substrate can be considered as a material having a surface on which carbon precursors are positioned; the specific material, thickness, and properties of the substrate are determined by the application: for example, for some sensors, the substrate may be a thin, flexible plastic film; for other applications, the substrate may be a rigid polyimide plate on which electronic circuitry can be mounted. An IR laser can directly irradiate the carbon source; alternatively, radiation from the IR laser can first pass through the substrate before reaching the carbon source, in which case there are two alternative scenarios: first, the substrate is substantially transparent to IR radiation, and the mechanism of carbon foam formation is as described above. In the second scenario, the substrate is substantially opaque to IR radiation: then, rapid heat transfer from the substrate to the carbon precursor material first creates a disordered, amorphous, non-graphene layer at the interface with the substrate, and then carbon foam forms in the subsurface region or encapsulation region within the carbon precursor material.

[0191] The carbon precursor material can be positioned and supported on a substrate, which can be defined by the following optional characteristics: The substrate is a plastic body, film, or foil.

[0192] The substrate is flexible.

[0193] The substrate is a polyimide circuit board.

[0194] The substrate has an extremely low absorption rate of the first laser beam.

[0195] The substrate is substantially optically transparent at one or more wavelengths of the first laser beam.

[0196] The substrate has a high absorption rate of the first laser beam, absorbing more than 60% of the first laser beam.

[0197] The substrate has a high absorption rate of the first laser beam, absorbing more than 60% of the first laser beam, and its thermal conductivity is at least 10 W / mK.

[0198] The surface of the carbon precursor material is transformed into disordered, amorphous, non-graphene material by a laser beam, and the disordered, amorphous, non-graphene material adheres or bonds to the substrate, thereby indirectly attaching the 3D carbon material foam to the substrate.

[0199] The substrate is formed of one or more of the following: silicon (Si), silicon dioxide (SiO2), gallium nitride (GaN), gallium arsenide (GaAs), and zinc oxide (ZnO).

[0200] The substrate is a silicon wafer.

[0201] The substrate is a silicon dioxide wafer.

[0202] The substrate is a wafer containing silicon and silicon dioxide.

[0203] The substrate is a carbon source.

[0204] The substrate is not a carbon source; for example, it is a metal, a dielectric material, or a screen-printed dielectric material.

[0205] The carbon precursor is positioned "above" the substrate (e.g., the carbon precursor is positioned closer to the laser source than the substrate).

[0206] The carbon precursor is positioned "below" the substrate (e.g., the carbon precursor is positioned further away from the laser source than the substrate).

[0207] Carbonization at the surface where the laser beam is incident can be defined by the following optional characteristics: The surface of the carbon precursor material is transformed into disordered, amorphous, non-graphene material by the first laser beam.

[0208] The disordered, amorphous, non-graphene material occupies a thickness below the surface of the adjacent carbon precursor material, which is approximately 1%, less than approximately 1%, less than approximately 5%, or less than approximately 10% of the total thickness of the carbon precursor material.

[0209] The disordered, amorphous, non-graphene material extends to a distance below the surface of the carbon precursor material, said distance being at least 10 μm.

[0210] The disordered, amorphous, non-graphene material extends from the outer surface of the carbon precursor material to a depth of 10 μm or less, or 20 μm or less, or 30 μm or less, or 40 μm or less, or 50 μm or less, or 100 μm or less.

[0211] The ablation laser beam or the second laser beam can be defined by the following optional characteristics: The parameters of a laser beam include one or more of the following: intensity, wavelength, pulse duration, pulse profile, scanning speed, and heat generated in the subsurface region or packaged region.

[0212] Changing the laser parameters alters the properties of carbon foam materials, enabling the production of carbon foams with properties optimized for different applications.

[0213] Changing laser parameters alters one or more of the following properties or parameters of carbon foam materials: the type of carbon nanostructure present (e.g., carbon nano-onion), defect size, defect distribution, defect degree, defect type, Raman D and 2D peaks, relative size of Raman D and 2D peaks, thickness or depth, flexibility, adhesion, porosity, conductivity, capacitance, absorption by organic solvents and aqueous solutions, hydrophilicity, EMI shielding, electrode quality, wettability, contact angle, and antifouling properties.

[0214] The laser beam (“second laser beam”) that ablates the amorphous non-graphene material formed above the encapsulated region or subsurface region in the carbon precursor is a CO2 laser.

[0215] The second laser beam alters the carbon foam as part of the process that exposes it.

[0216] The second laser beam alters the shape of the carbon foam as part of the process that exposes it.

[0217] The second laser beam is automatically controlled to scan over the same, and / or overlapping, and / or non-overlapping areas (e.g., raster scanning).

[0218] The wavelength of the laser beam used to ablate amorphous non-graphene materials is between 8 μm and 15 μm.

[0219] The second laser beam is a long IR laser, a UV laser, or a visible light laser.

[0220] The pulse frequency of the second laser beam is between 50 kHz and 500 kHz, and the scanning speed is between 9 cm / s and 40 cm / s.

[0221] The carbon precursor material has an absorption coefficient for the second laser beam greater than 100 cm⁻¹. -1 Or, the absorption coefficient of the second laser beam is higher than 200 cm⁻¹. -1 .

[0222] The absorption coefficient of the carbon precursor material for the second laser beam is 300 ± 50 cm⁻¹. -1 .

[0223] The laser power is typically in the range of 8-20 watts, with 12 W being optimal.

[0224] The typical operating range of laser focal length is 50 mm to 400 mm.

[0225] The second laser beam scans in a pattern that includes non-overlapping areas or lines.

[0226] The second laser beam scans with a pattern that matches the scanning pattern of the first laser beam.

[0227] The second laser beam is defocused.

[0228] The manufacturing process is a three-stage process involving the following steps: (a) irradiating a region below the surface of a carbon precursor material with a first laser beam at a manufacturing site to produce an unfinished carbon foam product; (b) transferring the unfinished carbon foam product to a customer-controlled manufacturing site; and (c) performing the laser ablation or treatment at the customer-controlled manufacturing site.

[0229] Carbon foam can be defined by the following optional characteristics: The carbon foam has a thickness of at least 50 μm.

[0230] The thickness of the carbon foam ranges from 50 μm to 300 μm.

[0231] Carbon foam is or includes multi-layered twisted or disordered multi-layered foam.

[0232] Carbon foam is or includes carbon foam with a defective spatial distribution, resulting in high electrochemical reactivity.

[0233] Carbon foam is or includes carbon foam with vacancy basal defects, resulting in high electrochemical reactivity.

[0234] The carbon:oxygen ratio of carbon foam is between 25:1 and 50:1.

[0235] Carbon foam has a fast electron transfer constant.

[0236] Carbon foam has one or more of the following properties: o Thickness or depth is easy to control It is more flexible than graphene made using conventional laser processes, which is highly brittle.

[0237] o It has strong adhesion to the underlying flexible substrate o High porosity o High conductivity o Capacitance or charge storage increases o Rapid absorption of organic solvents and water-based solutions o Higher hydrophilicity o EMI shielding high o Electrode quality enhancement The contact angle is approximately 20° or less.

[0238] The properties of carbon foam can be selected by choosing specific laser parameters to generate carbon foam materials with one or more of the following desired properties or parameters: defect size, defect distribution, defect degree, defect type, Raman D and 2D peaks, relative size of Raman D and 2D peaks, thickness or depth, flexibility, adhesion, porosity, conductivity, capacitance, absorption of organic solvents and water-based solutions, hydrophilicity, EMI shielding, electrode quality, wettability, contact angle, and antifouling properties.

[0239] Non-graphene carbon material foam Under a scanning electron microscope, conventional graphene foam appears to have large open-ring structures, typically 500 µm in size. Carbon foam generated using a dual-laser process looks very different; Figures 18-22 This is a SEM image of this Gii carbon foam.

[0240] Figure 23 This is a SEM image of carbon nano-onions, see "Raman spectroscopy of polyhedral carbon nano-onions", DOI: 10.1007 / s00339-015-9315-9 and "Carbon nano-onions: unique carbon nano-structures with fascinating properties and their potential applications", DOI:10.1016 / j.ica.2017.07.021. Its similarity to Gii carbon foam is obvious.

[0241] As previously mentioned, graphene foam possesses numerous characteristics: it is hydrophobic and has low wettability. Raman analysis of typical graphene foam reveals the following signature features: the absence of a D peak; a 2D peak higher than the G peak; and a D peak:G peak ratio close to zero. However, carbon foam generated using a dual-laser process does not exhibit these characteristics; it is hydrophilic with a contact angle below 20°; and it lacks the Raman spectral signature indicative of graphene: it displays a prominent D peak; a 2D peak significantly smaller than the G peak; and a D peak:G peak ratio significantly higher than zero. Figure 24 The Raman shifts of eight carbon foam sheets fabricated using a dual-laser process are shown, demonstrating the consistency of the Raman signature. It also exhibits a significant D peak; the 2D peak is smaller than the G peak; and the D:G peak ratio is significantly higher than zero. As we previously noted, this Raman spectrum shares many similarities with carbon nanotube onions. See also... Figure 15C Also from "Raman spectroscopy of polyhedral carbon nano-onions", DOI: 10.1007 / s00339-015-9315-9. The specific dual-laser parameters used to generate this low-resistivity carbon nano-onion variant of Gii carbon foam are shown in Table 5 below: Table 5

[0242] We can summarize it as follows: A carbon foam material, which is at least partially made by a method defined by any one of the features AL above, and which is hydrophilic with a contact angle of less than 20°.

[0243] A carbon foam material, which is at least partially made by a method defined by any one of the features AL above, and whose Raman spectrum exhibits a significant D peak; the 2D peak is smaller than the G peak; and the ratio of the D peak to the G peak is greater than zero.

[0244] A carbon nanotube onion material, which is at least partially made by a method defined by any one of the features AL above.

[0245] Please note that the Hall device can be characterized using these materials, and therefore we can summarize as follows: An apparatus comprising a carbon foam material made at least in part by a method defined in any of the features AL above, wherein the carbon foam material is hydrophilic and has a contact angle of less than 20°.

[0246] An apparatus comprising a carbon foam material made at least in part by a method defined as any one of the features AL above, wherein the Raman spectrum of the carbon foam material exhibits a significant D peak; the 2D peak is smaller than the G peak; and the ratio of the D peak to the G peak is greater than zero.

[0247] An apparatus comprising a carbon nanoparticle onion material, at least in part, made by a method defined as any one of the features AL above.

[0248] For convenience, the characteristics AL are summarized here: Group 1: Subsurface carbon foam Feature A: Carbon foam generated in the region below the surface of the carbon precursor material. Feature B: Carbon foam generated in the encapsulation region of the carbon precursor material. Feature C: Carbon foam generated in regions of the carbon precursor material, wherein said regions do not have substantial gas escape channels. Feature D: Amorphous non-graphene materials adhered to a substrate Group 2: Dual-laser processing Feature E: Carbon foam generated by laser ablation of the carbon foam region beneath the surface. Feature F: Non-graphene carbon foam generated by laser ablation of the carbon foam region beneath the surface. Feature G: Dual Laser Feature H: Electrical contacts positioned within carbon foam generated by laser ablation of the carbon foam region beneath the surface. Feature I: Electrical contacts are printed on a polyimide film, and then exposed carbon foam is produced. Feature J: High trajectory formed in carbon foam Feature K: Application of first and second lasers in different manufacturing facilities Feature L: Scalable high-speed manufacturing Part C: Carbon foam for electronic cigarette devices and THP (heated tobacco products) devices Part C.1 Analyzing Each Item Figure 25-34 The carbon foam described in the preceding sections possesses numerous properties that make it particularly interesting in two rapidly growing consumer categories: e-cigarettes and THP. In this section C, we will refer to... Figure 25-34 These characteristics are summarized below.

[0249] The carbon foam components described in this section can be used in electronic vaping devices (e.g., as heating elements to heat e-liquids) and as receptors in THP sticks. Carbon foam components can also be used in any other situation requiring heating of a substance (liquid, gel, or solid (powder or otherwise) or combinations thereof) with minimal contaminants, such as medical inhalation devices. The terms "vaping" or "vape" devices can include any type of electronic vaping device, including cartridge-based devices, single-use disposable devices, multiple-use disposable devices, mod-type electronic vaping devices, or liquid-refillable devices.

[0250] The first application of Gii carbon foam, which we describe in detail, is as a resistance heating element in electronic cigarette devices, replacing traditional resistance heating elements (typically stainless steel mesh, stainless steel wire, or a metal layer bonded to a ceramic substrate). Gii carbon foam heats uniformly and predictably when an electric current passes through it, making it a good candidate for this application; we will elaborate later in this Part C on several additional properties of Gii carbon foam (such as anti-fouling and high wettability) that make it particularly suitable for this application.

[0251] We from Figure 25 An overview of known types of electronic cigarette devices is given below. Figure 25 As shown, in a conventional e-cigarette device, a cylindrical metal mesh heating element 20 is placed inside a cylindrical flexible sleeve 21. Atomizable liquid drawn from an e-liquid reservoir 22 (typically an open-cell foam container) passes through the sleeve 21 via a wick (not shown) positioned laterally through a hole 23 in the sleeve 21. The e-liquid contacts the heated metal mesh 20 and evaporates within the cylindrical interior 24 (vapor generation chamber) of the metal mesh cylinder. The vapor is drawn in, air enters the air inlet 25, and is expelled by the user through the vapor passage 26 and outlet 27. The e-cigarette device also includes silicone seals 28 and 29 located at the top and bottom of the device to ensure no e-liquid leakage. A plastic shell 30 surrounds the foam liquid reservoir 22 and seals the e-liquid seals 28 and 29.

[0252] like Figure 26As shown, the Gii carbon foam heating element 40 can be used in place of the standard mesh heater 20 and wick assembly, keeping all other components and manufacturing steps identical. The cylindrical Gii atomizer 40 comprises a continuous carbon foam running through its entire thickness (e.g., the thickness of the precursor PI substrate), so that its outer surface draws liquid from the foam reservoir 30 via orifices 23. The Gii carbon foam heating element 40 heats up and vapor escapes directly into the vapor generation chamber 24.

[0253] Below, we will explain the advantages of using the Gii carbon foam heating element 40 over traditional heating element atomizers. Please note that Gii carbon foam can be used in any type of e-cigarette device, including single-use or disposable devices, or refillable, reusable devices.

[0254] Figure 27 This is a schematic diagram of the cross-section of the Gii carbon foam heating element: (See diagram below) Figure 28 As shown, the element is formed as a tightly wound small rectangular sheet, replacing the traditional cylindrical mesh heating element. (Back to...) Figure 27 We can see that the Gii carbon foam forms part of the entire volume 50; this entire volume is resistively heated; it will typically exhibit a resistance of about 1 ohm, like a conventional metal heater. Figure 28 The outer surface (dark gray) of the cylinder in the middle Figure 27 The top portion 51 faces and contacts the liquid in the liquid reservoir, and draws liquid from the reservoir; the liquid is heated as it passes through (indicated by arrow 55) the body 50 of Gii carbon foam material, and then evaporates on the lower surface 52, which forms the lower surface 52. Figure 28 The inner surface (light gray) of the cylinder is exposed to the steam generation chamber. As heated liquid evaporates from this inner heating surface 52, it attracts more liquid through the Gii carbon foam body 50 due to the carbon foam's excellent wettability and porosity; it is a highly efficient wicking material with uniform and rapid wetting. The combined, integrated heater and wick are formed on a single sheet of high-temperature polyimide film 53, safe and non-flammable up to 350°C (exceeding the typical temperature at which the atomizer will be heated). Screen-printed electrodes 54 provide a power path to the heating element. Note that... Figure 27 It is a cross-sectional view through the combined heating element and core; in the plan view, the carbon foam can form a curved trajectory, or be designed to heat the liquid uniformly in a controlled manner and core in any other pattern.

[0255] Furthermore, note that the Gii carbon foam serves both as a liquid core and directly heats the liquid; the Gii carbon foam does not require heating a separate heat-conducting layer that then heats the liquid: instead, the Gii carbon foam is in direct contact with the liquid to be heated. In an alternative embodiment, the Gii carbon foam can be used to heat the heat-conducting layer (which can be separate from the Gii carbon foam or formed from the underlying substrate used to manufacture the Gii carbon foam), and this heat-conducting layer then heats the liquid. However, this alternative embodiment can be more complex to manufacture, especially since it requires the presence of an additional separate heat-conducting layer, and is therefore not a preferred option.

[0256] Careful control of the liquid flow from the liquid absorption area to the heating element is crucial to preventing liquid leakage. Although... Figure 27 As illustrated, it is possible to use a single, typically uniform Gii carbon foam structure, but internal 3D structures can also be produced in the Gii manufacturing process. We... Figure 29 This property is utilized in the next variant shown, in which we separate the Gii carbon foam liquid absorption region 51 from the Gii heating region 52 by means of an internal microchannel 56 that restricts and controls the capillary flow of liquid to the heating section 52.

[0257] The aforementioned variant reuses the structure of conventional e-cigarettes, essentially replacing the mesh and cotton combination with a single Gii carbon foam structure. Further fundamental variants are possible, with the potential to fundamentally reduce the number of components, enabling rapid, fully automated atomizer assembly and thus lowering BOM costs.

[0258] Figure 30 A schematic plan view of the Gii carbon foam integrated atomizer is shown, which combines an e-liquid porous wicking section 51 (in contact with a liquid reservoir (typically with a 2 mL capacity), a single capillary microchannel 56, a heating section 52, and a power lead 54, all of which are manufactured as a single low-cost integrated item in a single multi-stage process, and all of which are fabricated on a monolithic high-temperature PI (polyimide) substrate 53.

[0259] Figure 31 A schematic side view of this structure is shown. Maintaining this structure as a flat unit allows for highly simplified and easy assembly of mouthpieces or cartridges for electronic cigarette devices (including single-use or disposable electronic cigarette devices, or refillable reusable electronic cigarette devices), as shown in Figure 32.

[0260] exist Figure 32AIn the image, we can see that the liquid wicking section 51 extends along one surface of the liquid reservoir 22 and continues as a flat structure to become the heater section 52 inside the atomizing chamber 24. This allows for the manufacture of a particularly flat mouthpiece or cartridge. The carbon foam structure includes screen-printed electrodes 54 that terminate at an electrical connector 57, which contacts an electrical connector in the body of an electronic cigarette device (not shown) that includes a battery and power electronics.

[0261] Because the Gii carbon foam and the underlying substrate are flexible, we can also bend the heating element 52 so that it is placed horizontally, as shown below. Figure 33 As shown, it is the same as in a conventional ceramic atomizer.

[0262] We can even bend the Gii carbon foam atomizer 180 degrees, so that the porous wicking region 51 in the liquid reservoir 22 is now located at the base of the reservoir 22, and the heating element 52 is directly below it, as... Figure 34 As shown. Similarly, the structure may not be formed from planar Gii carbon foam sheets bent 180 degrees, but from a single integrated Gii carbon foam structure, in which the porous region forms facing upward and enters the top layer in the reservoir, and the heating region faces downward and enters the steam generation chamber.

[0263] Part C2: Characteristics of Different Implementation Methods In this C2 section, we focus on several different features, many of which are implemented in the apparatus described earlier in this C section. Note that any one or more of these features 1-22 can be combined together.

[0264] Design and manufacturing Feature 1: Gii carbon foam can be formed into components of atomizing devices, such as resistance heating elements. Gii carbon foam possesses numerous properties that make it ideal for this purpose. For example, low drive voltage, high steady-state temperature, ultra-fast response, and excellent flexibility are all characteristics found in Gii carbon foam. As mentioned above, the carbon foam heating element can directly heat the liquid to be atomized; that is, it does not need to heat a separate heat-conducting element that is in direct contact with the liquid. The antifouling properties and high wettability of Gii carbon foam make direct contact between the carbon foam and the heated atomizable liquid the preferred approach.

[0265] We can summarize it as follows: A method for manufacturing a component substantially made of carbon foam for an atomizing device; wherein the method includes the step of manufacturing a conductive, non-metallic carbon foam component capable of wicking atomizing liquid using a high-temperature process generated by directing a laser beam toward a carbon-based precursor material such as a polymer or polyimide sheet.

[0266] A method for manufacturing a component substantially made of carbon foam for use in an electronic cigarette device; wherein the method includes the step of manufacturing a conductive, non-metallic carbon foam component capable of wicking an atomizable liquid using a method defined by any one of the features A–L above.

[0267] We can also summarize it as follows: An atomizing device includes a carbon foam component, such as a heating element or core, or a combination of heating element and core, which is at least partially made by the method described above.

[0268] The atomizing device may be a heater element, such as in or used in an electronic cigarette device or a medical inhaler device. The atomizable liquid may include a drug or therapeutic drug, or may include an electronic liquid for use in an electronic cigarette device.

[0269] Feature 2: Because Gii carbon foam is both porous for e-liquids and ohmically heated, it can be manufactured to form integrated structures that include liquid intake or wicking functionality (otherwise performed by porous cotton, foam, or ceramic elements – this function transfers e-liquid from an e-liquid reservoir (typically storing no more than 2 mL of e-liquid) to a heating element) and liquid heating functionality (otherwise performed by wire wound around the cotton / foam or by a sintered metal coating on a ceramic substrate). For example, the heating element and the liquid porous wicking element can be formed from the same polymer precursor material and can be a single integrated or homogeneous unit, with one part of the unit serving as the liquid wicking segment and another part serving as the heating segment. The liquid wicking segment can include one face (typically planar) of the carbon foam structure, and the heating segment can include the opposite face. Alternatively, the liquid wicking segment and the heating segment can be coplanar but physically separate.

[0270] Manufacturing parameters can be adjusted so that the carbon foam forming the porous element for taking in liquids has properties optimized for that function, and similarly, the carbon foam forming the heating element has properties optimized for that function—for example, different parameters are used to manufacture each of these elements.

[0271] We can summarize it as follows: A method of manufacturing (i) a heating element and (ii) a liquid porous wicking element, the heating element being used, for example, in an electronic cigarette device, the liquid porous wicking element being used, for example, in an electronic cigarette device, and configured to supply liquid to the heating element, both elements being substantially made of carbon foam and being conductive, non-metallic, and porous to the electronic liquid; And wherein the carbon foam heating element and the carbon foam liquid porous element are manufactured using (A) a laser-based high-temperature process applied to carbon precursor materials such as polymers or polyimide sheets or (b) any of the above features A–L, and wherein the heating element and the liquid porous element are manufactured to form an integrated structure.

[0272] We can further summarize it as follows: A method for manufacturing (i) a first component and (ii) a second component, both of which are substantially made of carbon foam and are conductive, non-metallic, and capable of wicking atomizing liquids; Furthermore, both of the components are manufactured using (A) a laser-based high-temperature process applied to carbon precursor materials such as polymers or polyimide sheets or (b) the method defined by any one of the above features A–L, and the components are manufactured to form an integrated structure.

[0273] The first component can be a heater element, and the second component can be a liquid wicking element.

[0274] We can also summarize it as follows: An atomizing device manufactured by this method.

[0275] Feature 3: High-speed, ultra-high capacity roll-to-roll or roll-to-sheet Gii carbon foam manufacturing of complete integrated components is possible: the component combines (a) a Gii carbon foam porous wicking section that transfers liquid from a local reservoir and (b) a Gii carbon foam heating element (e.g., coplanar with the porous section, or below the porous section using the G-Thru 3D process described below) that supplies liquid from the Gii carbon foam porous wicking section, wherein all components are manufactured on the same polymer (e.g., PI) substrate (separate and then bonded PI substrates are also possible).

[0276] We can summarize it as follows: A method for manufacturing a carbon foam component; wherein the method comprises: passing a continuous roll of carbon precursor material through a series of roll-to-roll or roll-to-sheet operations required for manufacturing the carbon foam component, the operations being performed at least in part using (a) a laser-based high-temperature process applied to the carbon precursor material, such as a polymer or polyimide sheet, or (b) a method defined in any one of the features A–L defined above.

[0277] This component can be a part used in electronic cigarette devices, such as a heating element or a liquid porous element.

[0278] We can also summarize it as follows: An atomizing device manufactured by this method.

[0279] Feature 4: Gii carbon foam can be fabricated with Gii carbon foam microchannels that guide liquid from a Gii carbon foam porous wicking element (e.g., a layer drawing liquid from a local reservoir) to a Gii carbon foam heating element, thereby enabling controlled capillary-based release of liquid to the heating element without leakage or excessive overflow from the heating element or excessive heat transfer to the liquid fed into the reservoir of the microchannel; this reuses the type of microchannel used in Gii carbon foam-based microfluidic devices (which were originally used in biosensors). Note that we typically use only a single microchannel, so that there is no current path through the porous element (for two microchannels, there may be a current path returning through the porous element, causing undesirable heating of the porous element).

[0280] We can summarize it as follows: A method for manufacturing a component substantially made of carbon foam for an atomizing device; wherein the method includes the steps of manufacturing a conductive, nonmetallic, and electron-fluid-porosity carbon foam component using (A) a laser-based high-temperature process applied to a carbon precursor material such as a polymer or polyimide sheet or (b) a method defined by any one of the features A–L above. Furthermore, the component described therein is a microchannel configured to provide controlled delivery of atomizable liquid from a liquid reservoir to a heating element.

[0281] We can also summarize it as follows: An electronic cigarette device includes a microchannel made at least in part by the method defined above, the microchannel being configured to provide controlled delivery of atomizable liquid from a liquid reservoir to a heating element.

[0282] Feature 5: The atomizer may include power electrodes for the Gii carbon foam heating element, all manufactured as part of the same Gii carbon foam manufacturing process, for example, directly on a PI substrate using a screen printing process, in which the Gii carbon foam is formed within the PI substrate. The electrodes may be conductive ink, silver, or carbon foam.

[0283] We can summarize it as follows: A method for manufacturing a component substantially made of carbon foam for an atomizing device; wherein the method includes the steps of manufacturing a conductive, non-metallic carbon foam component capable of wicking atomizing liquid using (A) a laser-based high-temperature process applied to a carbon precursor material such as a polymer or polyimide sheet or (b) a method defined by any one of the features A–L above. The component is a heating element, and the method includes the step of manufacturing (e.g., by screen printing) an electric electrode for the heating element on the same substrate as the heating element and as part of the same manufacturing process used to manufacture the heating element.

[0284] We can also summarize it as: an atomizing device, including components and electrical electrodes for said components, said atomizing device being manufactured using the method described above.

[0285] Feature 6: All the major functional components required for the atomizer can be manufactured using the same multi-step process used to manufacture Gii carbon foam-based devices: (a) a Gii carbon foam porous wicking element / layer that transfers liquid from a local reservoir; (b) a Gii carbon foam microchannel or structure that allows liquid to flow from the porous element in a controlled manner without leakage; (c) a Gii carbon foam heating element that is supplied with liquid from the Gii microchannel; and (d) electrodes that provide power to the Gii carbon foam heating element.

[0286] We can summarize it as follows: A method for manufacturing a component substantially made of carbon foam for an atomizing electronic cigarette device; wherein the method includes the steps of manufacturing a conductive, nonmetallic carbon foam component that is porous to electronic liquids using (A) a laser-based high-temperature process applied to a carbon precursor material such as a polymer or polyimide sheet or (b) a method defined by any one of the features A–L above. The components described therein are (a) a carbon foam porous wicking element / layer for transferring liquid from a local reservoir; (b) a carbon foam microchannel or structure that allows liquid to flow from the porous element in a controlled manner without leakage; and (c) a carbon foam heating element that is supplied with liquid from the microchannel. The method includes the step of manufacturing (e.g., by screen printing) an electric electrode for the heating element on the same substrate as the heating element and as part of the same manufacturing process used to manufacture the heating element.

[0287] We can also summarize it as: an atomizing device manufactured using this method.

[0288] Feature 7: Gii carbon foam is typically fabricated on a high-temperature PI film substrate (stable up to 350°C) that is non-porous, thus providing a liquid-impermeable boundary for the Gii carbon foam structure; this boundary can be designed to provide a non-porous liquid barrier to prevent liquid leakage. Therefore, in Figure 34 In the schematic diagram, the base of the liquid reservoir abuts against the Gii carbon foam structure, thereby forming a seal against the back of the Gii carbon foam structure and the nozzle to which the Gii carbon foam structure is mounted; the inherent compressibility of the Gii carbon foam structure (and the microchannels that allow liquid to flow through and into the heating element extending slightly into the depth of the PI membrane, rather than just onto the surface of the PI membrane) enables the formation of a liquid-tight seal.

[0289] We can summarize it as follows: A method for manufacturing a component substantially made of carbon foam for an atomizing device; wherein the method includes the steps of manufacturing a conductive, nonmetallic carbon foam component that is porous to an electronic liquid using (A) a laser-based high-temperature process applied to a carbon precursor material such as a polymer or polyimide sheet or (b) the method defined in any one of the features A–L above. Furthermore, a portion of the carbon-based precursor material is shaped or configured as the periphery, boundary, or surrounding of carbon foam components, such as heating elements or liquid wicking elements, to prevent liquid leakage.

[0290] We can also summarize it as: an atomizing device manufactured using this method.

[0291] Feature 8: The flexible PI substrate (carbon precursor material) can be bent or shaped into curved surfaces, such as cylinders, without the risk of Gii carbon foam structures (e.g., heating elements, liquid porous elements, etc.) peeling off. Other bent or folded substrates are also possible, such as glass and silicon.

[0292] We can summarize it as follows: A method for manufacturing a component made substantially of carbon foam for an atomizing electronic cigarette device; wherein the method includes the steps of manufacturing a conductive, nonmetallic carbon foam component that is porous to the electronic liquid using (A) a laser-based high-temperature process applied to a carbon precursor material such as a polymer or polyimide sheet or (b) the method defined in any one of the features A–L above. Furthermore, a portion of the carbon-based precursor material is a substrate that is folded or bent when it is located in the atomizing device.

[0293] We can also summarize it as: an atomizing device manufactured using this method.

[0294] Feature 9: The Gii carbon foam porous liquid intake layer can also be thermally insulating, thus preventing undesirable heating of the liquid in the reservoir (undesirable heating can make it difficult to maintain the heating element at a stable setpoint temperature). Conventional graphene can be highly thermally conductive (e.g., 5000 W / mK), while polyimide tape is thermally insulating (approximately 2 W / mK); Gii carbon foam has an in-plane thermal conductivity of approximately 4 W / mK. The in-plane thermal diffusivity is 1-2 mm. 2 / s. The specific heat per unit volume is approximately 2-3 MJ / m³K.

[0295] We can summarize it as follows: A method for manufacturing a component substantially made of carbon foam for an atomizing device; wherein the method includes the steps of manufacturing a conductive, non-metallic carbon foam component capable of wicking atomizing liquid using (A) a laser-based high-temperature process applied to a carbon precursor material such as a polymer or polyimide sheet or (b) the method defined in any one of the features A–L above. Furthermore, the components, such as liquid wicking elements, are configured to thermally insulate the liquid reservoir within the atomizing device from the heat generated by the heating element within the atomizing device.

[0296] We can also summarize it as: an atomizing device manufactured using this method.

[0297] Electronic cigarette performance Feature 10: Gii carbon foam has an easily measurable resistivity temperature coefficient (approximately -0.0013 / °C) and enables efficient ohmic heating; the temperature of the Gii carbon foam heating element can be accurately inferred from the delivered voltage / current in the e-cigarette device. The Gii carbon foam heating element also heats up rapidly to the closed-loop control setpoint and can be controlled to maintain that setpoint using PWM closed-loop feedback control and the known resistivity temperature coefficient.

[0298] We can summarize it as follows: A method for manufacturing a component substantially made of carbon foam for an atomizing device; wherein the method includes the steps of manufacturing a conductive, nonmetallic carbon foam component that is porous to an electronic liquid using (A) a laser-based high-temperature process applied to a carbon precursor material such as a polymer or polyimide sheet or (b) the method defined in any one of the features A–L above. Furthermore, the component is a heating element characterized by a known or measured resistivity temperature coefficient, and the component is configured to heat using a PWM closed-loop feedback control system that uses the known resistivity temperature coefficient.

[0299] We can also summarize it as: an atomizing device manufactured by this method, wherein the heating element is characterized by a known or measured resistivity temperature coefficient and is configured to be heated using a PWM closed-loop feedback control system that uses the known resistivity temperature coefficient.

[0300] Feature 11: Gii carbon foam heating elements exhibit rapid, uniform, isotropic resistance heating (e.g., they can maintain a uniform 280°C or any desired level across their surface) without localized hot spots (e.g., exceeding 400°C) that can generate aldehydes, etc. Because Gii heating elements can maintain a stable setpoint high temperature across their entire surface, this results in predictable, repeatable, high-quality performance for delivering the target nicotine output with minimal variation between or within puffs and optimal flavor.

[0301] We can summarize it as follows: A method for manufacturing a component substantially made of carbon foam for an atomizing device; wherein the method includes the steps of manufacturing a conductive, nonmetallic carbon foam component that is porous to an electronic liquid using (A) a laser-based high-temperature process applied to a carbon precursor material such as a polymer or polyimide sheet or (b) the method defined in any one of the features A–L above. And the component thereon is a heating element configured to heat uniformly and consistently on its surface.

[0302] We can also summarize it as: an atomizing device manufactured by this method; and an electronic cigarette device manufactured using the above method, wherein the component is a heating element configured to heat uniformly and consistently on its surface.

[0303] Feature 12: Gii carbon foam has excellent wettability to e-liquids, so Gii carbon foam heating elements can easily and uniformly absorb e-liquids from local reservoirs, and the e-liquids will be evenly distributed on the heating surface (which helps to heat evenly, generate uniform vapors across the entire surface, and avoid localized dry areas).

[0304] We can summarize it as follows: A method for manufacturing a component substantially made of carbon foam for use in an electronic cigarette device; wherein the method includes the steps of manufacturing a conductive, non-metallic carbon foam component that is porous to electronic liquids using (A) a laser-based high-temperature process applied to a carbon precursor material such as a polymer or polyimide sheet or (b) the method defined in any one of the features A–L above. Furthermore, the component described therein can be wetted with a contact angle of less than 20°.

[0305] We can also summarize it as: an atomizing device manufactured by this method, wherein the heating element can be wetted with a contact angle of less than 20°.

[0306] Feature 13: Gii has excellent anti-fouling properties, thus minimizing VG-based caramelization and extending the safe life of the heating element to potentially thousands of puffs.

[0307] We can summarize it as follows: A method for manufacturing a component substantially made of carbon foam for an atomizing device; wherein the method includes the steps of manufacturing a conductive, nonmetallic carbon foam component that is porous to an electronic liquid using (A) a laser-based high-temperature process applied to a carbon precursor material such as a polymer or polyimide sheet or (b) the method defined in any one of the features A–L above. Furthermore, the component is a heating element with anti-fouling properties, which allows the heating element to provide more than 300 puffs during normal use without significant carbonization or caramelization.

[0308] We can also summarize it as: an atomizing device manufactured using this method.

[0309] Feature 14: Gii carbon foam can be made into different (e.g., complex 3D) shapes to optimize the contact between the vortex and the Gii carbon foam heater, and thus optimize the content of nicotine / terpenoids / flavonoids and improve the flavor of the steam.

[0310] We can summarize it as follows: A method for manufacturing a component made substantially of carbon foam for an atomizing electronic cigarette device; wherein the method includes the steps of manufacturing a conductive, non-metallic carbon foam component that is porous to atomizing liquid using (A) a laser-based high-temperature process applied to a carbon precursor material such as a polymer or polyimide sheet or (b) a method defined by any one of the features A–L above. And the component therein is a heating element, which is formed in a way that alters the shape of the airflow on the heating element, for example, by increasing the content of nicotine or terpenoids or flavonoids, or by improving the steam flavor of inhaled steam, or by improving the presence of other steam components.

[0311] We can also summarize it as: an atomizing device manufactured by this method; and an electronic cigarette device comprising a carbon foam heating element manufactured by the above method, wherein the heating element is configured to alter the shape of the airflow on the heating element in a manner that increases the content of nicotine or terpenoids or flavonoids or improves the vapor flavor of the inhaled vapor.

[0312] E-cigarette safety Feature 15: Gii does not decompose or release unwanted compounds at normal operating temperatures. Gii is stable at high temperatures (e.g., when produced on high-temperature PI film substrates, it is stable at 350°C).

[0313] We can summarize it as follows: A method for manufacturing a component substantially made of carbon foam for an atomizing device; wherein the method includes the steps of manufacturing a conductive, nonmetallic carbon foam component that is porous to an electronic liquid using (A) a laser-based high-temperature process applied to a carbon precursor material such as a polymer or polyimide sheet or (b) the method defined in any one of the features A–L above. Furthermore, the carbon precursor is a high-temperature PI film that is essentially thermally stable at 350°C.

[0314] We can also summarize it as: an atomizing device manufactured using this method.

[0315] Feature 16: When thermal decomposition occurs, the combustion products of the Gii carbon foam heating element are only trace amounts of CO and H2. Therefore, even under dry vaping or malfunction conditions, there are no harmful vapor components. Consequently, the risk of metals or other contaminants in the vapor is minimal: Gii atomizers can set a new benchmark for vapor safety, thus establishing a high standard for future regulatory approvals (e.g., PMTA) that conventional atomizers may struggle to meet.

[0316] We can summarize it as follows: A method for manufacturing a component substantially made of carbon foam for an atomizing device; wherein the method includes the steps of manufacturing a conductive, nonmetallic carbon foam component that is porous to an electronic liquid using (A) a laser-based high-temperature process applied to a carbon precursor material such as a polymer or polyimide sheet or (b) the method defined in any one of the features A–L above. Furthermore, the combustion products of this component are primarily limited to CO and H2.

[0317] We can also summarize it as: an atomizing device manufactured using this method.

[0318] Gii carbon foam nanomaterials possess numerous unique properties as heating elements in non-liquid devices such as medical inhalers or as heating elements in heated tobacco sticks (such as THP (heated tobacco products, or "heat-not-burn" sticks)).

[0319] Feature 17: Gii carbon foam can be inductively heated using a typical 5 MHz to 7 MHz drive current; it is an ideal target or receptor for induction-heated tobacco sticks because it is very inexpensive, can be formed into thin, flexible strips, and can be heated uniformly and consistently over its surface; it is stable at temperatures up to 350°C (typically the highest temperature inside heated tobacco sticks like the iQoS Terea) because it can be formed from a carbon precursor that is a high-temperature PI film that is substantially thermally stable at 350°C. It does not release metal combustion products, unlike conventional metal receptors; its combustion products are essentially limited to very small amounts of CO and H2. It can be shaped to alter the airflow through the receptor in a way that increases the content of nicotine or terpenoids or flavonoids, or improves the flavor of the inhaled vapor.

[0320] We can summarize it as follows: A method for manufacturing a component made substantially of carbon foam for use in a tobacco heating product bar, wherein the method includes the step of manufacturing a conductive carbon foam component using (A) a laser-based high-temperature process applied to a carbon precursor material such as a polymer or polyimide sheet or (b) the method defined in any one of the features A–L above. And said component is an induction heating target or sensor configured for use in the tobacco heating product bar.

[0321] Another aspect is: A tobacco heating product bar comprising at least in part a carbon foam induction heating target or sensor made by the method described above.

[0322] Feature 18: As mentioned above, Gii carbon foam does not decompose or release unwanted compounds at normal operating temperatures. Gii carbon foam is stable at high temperatures (e.g., 350°C – it is produced on a high-temperature PI film substrate that is itself stable at 350°C).

[0323] We can summarize it as follows: A method for manufacturing a component made substantially of carbon foam for use in a tobacco heating product bar, wherein the method includes the step of manufacturing a conductive carbon foam component using (A) a laser-based high-temperature process applied to a carbon precursor material such as a polymer or polyimide sheet or (b) the method defined in any one of the features A–L above. And said component is an induction heating target or sensor configured for use in the tobacco heating product bar and stable at 350°C.

[0324] Another aspect is: a THP rod comprising a carbon foam target or receptor that is at least partially manufactured by the method and stable at 350°C.

[0325] Feature 19: When thermal decomposition occurs, the combustion products of the Gii carbon foam heating element are limited to only trace amounts of CO and H2. Therefore, even under dry-burning or malfunction conditions, there are no harmful vapor components. Thus, unlike conventional metal sensors, the risk of metals or other contaminants in the vapor is minimal: Gii carbon foam-based tobacco heating rods can set a new benchmark for THP vapor safety, thereby establishing a high standard for PMTA approvals that conventional atomizers may struggle to meet.

[0326] We can summarize it as follows: A method for manufacturing a component made substantially of carbon foam for use in a tobacco heating product bar, wherein the method includes the step of manufacturing a conductive carbon foam component using (A) a laser-based high-temperature process applied to a carbon precursor material such as a polymer or polyimide sheet or (b) the method defined in any one of the features A–L above. Furthermore, the component is an induction heating target or sensor, for which any combustion products are limited to CO and H2.

[0327] We can also summarize it as: a THP rod that includes at least in part a carbon foam target or receptor manufactured by this method.

[0328] Feature 20: Because the Gii carbon foam induction heating sensor stick is thermally conductive and highly flexible, this means that the Gii carbon foam sensor stick can be positioned within the body of the tobacco column in a way that optimizes vapor performance (e.g., optimal nicotine, flavor, and / or warmth): In conventional tobacco heating products, the induction heating sensor is typically a flat strip of metal passing through the diameter of the cylindrical tobacco column, and there is a limited range for induction heating designed to heat the tobacco material, for example, uniformly. Conversely, the tobacco closest to the flat metal strip is heated much more than the tobacco furthest from it. However, with Gii carbon foam, we can have thin, planar, spiral coils (like a sponge roll) within the tobacco column, for example, approximately concentric with the outer cylindrical surface of the tobacco column, making the distance between all tobacco areas and the Gii sensor strip much less variable, thus resulting in more uniform heating and better control over the components in the vapor (e.g., more precise delivery of nicotine).

[0329] We can summarize it as follows: A method for manufacturing a component made substantially of carbon foam for use in a tobacco heating product bar, wherein the method includes the step of manufacturing a conductive carbon foam component using (A) a laser-based high-temperature process applied to a carbon precursor material such as a polymer or polyimide sheet or (b) the method defined in any one of the features A–L above. And said component is an inductive heating target or sensor, and is configured to be positioned within a tobacco column in the rod, and is shaped to include curved sections.

[0330] We can also summarize it as: a THP rod that includes at least in part a curved carbon foam target or receptor manufactured by this method.

[0331] Feature 21: Tobacco heating products can heat the rod in several ways. In the previous section, we focused on induction heating. Another method is resistance heating, such as by resistively heating metal blades that penetrate the tobacco column, or by resistively heating a cylindrical metal element concentrically around the tobacco column in the rod. Gii carbon foam resistance heating elements can be used to replace the metal parts in both of these options.

[0332] We can summarize it as follows: A method for manufacturing a component made substantially of carbon foam for use in a tobacco heating product bar, wherein the method includes the step of manufacturing a conductive carbon foam component using (A) a laser-based high-temperature process applied to a carbon precursor material such as a polymer or polyimide sheet or (b) the method defined in any one of the features A–L above. And the component described therein is configured to penetrate the tobacco column or as a blade of a concentric heater surrounding the tobacco column.

[0333] We can also summarize it as: an atomizing device comprising blades, manufactured at least in part by the method, configured to penetrate a tobacco column or serve as a concentric heater surrounding the tobacco column.

[0334] Feature 22: Therapeutic Uses We can summarize it as follows: A method for manufacturing a component substantially made of carbon foam for a therapeutic drug inhalation device, wherein the method includes the step of manufacturing a conductive carbon foam component using (A) a laser-based high-temperature process applied to a carbon precursor material such as a polymer or polyimide sheet or (b) a method defined by any one of the features A–L above. And the component mentioned therein is a heating element for a therapeutic drug inhalation device.

[0335] The optional features include: The carbon precursor material is high-temperature polyimide, which is stable at 350°C.

[0336] Any combustion products of the heating element are limited to CO and H2.

[0337] Another aspect is: a therapeutic drug inhalation device comprising carbon foam, said carbon foam including a heating element made at least in part by the method described above.

[0338] While our specific focus here is exploring the applications of materials manufactured using any of the methods described in Feature AL of Part A, some of the device structures described in this Part C can be realized using different carbon materials, such as conventional laser-induced graphene foam. For further generalization, we also cover any methods or devices where the manufacturing method is not limited to those described in Feature AL, but extends to any known methods for manufacturing graphene or carbon foam. For further generalization, we also cover any methods or devices described in Features 1-22 of this Part C, but where the material is not limited to graphene or carbon foam, but is any other conductive but nonmetallic material, such as conductive nonmetallic ceramics; for Features 1-16 (i.e., e-cigarette-specific features), the material is porous to the e-liquid. For Features 17-21 (i.e., THP-specific features), the material can be inductively heated (e.g., using an HF magnetic field).

[0339] Part C.3 - Advantages of using Gii carbon foam in electronic cigarette devices and HNB devices In this Section C.3, we briefly reiterate the main advantages of using Gii carbon foam in electronic cigarette devices and HNB devices; we categorize these advantages into three areas: safety, performance, and manufacturability.

[0340] Gii nanomaterials have many unique properties when used in electronic cigarette heating elements: safety Due to its high thermal conductivity, uniform, isotropic resistance heating can be achieved (e.g., a uniform 280°C or any desired level can be maintained across its surface) without hot spots (e.g., exceeding 400°C) that can generate aldehydes, etc.

[0341] Gii does not decompose or release unwanted compounds at normal operating temperatures.

[0342] It is also stable at high temperatures (e.g., it can be produced on high-temperature PI film substrates, and is even stable at 350°C).

[0343] When thermal decomposition occurs, the combustion products are only CO and H2. Therefore, even under dry-burning conditions, there are no harmful vapor components.

[0344] The risk of metals or other contaminants in the vapor is minimal: this sets a new benchmark for vapor safety, thereby establishing a high standard for PMTA approval that conventional atomizers may find difficult to meet.

[0345] It can be produced on a completely non-porous PI film substrate, thus facilitating the manufacture of leak-free atomizers.

[0346] The resistivity coefficient is measurable, so you can accurately infer the temperature of the electronic cigarette heating element from the delivered voltage / current.

[0347] It heats up quickly to the setpoint and can be controlled using PWM closed-loop feedback control and a known resistivity temperature coefficient to maintain that setpoint.

[0348] Gii nanomaterials have many unique properties when used in electronic cigarette heating elements: performance It can maintain a stable setpoint high temperature across its entire surface, resulting in predictable, repeatable, high-quality performance, thereby delivering the target ACM with minimal variation and optimal flavor.

[0349] Due to the excellent wettability of the e-liquid, the Gii heating element can easily transfer or wick the e-liquid from the local reservoir, and the e-liquid is evenly distributed on the heating surface (which helps to heat evenly and avoid "dry burning").

[0350] Its excellent anti-fouling properties minimize VG-based caramelization and extend the safe lifespan of the heating element to potentially thousands of puffs.

[0351] It can be made into different shapes (e.g., complex, 3D) to optimize the contact between the vortex and Gii, thereby optimizing the content of nicotine / terpenoids / flavonoids and improving the flavor of the steam.

[0352] Gii nanomaterials have many unique properties when used in electronic cigarette heating elements: manufacturability Compared to simple acid etching of 316L steel wire, it can be mass-produced at a very low cost.

[0353] The integral PI membrane boundary with Gii can be designed to provide a liquid barrier, thereby preventing liquid leakage. Electrode contacts for Gii heating elements are easy to print – as part of the manufacturing process, i.e., directly printed on the PI substrate on which Gii is formed.

[0354] Different (complex) shapes can be formed, which include liquid intake and wicking functions in a two-part hybrid 3D structure (otherwise performed by cotton, foam or ceramic) and heating functions (otherwise performed by steel wire wrapped around cotton / foam or by a metal sintered coating on a ceramic substrate).

[0355] The Gii liquid intake and wicking layer are also highly thermally insulated – thus preventing unintended heating of the liquid in the reservoir (which could otherwise make it difficult to maintain the heating element at a stable setpoint temperature).

[0356] High-speed, high-capacity roll-to-roll or roll-to-sheet fabrication of complete integrated components, wherein the following are combined: (a) Gii porous sections that transfer liquid from local reservoirs, (b) Gii heating elements (e.g., all formed in a 3D structure created using G-Thru 3D process) that are supplied with liquid from the Gii porous sections, and (c) electrodes that provide power to the Gii heating elements, wherein all components are fabricated on the same PI substrate or separate but bonded PI substrates.

[0357] It has a flexible PI substrate that can be bent into shapes such as cylinders without the risk of peeling.

[0358] It can also be other substrates, such as glass or silicon.

Claims

1. (Atomizing Device Component) A method of manufacturing one or more components for an atomizing device, each component being substantially made of carbon foam, wherein the method includes the step of manufacturing one or more carbon foam components that are conductive, non-metallic and capable of wicking atomizing liquid using a high-temperature process generated by a laser beam directed at a carbon-based precursor material, such as a polymer or polyimide sheet.

2. The method of claim 1, further comprising the step of irradiating a subsurface region of the carbon precursor material, wherein parameters of the laser beam have been selected to generate carbon foam in the subsurface region.

3. The method according to any one of the preceding claims, comprising the step of irradiating an encapsulation region of the carbon precursor material, wherein the parameters of the laser beam have been selected to generate carbon foam in the encapsulation region.

4. The method according to any one of the preceding claims, comprising the step of irradiating a region beneath the surface of the encapsulated carbon precursor material, wherein the parameters of the laser beam have been selected to generate carbon foam in the region, and wherein the laser beam does not generate a significant gas escape path to the surface of the precursor material.

5. The method according to any one of the preceding claims, comprising the step of irradiating an internal region of the carbon precursor material located on a substrate, wherein the parameters of the laser beam have been selected to generate carbon foam in the region and to generate disordered, amorphous, non-graphene material between the carbon foam region and the substrate; wherein the disordered, amorphous, non-graphene material is directly adhered to the substrate or otherwise directly attached to the substrate.

6. The method according to any one of the preceding claims, comprising the following steps: (a) Irradiate the encapsulation region or subsurface region of the carbon precursor material with the laser beam to generate carbon foam in the encapsulation region or subsurface region and generate disordered, amorphous non-graphene material above the carbon foam; Then (b) laser ablation or treatment is performed to remove the disordered, amorphous non-graphene material and expose at least some of the carbon foam.

7. The method according to any one of the preceding claims, comprising the following steps: (a) The laser beam is irradiated into the encapsulation region or subsurface region of the carbon precursor material to generate carbon foam in the encapsulation region or subsurface region of the carbon precursor material and to generate disordered, amorphous non-graphene material above the carbon foam. Then (b) laser ablation or treatment is performed to remove the disordered, amorphous non-graphene material and expose at least some of the underlying carbon foam, and to convert at least some of the underlying carbon foam into non-graphene carbon foam.

8. The method according to any one of the preceding claims, comprising the following steps: (a) Irradiating an encapsulation region or subsurface region of the carbon precursor material below the surface of the material with the laser beam operating in a first frequency band to generate carbon foam in the encapsulation region or subsurface region. Then (b) a laser beam operating in the second frequency band is used to remove or ablate the material located above the carbon foam to expose at least some of the carbon foam.

9. The method according to any one of the preceding claims, comprising the following steps: (a) Irradiating an encapsulation region or subsurface region of the carbon precursor material below the surface of the material with the laser beam operating in a first frequency band to generate carbon foam in the encapsulation region or subsurface region, and then (b) Using a laser beam operating in a second frequency band to remove or ablate the material located above the carbon foam to expose at least some of the carbon foam; as well as (c) Attaching, printing or positioning one or more electrical contacts into the carbon foam.

10. The method according to any one of the preceding claims, comprising the following steps: (a) Screen printing electrical contacts onto or into the carbon precursor material; (b) Irradiating an encapsulation region or subsurface region of the carbon precursor material below the surface of the material with the laser beam operating in a first frequency band to generate carbon foam in the encapsulation region or subsurface region, wherein steps (a) and (b) may be performed in the order of (a) then (b) or (b) then (a); and (c) Using a laser beam operating in the second frequency band to remove or ablate the material located above the carbon foam to expose at least some of the carbon foam to which the electrical contact is connected.

11. The method according to any one of the preceding claims, comprising the following steps: (a) Irradiating an encapsulation region or subsurface region of the carbon precursor material below the surface of the material with the laser beam operating in a first frequency band to generate carbon foam in the encapsulation region or subsurface region, and then (b) Using a laser beam operating in a second frequency band to remove or ablate the material located above the carbon foam to expose at least some of the carbon foam; And the thickness or depth of the carbon foam is at least 50 μm.

12. The method according to any one of the preceding claims, comprising the following steps: (a) Irradiating an encapsulation region or subsurface region of the carbon precursor material below the surface of the material with the laser beam operating in a first frequency band to generate carbon foam in the encapsulation region or subsurface region, and then (b) Using a laser beam operating in a second frequency band to remove or ablate the material located above the carbon foam to expose at least some of the carbon foam; Step (a) is carried out in one manufacturing facility, while step (b) is carried out in a different facility.

13. The method according to any one of the preceding claims, wherein, The method includes a series of operations to pass a continuous roll of the carbon precursor film through a process required to manufacture the carbon foam component, which is at least partially manufactured by the method according to any one of claims 1-13.

14. The method according to any one of the preceding claims, wherein one of the components is a heating element.

15. The method according to any one of the preceding claims, wherein one of the components is an electrofluid porous wicking element configured to provide electrofluid to a heating element.

16. The method according to any one of the preceding claims, wherein the component is an integral structure comprising both a heating element and an electrofluid porous wicking element configured to provide electrofluid to the heating element.

17. The method according to any one of the preceding claims, wherein the component is an integral structure comprising both a heating element and an electronic liquid porous wicking element, and the manufacturing parameters of each element have been selected such that the carbon foam forming the porous element for wicking the electronic liquid has properties optimized for this function, and the carbon foam forming the heating element has properties optimized for this function.

18. The method according to any one of the preceding claims, wherein the component is a microchannel configured to provide controlled delivery of an electrofluid from a liquid reservoir to a heating element.

19. The method according to any one of the preceding claims, wherein the component is a heating element, and the method includes the step of manufacturing (e.g., by screen printing) an electric power electrode for the heating element on the same substrate as the heating element and as part of the same manufacturing process for manufacturing the heating element.

20. The method according to any one of the preceding claims, wherein the component is: (a) a carbon foam porous element / carbon foam porous layer that transfers electrofluid from a local reservoir; (b) a carbon foam microchannel or structure that allows the electrofluid to flow from the porous element in a controlled manner without leakage; and (c) a carbon foam heating element that is supplied with electrofluid from the microchannel. The method includes the step of manufacturing (e.g., by screen printing) an electric power electrode for the heating element on the same substrate as the heating element and as part of the same manufacturing process used to manufacture the heating element.

21. The method according to any one of the preceding claims, wherein at least a portion of the carbon-based precursor material is shaped or configured as the periphery, boundary, or surrounding of a carbon foam component to prevent liquid leakage, said carbon foam component being, for example, a heating element or an electronic liquid porous element.

22. The method according to any one of the preceding claims, wherein a portion of the carbon-based precursor material is a substrate that is folded or bent when positioned in the electronic cigarette device.

23. The method according to any one of the preceding claims, wherein the component, such as an e-liquid porous wicking element, is configured to thermally insulate the e-liquid reservoir in the e-cigarette device from the heating element in the e-cigarette device.

24. The method according to any one of the preceding claims, wherein the component is a heating element characterized by a known or measured resistivity temperature coefficient, and the component is further configured to heat using a PWM closed-loop feedback control system that uses the known resistivity temperature coefficient.

25. The method according to any one of the preceding claims, wherein the component is a heating element configured to heat uniformly and consistently across its surface.

26. The method according to any one of the preceding claims, wherein the component is wettable by an electro-liquid with a contact angle of less than 20°.

27. The method of any of the preceding claims, wherein the component is a heating element with anti-fouling properties that enable the heating element to provide more than 300 suctions or inhalations during normal use without significant carbonization or caramelization.

28. The method of any of the preceding claims, wherein the component is a heating element configured to alter the shape of the airflow passing through the heating element in a manner that increases the content of nicotine or terpenoids or flavonoids or improves the steam flavor of inhaled vapor.

29. The method of any of the preceding claims, wherein the component is a heating element configured to alter the shape of the airflow on the heating element in a manner that increases the content of nicotine or terpenoids or flavonoids or improves the steam flavor of inhaled steam.

30. The method according to any one of the preceding claims, wherein the carbon precursor is a high-temperature PI film that is substantially thermally stable at 350°C.

31. The method according to any one of the preceding claims, wherein the component has combustion products substantially limited to CO and H2.

32. (Tobacco Heating Products) A method for manufacturing a component substantially made of carbon foam for use in a tobacco heating product rod; wherein the method includes the step of manufacturing a conductive and non-metallic carbon foam component using a high-temperature process generated by a laser beam directed at a carbon precursor material, such as a polymer or polyimide sheet. The component described therein is an induction heating target or sensor configured for use in a tobacco heating product bar.

33. The method of claim 32, further comprising the step of irradiating a subsurface region of the carbon precursor material, wherein parameters of the laser beam are selected to generate carbon foam in the subsurface region.

34. The method according to any one of claims 32-33, comprising the step of irradiating an encapsulation region of the carbon precursor material, wherein parameters of the laser beam are selected to generate carbon foam in the encapsulation region.

35. The method according to any one of claims 32-34, comprising the step of irradiating a region beneath the surface of the encapsulated carbon precursor material, wherein parameters of the laser beam are selected to generate carbon foam in the region, and wherein the laser beam does not generate a significant gas escape path to the surface of the precursor material.

36. The method according to any one of claims 32-35, comprising the step of irradiating an internal region of the carbon precursor material located on a substrate, wherein parameters of the laser beam are selected to generate carbon foam in the region and to generate disordered, amorphous, non-graphene material between the carbon foam region and the substrate; wherein the disordered, amorphous, non-graphene material is directly adhered to the substrate or otherwise directly attached to the substrate.

37. The method according to any one of claims 32-36, comprising the following steps: (a) Irradiate the encapsulation region or subsurface region of the carbon precursor material with a laser beam to generate carbon foam in the encapsulation region or subsurface region and generate disordered, amorphous non-graphene material above the carbon foam; Then (b) laser ablation or treatment is performed to remove the disordered, amorphous non-graphene material and expose at least some of the carbon foam.

38. The method according to any one of claims 32-37, comprising the following steps: (a) Irradiating the encapsulation region or subsurface region of the carbon precursor material with a laser beam to generate carbon foam in the encapsulation region or subsurface region of the carbon precursor material and to generate disordered, amorphous non-graphene material above the carbon foam. Then (b) laser ablation or treatment is performed to remove the disordered, amorphous non-graphene material and expose at least some of the underlying carbon foam, and to convert at least some of the underlying carbon foam into non-graphene carbon foam.

39. The method according to any one of claims 32-38, comprising the following steps: (a) Irradiating an encapsulation region or subsurface region of the carbon precursor material below the surface of the material with a laser beam operating in a first frequency band to generate carbon foam in the encapsulation region or subsurface region. Then (b) a laser beam operating in the second frequency band is used to remove or ablate the material located above the carbon foam to expose at least some of the carbon foam.

40. The method according to any one of claims 32 to 39, comprising the following steps: (a) Irradiating an encapsulation region or subsurface region of the carbon precursor material below the surface of the material with a laser beam operating in a first frequency band to generate carbon foam in the encapsulation region or subsurface region, and then (b) Using a laser beam operating in a second frequency band to remove or ablate the material located above the carbon foam to expose at least some of the carbon foam; And the thickness or depth of the carbon foam is at least 50 μm.

41. The method according to any one of claims 32-40, wherein the method comprises a series of operations required to manufacture the carbon foam component by passing a continuous roll of the carbon precursor film through a series of operations.

42. The method according to any one of claims 32-41, wherein the sensor is configured to heat uniformly and consistently across its surface.

43. The method of any one of claims 32-42, wherein the receptor is configured to alter the shape of the airflow passing through the receptor in a manner that increases the content of nicotine or terpenoids or flavonoids or improves the vapor flavor of inhaled vapor.

44. The method according to any one of claims 32-43, wherein the carbon precursor is a high-temperature PI film that is substantially thermally stable at 350°C.

45. The method according to any one of claims 32-44, wherein the receptor has combustion products substantially limited to CO and H2.

46. ​​The method according to any one of claims 32-44, wherein the receptor is configured to be positioned within a tobacco column in the rod and is shaped to include a curved section.

47. (Atomizing device) An atomizing device comprising one or more carbon foam components manufactured using the method of any one of claims 1-31.

48. The atomizing device according to claim 47, wherein the component is any one or more of the following: a heating element, a liquid porous wicking element, and a liquid microchannel.

49. The atomizing device according to claims 47-48, wherein the component is a combination of a heating element and a liquid porous wicking element.

50. The atomizing device according to claims 47-49, wherein the component is a heating element characterized by a known or measured resistivity temperature coefficient, and is configured to perform heating using a PWM closed-loop feedback control system that uses the known resistivity temperature coefficient of the heating element.

51. The atomizing device according to claims 47-50, wherein the component is a heating element configured to heat uniformly and consistently across its surface.

52. The atomizing device according to claims 47-51, wherein the component is wettable with a liquid at a contact angle of less than 20°.

53. The atomizing device according to claims 47-52, wherein the component is a heating element, the heating element being configured to alter the shape of the airflow on the heating element in a manner that increases the content of nicotine or terpenoids or flavonoids or improves the vapor flavor of the inhaled vapor.

54. The atomizing device according to claims 47-53, wherein the carbon precursor is a high-temperature PI film that is substantially thermally stable at 350°C.

55. The atomizing device according to claims 47 to 53, wherein it is a cartridge-based electronic cigarette device, or a single-use disposable electronic cigarette device, or a multiple-use disposable electronic cigarette device, or a modular electronic cigarette device, or a liquid-refillable electronic cigarette device.

56. (THP product) A tobacco heating product bar comprising a carbon foam induction heating target or sensor made at least in part by the method of any one of claims 32-46.

57. The tobacco heating product bar of claim 56, wherein the sensor is configured to heat uniformly and consistently across its surface.

58. The tobacco heating product bar according to claims 56-57, wherein the receptor is configured to alter the shape of the airflow passing through the receptor in a manner that increases the content of nicotine or terpenoids or flavonoids or improves the vapor flavor of the inhaled vapor.

59. The tobacco heating product bar according to claims 56-58, wherein the carbon precursor is a high-temperature PI film that is substantially thermally stable at 350°C.

60. The tobacco heating product bar according to claims 56-59, wherein the sensor has combustion products substantially limited to CO and H2.

61. The tobacco heating product bar according to claims 56-60, wherein the sensor is configured to be positioned within a tobacco column in the bar and is shaped to include a curved section.

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