Aerosol-generating component

Abstract

An aerosol-generating component for use as part of a non-combustible aerosol supply system. The aerosol-generating component comprises a carbon allotrope 101 supported on an electrically insulating substrate 102. At least one aperture 105 extends through the electrically insulating substrate 102.

Description

Aerosol generating components Technical Field

[0001] This invention relates to an aerosol generating component, particularly an aerosol generating component for use in a non-flammable aerosol supply system. The invention also relates to an aerosol generating assembly including the aerosol generating component, an aerosol generating system including the aerosol generating component or the aerosol generating assembly, and a method for forming the aerosol generating component. Background Technology

[0002] Non-flammable aerosol supply systems that generate aerosols for user inhalation are known in the art. Such systems typically include an aerosol generating component capable of converting aerosolizable materials into aerosols. In some cases, the generated aerosol is a condensed aerosol, whereby the aerosolizable material is first vaporized and then allowed to condense into an aerosol. In other cases, the generated aerosol is produced by the atomization of aerosolizable materials. This atomization can be mechanically initiated, for example by subjecting the aerosolizable material to vibration to form small particulate material entrained in the airflow. Alternatively, this atomization can be induced electrostatically or otherwise (e.g., by using pressure).

[0003] Because such an aerosol supply system is designed to generate aerosols for users to inhale, the characteristics of the generated aerosols should be considered. These characteristics may include aerosol particle size, the total amount of aerosols generated, etc.

[0004] In cases where aerosol delivery systems are used to simulate the smoking experience (e.g., as e-cigarettes or similar products), the control of these different characteristics is particularly important because users may expect to generate specific sensory experiences from the use of the system.

[0005] The goal is to provide a non-flammable aerosol supply system with improved control over these characteristics. Summary of the Invention

[0006] According to a first aspect of this disclosure, an aerosol generating component is provided for use as part of a non-combustible aerosol provision system, the aerosol generating component including an allotrope of carbon supported on an electrically insulating substrate, wherein at least one pore extends through the electrically insulating substrate.

[0007] In some embodiments, the carbon allotrope comprises one or more graphene layers. Where more than one graphene layer is present, at least two graphene layers may be non-parallel to each other. Where more than one graphene layer is present, at least two graphene layers may be parallel to each other. For example, the carbon allotrope may be bilayer graphene. In some embodiments, the carbon allotrope (e.g., one or more graphene layers) comprises or is in the form of three-dimensional graphene.

[0008] In some implementations, the electrically insulating substrate is thermally insulating.

[0009] In some embodiments, the thermal conductivity of the electrically insulating substrate is not greater than 0.5 W / m. -1 k -1 .

[0010] In some implementations, the electrically insulating substrate is non-porous.

[0011] In some embodiments, the carbon allotrope has a length of no more than 5 mm and a width of no more than 5 mm.

[0012] In some embodiments, the carbon allotrope has a length of at least 0.5 mm and a width of at least 0.5 mm.

[0013] In some embodiments, at least one hole, or each of at least one hole, has a diameter of not more than 500 μm.

[0014] In some embodiments, at least one hole, or each of at least one hole, has a diameter of at least 50 μm.

[0015] In some embodiments, the electrically insulating substrate includes a first surface and a second surface, wherein the first surface and the second surface are opposite to each other, and a carbon allotrope is loaded on the first surface.

[0016] In some implementations, at least one hole extends from the first surface to the second surface.

[0017] In some embodiments, the distance between the edge defined by the perimeter of one of the at least one apertures along the surface of the electrically insulating substrate and the edge defined by the perimeter of any other aperture is no greater than 1 mm.

[0018] In some embodiments, the corresponding edge is: an edge defined by the periphery of one of the at least one holes and another edge defined by the periphery (e.g., outer periphery) of the electrically insulating substrate; and / or an edge defined by the periphery of one of the at least one holes and another edge defined by the periphery of the other of the at least one holes; and / or an edge defined by the periphery (e.g., outer periphery) of the electrically insulating substrate and another edge defined by the periphery (e.g., outer periphery) of the electrically insulating substrate.

[0019] In some implementations, the carbon allotrope is formed in the form of multiple nanotubes.

[0020] In some implementations, the carbon allotrope is formed in the form of open-cell foam.

[0021] In some implementations, the carbon allotropes are formed in the form of multiple sheets.

[0022] In some embodiments, the carbon allotrope has a total thickness ranging from 0.345 nm to 100 μm.

[0023] In some implementations, carbon allotropes are formed via printing, laser-induced graphene formation, and chemical vapor deposition.

[0024] In some embodiments, at least one hole or each of at least one hole defines a closed shape.

[0025] In some embodiments, the contact area between the carbon allotrope and the electrically insulating substrate defines an outermost perimeter, wherein an imaginary line extends along the contact area from a portion of the outermost perimeter to an opposite portion of the outermost perimeter, wherein the substrate extends axially from the imaginary line by no more than 100% of the length of the imaginary line.

[0026] In some embodiments, carbon allotropes include disordered graphite and / or amorphous carbon.

[0027] In some embodiments, the Raman spectrum of the carbon allotrope includes G and D bands, with the G band peak at approximately 1500 cm⁻¹. -1 Approximately 1650 cm -1 Within the Raman shift range, and the D-band peak is at approximately 1250 cm⁻¹. -1 Approximately 1400 cm -1 Within the Raman shift range, the intensity of the D band peak I D The intensity of the G-band peak I G The ratio I D / I G It ranges from about 0.8 to about 2, preferably from about 1 to about 1.8.

[0028] According to a second aspect of this disclosure, an assembly is provided for use as part of a non-flammable aerosol supply system, the assembly including an aerosol generating component according to a first aspect of this disclosure, and a first channel extending to at least one orifice.

[0029] In some implementations, the first channel is a capillary channel.

[0030] In some implementations, the first channel is formed at least partially by the second surface.

[0031] In some embodiments, the aerosol generating component includes a structure, the second surface and the structure being spaced apart from each other to at least partially define the first channel.

[0032] According to a third aspect of this disclosure, a non-flammable aerosol supply system is provided, comprising: an aerosol generating component according to a first aspect of this disclosure or an aerosol generating assembly according to a second aspect of this disclosure; and one or more of a power supply and a controller. Attached Figure Description

[0033] Various embodiments will now be described in detail by way of example only with reference to the accompanying drawings, in which: FIG1 is a schematic diagram (not to scale) of a non-flammable aerosol supply system according to the present disclosure; FIG2 is a side view of an aerosol generating component according to the present disclosure; FIG3 is a perspective view of the aerosol generating component of FIG2; FIG4A is a schematic diagram of an aerosol generating component according to the present disclosure, wherein the carbon allotrope is formed in the form of one or more graphene layers in the form of open-cell foam; FIG4B is a schematic diagram of an aerosol generating component according to the present disclosure, wherein the carbon allotrope is formed in the form of one or more graphene layers in the form of multiple sheets; FIG4C is a schematic diagram of an aerosol generating component according to the present disclosure, wherein the carbon allotrope is formed in the form of one or more graphene layers in the form of multiple nanotubes; FIG5A shows a plan view of an aerosol generating assembly according to the present disclosure; FIG5B shows a side view of the aerosol generating assembly of FIG5A; FIG5C is a schematic diagram of the aerosol generating assembly of FIG5A (aerosol generating material delivery components are not shown); FIG6A shows... Figure 6A shows a perspective view of an aerosol generating assembly according to the present disclosure; Figure 6B is a schematic diagram of the aerosol generating assembly of Figure 6A; Figure 7A shows a plan view of an aerosol generating component according to the present disclosure; Figure 7B is a thermal diagram of the aerosol generating component of Figure 7A, wherein the aerosol generating component is energized; Figure 8A is a schematic diagram of an aerosol generating component according to the present disclosure, wherein the aerosol generating component includes a heating section and one or more aerosolizable material supply sections extending from the heating section; Figure 8B is a thermal diagram of the aerosol generating component of Figure 8A, wherein the aerosol generating component is energized; Figure 9 shows a plan view of an aerosol generating component according to the present disclosure; Figure 10A shows a graph of the energy density, mass loss, and efficiency of the aerosol generating component according to the present disclosure; Figure 10B shows a table of the data in Figure 10A; Figure 11A shows an aerosol generating assembly according to the present disclosure; Figure 11B shows the efficiency (J / mg; square data points) and volatilization rate of the assembly in Figure 11A. Figure 11A shows a graph of efficiency (J / mg; square data points) as a function of applied energy (J); Figure 11C shows a microscopic image of a portion of the aerosol generating component of the assembly of Figure 11A; Figure 12A shows an aerosol generating assembly according to the present disclosure; Figure 12B shows a graph of efficiency (J / mg; square data points) and evaporation rate (mg / s; round data points) of the assembly of Figure 12A as a function of applied energy (J); Figure 13A shows an aerosol generating assembly according to the present disclosure; Figure 13B shows a graph of efficiency (J / mg; square data points) and evaporation rate (mg / s; round data points) of the assembly of Figure 13A as a function of applied energy (J); Figure 14A shows test data of the aerosol generating assembly according to the present disclosure; Figure 14B shows an efficiency graph using the data from Figure 14A as a function of power density;Figure 15A is a side view of the aerosol generating assembly according to the present disclosure; Figure 15B is a plan view of the aerosol generating assembly of Figure 15A; Figure 16 is a schematic diagram of the aerosol generating assembly according to the present disclosure; Figure 17A shows a schematic diagram of the assembly according to the present disclosure in a plan view; Figure 17B shows a schematic diagram of the assembly of Figure 17A in a plan view; Figure 17C shows another schematic diagram of the assembly of Figure 17A in a plan view; Figure 18A shows a schematic diagram of the assembly according to the present disclosure in a plan view; Figure 18B shows a schematic diagram of the assembly of Figure 18A in a side view; Figure 19A shows a schematic diagram of the assembly according to the present disclosure in a side view. Figure 19B shows a schematic diagram of the component according to the present disclosure in a side view; Figure 19C shows a schematic diagram of the component according to the present disclosure in a side view; Figure 20 shows a schematic diagram of the aerosol generating component according to the present disclosure in a bottom view; Figure 21 shows a schematic diagram of the embodiment of Figure 20 in a top view; Figure 22 shows a schematic diagram of an alternative embodiment of Figure 20 in a top view; Figure 23 shows a schematic diagram of the embodiment of Figure 21 in a side view along the longitudinal extent of the aerosol generating component; and Figure 24 shows the Raman spectrum of a carbon allotrope sample, where the x-axis corresponds to the Raman shift (cm). -1 And the y-axis corresponds to the intensity (count), with D-band peaks, G-band peaks and 2D-band peaks. Detailed Implementation

[0034] This document discusses / describes aspects and features of certain embodiments and implementations. Some aspects and features of certain embodiments and implementations can be conventionally implemented, and for the sake of brevity, these aspects and features are not discussed / described in detail. Therefore, it should be understood that the aspects and features of the aerosol generating components, aerosol generating assemblies, systems, and methods discussed herein, which are not described in detail, can be implemented using any conventional techniques for implementing these aspects and features.

[0035] As described above, this disclosure relates to, but is not limited to, non-flammable aerosol supply systems, articles, aerosol generating components, and aerosol generating parts that generate aerosols from aerosol generating materials (also referred to herein as “aerosolizable materials”).

[0036] According to this disclosure, a "non-flammable" aerosol supply system is a system in which the aerosol-generating material of the aerosol supply system (or its components) does not burn or ignite, in order to facilitate the delivery of at least one substance to a user.

[0037] In some implementations, the non-flammable aerosol supply system is an electrically powered non-flammable aerosol supply system.

[0038] In some implementations, the non-flammable aerosol supply system is an electronic cigarette, also known as an electronic cigarette device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol generating material is not necessary.

[0039] In some implementations, the non-combustible aerosol supply system is an aerosol-generating material heating system, also known as a heated non-combustible system. An example of such a system is a tobacco heating system.

[0040] In some embodiments, the non-flammable aerosol supply system is a mixing system that uses a combination of aerosol-generating materials to generate aerosols, one or more of which can be heated. Each of the aerosol-generating materials can be in, for example, solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the mixing system includes liquid or gel aerosol-generating materials and solid aerosol-generating materials. Solid aerosol-generating materials may include, for example, tobacco or non-tobacco products.

[0041] Typically, a non-flammable aerosol supply system may include a non-flammable aerosol supply device and consumables used in conjunction with the non-flammable aerosol supply device.

[0042] In some embodiments, this disclosure relates to consumables comprising aerosol-generating materials and configured for use with non-flammable aerosol supply devices. Throughout this disclosure, these consumables are sometimes referred to as articles.

[0043] In some embodiments, a non-flammable aerosol supply system, such as its non-flammable aerosol supply device, may include a power source and a controller. For example, the power source may be an electric power source or an exothermic power source. In some embodiments, the exothermic power source includes a carbon substrate that can be energized to distribute power in the form of heat to aerosol-generating or heat-transferring material adjacent to the exothermic power source.

[0044] In some embodiments, a non-flammable aerosol supply system may include an area for receiving consumables, an aerosol generator, an aerosol generation area, a housing, a nozzle, a filter, and / or an aerosol modifier.

[0045] In some embodiments, consumables used with the non-flammable aerosol supply device may include aerosol generating material, an aerosol generating material storage area (which may be referred to herein as a reservoir for aerosolizable material), an aerosol generating material transfer component (also referred to herein as an aerosolizable material transfer component), an aerosol generator (also referred to herein as an aerosol generating component), an aerosol generating area (also referred to herein as an aerosol generating chamber), a housing, packaging, a filter, a mouthpiece, and / or an aerosol modifier.

[0046] Throughout the following description, the terms "e-cigarette" and "electronic cigarette" may sometimes be used. However, it should be understood that these terms are used interchangeably with the non-flammable aerosol (vapor) supply system described above.

[0047] The systems described herein typically generate inhalable aerosols through the vaporization of aerosol-generating materials.

[0048] In some embodiments, the substance to be delivered may be an aerosol-generating material. The aerosol-generating material may comprise one or more active ingredients, one or more flavoring agents, one or more aerosol-forming agent materials, and / or one or more other functional materials.

[0049] As used herein, active substances can be physiologically active substances, which are materials intended to achieve or enhance physiological responses. Active substances can be, for example, selected from nutritional supplements, nootropics, and psychoactive agents. Active substances can be naturally occurring or synthetically obtained. Active substances may include, for example, nicotine, caffeine, taurine, theophylline, vitamins (such as B6, B12, or C), melatonin, or components, derivatives, or combinations thereof. Active substances may also include one or more components, derivatives, or extracts of tobacco or another botanical material (plant, herbal medicine).

[0050] In some embodiments, the active substance includes nicotine. In other embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0051] As indicated herein, active substances may include or be derived from one or more plant materials or their components, derivatives, or extracts. As used herein, the term "plant material" includes any material derived from plants, including but not limited to extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, bark, shells, etc. Alternatively, the material may include naturally occurring active compounds found in plant materials or synthetically obtained active compounds. The material may be in the form of liquid, gas, solid, powder, dust, pulverized particles, granules, pellets, fragments, strips, sheets, etc. Exemplary plant materials include tobacco, eucalyptus, star anise, cocoa, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, bay leaf, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea (such as green or black tea), thyme, clove, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, and cumin. Nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, holly, perilla, turmeric, turmeric root, sandalwood, coriander leaf, bergamot, orange blossom, myrtle, blackcurrant, valerian, allspice, nutmeg peel, damiensis, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, geranium, mulberry, ginseng, theanine, theophylline, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. Mint can be selected from the following varieties: wild mint (Mentha Arventis), cultivated mint (Mentha cv), Egyptian mint (Mentha niliaca), peppermint (Mentha piperita), cultivated lemon peppermint (Mentha piperita citrata cv), cultivated peppermint (Mentha piperita cv), spearmint (Mentha spicata crispa), heartleaf mint (Mentha cardifolia), longleaf mint (Memtha longifolia), pineapple mint (Mentha suaveolens variegata), lip mint (Mentha pulegium), cultivated spearmint (Mentha spicata cv), and roundleaf mint (Mentha suaveolens).

[0052] In some embodiments, the active substance includes or is derived from one or more plant materials or their components, derivatives or extracts, and the plant material is tobacco.

[0053] In some embodiments, the active substance includes or is derived from one or more plant materials or components, derivatives or extracts thereof, and the plant materials are selected from eucalyptus, star anise and cocoa.

[0054] In some embodiments, the active substance includes or is derived from one or more plant materials or components, derivatives or extracts thereof, and the plant materials are selected from rooibos tea and fennel.

[0055] In some implementations, the substance to be delivered includes a flavoring agent.

[0056] As used herein, the terms “flavor” and “flavorant” refer to materials that, where permitted by local regulations, can be used in products intended to produce a desired taste, aroma, or other sensory experience for adult consumers. These can include naturally occurring flavoring materials, plant materials, extracts of plant materials, synthetically obtained materials, or combinations thereof (e.g., tobacco, licorice, hydrangea, eugenol, Japanese white bark magnolia). Leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, anise seed, cinnamon, turmeric, Indian spices, Asian spices, herbs, holly, cherry, berries, raspberry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruits, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Durham label, bourbon whiskey, Scotch whisky Whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, bitter bean husk, nutmeg, sandalwood, bergamot, geranium, arabesque tea, sorghum, areca leaf, coriander, pine, honey extract, rose oil, vanilla, lemon oil, orange oil, neroli, cherry blossom, cinnamon, coriander, cognac, jasmine, ylang-ylang, sage, fennel, mustard, green bell pepper, ginger, coriander, coffee, from any kind Peppermint oil, eucalyptus, star anise, cocoa, lemongrass, rooibos tea, flax, ginkgo leaves, hazelnuts, hibiscus, bay leaves, yerba mate, orange peel, rose, tea (such as green or black tea), thyme, juniper, elderflower, basil, bay leaves, fennel, oregano, chili peppers, rosemary, saffron, lemon peel, mint, perilla, turmeric, coriander, myrtle, blackcurrant, valerian, Spanish bell pepper, nutmeg, sprig salsa, marjoram, olive, lemon balm, lemon balm This product may contain leeks, chives, parsley, verbena, tarragon, limonene, thymol, camphene, flavor enhancers, bitter taste receptor blockers, sensory receptor activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, plant materials, or breath fresheners. These may be imitation, synthetic, or natural ingredients or blends thereof. They may be in any suitable form, such as liquids (e.g., oils), solids (e.g., powders), or gases.

[0057] In some embodiments, the flavoring agent includes menthol, spearmint, and / or peppermint. In some embodiments, the flavoring agent includes flavoring components of cucumber, blueberry, citrus fruits, and / or cranberry. In some embodiments, the flavoring agent includes eugenol. In some embodiments, the flavoring agent includes flavoring components extracted from tobacco.

[0058] In some embodiments, in addition to or in place of aroma or taste receptors, flavoring agents may include sensates (somatosensory agents) designed to induce somatic sensations that are typically chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve), and these may include agents that provide heating, cooling, tingling, or numbing effects. Suitable heat-effecting agents may be, but are not limited to, vanillyl ether, and suitable coolants may be, but are not limited to, eucalyptol, WS-3.

[0059] Aerosol-generating materials (“aerosolizable materials”) are materials that are capable of generating aerosols, for example, when heated, irradiated, or otherwise powered. Aerosol-generating materials may be in the form of, for example, liquids or gels, and may or may not contain active substances and / or flavorings.

[0060] Aerosol-generating materials may contain one or more active substances and / or flavoring agents, one or more aerosol-forming agent materials, and optionally one or more other functional materials.

[0061] Aerosol forming agent materials may include one or more components capable of forming aerosols. In some embodiments, the aerosol forming agent material may include one or more of the following: glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butanediol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl caprylate, triethyl citrate, glyceryl triacetate, a mixture of glyceryl diacetate, benzyl benzoate, benzyl phenylacetate, glyceryl tribocylate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0062] One or more other functional materials may include one or more of pH adjusters, colorants, preservatives, adhesives, fillers, stabilizers, and / or antioxidants.

[0063] As used herein, the term "consumable" can refer to an article containing or composed of aerosol-generating material, which is intended in whole or in part for consumption by a user during use. Consumables may include one or more other components, such as aerosol-generating material storage areas, aerosol-generating material transfer components, aerosol-generating areas, housings, packaging, mouthpieces, filters, and / or aerosol modifiers. Consumables may also include aerosol generators, such as heaters, which heat the aerosol-generating material to generate aerosols during use. Heaters may include, for example, combustible materials, electrically conductive materials, or sensors. Consumables may be adapted to contain (or include) aerosol-generating materials. In this way, consumables may, but do not necessarily, contain (or include) aerosol-generating materials.

[0064] As used herein, the term "receptor" refers to a heatable material that is penetrated by a changing magnetic field, such as an alternating magnetic field. A receptor can be a conductive material, such that its penetration by the changing magnetic field induces induction heating of the heating material. The heating material can be a magnetic material, such that its penetration by the changing magnetic field induces hysteresis heating of the heating material. A receptor can be both conductive and magnetic, such that it can be heated by two heating mechanisms. In this document, a device constructed to generate a changing magnetic field is referred to as a magnetic field generator.

[0065] As used herein, the term "part" refers to a part, segment, unit, module, component, or the like of an electronic cigarette or similar device that may contain several smaller parts or elements within an outer housing or wall. An electronic cigarette may be formed or constructed from one or more such parts, and these parts may be removably or detachably connected to each other, or may be permanently joined together during manufacturing to define the entire electronic cigarette. This disclosure applies to (but is not limited to) systems comprising two parts detachably connected to each other and configured, for example, to house a consumable / produce part (also referred to herein as a cartridge or cartomiser) capable of housing aerosol-generating material, and a device / control unit having a battery for providing electrical power to operate elements for generating vapor from the aerosol-generating material.

[0066] Aerosol modifiers are typically substances located downstream of the aerosol generation region, configured to modify the generated aerosols, for example, by altering their taste, aroma, acidity, or other characteristics. Aerosol modifiers can be provided in aerosol modifier release components operable to selectively release the aerosol modifier.

[0067] Aerosol modifiers may be, for example, additives or adsorbents. Aerosol modifiers may, for example, contain one or more of flavoring agents, coloring agents, water, and carbon adsorbents. Aerosol modifiers may be, for example, solid, liquid, or gel. Aerosol modifiers may be in powder, filament, or granular form. Aerosol modifiers may not contain filter materials.

[0068] An aerosol generator (or aerosol generating component) is an apparatus configured to generate aerosols from an aerosol generating material. In some embodiments, an aerosol generator is configured to subject the aerosol generating material to thermal energy in order to release one or more volatiles from the aerosol generating material to form an aerosol. In some embodiments, an aerosol generator is configured to generate aerosols from the aerosol generating material without heating. For example, an aerosol generator may be configured to subject the aerosol generating material to one or more of vibration, increased pressure, or electrostatic energy.

[0069] Figure 1 is a height schematic diagram (not to scale) of an exemplary non-flammable aerosol supply system such as an electronic cigarette 10. The electronic cigarette 10 has a generally cylindrical shape extending along a longitudinal axis indicated by a dashed line and includes two main components: a control or power component or section 20 (which may be referred to herein as a “device”) and a cartridge assembly or section 30 that operates as a vapor-generating component (which may be referred to herein as a “product”, “consumable”, “vaporizing cartridge”, or “cartridge”).

[0070] Article 30 includes a storage chamber (also referred to herein as a “reservoir”) 3 containing an aerosolizable material, which includes, for example, a liquid formulation from which an aerosol is generated. The liquid formulation may or may not contain nicotine. As an example, the aerosolizable material may include about 1 to 3% nicotine and 50% glycerin, with the remainder comprising primarily propylene glycol, and may also include other components such as water or flavorings. The storage chamber 3 is in the form of a storage tank, i.e., a container or receiver in which the aerosolizable material can be stored, allowing the aerosolizable material to move and flow freely within the boundaries of the container or receiver (if liquid). Alternatively, the storage chamber 3 may contain a large amount of absorbent material, such as cotton filler or glass fiber to hold the aerosolizable material within a porous structure. The storage chamber 3 may be sealed during manufacturing after filling so that it is disposable after the aerosolizable material has been consumed, or it may have an inlet port or other opening through which new aerosolizable material may be added. Article 30 also includes an electro-aerosol generating component 4 located outside the storage chamber 3 for generating an aerosol through the vaporization of the aerosolizable material. In several instances, the aerosol generating component is a heating element (heater) that heats the aerosolizable material by the passage of an electric current (via resistance or induction heating) to raise its temperature until it evaporates. An aerosol generating material transfer component (not shown in Figure 1), such as a liquid conduit arrangement like a wick or other porous element, may be provided to deliver the aerosolizable material from the storage chamber 3 to the aerosol generating component 4. The aerosol generating material transfer component may have one or more portions located inside the storage chamber 3 to be able to absorb the aerosolizable material and transfer it by wicking or capillary action to other portions of the aerosol generating material transfer component in contact with the aerosol generating component 4. The aerosolizable material is thus vaporized and replaced by new aerosolizable material transferred from the aerosol generating material transfer component to the aerosol generating component 4.

[0071] Other arrangements of heaters and absorbent cores, or parts that perform the same function, are sometimes referred to as atomizers or atomizer assemblies. Various designs are possible compared to the highly schematic representation in Figure 1, where the parts can be arranged differently. For example, the absorbent core can be a completely separate element from the aerosol generating component.

[0072] In some cases, the aerosol generating material transfer component 4 (e.g., a liquid conduit) for delivering the liquid used to generate vapor can be at least partially formed by one or more slots, tubes, or channels between the storage chamber and the aerosol generating component, the slots, tubes, or channels being narrow enough to support capillary action to draw the source liquid from the storage chamber and deliver it for vaporization. Generally, an atomizer can be considered as an aerosol generating component 4 capable of generating vapor from an aerosolizable material delivered to the atomizer and an aerosol generating material transfer component (e.g., a liquid conduit) capable of delivering or conveying liquid from the storage chamber 3 or a similar liquid reservoir to the aerosol generating component via capillary force.

[0073] Typically, the aerosol generating component is at least partially located within the aerosol generating chamber, which forms part of the airflow channel through the electronic cigarette / system. Vapor generated by the aerosol generating component is driven into the chamber, and as air flows through the chamber, above and around the aerosol generating component, it collects the generated vapor, thereby condensing it to form the desired aerosol.

[0074] Returning to Figure 1, the cartridge assembly 30 also includes a mouthpiece 35 with an opening or air outlet through which the user can inhale the aerosol generated by the aerosol generating component 4 and delivered through the airflow channel.

[0075] The power unit (or device) 20 includes a battery cell 5 (e.g., a "battery"), which may be rechargeable, to provide power to the electrical components of the electronic cigarette 10, particularly the aerosol generating unit 4. Additionally, a printed circuit board 28 and / or other electronic devices or circuits are present for overall control of the electronic cigarette 10. When vapor is needed, for example, in response to a signal from a pressure sensor or airflow sensor (not shown), the control electronics / circuit connect the aerosol generating element 4 to the battery 5. The pressure sensor or airflow sensor detects inhalation on the system 10, during which air enters through one or more air inlets 26 in the wall of the power unit 20 to flow along an airflow channel. When the aerosol generating unit 4 receives power from the battery cell 5, it causes an aerosolizable material delivered from the storage chamber 3 to evaporate to generate an aerosol, which is then inhaled by the user through an opening in the mouthpiece 35. As the user inhales at the mouthpiece 35, the aerosol is transported to the mouthpiece 35 along an airflow channel (not shown) that connects the air inlets 26 to an air outlet. Therefore, the airflow path through the electronic cigarette is defined between the air inlet leading to the atomizer (which may or may not be located in the power component 20) and the air outlet at the mouthpiece. In use, the airflow direction along this airflow path is from the air inlet to the air outlet, such that the atomizer can be described as being arranged downstream of the air inlet and upstream of the air outlet.

[0076] In this particular example, the power component 20 and the cartridge assembly 30 are separate parts that are detachable from each other by separating them in a direction parallel to the longitudinal axis, as indicated by the solid arrows in Figure 1. When the device 10 is in use, components 20, 30 are connected together by mating engagement elements 21, 31 (e.g., screws, magnetic, or bayonet fittings) that provide mechanical and electrical connectivity between the power section 20 and the cartridge assembly 30. However, this is only an exemplary arrangement, and different components may be distributed differently between the power section 20 and the cartridge assembly 30, and may include other components and elements. The two sections 20, 30 may be connected end-to-end in the longitudinal configuration as shown in Figure 1 or in different configurations (e.g., parallel, side-by-side arrangement). The non-flammable aerosol supply system 10 may or may not be generally cylindrical and / or have a generally longitudinal shape. Any one or both segments may be intended to be discarded and replaced when depleted (e.g., when the reservoir is empty or the battery is flat), or intended for multiple uses through actions such as refilling the reservoir, recharging the battery, or replacing the atomizer. Alternatively, the electronic cigarette 10 may be an integrated device (disposable or refillable / rechargeable) that cannot be divided into two or more parts, in which case all components are contained within a single body or housing. Examples of the invention are applicable to any of these constructions and other constructions that a person skilled in the art will recognize.

[0077] As described above, one type of aerosol generating component (such as a heating element) that can be used in the atomizing portion (the portion configured to generate vapor from a source liquid) of an electronic cigarette 10 combines heating and liquid delivery functions through both conductivity (resistance) and porosity. Note that conductivity (resistance) refers to a component having the ability to generate heat in response to the flow of an electric current. This flow can be imparted by so-called resistance heating or induction heating. The aerosol generating component can be in sheet form, i.e., a planar shape with a thickness many times smaller than its length or width. A planar aerosol generating component can define a curved plane, and in these cases, reference to a planar aerosol generating component forming a plane refers to an imaginary plane forming the best-fit plane through the component.

[0078] Aerosol generating components (e.g., their carbon allotropes) may include appropriately sized pores and / or gaps to provide capillary forces for wicking aerosolizable materials (e.g., liquids). Therefore, aerosol generating components (e.g., their carbon allotropes) can also be considered porous to facilitate the absorption and distribution of aerosolizable materials (e.g., liquids). Furthermore, the presence of pores and / or gaps can mean that air can permeate through the aerosol generating component. Moreover, at least a portion of the aerosol generating component is conductive and therefore suitable for resistance heating, whereby an electric current flowing through a resistive material generates heat.

[0079] An aerosol generating component (e.g., which is flat and / or sheet-like) may be arranged within a non-flammable aerosol supply system (e.g., an electronic cigarette) such that the aerosol generating component is located within an aerosol generating chamber forming part of an airflow channel. The aerosol generating component may be oriented within the chamber such that airflow through the chamber can flow in a surface direction (i.e., substantially parallel to the plane of the aerosol generating component). Examples of this configuration can be found in WO2010 / 045670 and WO2010 / 045671, the contents of which are incorporated herein by reference in their entirety. Air can thus flow through the aerosol generating component (e.g., its carbon allotropes) and collect vapor. Thus, aerosol generation becomes efficient. In an alternative embodiment, the aerosol generating component may be oriented within the chamber such that airflow through the chamber can flow in a direction substantially transverse to the surface direction (i.e., substantially orthogonal to the plane of the aerosol generating component). An example of this configuration can be found in WO2018 / 211252, the contents of which are incorporated herein by reference in their entirety.

[0080] Aerosol generating components (e.g., their carbon allotropes) can have a high degree of porosity. High porosity ensures that the heat generated by the aerosol generating component is primarily used for liquid evaporation and achieves high efficiency. Porosities greater than 50% are conceivable. In one embodiment, the porosity of the aerosol generating component is 50% or greater, 60% or greater, or 70% or greater.

[0081] The aerosol generating component can form a generally flat structure, including first and second surfaces. The generally flat structure can take the form of any two-dimensional shape, such as a circle, semicircle, triangle, square, rectangle, and / or polygon. The aerosol generating component can have a uniform thickness.

[0082] When the aerosol generating component (e.g., its carbon allotrope) is formed of a resistive material, current is allowed to flow through the aerosol generating component (e.g., its carbon allotrope) to generate heat (so-called Joule heating). The resistance of the aerosol generating component (e.g., its carbon allotrope) can be suitably selected for this purpose. For example, the aerosol generating component (e.g., its carbon allotrope) can have a resistance of 2 ohms or less, such as 1.8 ohms or less, 1.7 ohms or less, 1.6 ohms or less, 1.5 ohms or less, 1.4 ohms or less, 1.3 ohms or less, 1.2 ohms or less, 1.1 ohms or less, 1.0 ohms or less, 0.9 ohms or less, 0.8 ohms or less, 0.7 ohms or less, 0.6 ohms or less, or 0.5 ohms or less. Parameters of the aerosol generating component (e.g., its carbon allotrope), such as material, thickness, width, length, porosity, etc., can be selected to provide the desired resistance. In this regard, a relatively low resistance will help draw higher power from the source, which can be beneficial for producing a high aerosolization rate. On the other hand, the resistance should not be so low as to compromise the integrity of the aerosol generator (e.g., its carbon allotrope). For example, the resistance should not be lower than 0.5 ohms.

[0083] In one aspect of this disclosure, an aerosol generating component 100 is provided for use as part of a non-flammable aerosol supply system, the aerosol generating component 100 including a carbon allotrope 101 loaded on an electrically insulating substrate 102.

[0084] Examples of aerosol generating components 100 are shown in Figures 2 to 19C.

[0085] It has been found that, in the case of a non-flammable aerosol supply system, the aerosol generating component 100 exhibits the desired heating and aerosolization performance.

[0086] The carbon allotrope 101 is loaded onto the electrically insulating substrate 102. In this way, the carbon allotrope 101 is loaded directly or indirectly onto the electrically insulating substrate 102.

[0087] The electrically insulating substrate 102 may be porous. Alternatively, the electrically insulating substrate 102 may be non-porous.

[0088] The electrically insulating substrate 102 may comprise one or more layers. At least one layer may be porous. At least one layer may be non-porous. For example, at least one layer may be porous and at least one layer may be non-porous.

[0089] At least one of the layers can be formed in the form of a coating.

[0090] The electrically insulating substrate 102 may include at least two layers, wherein the layer in direct contact with the carbon allotrope 101 is porous, and at least one other layer is non-porous.

[0091] The electrically insulating substrate 102 may include at least two layers, wherein the layer in direct contact with the carbon allotrope 101 is non-porous, and at least one other layer is porous.

[0092] The electrically insulating substrate 102 can be made of any suitable conductive material. Specifically, the electrically insulating substrate 102 can be thermally insulating (in this case, the substrate can be referred to as "electrically insulating and thermally insulating substrate 102"). The electrically insulating substrate 102 may have a strength not exceeding 5 Wm. -1 k -1 Thermal conductivity. The electrically insulating substrate 102 may have a thermal conductivity of no more than 3 W / m². -1 k -1 Thermal conductivity. The electrically insulating substrate 102 may have a thermal conductivity of not more than 2 W / m. -1 k -1 Thermal conductivity. The electrically insulating substrate 102 may have a thermal conductivity of not more than 1 W / m. -1 k -1 The thermal conductivity. The electrically insulating substrate 102 may have a thermal conductivity of not more than 0.5 W / m. -1 k -1 The thermal conductivity. The electrically insulating substrate 102 may have a thermal conductivity of not more than 0.2 W / m. -1 k -1 The thermal conductivity. The electrically insulating substrate 102 may have a thermal conductivity of not more than 0.1 W / m. -1 k -1 Thermal conductivity.

[0093] For example, the electrically insulating substrate 102 can be selected from the group consisting of plastics, glass, paper, and ceramics. For example, when the electrically insulating substrate 102 comprises one or more layers, each layer can be independently selected from the group consisting of plastics, glass, paper, and ceramics.

[0094] The plastic may be selected from polysulfone (PSU), poly(ether sulfone) (PES), polyimide (PI), poly(phenylene sulfide) (PPS), polyether ether ketone (PEEK), and polyether ketone (PEK). In some embodiments, the polyimide (PI) is selected from polyether imide (PEI) and polyamide-imide (PAI). In some embodiments, the polyimide is poly(4,4'-oxydiphenylene-pyromellitictetracarboxyimide). Poly(4,4'-oxydiphenylene-pyromellitictetracarboxyimide) is commercially available from DuPont under the trade name Kapton® HN (and other Kapton® products).

[0095] The glass may be selected from the group consisting of silicate glass and non-silicate glass. In some embodiments, the silicate glass is borosilicate glass or quartz glass (fused silica). The glass may be flexible. The glass may be non-porous.

[0096] The electrically insulating substrate 101 (e.g., at least one layer thereof) may have a porous structure formed by pillars and interstitial pores (also referred to herein as voids and / or gaps). A carbon allotrope 101 may be formed on the pillars to form a coating. For example, the interstitial pores of the coated electrically insulating substrate may have an average pore diameter of 0.5 to 40 μm (although this can vary). The average pore diameter may be a mean pore diameter or a median pore diameter. Methods for determining the average pore diameter may include (but are not limited to) mercury porosimetry or gas adsorption. These methods are familiar to those skilled in the art.

[0097] The electrically insulating substrate 102 may be formed in the form of a sheet (which may be curved or substantially flat). The electrically insulating substrate 102 may be substantially flat. In some embodiments, the electrically insulating substrate 102 may be formed in the form of a plate, strip (as shown in Figures 2, 3, 5A, 5B, 6A, and 6B), or rod. As shown in Figures 2 through 9, the electrically insulating substrate 102 may be elongated.

[0098] In some embodiments, the cross-sectional area of ​​the electrically insulating substrate 102 perpendicular to its longitudinal direction (e.g., length) is polygonal (e.g., square, rectangular, or triangular). Alternatively, the cross-sectional area of ​​the electrically insulating substrate 102 perpendicular to its longitudinal direction (e.g., length) is curved (e.g., circular, oval, or elliptical).

[0099] In some embodiments, the electrically insulating substrate 102 has a thickness from 100 μm to 4 mm. In some embodiments, the electrically insulating substrate 102 has a thickness from 200 μm to 3 mm. In some embodiments, the electrically insulating substrate 102 has a thickness from 400 μm to 2 mm.

[0100] In some embodiments, the electrically insulating substrate 102 has a thickness of 5 μm to 500 μm. In some embodiments, the electrically insulating substrate 102 has a thickness of 10 μm to 500 μm. In some embodiments, the electrically insulating substrate 102 has a thickness of 50 μm to 500 μm. In some embodiments, the electrically insulating substrate 102 has a thickness from 100 μm to 500 μm. In some embodiments, the electrically insulating substrate 102 has a thickness from 50 μm to 300 μm. In some embodiments, the electrically insulating substrate 102 has a thickness from 80 μm to 250 μm. In some embodiments, the electrically insulating substrate 102 has a thickness from 100 μm to 200 μm. For example, the thickness of the electrically insulating substrate 102 is indicated by "T" in FIG. 2. S "express.

[0101] In some embodiments, the electrically insulating substrate 102 has a length of 1 mm to 50 mm. In some embodiments, the electrically insulating substrate 102 has a length of 2 mm to 40 mm. In some embodiments, the electrically insulating substrate 102 has a length from 5 mm to 30 mm. In some embodiments, the electrically insulating substrate 102 has a length of 10 mm to 30 mm. In some embodiments, the electrically insulating substrate 102 has a length of 10 mm to 25 mm. In some embodiments, the electrically insulating substrate 102 has a length of 10 mm to 20 mm. In some embodiments, the electrically insulating substrate 102 has a length of 12 mm to 18 mm. For example, the length of the electrically insulating substrate 102 is indicated by "L" in FIG. 2. S "express.

[0102] In some embodiments, the electrically insulating substrate 102 has a width from 0.5 mm to 50 mm. In some embodiments, the electrically insulating substrate 102 has a width from 0.5 mm to 20 mm. In some embodiments, the electrically insulating substrate 102 has a width from 0.5 mm to 10 mm. In some embodiments, the electrically insulating substrate 102 has a width from 0.5 mm to 5 mm. In some embodiments, the electrically insulating substrate 102 has a width from 0.5 mm to 3 mm. In some embodiments, the electrically insulating substrate 102 has a width from 1 mm to 50 mm. In some embodiments, the electrically insulating substrate 102 has a width from 1 mm to 20 mm. In some embodiments, the electrically insulating substrate 102 has a width from 1 mm to 10 mm. In some embodiments, the electrically insulating substrate 102 has a width from 1 mm to 5 mm. In some embodiments, the electrically insulating substrate 102 has a width from 1 mm to 3 mm. For example, in FIG3, it is marked with "W". S "" indicates the width of the electrically insulating substrate 102.

[0103] In some embodiments, the carbon allotrope 101 has a length of 1 mm to 50 mm. In some embodiments, the carbon allotrope 101 has a length of 2 mm to 40 mm. In some embodiments, the carbon allotrope 101 has a length of 5 mm to 30 mm. In some embodiments, the carbon allotrope 101 has a length of 10 mm to 30 mm. In some embodiments, the carbon allotrope 101 has a length of 10 mm to 25 mm. In some embodiments, the carbon allotrope 101 has a length of 10 mm to 20 mm. In some embodiments, the carbon allotrope 101 has a length of 12 mm to 18 mm. In Figure 2, the length of the carbon allotrope 101 is shown to be approximately the same as the length Ls of the substrate 102 (although it will be understood that this can be varied).

[0104] In some embodiments, the carbon allotrope 101 has a width from 0.5 mm to 50 mm. In some embodiments, the carbon allotrope 101 has a width from 0.5 mm to 20 mm. In some embodiments, the carbon allotrope 101 has a width from 0.5 mm to 10 mm. In some embodiments, the carbon allotrope 101 has a width from 0.5 mm to 5 mm. In some embodiments, the carbon allotrope 101 has a width from 1 mm to 50 mm. In some embodiments, the carbon allotrope 101 has a width from 1 mm to 20 mm. In some embodiments, the carbon allotrope 101 has a width from 1 mm to 10 mm. In some embodiments, the carbon allotrope 101 has a width from 1 mm to 5 mm. In some embodiments, the carbon allotrope 101 has a width from 1 mm to 3 mm. In Figure 3, the width of carbon allotrope 101 is shown to be approximately the same as the width Ws of substrate 102 (although it will be understood that this can be changed).

[0105] The aerosol generating component 100 may include a capillary structure. Providing a capillary structure facilitates the efficient delivery of aerosolizable materials through the bulk structure of the aerosol generating component 100 and / or onto the surface of one or more layers of the carbon allotrope 101.

[0106] In some embodiments, the carbon allotrope 101 includes a capillary structure. Alternatively or additionally, the electrically insulating substrate 102 may include a capillary structure. For example, as described above, the capillary structure may be provided by the porous structure of the electrically insulating substrate 102 (if present). The capillary structure may additionally or alternatively be provided by one or more channels or trenches in the electrically insulating substrate 102 (if present).

[0107] The carbon allotrope 101 may include pores. For example, the carbon allotrope 101 may be porous. The carbon allotrope 101 may be permeable, for example, permeable to liquids and / or gases.

[0108] The carbon allotrope 101 may be at least partially exposed. The carbon allotrope 101 may be a monolithic material.

[0109] The carbon allotrope 101 may have a heating surface. The heating surface may be partially or completely exposed. During use, aerosols may be emitted from the heating surface.

[0110] In some embodiments, the carbon allotrope 101 includes a capillary structure, and the electrically insulating substrate 102 also includes a capillary structure. In other embodiments, the carbon allotrope 101 includes a capillary structure, and the electrically insulating substrate 102 is non-porous (and does not include a capillary structure). It has been found that providing a non-porous substrate 102 reduces the exposure of the carbon allotrope to the bulk aerosolizable material during use (as opposed to embodiments having a porous substrate 102), thereby improving the efficiency of the aerosol component 100. In this way, the aerosolizable material can be supplied to the carbon allotrope 101 through at least one pore 105 rather than via the bulk structure of the substrate 102 (which may be the case when the substrate 102 is porous).

[0111] The aerosol generating component 100 includes a carbon allotrope 101 loaded on an electrically insulating substrate 102.

[0112] It has been found that the carbon allotrope 101 provides an efficient aerosol-generating component. The carbon allotrope 101 provides a carbonaceous surface for distributing and aerosolizing aerosolizable materials during use. When the carbon allotrope 101 is heated to its aerosolization temperature, the carbonaceous surface possesses a high surface free energy, thus exhibiting high wettability. In this way, when the carbon allotrope 101 is heated to its aerosolization temperature, a thin layer of aerosolizable material can be uniformly distributed on the carbonaceous surface of the carbon allotrope 101 and effectively aerosolized. Furthermore, the carbon allotrope 101 has a high power density, low thermal mass, and allows for the formation of small volumes of aerosolizable material thinly on a given surface area of ​​the carbon allotrope (as opposed to materials that cannot be thinly formed on their surface). This provides efficient energy transfer to the aerosolizable material during use.

[0113] Carbon allotropes 101 may include carbon atoms structured to contain multiple carbon-carbon bonds located in the same plane. For example, carbon allotropes 101 may include graphite. In the case where carbon allotropes 101 include graphite, the allotropes comprise multiple stacked layers of carbon atoms, each layer having carbon atoms bonded to three adjacent carbon atoms in that layer, wherein each bond is located in the same plane to form a hexagonal lattice structure. Non-covalent bonding exists between the stacked layers.

[0114] Therefore, graphite comprises multiple stacked carbon layers, wherein the carbon layers are parallel to each other. There are two forms of graphite: α-graphite, in which the layers are stacked in an ABA pattern; and β-graphite, in which the layers are stacked in an ABC pattern.

[0115] The carbon allotrope 101 may also contain graphene. For example, the carbon allotrope 101 may be graphene. In the case that the carbon allotrope 101 is graphene, a single layer of carbon atoms (i.e., a carbon layer one atom thick) is arranged to form a hexagonal lattice structure.

[0116] It has been found that the use of graphene provides a particularly effective aerosol generating component. Advantageously, graphene's high thermal and electrical conductivity allows it to effectively dissipate heat, reduce temperature variations, and mitigate the severity of hot spots when hot spots (localized areas of elevated temperature that may occur during use when a portion of the heated aerosol generating component dries out) form. Consequently, the aerosol generating component can operate at high power levels with a reduced risk of hot spots causing damage to the component. Furthermore, graphene is elastic and therefore conforms to thermal expansion during use (e.g., thermal expansion of the electrically insulating substrate). Thus, the aerosol generating component resists degradation due to the difference in the coefficients of thermal expansion between graphene and the electrically insulating substrate 102.

[0117] It has also been found that the use of graphene can provide reduced battery throughput and thus extended battery life. Furthermore, the use of graphene can provide reduced battery size requirements and therefore improved packaging efficiency, for example, in terms of cost and space requirements. In addition, the use of graphene can facilitate the rapid volatilization of aerosolizable materials, which can enhance the user experience by reducing the time it takes for an aerosol to be generated in response to the user's first inhalation ("puff"). Furthermore, the use of graphene can contribute to consistency between inhalations ("puff-to-puff consistency"). The use of graphene can also provide some of the user experience advantages associated with cigarettes manufactured in conventional factories.

[0118] In the case where the carbon allotrope 101 includes graphene, more than one graphene layer may exist.

[0119] When more than one graphene layer 101 is loaded on an electrically insulating substrate 102, at least two of the graphene layers 101 can be non-parallel relative to each other. "Non-parallel" means that an imaginary plane passing through one graphene layer 101 (or a best-fit imaginary plane passing through a non-planar graphene layer 101) is not parallel to an imaginary plane passing through another graphene layer 101 (or a best-fit imaginary plane passing through another non-planar graphene layer 101). In use, the graphene layers 101 are electrically connected to form current paths. By providing non-parallel graphene layers, a porous graphene structure can be provided. The combination of graphene's porosity and low surface energy at typical aerosolization temperatures allows aerosolizable materials to be efficiently distributed not only on the outermost surface of graphene but also on the bulk structure of graphene. In effect, the aerosolizable material can be configured to be in close contact with the increased surface area of ​​the heating material provided by the graphene layers. This provides highly efficient and effective aerosolization performance.

[0120] For example, at least three, at least four, at least five, at least six, at least eight, or at least ten of the graphene layers 101 are not parallel to each other.

[0121] When more than one graphene layer 101 is loaded on an electrically insulating substrate 102, at least two of the graphene layers 101 can be parallel to each other. For example, the carbon allotrope 101 can be a bilayer graphene.

[0122] For example, as shown in Figures 4A to 4C, some of the graphene layers 101 can directly contact the electrically insulating substrate 101, while some graphene layers 101 can be disposed on top of other graphene layers 101.

[0123] What will be understood is the assumption of other carbon allotropes 101.

[0124] In some preferred embodiments, the carbon allotrope 101 comprises disordered graphite and / or amorphous carbon. In some preferred embodiments, the carbon allotrope 101 is selected from the group consisting of disordered graphite, amorphous carbon, or combinations thereof.

[0125] The Raman spectrum of carbon allotrope 101 includes the G and D bands. The Raman spectrum of carbon allotrope 101 also includes the 2D band.

[0126] In some preferred embodiments, the Raman spectrum of carbon allotrope 101 includes approximately 1500 cm⁻¹. -1 Approximately 1650 cm -1 The G-band peaks are located within the Raman shift range. In this embodiment, the Raman spectrum of carbon allotrope 101 can include a range from approximately 1250 cm⁻¹. -1 Approximately 1400 cm-1 The D-band peaks are located within the Raman shift range. In this embodiment, the Raman spectrum of the carbon allotrope 101 can include a range from approximately 2600 cm⁻¹. -1 Approximately 2750 cm -1 2D band peaks within the Raman shift range.

[0127] For example, in some preferred embodiments, the Raman spectrum of carbon allotrope 101 includes approximately 1550 cm⁻¹. -1 Approximately 1590 cm -1 The G-band peak is located within the Raman shift range. In such an embodiment, the Raman spectrum of carbon allotrope 101 can include a range from approximately 1310 cm⁻¹. -1 Approximately 1340 cm -1 The D-band peak is located within the Raman shift range. In this embodiment, the Raman spectrum of carbon allotrope 101 can be contained within approximately 2620 cm⁻¹. -1 Approximately 2680 cm -1 2D band peaks within the Raman shift range.

[0128] Intensity of D band peak I D The intensity of the G-band peak I G The ratio I D / I G It can range from approximately 0.8 to approximately 2. Ratio I D / I G It can range from approximately 0.9 to approximately 1.9. Ratio I D / I G It can range from about 1 to about 1.8.

[0129] The G-band peak can have a value of approximately 30 cm⁻¹. -1 Approximately 100 cm -1 The full width at half maximum (FWHM) at the G-band peak can range from approximately 30 cm⁻¹. -1 Approximately 70 cm -1 FWHM.

[0130] 2D bands can follow either a Gaussian curve model or a Lorentzian curve model.

[0131] Any of the above-mentioned features associated with Raman spectroscopy can be combined. For example, in some preferred embodiments, the Raman spectrum of carbon allotrope 101 includes G and D bands, wherein the G band peak is at approximately 1500 cm⁻¹. -1 Approximately 1650 cm -1 Within the Raman shift range, and the D-band peak is at approximately 1250 cm⁻¹. -1 Approximately 1400 cm -1 Within the Raman shift range, the intensity of the D band peak ID The intensity of the G-band peak I G The ratio I D / I G It ranges from about 0.8 to about 2. For example, in some preferred embodiments, the Raman spectrum of carbon allotrope 101 includes G and D bands, wherein the G band peak is at about 1550 cm⁻¹. -1 Approximately 1590 cm -1 Within the Raman shift range, and the D-band peak is at approximately 1310 cm⁻¹. -1 Approximately 1340 cm -1 Within the Raman shift range, the intensity of the D band peak I D The intensity of the G-band peak I G The ratio I D / I G It is from about 1 to about 1.8.

[0132] For example, in some preferred embodiments, the carbon allotrope 101 is porous. For example, in some preferred embodiments, the carbon allotrope 101 is formed in the form of foam. The carbon allotrope 101 is conductive.

[0133] In this paper, Raman microscopy was used to measure Raman spectra. A laser wavelength of 638 nm was used for Raman microscopy. A grating with 1800 grooves / mm was used for Raman microscopy. A laser power of 10.9 mW was used for Raman microscopy. A 5-second acquisition time was used for Raman microscopy. Twenty accumulations were used for Raman microscopy. A 300 μm confocal pinhole was used for Raman microscopy. The measurement range was from approximately 1000 cm⁻¹. -1 Up to about 3000 cm -1 Raman microspectroscopy was performed within the specified wavelength range. In this study, Raman microspectroscopy was performed using a microscope objective with a 50x LWD (long working distance) and a 0.8 NA (numerical aperture). A HoribaXplora Plus Raman microspectrometer was used for the procedure. The Raman microspectroscopy was performed at 21°C. The carbon allotrope 101 subjected to Raman microspectroscopy was not used in this study. That is, the carbon allotrope 101 was not used to generate aerosols and / or was not heated to the typical aerosolization temperature (after the fabrication of the carbon allotrope 101).

[0134] The inventors have used Raman microscopy to analyze various carbon allotropes 101 samples.

[0135] Each carbon allotrope 101 sample was prepared by laser irradiation of a polyimide (poly(4,4'-oxydiphenylene-pyromellitictetracarboximide), Kapton® HN, DuPont) substrate 102 (an electrically insulating substrate). Each polyimide substrate had a length of approximately 4.5 mm, a width of approximately 4.5 mm, and a thickness of approximately 125 μm, and was shaped into a rectangular prism. This involved irradiating approximately 4.5 mm by approximately 2 mm (i.e., approximately 9 mm) of each polyimide substrate with a laser beam. 2 The area of ​​the rectangle was used to form carbon allotropes 101. Raman microspectroscopy was performed on each carbon allotrope 101 sample. Each carbon allotrope 101 sample was porous and conductive.

[0136] Unconstrained by theory, Raman spectroscopy is considered a non-destructive vibrational spectroscopy technique that uses a laser to excite bonds within a sample (e.g., carbon) and interprets the inelastic scattering of bond vibrations as relative Raman shifts. Inelastic scattering from interactions with the sample produces these relative Raman shifts, thereby generating spectra that can be used to interpret the characteristics and / or properties of the sample. To characterize carbon allotropy 101 samples, studies can be conducted typically at approximately 1329 cm⁻¹. -1 The D band observed at approximately 1579 cm⁻¹ -1 The G-band observed at [location], and typically at approximately 2630 cm [location] -1 The peak position of the 2D band observed at [location]. The D band can be called the "disorder band" and is the sp[value] of carbon in the sample. 3 Indicator of hybridization. The G-band, also known as the "graphene band," is used to determine the sp(s) structure of carbon within a sample. 2 Hybridization. For example, the Raman spectrum of a pristine graphene sample will typically include a high-intensity, narrow G band and no D band. The Raman spectrum of a graphite sample typically includes both G and D bands, with the D band being less intense than the G band. D / I G The ratio can be determined by the intensity (au) of the D band peak (I) D The count of ) and the intensity of the G-band peak (I) G The count of peaks can be used to determine the presence of carbon allotropes within a sample. 2D bands can also be used to determine the morphology of allotropes by interpreting the area under the curve and the peak position. For example, crystalline graphite typically exhibits a sharp and narrow peak curve conforming to a Lorentz curve fitting model, while samples containing amorphous carbon typically exhibit a wider and flatter 2D band conforming to a Gaussian curve fitting model. The full width at half maximum (FWHM) of a peak can also be used to determine the crystallinity within a sample. The FWHM is measured by determining the width of the peak in question at half the total intensity of the sample.

[0137] Raman microspectroscopy involved measuring the Raman spectrum of each sample using a Horiba Xplora Plus Raman microspectrometer with the following parameters: a laser wavelength of 638 nm; a grating with 1800 grooves / mm; a 5-second acquisition time; 20 accumulations (20 spectra); a laser power of 10.9 mW; a confocal pinhole of 300 μm; and a range from approximately 1000 cm⁻¹. -1 Approximately 3000 cm -1 The wavelength range.

[0138] Raman microscopy was performed at 21°C.

[0139] The carbon allotrope 101 sample subjected to Raman microscopy was not used.

[0140] The Raman spectra of each carbon allotrope 101 sample include the G band and the D band, with the G band peak at approximately 1550 cm⁻¹. -1 Approximately 1590 cm -1 Within the Raman shift range, and the D-band peak is at approximately 1310 cm⁻¹. -1 Approximately 1340 cm -1 Within the Raman shift range, the intensity of the D band peak I D The intensity of the G-band peak I G The ratio I D / I G The values ​​range from 1 to 1.8. The Raman spectra of each carbon allotrope 101 sample are from approximately 2620 cm⁻¹. -1 Approximately 2680 cm -1 The Raman shift range includes 2D band peaks. In the Raman spectra of each carbon allotrope 101 sample, the G band peak has a range from approximately 45 cm⁻¹. -1 Approximately 62 cm -1 The full width at half maximum (FWHM) of the peaks. In the Raman spectra of each carbon allotrope 101 sample, the 2D bands typically follow a Lorentz curve fitting model.

[0141] Raman spectra of each carbon allotrope 101 sample indicate that the sample includes disordered graphite, amorphous carbon, or a combination thereof.

[0142] Figure 24 shows the Raman spectrum of one of the carbon allotropes 101 samples. The sample was not used. As shown in Figure 24, the spectrum is at approximately 1573 cm⁻¹. -1 A G-band peak was observed at approximately 1320 cm⁻¹. -1 A D-band peak was observed at approximately 2630 cm⁻¹. -1 A 2D band peak was observed at [location]. The intensity of the G band peak is I. G The intensity of the D band peak I D The ratio I G / ID It is approximately 1.6. The G-band peak has a length of approximately 62 cm⁻¹. -1 The FWHM 2D band follows a Lorentz curve fitting model.

[0143] The inventors have discovered that carbon allotropes 101 comprising disordered graphite, amorphous carbon, or combinations thereof provide particularly effective aerosol generating components. Such carbon allotropes 101 have been found to effectively dissipate heat, reduce temperature variations, and mitigate the severity of any hot spots. This carbon allotrope 101 exhibits low electrical resistance (and high electrical conductivity), making it particularly suitable for use in non-flammable aerosol supply systems. Such carbon allotropes 101 also promote efficient liquid distribution, for example, on and / or within the surface of the carbon allotrope.

[0144] Carbon allotrope 101 can have 100 Wm -1 k -1 Up to 5500 Wm -1 k -1 Thermal conductivity. Carbon allotrope 101 can have 100 W / m². -1 k -1 Up to 4000 Wm -1 k -1 Thermal conductivity. Carbon allotrope 101 can have 100 W / m². -1 k -1 Up to 2000 Wm -1 k -1 Thermal conductivity. Carbon allotrope 101 can have 150 W / m². -1 k -1 Up to 1000 Wm -1 k -1 Thermal conductivity. Carbon allotrope 101 can have 180 W / m². -1 k -1 Up to 700 Wm -1 k -1 Thermal conductivity. Carbon allotropes 101 can have thermal conductivity ranging from 200 W / m². -1 k -1 Up to 500 Wm -1 k -1 Thermal conductivity.

[0145] Carbon allotropes 101 can have a range from 1 Sm -1 Up to 2.5×10 6 Sm -1 The electrical conductivity. Carbon allotrope 101 can have a conductivity of 100 Sm. -1 Up to 1.0×10 6 Sm -1 The electrical conductivity. Carbon allotropes 101 can have electrical conductivity ranging from 200 Sm.-1 Up to 100,000 Sm -1 The electrical conductivity. Carbon allotrope 101 can have 400 Sm. -1 Up to 50000 Sm -1 The electrical conductivity. Carbon allotropes 101 can have electrical conductivity ranging from 500 Sm. -1 Up to 10000 Sm -1 The electrical conductivity. Carbon allotrope 101 can have a conductivity of 600 Sm. -1 Up to 5000 Sm -1 The electrical conductivity. Carbon allotrope 101 can have 800 Sm. -1 Up to 3000 Sm -1 The electrical conductivity. Carbon allotrope 101 can have 900 Sm. -1 Up to 1300 Sm -1 The electrical conductivity.

[0146] Carbon allotropes 101 can exhibit nonlinear elasticity.

[0147] In the case where carbon allotropes 101 include graphene, the carbon allotropes (e.g., one or more graphene layers) can include or be in the form of three-dimensional graphene (which may be referred to as porous graphene or laser-induced graphene (LIG)). Three-dimensional graphene can be considered as one or more graphene sheets (or layers) folded back (e.g., on each other) to form a three-dimensional structure. Without being bound by theory, it is thought that interatomic bonds in three-dimensional graphene are formed between predominantly sp2 hybridized orbitals, and that the predominant local coordination of carbon atoms in three-dimensional graphene is similar to that in two-dimensional graphene, allowing two-dimensional and three-dimensional graphene to possess similar electronic properties. Graphene foam (described below) can be considered an example of three-dimensional graphene.

[0148] In embodiments including one or more graphene layers 101, the one or more layers can be provided in various forms. For example, the one or more graphene layers 101 can be formed in the form of multiple three-dimensional structures. The three-dimensional graphene structure can be selected from cubes, cuboids, pyramids, cylinders (e.g., tubes), spheres, pyramids, and / or prisms. Those skilled in the art will be familiar with methods for producing three-dimensional graphene structures, including (but not limited to) arc discharge, laser ablation, high-pressure carbon monoxide dismutation, and chemical vapor deposition.

[0149] Carbon allotropes 101 can be formed in the form of foam. Carbon allotropes 101 can be formed in the form of open-cell foam. Carbon allotropes 101 may include capillary structures. Open-cell foam may include capillary structures.

[0150] Figures 4A to 4C show examples in which one or more layers 101 can be provided.

[0151] As shown in Figure 4A, a carbon allotrope (e.g., one or more graphene layers) 101 can be formed in the form of an open-cell foam (which may be referred to herein as "graphene foam"; see, for example, High-Resolution Laser-Induced Graphene. Flexible Electronics beyond the Visible Limit; Michael G. Stanford, et al., ACS Applied Materials & Interfaces 202012 (9), 10902-10907). The graphene foam may include capillary structures. Graphene foam can be formed by vapor deposition, such as chemical vapor deposition. The graphene foam includes a three-dimensional open-cell structure through which aerosolizable materials can traverse, for example, through capillary action.

[0152] Graphene foam has been found to exhibit particularly effective liquid delivery (e.g., wicking) properties, for example, compared to conventional liquid delivery materials such as cotton. For instance, graphene foam is capable of delivering (e.g., wicking) aerosolizable materials at a rate of 3 µL / s.

[0153] As shown in Figure 4B, a carbon allotrope (e.g., one or more graphene layers) 101 can be formed in the form of multiple sheets. Gaps can exist between the sheets. The gaps between the sheets can provide a capillary structure. Aerosolizable materials can, for example, traverse the gaps through capillary action.

[0154] As shown in Figure 4C, a carbon allotrope (e.g., one or more graphene layers) 101 can be formed in the form of multiple nanotubes. Gaps may exist between the nanotubes. The gaps between the nanotubes and / or the tubular spaces within the nanotubes can provide a capillary structure. Aerosolizable materials can, for example, traverse the gaps and / or tubular spaces through capillary action.

[0155] Carbon allotropes (e.g., one or more graphene layers 101) can be sintered onto the substrate 102. Sintering has been found to increase the mechanical strength and / or damage resistance of one or more graphene layers 101.

[0156] According to this disclosure, a carbon allotrope 101 is loaded on an electrically insulating substrate 102. The thickness of the carbon allotrope 101 can vary depending on the properties of the electrically insulating substrate 102 and the arrangement of the carbon allotrope 101 on the electrically insulating substrate 102. The thickness of the carbon allotrope 101 is understood to refer to the range of the carbon allotrope 101 orthogonally measured between the loading surface of the electrically insulating substrate 102 and the outer surface of the carbon allotrope 101. In this respect, the outer surface refers to the surface of the carbon allotrope 101 that does not have another layer loaded thereon when viewed orthogonally from the loading surface of the electrically insulating substrate 102. In the case where the carbon allotrope 102 includes internal holes, these internal holes are effectively ignored in the thickness measurement. By way of example, the first exemplary carbon allotrope 101 and the second exemplary carbon allotrope 101 will have the same thickness only when the first exemplary allotrope has internal holes and the second exemplary allotrope does not. The thickness of the carbon allotrope 101 can refer to the thickness of a single layer or multiple layers. Those skilled in the art will know suitable methods for measuring the thickness of the carbon allotrope 101, such as electron microscopy.

[0157] In some embodiments, the carbon allotrope 101 has a thickness of no more than 500 nm. In some embodiments, the carbon allotrope 101 has a thickness of no more than 400 nm. In some embodiments, the carbon allotrope 101 has a thickness of no more than 300 nm. In some embodiments, the carbon allotrope 101 has a thickness of no more than 200 nm. In some embodiments, the carbon allotrope 101 has a thickness of no more than 100 μm. In some embodiments, the carbon allotrope 101 has a thickness of no more than 80 μm. In some embodiments, the carbon allotrope 101 has a thickness of no more than 60 μm. In some embodiments, the carbon allotrope 101 has a thickness of no more than 50 μm. In some embodiments, the carbon allotrope 101 has a thickness of no more than 30 μm. In some embodiments, the carbon allotrope 101 has a thickness of no more than 20 μm. In some embodiments, the carbon allotrope 101 has a thickness of no more than 10 μm. In some embodiments, the carbon allotrope 101 has a thickness of no more than 5 μm. In some embodiments, the carbon allotrope 101 has a thickness of no more than 1 μm. The thickness of the carbon allotrope 101 is represented by "t" in Figures 4A to 4C.

[0158] For example, when the carbon allotrope 101 exists as a single layer of graphene, its thickness will have a natural lower limit corresponding to the thickness of a single layer of graphene, which may be 0.345 nm. However, when the carbon allotrope 101 exists as a multilayer graphene, its thickness will be greater than 0.345 nm. In some embodiments, the carbon allotrope 101 has a thickness of at least 0.7 nm. In some embodiments, the carbon allotrope 101 has a thickness of at least 1 nm. In some embodiments, the carbon allotrope 101 has a thickness of at least 2 nm. In some embodiments, the carbon allotrope 101 has a thickness of at least 5 nm. In some embodiments, the carbon allotrope 101 has a thickness of at least 10 nm. In some embodiments, the carbon allotrope 101 has a thickness of at least 20 nm.

[0159] In some embodiments, the carbon allotrope 101 has a thickness from 0.345 nm to 500 μm. In some embodiments, the carbon allotrope 101 has a thickness from 0.345 nm to 400 μm. In some embodiments, the carbon allotrope 101 has a thickness from 0.345 nm to 300 μm. In some embodiments, the carbon allotrope 101 has a thickness from 0.345 nm to 200 μm. In some embodiments, the carbon allotrope 101 has a thickness from 0.345 nm to 100 μm. In some embodiments, the carbon allotrope 101 has a thickness from 0.345 nm to 80 μm. In some embodiments, the carbon allotrope 101 has a thickness from 0.345 nm to 60 μm. In some embodiments, the carbon allotrope 101 has a thickness from 0.345 nm to 50 μm. In some embodiments, the carbon allotrope 101 has a thickness from 0.345 nm to 40 μm. In some embodiments, the carbon allotrope 101 has a thickness from 0.345 nm to 30 μm. In some embodiments, the carbon allotrope 101 has a thickness from 0.345 nm to 20 μm. In some embodiments, the carbon allotrope 101 has a thickness from 0.345 nm to 10 μm. In some embodiments, the carbon allotrope 101 has a thickness from 0.345 nm to 1 μm. In some embodiments, the carbon allotrope 101 has a thickness from 0.345 nm to 500 nm. In some embodiments, the carbon allotrope 101 has a thickness from 0.345 nm to 200 nm. In some embodiments, the carbon allotrope 101 has a thickness from 0.345 nm to 100 nm. In some embodiments, the carbon allotrope 101 has a thickness from 0.345 nm to 50 nm. In some embodiments, the carbon allotrope 101 has a thickness from 0.345 nm to 20 nm. In some embodiments, the carbon allotrope 101 has a thickness from 0.345 nm to 10 nm.

[0160] In some embodiments, the carbon allotrope 101 has a thickness ranging from 1 μm to 500 μm. In some embodiments, the carbon allotrope 101 has a thickness ranging from 1 μm to 400 μm. In some embodiments, the carbon allotrope 101 has a thickness ranging from 1 μm to 300 μm. In some embodiments, the carbon allotrope 101 has a thickness ranging from 1 μm to 200 μm. In some embodiments, the carbon allotrope 101 has a thickness ranging from 1 μm to 100 μm. In some embodiments, the carbon allotrope 101 has a thickness ranging from 1 μm to 80 μm.

[0161] In some embodiments, the carbon allotrope 101 has a thickness ranging from 10 μm to 500 μm. In some embodiments, the carbon allotrope 101 has a thickness ranging from 10 μm to 400 μm. In some embodiments, the carbon allotrope 101 has a thickness ranging from 10 μm to 300 μm. In some embodiments, the carbon allotrope 101 has a thickness ranging from 10 μm to 200 μm. In some embodiments, the carbon allotrope 101 has a thickness ranging from 10 μm to 100 μm. In some embodiments, the carbon allotrope 101 has a thickness ranging from 10 μm to 80 μm.

[0162] In some embodiments, the carbon allotrope 101 has a thickness ranging from 20 μm to 500 μm. In some embodiments, the carbon allotrope 101 has a thickness ranging from 20 μm to 400 μm. In some embodiments, the carbon allotrope 101 has a thickness ranging from 20 μm to 300 μm. In some embodiments, the carbon allotrope 101 has a thickness ranging from 20 μm to 200 μm. In some embodiments, the carbon allotrope 101 has a thickness ranging from 20 μm to 100 μm. In some embodiments, the carbon allotrope 101 has a thickness ranging from 20 μm to 80 μm.

[0163] In some embodiments, the carbon allotrope 101 has a thickness of 1 nm to 1 μm. In some embodiments, the carbon allotrope 101 has a thickness of 1 nm to 500 nm. In some embodiments, the carbon allotrope 101 has a thickness of 1 nm to 200 nm. In some embodiments, the carbon allotrope 101 has a thickness of 1 nm to 100 nm. In some embodiments, the carbon allotrope 101 has a thickness of 1 nm to 50 nm. In some embodiments, the carbon allotrope 101 has a thickness of 1 nm to 20 nm. In some embodiments, the carbon allotrope 101 has a thickness of 1 nm to 10 nm.

[0164] In some embodiments, the carbon allotrope 101 has a thickness from 2 nm to 1 μm. In some embodiments, the carbon allotrope 101 has a thickness from 2 nm to 500 nm. In some embodiments, the carbon allotrope 101 has a thickness from 2 nm to 200 nm. In some embodiments, the carbon allotrope 101 has a thickness from 2 nm to 100 nm. In some embodiments, the carbon allotrope 101 has a thickness from 2 nm to 50 nm. In some embodiments, the carbon allotrope 101 has a thickness from 2 nm to 20 nm. In some embodiments, the carbon allotrope 101 has a thickness from 2 nm to 10 nm.

[0165] In some embodiments, the carbon allotrope 101 has a thickness from 5 nm to 1 μm. In some embodiments, the carbon allotrope 101 has a thickness from 5 nm to 500 nm. In some embodiments, the carbon allotrope 101 has a thickness from 5 nm to 200 nm. In some embodiments, the carbon allotrope 101 has a thickness from 5 nm to 100 nm. In some embodiments, the carbon allotrope 101 has a thickness from 5 nm to 50 nm. In some embodiments, the carbon allotrope 101 has a thickness from 5 nm to 20 nm. In some embodiments, the carbon allotrope 101 has a thickness from 5 nm to 10 nm.

[0166] In some embodiments, the carbon allotrope 101 is loaded on at least 50% of the surface 102a (e.g., the first surface) of the electrically insulating substrate 102. In some embodiments, the carbon allotrope 101 is loaded on at least 70% of the surface 102a of the electrically insulating substrate 102. In some embodiments, the carbon allotrope 101 is loaded on at least 90% of the surface 102a of the electrically insulating substrate 102. In some embodiments, the carbon allotrope 101 is loaded on substantially 100% of the surface 102a of the electrically insulating substrate 102.

[0167] The surface 102a on which the carbon allotrope 101 is loaded can provide at least 30% of the outer surface area of ​​the electrically insulating substrate 102. The surface 102a on which the carbon allotrope 101 is loaded can provide at least 40% of the outer surface area of ​​the electrically insulating substrate 102. The surface 102a on which the carbon allotrope 101 is loaded can provide at least 45% of the outer surface area of ​​the electrically insulating substrate 102.

[0168] In some embodiments, the surface 102a on which the carbon allotrope 101 is loaded is curved.

[0169] In some embodiments, the surface 102a on which the carbon allotrope 101 is loaded is substantially flat.

[0170] The surface 102a on which the carbon allotrope 101 is loaded can be the main surface. A "main surface" is the surface with the largest (or most common) area relative to the other surfaces of the electrically insulating substrate 102. For example, the main surface of a rectangular prism-shaped electrically insulating substrate 102 having a length of 15 cm, a width of 2 cm, and a height of 1 cm is a surface defined by its length and width (where both exist). In each of Figures 3, 5A, 6A, 7A, 7B, 8A, and 8B, one or more graphene layers 101 are shown loaded on the main surface of the electrically insulating substrate 102.

[0171] The aerosol generating component 100 may include one or more electrodes 103 arranged to be in electrical contact with the carbon allotrope 101. The one or more electrodes 103 may be arranged to be in direct electrical contact with the carbon allotrope 101. The one or more electrodes 103 are configured to form an electrical connection with a power source, such that electrical power can be delivered to the aerosol generating component 100 (e.g., the carbon allotrope 101).

[0172] The aerosol generating component 100 may include two electrodes 103, each electrode 103 being arranged to be in electrical contact with the carbon allotrope 101. In embodiments with two electrodes 103, one of the electrodes may be arranged toward or at an end of the aerosol generating component 100, and the other electrode 103 may be arranged toward or at an opposite end of the aerosol generating component 100.

[0173] One or more electrodes 103 are made of any suitable conductive material. For example, one or more electrodes 103 may be selected from copper, silver or gold.

[0174] One or more electrodes 103 may be sintered onto the carbon allotrope 101. Sintering may be performed at temperatures ranging from 100°C to 300°C, such as from 120°C to 200°C. Sintering may be performed for a duration ranging from 5 seconds to 5 minutes, such as from 10 seconds to 3 minutes. Those skilled in the art will understand that sintering conditions may vary.

[0175] In one aspect of this disclosure, the carbon allotrope 101 is configured such that the contact angle between the glycerol droplet and the surface of the carbon allotrope 101 is no greater than 20 degrees at a temperature of 150°C.

[0176] Contact angle can be measured using the Wilhelmy plate method, EM, simulation, or a goniometer. Contact angle can also be measured optically. For example, contact angle can be measured by photography. Those skilled in the art are familiar with these methods of measuring contact angle.

[0177] What will be understood is that the "contact angle" is the angle at which a liquid-vapor interface encounters a solid surface, and the contact angle quantifies the wettability of a liquid on a solid surface using Young's equation:

[0178] γ S It is the surface tension of a solid, γ L It is the surface tension of the liquid, and γ SL It is the boundary tension between the solid and the liquid (solid-liquid interface energy), and θ is the contact angle.

[0179] It has been found that when the carbon allotrope 101 is constructed in this way, during use, the aerosolizable material can form a thin layer uniformly distributed on the surface of the carbon allotrope 101, and the aerosolizable material can be effectively distributed throughout the entire bulk structure of the carbon allotrope 101. Furthermore, the aerosolizable material can be rapidly distributed on the carbon allotrope 101, and the volatilized aerosolizable material can be rapidly replenished. In addition, the aerosol generating component 100 has a reduced tendency to "dry out," meaning that the aerosol generating component 100 or a portion thereof may inadvertently dry out because the rate of replenishment of the aerosolizable material is less than the rate of volatilization of the aerosolizable material.

[0180] The temperature at which the contact angle is measured can refer to the temperature measured at the surface of the carbon allotrope on which glycerol droplets are provided.

[0181] At 150°C, the contact angle between a glycerol droplet and the surface of the carbon allotrope 101 may not exceed 18 degrees. At 150°C, the contact angle between a glycerol droplet and the surface of the carbon allotrope 101 may not exceed 16 degrees. At 150°C, the contact angle between a glycerol droplet and the surface of the carbon allotrope 101 may not exceed 14 degrees. At 150°C, the contact angle between a glycerol droplet and the surface of the carbon allotrope 101 may not exceed 12 degrees. At 150°C, the contact angle between a glycerol droplet and the surface of the carbon allotrope 101 may not exceed 10 degrees.

[0182] At a temperature of 20°C, the contact angle between the glycerol droplet and the surface of the carbon allotrope 101 can be from 70 degrees to 130 degrees, such as from 80 degrees to 110 degrees.

[0183] Carbon allotropes 101 may contain one or more dopants.

[0184] One or more dopants may include n-dopants (n-type dopants). n-dopants may be selected from the group consisting of free phosphorus and nitrogen.

[0185] One or more dopants may include p-dopants (p-type dopants). P-dopants may be selected from the group consisting of free boron and sulfur.

[0186] It has been found that the presence of such dopants promotes a reduction in contact angle and thus improves wettability.

[0187] In one aspect of this disclosure, the electrically insulating substrate 102 is elongated and has an aspect ratio ranging from 5:1 to 50:1. Such an aspect ratio has been found to provide the desired heating performance in use.

[0188] For example, the electrical insulating substrate 102 can have an aspect ratio from 5:1 to 40:1. The electrical insulating substrate 102 can have an aspect ratio from 5:1 to 35:1. The electrical insulating substrate 102 can have an aspect ratio from 5:1 to 30:1. The electrical insulating substrate 102 can have an aspect ratio from 5:1 to 25:1. The electrical insulating substrate 102 can have an aspect ratio from 5:1 to 22:1.

[0189] For example, the electrical insulating substrate 102 can have an aspect ratio from 8:1 to 40:1. The electrical insulating substrate 102 can have an aspect ratio from 8:1 to 35:1. The electrical insulating substrate 102 can have an aspect ratio from 8:1 to 30:1. The electrical insulating substrate 102 can have an aspect ratio from 8:1 to 25:1. The electrical insulating substrate 102 can have an aspect ratio from 8:1 to 22:1.

[0190] In one aspect of this disclosure, the carbon allotrope 101 includes an elongated heating surface having an aspect ratio of 5:1 to 50:1. Such an aspect ratio has been found to provide the desired heating performance in use. In particular, this aspect ratio has been found to exhibit the desired aerosolization rate and energy efficiency.

[0191] The heated surface can be considered as part of the carbon allotrope 101 that reaches the temperature at which the aerosolizable material is aerosolized during use.

[0192] For example, the heating surface of the carbon allotrope 101 can have an aspect ratio of 5:1 to 40:1. The heating surface of the carbon allotrope 101 can have an aspect ratio of 5:1 to 35:1. The heating surface of the carbon allotrope 101 can have an aspect ratio of 5:1 to 30:1. The heating surface of the carbon allotrope 101 can have an aspect ratio of 5:1 to 25:1. The heating surface of the carbon allotrope 101 can have an aspect ratio of 5:1 to 22:1.

[0193] For example, the heating surface of the carbon allotrope 101 can have an aspect ratio of 8:1 to 40:1. The heating surface of the carbon allotrope 101 can have an aspect ratio of 8:1 to 35:1. The heating surface of the carbon allotrope 101 can have an aspect ratio of 8:1 to 30:1. The heating surface of the carbon allotrope 101 can have an aspect ratio of 8:1 to 25:1. The heating surface of the carbon allotrope 101 can have an aspect ratio of 8:1 to 22:1.

[0194] The heating surface of carbon allotrope 101 can be substantially flat.

[0195] Figures 10A and 10B illustrate the relationship between energy density, efficiency, and mass loss data of the aerosol generating component 100 according to this disclosure. In this particular embodiment, the aerosol generating component 100 traverses an aerosol generating material transfer component, which is a reservoir of aerosolizable material (as shown in Figures 6A and 6B). The aerosol generating component 100 contacts the surface of the aerosolizable material in the reservoir. The energy density indicates the energy density provided per mm² by the aerosol generating component 100. 2 The amount of energy required. Efficiency (cross in Figure 10A) corresponds to the amount of energy required for the aerosol generating component 100 to volatilize 1 mg of aerosolizable material, which in this case is an aqueous solution of glycerol (50 wt.% glycerol). Mass change (loss; circle in Figure 10A) corresponds to the mass of aerosolized aerosolizable material, in mg, after a 20-second heater run time. The aerosol generating component 100 has varying lengths and widths and each comprises multiple graphene layers 101 disposed on a polyimide substrate 102, wherein the multiple graphene layers 101 are not parallel to each other. Lower efficiency values ​​(J / mg) are preferred, and higher mass change loss values ​​(mg) are preferred.

[0196] In one aspect of this disclosure, at least one elongate aperture 104 extends through the aerosol generating component 100.

[0197] Examples of such aerosol generating component 100 are shown in Figures 7A and 7B.

[0198] The presence of at least one pore increases the edge length and direct surface area of ​​the aerosol generating component 100 available for contact with the aerosol generating material. It has been found that, despite the presence of at least one pore, heat is uniformly distributed across the aerosol generating component 100 during use. This uniform heat distribution advantageously provides consistent aerosolization and reduces the tendency to form “hot spots.” This is illustrated in Figure 7B, which is a thermal diagram of the aerosol generating component 100 of Figure 7A in use, wherein the aerosol generating component 100 is powered by an electrical source.

[0199] As shown in Figures 7A and 7B, a plurality of elongated orifices 104 may extend through the aerosol generating component 100. For example, at least two, at least three, at least four, at least five, or at least six elongated orifices 104 may extend through the aerosol generating component 100. The elongated orifices, or each elongated orifice 104, may be linear. Alternatively, the elongated orifices, or each elongated orifice, may be non-linear.

[0200] The elongated apertures, or each elongated aperture 104, may extend substantially parallel to the axis of the aerosol generating component 100 (e.g., the electrically insulating substrate 102). For example, the elongated apertures, or each elongated aperture 104, may extend substantially parallel to the longitudinal extent (e.g., the longitudinal axis) of the aerosol generating component 100 (e.g., the electrically insulating substrate 102). For example, the elongated apertures, or each elongated aperture 104, may extend substantially parallel to the lateral extent (e.g., the lateral axis) of the aerosol generating component 100 (e.g., the electrically insulating substrate 102).

[0201] In embodiments including a plurality of elongated holes 104, the elongated holes 104 may be arranged side by side. In embodiments including a plurality of elongated holes 104, the elongated holes 104 may be arranged parallel to each other. For example, at least two, at least three, at least four, at least five, or at least six of the elongated holes 104 may be arranged parallel to each other, and one or more elongated holes 104 may not be parallel to each other.

[0202] For example, in the aerosol generating component 100 of Figures 7A and 7B, elongated holes 104 extend parallel to the longitudinal extent (e.g., longitudinal axis) of the aerosol generating component 100 (electrically insulating substrate 102), are spaced apart from each other, are arranged side by side, and are arranged parallel to each other.

[0203] The elongated hole, or each elongated hole 104, can have a width from 0.05 mm to 2 mm. The elongated hole, or each elongated hole 104, can have a width from 0.05 mm to 1.5 mm. The elongated hole, or each elongated hole 104, can have a width from 0.1 mm to 1 mm. The elongated hole, or each elongated hole 104, can have a width from 0.2 mm to 0.8 mm. The elongated hole, or each elongated hole 104, can have a width from 0.3 mm to 0.6 mm.

[0204] The elongated orifice, or each elongated orifice 104, may have a length ranging from 5% to 95% of the length of the aerosol generating component 100. The elongated orifice, or each elongated orifice 104, may have a length ranging from 20% to 95% of the length of the aerosol generating component 100. The elongated orifice, or each elongated orifice 104, may have a length ranging from 40% to 95% of the length of the aerosol generating component 100. The elongated orifice, or each elongated orifice 104, may have a length ranging from 50% to 95% of the length of the aerosol generating component 100. The elongated orifice, or each elongated orifice 104, may have a length ranging from 60% to 95% of the length of the aerosol generating component 100. The elongated orifice, or each elongated orifice 104, may have a length ranging from 70% to 95% of the length of the aerosol generating component 100. The elongated orifice, or each elongated orifice 104, may have a length ranging from 80% to 95% of the length of the aerosol generating component 100. The elongated orifice or each elongated orifice 104 may have a length of 90% to 95% of the length of the aerosol generating component 100.

[0205] The elongated hole, or each elongated hole 104, can have a length from 1 mm to 45 mm. The elongated hole, or each elongated hole 104, can have a length from 2 mm to 40 mm. The elongated hole, or each elongated hole 104, can have a length from 5 mm to 30 mm. The elongated hole, or each elongated hole 104, can have a length from 5 mm to 20 mm. The elongated hole, or each elongated hole 104, can have a length from 5 mm to 18 mm. The elongated hole, or each elongated hole 104, can have a length from 5 mm to 18 mm. The elongated hole, or each elongated hole 104, can have a length from 10 mm to 18 mm.

[0206] In the aerosol generating component 100 of Figures 7A and 7B, the aerosol generating component 100 has a length of 20 mm, a width of 1.0 mm, and a total thickness of 0.15 mm, and each elongated hole 104 has a length of 18 mm and a width of 0.5 mm. Specifically, the substrate (polyimide) 102 has a length of 20 mm, a width of 1.0 mm, and a thickness of 0.10 mm (100 μm). Carbon allotropes (graphene layers, multiple layers that are not parallel to each other) 102 substantially cover the entire upper surface of the electrically insulating substrate 102. The carbon allotropes have a thickness of 0.05 mm (50 μm).

[0207] The carbon allotrope 101 may include a first outer edge and a second outer edge. The first and second outer edges may be electrically connected to each other. The first and second outer edges may be opposing edges. An electrical path may extend between the first and second outer edges. At least one elongated aperture 104 may be provided between the first and second outer edges. At least one elongated aperture 104 may extend in a plane defined by the outer surface of the carbon allotrope 101. At least one elongated aperture 104 may extend through both the carbon allotrope 101 and the electrically insulating substrate 102.

[0208] In one aspect of this disclosure, the aerosol generating component 100 includes a heating section 100a. The aerosol generating component 100 may include at least one aerosolizable material supply section 100b. The at least one aerosolizable material supply section may extend from the heating section 101. This aerosol generating component 100 is shown in Figures 8A and 8B.

[0209] By means of a heating section 100a and at least one aerosolizable material supply section 100b, it has been found that the aerosol generating component exhibits improved transfer of aerosolizable material to the aerosol generating component 100 and improved aerosolization efficiency. Specifically, at least one aerosolizable material supply section 100b effectively transfers the aerosolizable material to the heating section 100a. Furthermore, it has been found that when the aerosol generating component 100 is powered, heat energy does not significantly diffuse to at least one aerosolizable material supply section 100b. This is illustrated in FIG8B, which is a thermal diagram using the aerosol generating component 100 of FIG8A, wherein the aerosol generating component 100 is powered by an electric power source to reach the aerosolization temperature. Moreover, by using at least one aerosolizable material supply section 100b to supply the aerosolizable material to the heating section 100a, the problem of vapor formation between the outer surface of the heating section and the aerosolizable material is reduced or prevented. This occurs when aerosolizable material is directly supplied to the outer surface of the heating element and can lead to accidental ejection of the aerosolizable material (e.g., "splashing" or "spraying").

[0210] As shown in Figures 8A and 8B, the heating element 100a can be elongated. For example, the heating element 100a can be formed in the form of a plate, strip, or rod. The heating element 100a can be linear. Alternatively, the heating element 100a can be non-linear.

[0211] The heating element 100a may include a carbon allotrope 101 and a substrate 102, or may be composed of a carbon allotrope 101 and a substrate 102. The heating element 100a may be composed of a carbon allotrope 101.

[0212] The heating element 100a may have a length from 1 mm to 50 mm. In some embodiments, the heating element 100a has a length from 2 mm to 40 mm. In some embodiments, the heating element 100a has a length from 5 mm to 30 mm. In some embodiments, the heating element 100a has a length from 10 mm to 30 mm. In some embodiments, the heating element 100a has a length from 10 mm to 25 mm. In some embodiments, the heating element 100a has a length from 10 mm to 20 mm.

[0213] The heating element 100a may have a width from 0.5 mm to 50 mm. In some embodiments, the heating element 100a has a width from 0.5 mm to 20 mm. In some embodiments, the heating element 100a has a width from 0.5 mm to 10 mm. In some embodiments, the heating element 100a has a width from 0.5 mm to 5 mm. In some embodiments, the heating element 100a has a width from 1 mm to 50 mm. In some embodiments, the heating element 100a has a width from 1 mm to 20 mm. In some embodiments, the heating element 100a has a width from 1 mm to 10 mm. In some embodiments, the heating element 100a has a width from 1 mm to 5 mm. In some embodiments, the heating element 100a has a width from 1 mm to 3 mm.

[0214] The aerosol generating component 100 may include a plurality (e.g., at least two, three, four, five, or six) aerosolizable material supply sections 100b, each extending from the heating section 100a. As shown in Figures 8A and 8B, the aerosolizable material supply sections or each aerosolizable material supply section 100b may extend from the side of the heating section 100a. As shown in Figures 8A and 8B, the aerosolizable material supply sections or each aerosolizable material supply section 100b may extend laterally into the longitudinal range of the heating section 100a. The aerosolizable material supply sections or each aerosolizable material supply section 100b may extend from the side of the heating section 100a.

[0215] The aerosol generating component 100 can be substantially flat. In this way, the heating unit 100a and at least one aerosolizable material supply unit 100b can be arranged in the same plane.

[0216] The aerosolizable material supply section or each aerosolizable material supply section 100b may be elongated 100a. For example, the aerosolizable material supply section or each aerosolizable material supply section 100b may be formed in the form of a plate, strip, or rod. The aerosolizable material supply section or each aerosolizable material supply section 100b may be linear.

[0217] The aerosolizable material supply section or each aerosolizable material supply section 100b may have an aspect ratio of 1:1 to 5:1. The width of the aerosolizable material supply section or each aerosolizable material supply section 100b may be 1 to 3 mm. The length of the aerosolizable material supply section or each aerosolizable material supply section 100b may be 1 to 15 mm.

[0218] The aerosolizable material supply section or each aerosolizable material supply section 100b may gradually narrow. For example, as shown in Figures 8A and 8B, the aerosolizable material supply section or each aerosolizable material supply section 100b may gradually narrow away from the elongated heating section 100a.

[0219] At least one aerosolizable material supply section 100b may be porous. At least one aerosolizable material supply section 100b may include capillary material. At least one aerosolizable material supply section 100b may have any characteristics of an electrically insulating substrate as defined herein.

[0220] As shown in Figures 8A and 8B, the heating section 100a may have a longitudinal range (e.g., a longitudinal axis). The aerosolizable material supply section or each aerosolizable material supply section 100b may extend obliquely or orthogonally from the longitudinal range of the heating section 100a.

[0221] The heating unit 100a includes a carbon allotrope 101 disposed on an electrically insulating substrate 102. Each aerosolizable material supply unit or each aerosolizable material supply unit 100b includes an electrically insulating substrate 102.

[0222] In some embodiments (e.g., in Figures 7A, 7B, 8A, and 8B), at least one aerosolizable material supply portion 100b includes a carbon allotrope 101 and an electrically insulating substrate 102. In some embodiments, at least one aerosolizable material supply portion 100b includes an electrically insulating substrate 102, such as a portion of the electrically insulating substrate 102 on which the carbon allotrope is not loaded (according to Figures 7A, 7B, 8A, and 8B).

[0223] In some embodiments, the heating element 100a and the substrate 102 are integrally formed.

[0224] In one aspect of this disclosure, an aerosol generation assembly is provided, including an aerosol generation component 100 of any aspect of this disclosure and an aerosol generation material transfer component 200 for supplying aerosol generation material to the aerosol generation component 100.

[0225] Figures 5A to 6C show examples of aerosol generation components.

[0226] The aerosol generating material transfer component 200 can be used to passively supply aerosol generating material to the aerosol generating component 100. "Passively supplying" means that the aerosol generating material transfer component 200 does not require power to transport the aerosol generating material to the aerosol generating component 100. For example, the aerosol generating material transfer component 200 may include a porous structure. For example, the aerosol generating material transfer component 200 may include a capillary structure. Capillary structures have been found to be particularly effective for transferring aerosolizable materials to the aerosol generating component 101.

[0227] As shown in Figures 5A to 5C, the aerosol generating material transfer component 200 may include at least one capillary channel 201 having an outlet 202. The outlet 202 may be arranged adjacent to the aerosol generating component 100 (e.g., one or more graphene layers 101 and / or substrate 102) such that aerosolizable material exiting the outlet 202 directly contacts the aerosol generating component. In the orientations shown in Figures 5A to 5C, the outlet 202 is arranged to supply aerosol generating material from above or beside the aerosol generating component 100 relative to gravity.

[0228] As shown in Figures 5A to 5C, a capillary channel (or each) 201 may be formed by a first layer (e.g., a capillary layer) 203 and a second layer (e.g., a base layer) 204. In Figures 5A to 5B, the first layer 203 and the second layer 204 are spaced apart by approximately 0.1 mm to 0.5 mm (although the spacing may vary). The outlet 202 of the capillary channel 201 may be located at the end of the first layer 203 and the second layer 204, adjacent to the aerosol generating component 100 (e.g., carbon allotrope 101 and / or substrate 102). At least one capillary channel 201 may be provided in various forms. A capillary channel or each capillary channel 101 may include a groove or a conduit. In some embodiments, the aerosol generating component may include multiple capillary channels (each capillary channel may independently include any features of the capillary channels described herein).

[0229] The first layer 203 can be formed of any of plastic, glass, paper, and ceramic. The first layer 203 can be non-porous. The second layer 204 can be formed of any of plastic, glass, paper, and ceramic. The second layer 204 can be non-porous. In Figures 5A and 5B, each of the first layer 203 and the second layer 204 is formed of glass.

[0230] As shown in Figures 6A and 6B, the aerosol generating material transfer component 200 may include a reservoir 210. For example, the aerosol generating component 100 may extend across the reservoir 210. In the orientation shown in Figures 6A and 6B, the reservoir 210 is arranged to supply aerosol generating material from below the aerosol generating component 100 to the aerosol generating component 100 relative to gravity. The reservoir 210 may be configured to include a quantity of aerosolizable material such that the aerosolizable material directly contacts the aerosol generating component 100 (e.g., one or more graphene layers 101), such as its outer surface, particularly the surface provided by the one or more graphene layers 101.

[0231] The aerosol generating assembly may include a moving mechanism (not shown) for moving (e.g., raising or lowering) the aerosol generating component 100 to maintain direct contact between the aerosol generating component 100 and any aerosolizable material in the reservoir 210. The moving mechanism may be automatically controlled by a controller.

[0232] In one aspect of this disclosure, at least one aperture 105 extends through an electrically insulating substrate 102. Examples of aerosol generating assemblies including such an aerosol generating component 100 are shown in Figures 11A, 12A, and 13A. Exemplary aerosol generating assemblies and aerosol generating components 100 are schematically depicted in Figures 15B and 15C. An exemplary aerosol generating component 100 is schematically depicted in Figure 16. Only some apertures 105 are shown in the figures. It should be understood that other apertures (not shown) may be present.

[0233] It has been found that using at least one pore 105 facilitates the efficient delivery of aerosolizable material to the carbon allotrope 101. Specifically, the aerosolizable material can be delivered from the surface of the substrate 102 opposite to the surface supporting the carbon allotrope 101 through at least one pore 105 to the carbon allotrope 101. In this way, the aerosolizable material delivered through at least one pore can be distributed throughout the carbon allotrope 101, while the carbon allotrope 101 can be isolated from the bulk aerosolizable material by the substrate 102. This reduces heat loss and improves aerosolization efficiency. Particularly high performance can be observed in embodiments where the carbon allotrope 101 includes one or more graphene layers. Without being bound by theory, it is believed that the high wettability of graphene (especially when graphene is heated) combined with the delivery of the aerosolizable material through at least one pore facilitates the diffusion of a thin layer of aerosolizable material on the graphene, while the graphene can be isolated from the bulk aerosolizable material by the substrate 102. In this arrangement, aerosolization is particularly effective.

[0234] In each of Figures 11A, 12A, and 13A, the carbon allotrope 101 is formed as a plurality of graphene layers 101 in the form of foam (i.e., graphene foam). The plurality of graphene layers 101 are not parallel to each other. The graphene layers 101 are disposed on a polyimide substrate 102. In each of these embodiments, the thickness of the carbon allotrope 101 is 40 to 50 μm, and the thickness of the substrate 102 is 125 to 130 μm. It should be understood that the thickness of the carbon allotrope 101 and the thickness of the substrate 102 can vary.

[0235] The electrically insulating substrate 102 may be thermally insulating. For example, the electrically insulating substrate 102 may have a thermal insulation value of no more than 5 Wm. -1 k -1 Thermal conductivity. The electrically insulating substrate 102 may have a thermal conductivity of no more than 3 W / m². -1 k -1 Thermal conductivity. The electrically insulating substrate 102 may have a thermal conductivity of no more than 2 W / m². -1 k -1 Thermal conductivity. The electrically insulating substrate 102 may have a thermal conductivity of not more than 1 W / m. -1 k -1 The thermal conductivity. The electrically insulating substrate 102 may have a thermal conductivity of not more than 0.5 W / m. -1 k -1 The thermal conductivity. The electrically insulating substrate 102 may have a thermal conductivity of not more than 0.2 W / m. -1 k -1 The thermal conductivity. The electrically insulating substrate 102 may have a thermal conductivity of not more than 0.1 W / m. -1 k -1 Thermal conductivity. Using a thermally insulating substrate 102 helps reduce heat loss and thus improve efficiency.

[0236] The electrically insulating substrate 102 may be non-porous. Using a non-porous substrate 102 can facilitate the controlled delivery of aerosolizable materials to the carbon allotrope 101 through only at least one pore 105 and helps to reduce heat loss, thereby improving efficiency.

[0237] The electrically insulating substrate 102 may be substantially flat. As shown in Figures 15A and 15B, the electrically insulating substrate 102 may include a first surface 102a and a second surface 102b, which are opposite to each other, and a carbon allotrope 101 is loaded on the first surface 102a (as shown in Figures 11A, 12A, and 13A). At least one hole 105 extends from the first surface 102a to the second surface 102b. That is, at least one hole 105 extends through a portion of the substrate 102 in a through-hole manner. The first surface 102a and the second surface 102b may each extend in the plane of the electrically insulating substrate 102.

[0238] At least one hole 105, or each of at least one hole 105, may be located within the periphery (e.g., outer periphery) of the electrically insulating substrate 102 (as shown in Figures 11A, 12A, 13A, 15A, 15B, and 16). For example, at least one hole, or each of at least one hole, may define a closed shape (as shown in Figures 11A, 12A, 13A, 15A, 15B, and 16).

[0239] It has been found that the delivery rate of aerosolizable materials can be adjusted by changing the size of at least one pore. At least one pore, or each of at least one pore, may have a diameter of no more than 500 μm. At least one pore, or each of at least one pore, may have a diameter of no more than 400 μm. At least one pore, or each of at least one pore, may have a diameter of no more than 300 μm. At least one pore, or each of at least one pore, may have a diameter of no more than 250 μm. At least one pore, or each of at least one pore, may have a diameter of at least 10 μm. At least one pore, or each of at least one pore, may have a diameter of at least 20 μm. At least one pore, or each of at least one pore, may have a diameter of at least 50 μm. At least one pore, or each of at least one pore, may have a diameter of at least 100 μm. At least one pore, or each of at least one pore, may have a diameter of at least 150 μm. For example, in Figure 11A, each pore 105 has a diameter of approximately 200 μm, as determined by optical microscopy (as shown in Figure 11C). In Figures 12A and 13A, the diameter of each aperture 105 is also approximately 200 μm. It should be understood that other forms of microscopy, such as electron microscopy, X-ray microscopy, and scanning probe microscopy, can be used to determine the diameter of this aperture or each aperture 105.

[0240] The number of holes 105 can be varied. For example, in each of Figures 11A and 12A, a plurality of spaced-apart holes are provided along the length and width of the substrate 102. In Figure 13A, a plurality of (e.g., two) spaced-apart holes are provided along the width of the substrate 102.

[0241] At least one hole 105 may include a plurality of holes 105. That is, the aerosol generating component 100 may include a plurality of holes 105, each extending through the electrically insulating substrate 102. The plurality of holes 105 may each extend from a first surface 102a to a second surface 102b. The plurality of holes 105 may be spaced apart from each other. The plurality of holes 105 may include at least three holes.

[0242] Multiple holes 105 can be formed into an array or a two-dimensional pattern. For example, multiple holes 105 can be formed into an array or a two-dimensional pattern on a first surface 102a and / or a second surface 102b.

[0243] At least one hole 105 can take many forms. In some embodiments, at least one hole 105 includes at least one slot. In some embodiments, multiple holes 105 include multiple slots (e.g., at least three slots). In some embodiments, at least one hole 105 includes at least one hole. In some embodiments, multiple holes 105 include multiple holes (e.g., at least three holes). In some embodiments, multiple holes 105 include at least one slot and at least one hole. In some embodiments, multiple holes 105 include multiple slots (e.g., at least three slots) and at least one hole. In some embodiments, multiple holes 105 include at least one slot and multiple holes (e.g., at least three holes). In some embodiments, multiple holes 105 include multiple slots (e.g., at least three slots) and multiple holes (e.g., at least three holes).

[0244] It has been found that providing at least one slot 105 facilitates the efficient delivery of aerosolizable material to the carbon allotrope 101. Specifically, it has been found that providing at least one slot 105 improves the wicking potential of the carbon allotrope 101 and thereby facilitates a stable supply of aerosol-generating material to the carbon allotrope 101. These advantages are particularly evident where the carbon allotrope 101 forms in the form of foam and / or exhibits a high aerosol generation rate in use.

[0245] It will be understood that a slot can define an elongated opening, while a hole can define an opening with similar length and width measurements (e.g., approximately 1:1).

[0246] Each slot 105 may define an opening with a width not exceeding 500 μm. Each slot 105 may define an opening with a width not exceeding 400 μm. Each slot 105 may define an opening with a width not exceeding 300 μm. Each slot 105 may define an opening with a width not exceeding 250 μm. Each slot 105 may define an opening with a width of at least 10 μm. Each slot 105 may define an opening with a width of at least 2 μm. Each slot 105 may define an opening with a width of at least 50 μm. Each slot 105 may define an opening with a width of at least 100 μm. Each slot 105 may define an opening with a width of at least 150 μm.

[0247] Each slot 105 may define an opening having an aspect ratio of at least 2:1. Each slot 105 may define an opening having an aspect ratio of at least 3:1. Each slot 105 may define an opening having an aspect ratio of at least 4:1. Each slot 105 may define an opening having an aspect ratio of at least 5:1. Each slot 105 may define an opening having an aspect ratio of at least 6:1. Each slot 105 may define an opening having an aspect ratio of at least 8:1. Each slot 105 may define an opening having an aspect ratio of at least 10:1. Each slot 105 may define an opening having an aspect ratio of at least 20:1. Each slot 105 may define an opening having an aspect ratio of at least 50:1. Each slot 105 may define an opening having an aspect ratio of at least 80:1. A slot or each slot 105 may define an opening extending between opposite sides of an electrically insulating substrate 102.

[0248] A slot, or each slot 105, may extend through a plane that passes through the electrically insulating substrate 102. The slot, or each slot 105, may divide the electrically insulating substrate 102.

[0249] The aperture or each aperture 105 may have a diameter not exceeding 500 μm. The aperture or each aperture 105 may have a diameter not exceeding 400 μm. The aperture or each aperture 105 may have a diameter not exceeding 300 μm. The aperture or each aperture 105 may have a diameter not exceeding 250 μm. The aperture or each aperture 105 may have a diameter of at least 10 μm. The aperture or each aperture 105 may have a diameter of at least 20 μm. The aperture or each aperture 105 may have a diameter of at least 50 μm. The aperture or each aperture 105 may have a diameter of at least 100 μm. The aperture or each aperture 105 may have a diameter of at least 150 μm.

[0250] Multiple slots 105 can be arranged side by side. Multiple slots 105 can be arranged in parallel.

[0251] When the aerosol generating component 100 includes two electrodes 103, the slot 105 may be angled (or orthogonal) relative to an imaginary straight line extending between the two electrodes 103. Alternatively, the slot 105 may be parallel relative to an imaginary straight line extending between the two electrodes 103.

[0252] Figures 20 to 23 illustrate an embodiment with a plurality of slots 105. As shown in the embodiments of Figures 20, 21, and 23, the slots 105 are spaced apart from each other and arranged side-by-side and parallel to each other, and each slot is orthogonal to an imaginary straight line extending between two electrodes 103 (although the electrodes 103 are not shown, their positions are indicated in Figure 20). As shown in the embodiments of Figures 20 and 22, the slots 105 are spaced apart from each other and arranged side-by-side and parallel to each other, and each slot is parallel to an imaginary straight line extending between two electrodes 103 (although the electrodes 103 are not shown, their positions are indicated in Figure 20). The aerosol generating component 100 in the embodiments of Figures 20 to 23 is substantially sheet-like or substantially flat.

[0253] Carbon allotrope 101 can be loaded on at least 50% of the first surface 102a. Carbon allotrope 101 can be loaded on at least 60% of the first surface 102a. Carbon allotrope 101 can be loaded on at least 70% of the first surface 102a. Carbon allotrope 101 can be loaded on at least 80% of the first surface 102a. Carbon allotrope 101 can be loaded on at least 90% of the first surface 102a. Carbon allotrope 101 can be loaded on essentially 100% of the first surface 102a.

[0254] As discussed herein, the electrically insulating substrate 102 may be substantially flat. Holes, or each hole 105, may extend through the plane of the electrically insulating substrate 102. Holes, or each hole 105, may extend through the electrically insulating substrate 102 orthogonally to the plane of the electrically insulating substrate 102.

[0255] Along the surface of the electrically insulating substrate 102, the distance between the edge defined by the periphery of one of the at least one holes 105 and any edge defined by the periphery (e.g., the outer periphery) of the electrically insulating substrate 102 may not exceed 2 mm. Along the surface of the electrically insulating substrate 102, the distance between the edge defined by the periphery of one of the at least one holes 105 and any edge defined by the periphery (e.g., the outer periphery) of the electrically insulating substrate 102 may not exceed 1 mm. Along the surface of the electrically insulating substrate 102, the distance between the edge defined by the periphery of one of the at least one holes 105 and any edge defined by the periphery (e.g., the outer periphery) of the electrically insulating substrate 102 may not exceed 0.8 mm. Along the surface of the electrically insulating substrate 102, the distance between the edge defined by the periphery of one of the at least one holes 105 and any edge defined by the periphery (e.g., the outer periphery) of the electrically insulating substrate 102 may not exceed 0.5 mm. Along the surface of the electrically insulating substrate 102, the distance between the edge defined by the periphery of one of the holes 105 in at least one hole and any edge defined by the periphery (e.g., the outer periphery) of the electrically insulating substrate 102 may not be greater than 0.4 mm.

[0256] Along the surface of the electrically insulating substrate 102, the distance between the edge defined by the periphery of one of the holes 105 in at least one hole and any edge defined by the periphery (e.g., the outer periphery) of the electrically insulating substrate 102 may be greater than zero. The distance between the edge defined by the periphery of one of the holes 105 in at least one hole and any edge defined by the periphery (e.g., the outer periphery) of the electrically insulating substrate 102 may be at least 0.1 mm.

[0257] Along the surface of the electrically insulating substrate 102, the distance between the edge defined by the periphery of one of the at least one holes 105 and the edge defined by the periphery of any other hole 105 may not exceed 2 mm. Along the surface of the electrically insulating substrate 102, the distance between the edge defined by the periphery of one of the at least one holes 105 and the edge defined by the periphery of any other hole 105 may not exceed 1 mm. Along the surface of the electrically insulating substrate 102, the distance between the edge defined by the periphery of one of the at least one holes 105 and the edge defined by the periphery of any other hole 105 may not exceed 0.8 mm. Along the surface of the electrically insulating substrate 102, the distance between the edge defined by the periphery of one of the at least one holes 105 and the edge defined by the periphery of any other hole 105 may not exceed 0.5 mm. Along the surface of the electrically insulating substrate 102, the distance between the edge defined by the periphery of one of the at least one holes 105 and the edge defined by the periphery of any other hole 105 may not exceed 0.4 mm.

[0258] Along the surface of the electrically insulating substrate 102, the distance between the edge defined by the periphery of one of the at least one holes 105 and the edge defined by the periphery of any other hole 105 in the at least one hole may be greater than zero. Along the surface of the electrically insulating substrate 102, the distance between the edge defined by the periphery of one of the at least one holes 105 and the edge defined by the periphery of any other hole 105 in the at least one hole may be at least 0.1 mm.

[0259] Along the surface of the electrically insulating substrate 102, the distance between an edge defined by the periphery (e.g., outer periphery) of the electrically insulating substrate 102 and any other edge defined by the periphery (e.g., outer periphery) of the electrically insulating substrate 102 may not exceed 2 mm. Along the surface of the electrically insulating substrate 102, the distance between an edge defined by the periphery (e.g., outer periphery) of the electrically insulating substrate 102 and any other edge defined by the periphery (e.g., outer periphery) of the electrically insulating substrate 102 may not exceed 1 mm. Along the surface of the electrically insulating substrate 102, the distance between an edge defined by the periphery (e.g., outer periphery) of the electrically insulating substrate 102 and any other edge defined by the periphery (e.g., outer periphery) of the electrically insulating substrate 102 may not exceed 0.8 mm. Along the surface of the electrically insulating substrate 102, the distance between an edge defined by the periphery (e.g., outer periphery) of the electrically insulating substrate 102 and any other edge defined by the periphery (e.g., outer periphery) of the electrically insulating substrate 102 may not exceed 0.5 mm. Along the surface of the electrically insulating substrate 102, the distance between the edge defined by the periphery (e.g., the outer periphery) of the electrically insulating substrate 102 and any other edge defined by the periphery (e.g., the outer periphery) of the electrically insulating substrate 102 may not be greater than 0.4 mm.

[0260] Along the surface of the electrically insulating substrate 102, the distance between an edge defined by the periphery (e.g., outer periphery) of the electrically insulating substrate 102 and any other edge defined by the periphery (e.g., outer periphery) of the electrically insulating substrate 102 may be greater than zero. The distance between an edge defined by the periphery (e.g., outer periphery) of the electrically insulating substrate 102 and any other edge defined by the periphery (e.g., outer periphery) of the electrically insulating substrate 102 may be at least 0.1 mm.

[0261] The surface along which the distance is measured can be the surface of the electrically insulating substrate 102 loaded with carbon allotropes 101. The surface of the electrically insulating substrate 102 loaded with carbon allotropes can be referred to as the "load surface". The surface along which the distance is measured can be the first surface 102a.

[0262] The above concepts are illustrated in Figure 16. Specifically, Figure 16 shows the distances d1, d2, and d3 between corresponding edges e1, e2, e3, and e4 of the electrically insulating substrate 102 along its surface. As mentioned above, the distances between the corresponding edges along the surface cannot exceed a specific value. Figure 16 shows: the distance d1 between the edge e2 defined by the periphery of the hole 105 and the edge e1 defined by the periphery (e.g., outer periphery) of the electrically insulating substrate; the distance d2 between the edge e1 defined by the periphery (e.g., outer periphery) of the electrically insulating substrate 102 and the edge e3 defined by the periphery (e.g., outer periphery) of the electrically insulating substrate 102; and the distance d3 between the edge e2 defined by the periphery of the hole 105 and the edge e4 defined by the periphery of another hole 105.

[0263] It has been found that adjusting the distance along the surface of the electrically insulating substrate 102 between corresponding edges can improve aerosolization performance by improving efficiency and / or reducing or preventing the "drying out" and / or degradation of the aerosol generating component 100. Without being bound by theory, it is considered that reducing the distance between the corresponding edges means that the aerosolizable material can be uniformly distributed on the carbon allotrope 101. In other words, if the distance is too large, the aerosolizable material may vaporize before reaching certain areas of the carbon allotrope 101, which reduces efficiency and can lead to the formation of hot spots in such areas.

[0264] The carbon allotrope 101 may have a length not exceeding 25 mm. The carbon allotrope 101 may have a length of at least 0.5 mm. The carbon allotrope 101 may have a length of at least 15 mm.

[0265] Carbon allotropes 101 may have a width of no more than 6 mm. Carbon allotropes 101 may have a width of no more than 5 mm. Carbon allotropes 101 may have a width of no more than 4 mm. Carbon allotropes 101 may have a width of no more than 3 mm. Carbon allotropes 101 may have a width of no more than 2 mm. Carbon allotropes may have a width of at least 0.5 mm.

[0266] For example, with respect to Figure 11A, carbon allotrope 101 has a length of approximately 19.5 mm and a width of approximately 1.7 mm (see “Graphene foam with holes (cut down)” in Figure 14A).

[0267] The contact area between the carbon allotrope 101 and the substrate 102 may define an outer periphery. The substrate 102 may extend from the outer periphery. An imaginary line may extend along the contact area from a portion of the outer periphery to an opposite portion of the outer periphery. The substrate 102 may extend axially from the imaginary line for no more than 100% of the length of the imaginary line. The substrate 102 may extend axially from the imaginary line for no more than 80% of the length of the imaginary line. The substrate 102 may extend axially from the imaginary line for no more than 60% of the length of the imaginary line. The substrate 102 may extend axially from the imaginary line for no more than 5 mm. The substrate 102 may extend axially from the imaginary line for no more than 4 mm. The substrate 102 may extend axially from the imaginary line for no more than 3 mm. The substrate 102 may extend axially from the imaginary line for no more than 2 mm. In Figure 11A, the substrate extends approximately 1 mm from the imaginary line. This size helps guide the aerosolizable material toward the carbon allotrope 101 and reduces the accumulation of aerosolizable material near the second surface 102b. In some embodiments, the substrate 102 can extend from the carbon allotrope 101 when the aerosol generating component 100 is observed to be orthogonal to the surface (or flat surface) of the substrate 102 carrying the carbon allotrope. The extension may be no greater than 5 mm. The extension may be no greater than 4 mm. The extension may be no greater than 3 mm. The extension may be no greater than 2 mm. In FIG. 11A, the extension is about 1 mm. This size helps guide the aerosolizable material toward the carbon allotrope 101 and reduces the accumulation of aerosolizable material near the second surface 102b.

[0268] One or more electrodes 103 may be arranged to make electrical contact with the carbon allotrope 101. Each of the one or more electrodes 103 may comprise or be formed of copper, silver, or gold. In FIG. 11A, the respective electrodes 103 are arranged to make electrical contact with the respective ends of the carbon allotrope 101, and each electrode 103 is a screen-printed copper electrode. In FIG. 11A, each electrode 103 covers a portion of the length of the carbon allotrope 101. The length in FIG. 14A does not include the length covered by the electrodes. In this context, the carbon allotrope 101 may be considered as a carbon allotrope 101 suitable for generating aerosols from aerosolizable materials.

[0269] In Figure 11A, the resistance of carbon allotrope 101 measured between electrodes 103 at room temperature is 200 Ω.

[0270] Referring to the schematic diagrams of Figures 15A and 15B, the assembly may include a first channel 106 (alternately designated 201) extending into at least one aperture 105. The first channel 106 may be a capillary channel. In this manner, the first channel 106 may be configured to deliver aerosolizable material to at least one aperture 105 via capillary action. The first channel 106 may be formed at least partially by a second surface 102b. The assembly may include structures 107a, 107b, and 107c. The second surface 102b and at least a portion of the structures (e.g., a segment of structure 107a) may define the first channel 106. The second surface 102b and at least a portion of the structures (e.g., a segment of structure 107a) may be spaced apart from each other to at least partially define the first channel 106. For example, the structure may include a central segment 107a disposed between one or more (e.g., two) outer segments 107b, 107c. A substrate 102 may be loaded on structures 107a, 107b, and 107c. For example, substrate 102 may be loaded on one or more portions of the structure, such as outer segments 107b, 107c. The structure or any segment thereof may be made of any material from which substrate 102 can be manufactured, as defined herein. The structure may at least partially define one or more reservoirs 108 (or alternatively designated 210) for aerosolizable materials. Reservoirs 108 may be adjacent to channel 106.

[0271] The first channel 106 may have a height of no more than 2 mm. The first channel 106 may have a height of no more than 1 mm. The first channel 106 may have a height of no more than 0.5 mm.

[0272] The first channel 106 may have a height of no more than 2 mm. The first channel 106 may have a height of no more than 1 mm. The first channel 106 may have a height of no more than 0.8 mm. The first channel 106 may have a height of no more than 0.5 mm.

[0273] The component can be configured such that aerosolizable material can be transferred to carbon allotropes 101 only by flowing through a first channel 106 and at least one pore 105.

[0274] In Figure 11A, structure 107 includes a glass central section and two plastic outer sections. In use, the aerosolizable material in reservoir 108 flows through channel 106 (which is a capillary channel), through at least one hole 105, and into carbon allotrope 101.

[0275] Figure 11B shows the efficiency (J / mg; square data points) and evaporation rate (mg / s; circular data points) of the component in Figure 11A as a function of applied energy (J). The applied energy is the energy applied to the carbon allotrope 101 and is set to different values ​​by varying the current. The aerosolizable material comprises 50 wt.% VG and 50 wt.% water (based on the weight of the aerosolizable material).

[0276] Referring to Figure 11B, 300 mA (applied energy of 52 J) provides optimal performance. At this power level (approximately 17.3 W), the energy efficiency is approximately 2 J / mg and the evaporation rate is approximately 9 mg / s (27 mg aerosolized within a 3-second run).

[0277] The carbon allotrope 101 may have a length not exceeding 12 mm. The carbon allotrope 101 may have a length of at least 0.5 mm. The carbon allotrope 101 may have a length of at least 7 mm.

[0278] Carbon allotropes 101 may have a width of no more than 6 mm. Carbon allotropes 101 may have a width of no more than 5 mm. Carbon allotropes 101 may have a width of no more than 4 mm. Carbon allotropes 101 may have a width of no more than 3 mm. Carbon allotropes 101 may have a width of no more than 2 mm. Carbon allotropes may have a width of at least 0.5 mm.

[0279] For example, regarding Figure 12A, carbon allotrope 101 has a length of about 9.5 mm and a width of about 1.7 mm (see “Graphene foam with holes (cut, truncated)” in Figure 14A).

[0280] In Figure 12A, the corresponding electrodes 103 are arranged to make electrical contact with the corresponding ends of the carbon allotrope 101. One electrode 103 is a screen-printed copper electrode, and the other electrode is a silver epoxy electrode (it will be understood that the electrode materials can be changed). In Figure 12A, each electrode covers a portion of the length of the carbon allotrope 101.

[0281] In Figure 12A, the resistance of the carbon allotrope 101, measured between the electrodes at room temperature, is 53 Ω. The components of Figure 12A include capillary channel 106 and structures 107a, 107b, and 107c, in a manner similar to those described with respect to Figure 11A.

[0282] Figure 12B shows the efficiency (J / mg; square data points) and evaporation rate (mg / s; circular data points) of the component in Figure 12A as a function of applied energy (J). The applied energy is the energy applied to the carbon allotrope 101 and is set to different values ​​by varying the current. The aerosolizable material comprises 50 wt.% VG and 50 wt.% water (based on the weight of the aerosolizable material). Data points marked with circles are considered outliers.

[0283] Referring to Figure 12B, 600 mA (applied energy 56 J) provides optimal performance. At this power level (approximately 18.7 W), the energy efficiency is approximately 1.7 J / mg and the evaporation rate is approximately 11 mg / s (approximately 33 mg aerosolized within a 3-second run).

[0284] The inventors have identified that the center of the carbon allotrope 101 has a tendency to dry out at the end of each run. The reservoir 108 has a capacity of approximately 65 mg. The inventors have found that using a larger reservoir can potentially cause aggregation of aerosolizable material on the carbon allotrope 101, resulting in bubbling and lower efficiency.

[0285] Carbon allotropes 101 may have a length not exceeding 6 mm. Carbon allotropes 101 may have a length not exceeding 5 mm. Carbon allotropes 101 may have a length not exceeding 4 mm. Carbon allotropes 101 may have a length not exceeding 3 mm. Carbon allotropes 101 may have a length not exceeding 2 mm. Carbon allotropes 101 may have a length of at least 0.5 mm. Carbon allotropes may have a width of at least 1 mm. Carbon allotropes may have a width of at least 1.3 mm.

[0286] Carbon allotropes 101 may have a width of no more than 6 mm. Carbon allotropes 101 may have a width of no more than 5 mm. Carbon allotropes 101 may have a width of no more than 4 mm. Carbon allotropes 101 may have a width of no more than 3 mm. Carbon allotropes 101 may have a width of no more than 2 mm. Carbon allotropes may have a width of at least 0.5 mm. Carbon allotropes may have a width of at least 1 mm. Carbon allotropes may have a width of at least 1.3 mm.

[0287] For example, regarding Figure 13A, carbon allotrope 101 has a length of about 1.8 mm and a width of about 1.7 mm (see “Pore-filled graphene foam (square)” in Figure 14A).

[0288] In Figure 13A, the corresponding electrode 103 is arranged to make electrical contact with the corresponding end of the carbon allotrope 101. Each electrode corresponds to a silver epoxy resin electrode. In Figure 13A, each electrode covers a portion of the length of the carbon allotrope 101.

[0289] In Figure 13A, the resistance of the carbon allotrope 101, measured between electrodes 103 at room temperature, is 13 Ω. The components of Figure 12A include capillary channels 106 and structures 107a, 107b, and 107c, in a manner similar to those described with respect to Figure 11A.

[0290] Figure 13B shows the efficiency (J / mg; square data points) and evaporation rate (mg / s; circular data points) of the component in Figure 13A as a function of applied energy (J). The applied energy is the energy applied to the carbon allotrope 101 and is set to different values ​​by varying the current. The aerosolizable material comprises 50 wt.% VG and 50 wt.% water (based on the weight of the aerosolizable material).

[0291] Referring to Figure 13B, 500 mA (applied energy of 13.7 J; power of 4.6 W) results in an energy efficiency of approximately 1.78 J / mg and an evaporation rate of approximately 2.6 mg / s. 600 mA (applied energy of 19.2 J; power of 6.4 W) results in an energy efficiency of 1.69 J / mg and an evaporation rate of 3.8 mg / s. The component in Figure 13A exhibits stable performance and is suitable for reusability. Figure 13B shows that the component in Figure 13A can provide particularly desirable aerosolization performance (e.g., in terms of evaporation rate and efficiency) in the case of a non-flammable aerosol supply system.

[0292] At least one pore, or each of at least one pore 105, may extend through the carbon allotrope 101. The carbon allotrope 101 may extend on the periphery of at least one pore 105 or each of the pores 105. For example, the carbon allotrope 101 may partially (or at least partially or completely) cover at least one pore, or each of the pores 105. Such a configuration facilitates the extraction of aerosolizable material from at least one pore 105 onto and / or through the carbon allotrope 101. For example, in the case where the carbon allotrope 101 comprises graphene, the high wettability of graphene has been found to be particularly effective in facilitating the extraction of aerosolizable material from at least one pore 105.

[0293] Figure 14A compares test data according to various embodiments of the present disclosure, wherein each of “supported bridge (load bridge) 20 x 0.5”, “supported bridge 20 x 1”, “supported bridge 20 x 2”, and “supported bridge 20 x 3” corresponds to an assembly comprising a graphene foam (carbon allotrope) loaded on the upper surface of a polyimide substrate having a thickness of 125 to 130 μm, and the graphene foam having a thickness of 40 to 50 μm. The length and width of each assembly are shown in Figure 14A.

[0294] "Pore-filled graphene foam (cut)" corresponds to the component in Figure 11A.

[0295] "Pore-filled graphene foam (cut, truncated)" corresponds to the component in Figure 12A.

[0296] "Porous graphene foam (square) at 500 mA" corresponds to the component in Figure 13A.

[0297] "A square graphene foam with pores at 600 mA" corresponds to the component in Figure 13A.

[0298] Each of the support bridge instances was tested for 20 seconds of runtime, while the other instances were tested for 3 seconds of runtime (as discussed above).

[0299] For the support bridge example, energy efficiency decreases as a function of increasing power density. The circled data points in Figure 14B are considered outliers. For the components in Figures 11A, 12A, and 13A, energy efficiency remains fairly constant as a function of increasing power density.

[0300] As shown in Figure 14B, the component in Figure 13A exhibits energy efficiency and excellent aerosolization performance. In Figure 14B, the data points for "support bridges" are represented by squares and the data points for "porous graphene foam" are represented by circles.

[0301] In one aspect of this disclosure, an assembly is provided for use as part of a non-flammable aerosol supply system, the assembly comprising an aerosol generating component 101 and at least one path 301, 301', 301'', 301''', 301'''' leading to the aerosol generating component, each of the at least one path or at least one path 301 being configured to transfer an aerosolizable material toward the aerosol generating component 301 using electrowetting. The assembly may have any of the features according to any other aspect of this disclosure.

[0302] Electrowetting can be defined as the decrease in the contact angle between a solid and a liquid when a sufficiently large driving voltage is applied to the solid-liquid interface (see Electrowetting-on-dielectric characteristics of ZnO nanorods, Kim, JH., Lee, JH., Mirzaei, A. et al., Sci Rep10, 14194 (2020)). In “direct electrowetting,” a voltage is applied between the liquid and the electrode. Charge and dipoles redistribute at the liquid-solid interface, altering the surface tension of the liquid and resulting in a decrease in its contact angle. However, direct electrowetting can electrolyze the liquid before any change in the contact angle, which may be undesirable. To address this issue, “electroplated on dielectric” (EWOD) can be used. In EWOD, a dielectric material is sandwiched between the liquid and the electrode. EWOD is effective for significantly altering the contact angle of the liquid because the dielectric layer effectively blocks charge transfer processes at the liquid / electrode interface, thus eliminating unintentional electrolysis.

[0303] It has been found that, in the context of a non-flammable aerosol supply systems, electrowetting can be used to precisely control the flow rate (e.g., by mass or volume) of aerosol-generating material. Specifically, the inventors have incorporated electrowetting technology into components for use as part of a non-flammable aerosol supply system to provide an apparatus for controlling the flow rate of aerosol-generating material toward an aerosol-generating component of the component. The ability to precisely control the flow rate contributes to providing an efficient non-flammable aerosol supply system that exhibits the desired aerosolization performance. For example, the flow rate can be adjusted to substantially match the maximum evaporation rate of the aerosolizable material. For example, when power is supplied to the aerosol-generating component using pulse width modulation (or at a duty cycle of less than 100%), the flow rate can be adjusted such that the aerosolizable material is transferred (e.g., continuously in the form of one or more droplets) into contact with the aerosol-generating component during a specific period of the pulse width modulation (or duty cycle). For example, the flow rate can be adjusted such that one or more droplets of aerosolizable material are sequentially transferred to the aerosol generating component, such that each droplet contacts the aerosol generating component during a power-on period of the pulse width modulation. Alternatively, the flow rate can be adjusted such that one or more droplets of aerosolizable material are sequentially transferred to the aerosol generating component, such that the aerosolizable material does not transfer to contact the aerosol generating component during a power-off period of the pulse width modulation. Pulse width modulation is described in more detail below.

[0304] At least one path or each of at least one path 301 may be configured to transfer one or more droplets of aerosolizable material toward the aerosol generating component 101 using electrowetting.

[0305] At least one path 301, or each of at least one path 301, can be configured to sequentially transfer one or more droplets of aerosolizable material toward the aerosol generating component 101 using electrowetting. That is, droplets can be transferred one by one toward the aerosol generating component 101 using electrowetting.

[0306] The droplet or each droplet may have a mass of 0.045 mg to 1.30 mg. For example, the droplet or each droplet may have a mass of 0.060 mg to 1.00 mg. For example, the droplet or each droplet may have a mass of 0.080 mg to 0.80 mg. For example, the droplet or each droplet may have a mass of 0.090 mg to 0.60 mg. For example, the droplet or each droplet may have a mass of 0.10 mg to 0.40 mg. For example, the droplet or each droplet may have a mass of about 0.25 mg.

[0307] The droplet, or each droplet, can have a volume from 0.05 µL to 1.30 µL. For example, the droplet, or each droplet, can have a volume from 0.060 µL to 1.00 µL. For example, the droplet, or each droplet, can have a volume from 0.080 µL to 0.80 µL. For example, the droplet, or each droplet, can have a volume from 0.090 µL to 0.60 µL. For example, the droplet, or each droplet, can have a volume from 0.10 µL to 0.40 µL. For example, the droplet, or each droplet, can have a volume of about 0.25 µL.

[0308] Aerosolizable materials can be transferred at flow rates from 0.2 µL / s to 20 µL / s. Aerosolizable materials can be transferred at flow rates from 0.4 µL / s to 10 µL / s. Aerosolizable materials can be transferred at flow rates from 0.6 µL / s to 5.0 µL / s. Aerosolizable materials can be transferred at flow rates from 1.0 µL / s to 3.0 µL / s. Aerosolizable materials can be transferred at flow rates from 1.5 µL / s to 2.5 µL / s. For example, aerosolizable materials can be transferred at a flow rate of approximately 2.1 µL / s. Different flow rates are envisioned.

[0309] Figures 17A to 19C illustrate exemplary components according to this disclosure.

[0310] Referring to Figures 17A to 17C, path 301 leads to aerosol generating component 101 and is configured to transfer aerosolizable material toward aerosol generating component 101 by electrowetting. Specifically, path 301 is configured to sequentially transfer one or more droplets of aerosolizable material toward aerosol generating component 101 by electrowetting.

[0311] The aerosol generating component 101 may include a carbon allotrope 101. The carbon allotrope 101 may be as defined with respect to any other aspect of this disclosure. For example, the carbon allotrope 101 may include graphene. For example, the carbon allotrope 101 may include one or more graphene layers. For example, the carbon allotrope 101 (e.g., one or more graphene layers) may include three-dimensional graphene or be in the form of three-dimensional graphene. When more than one graphene layer is present, at least two of these layers may not be parallel to each other.

[0312] At least one path or each of at least one path 301 leads to the aerosol generating component 101. The path or each path 301 may terminate adjacent to the aerosol generating component 101. Thus, the aerosolizable material at the end of the path or each path 301 may come into contact with the aerosol generating component 101 or may be transferred therefrom, for example, via holes or channels (e.g., under capillary force).

[0313] At least one path or each of at least one path 301 is used to transfer an aerosolizable material toward an aerosol-generating component using electrowetting. Electrowetting may be electrowetting on dielectric (EWOD).

[0314] At least one path 301 or each of at least one path 301 may include an upstream portion 301a and a downstream portion 301b.

[0315] "Upstream" and "downstream" refer to the relative proximity of portion 301a (etc.) to aerosol generating component 101. For example, the downstream portion is closer to the aerosol generating component than the upstream portion.

[0316] At least one path or each of at least one path 301 may include a plurality of downstream portions 301b, 301c, 301d, etc. The plurality of downstream portions 301b (etc.) includes a terminal downstream portion 301d. The terminal downstream portion may be considered as the downstream portion 301b (etc.) closest to the aerosol generating component 101 (relative to the portion 301b (etc.) of the path 301).

[0317] Parts 301a, 301b, etc., can be selectively connected to a power source. In this way, parts 301a, 301b, etc., can be selectively connected to or disconnected from a power source. Furthermore, the voltage at each part of parts 301a, 301b, etc., can be controlled independently.

[0318] Each portion 301a, 301b, etc. may include an electrode. Each portion 301a(etc.) may include a dielectric material (e.g., a dielectric layer). Each portion 301a(etc.) may include a dielectric material (e.g., a layer) loaded on the electrode. Each portion 301a(etc.) may include a hydrophobic surface (e.g., an outer surface). Each dielectric material (e.g., a layer) may include a hydrophobic surface (e.g., an outer surface). Alternatively, the hydrophobic surface may be separate from the dielectric layer (and may be in the form of a hydrophobic layer loaded on the dielectric material). Each portion 301a, 301b, etc. may be referred to as an "electrowetting element".

[0319] The electrodes, or each electrode, can be any conductive material. For example, the electrodes, or each electrode, can be or include copper and / or aluminum and / or chromium and / or gold and / or carbon-based conductors such as graphene. Other electrode materials may also be used.

[0320] The dielectric layer, or each dielectric layer, may be or include silicon dioxide, aluminum oxide, tantalum pentoxide, SU-8 (bisphenol A phenolic epoxy resin dissolved in an organic solvent, such as γ-butyrolactone or cyclopentanone), or polydimethylsiloxane. Other dielectric layer materials may also be used.

[0321] The hydrophobic layer, or each hydrophobic layer, may be a fluorinated material (e.g., a fluoropolymer, such as poly(1,1,2,2-tetrafluoroethylene) under the trademark Teflon). The hydrophobic layer, or each hydrophobic layer, may be or contain polydimethylsiloxane (e.g., a polydimethylsiloxane coating). Other hydrophobic layer materials may also be used.

[0322] As shown in Figures 17A to 19C, parts 301a (etc.) can be discrete. That is, parts 301a (etc.) can be separated from each other.

[0323] At least one path or each of at least one path 301 may be curved or straight (or axial). At least one path or each of at least one path 301 may be substantially flat.

[0324] Each portion 301a (etc.) may define an outer surface. The outer surface is for contact with the aerosolizable material in use. The outer surface may be flat. The portions 301a (etc.) (e.g., their outer surfaces) may be arranged in the same plane. Each portion 301a (etc.) (e.g., each of its outer surfaces) may be arranged adjacent to at least one other portion 301a (etc.) (e.g., at least one other flat surface of its).

[0325] The area of ​​the outer surface of the upstream portion or each upstream portion 301a may be greater than the area of ​​the outer surface of the downstream portion or each downstream portion 301b (etc.). The area of ​​the outer surface of the upstream portion or each upstream portion 301a may be at least 20% larger than the area of ​​the outer surface of the downstream portion or each downstream portion 301b (etc.). The area of ​​the outer surface of the upstream portion or each upstream portion 301a may be at least 50% larger than the area of ​​the outer surface of the downstream portion or each downstream portion 301b (etc.). The area of ​​the outer surface of the upstream portion or each upstream portion 301a may be at least 100% larger than the area of ​​the outer surface of the downstream portion or each downstream portion 301b (etc.). The area of ​​the outer surface of the upstream portion or each upstream portion 301a may be at least 200% larger than the area of ​​the outer surface of the downstream portion or each downstream portion 301b (etc.). The area of ​​the outer surface of the upstream portion or each upstream portion 301a may be at least 500% larger than the area of ​​the outer surface of the downstream portion or each downstream portion 301b (etc.).

[0326] The outer surface of the upstream portion or each upstream portion 301a may have a diameter not exceeding 500 mm. 2 The area. The outer surface of the upstream portion or each upstream portion 301a may have an area not exceeding 200 mm. 2 The area. The outer surface of the upstream portion or each upstream portion 301a may have an area not exceeding 100 mm. 2 The area. The outer surface of the upstream portion or each upstream portion 301a may have at least 1 mm. 2 The area. The outer surface of the upstream portion or each upstream portion 301a may have at least 10 mm. 2 The area.

[0327] The outer surface of the downstream portion or each downstream portion 301b (etc.) may have a diameter not exceeding 10 mm. 2 The area. The outer surface of the downstream portion or each downstream portion 301b (etc.) may have an area not exceeding 5 mm. 2 The area. The outer surface of the downstream portion or each downstream portion 301b (etc.) may have an area not exceeding 4 mm. 2 The area. The outer surface of the downstream portion or each downstream portion 301b (etc.) may have at least 1 mm. 2 The area. The outer surface of the downstream portion or each downstream portion 301b (etc.) can be approximately 2.5 mm. 2 .

[0328] The outer surfaces of the downstream portions 301b (etc.) may have the same surface area as each other.

[0329] In Figures 17A through 19C, at least one path or each of at least one path 301 includes an upstream portion 301a and three downstream portions 301b, 301c, and 301d. The downstream portions 301b, 301c, and 301d include a first downstream portion 301b, a second downstream portion 301c, and a final downstream portion. Each of portions 301a, 301b, etc., defines a flat surface (outer surface), and the flat surfaces are arranged in the same plane. Each path 301 is substantially straight. Therefore, each path 301 is substantially flat. In each path 301, portions 301a, 301b, etc., are arranged sequentially: 301a, then 301b, then 301c, then 301d. Each of portions 301a, 301b, 301c, and 301d includes a dielectric layer loaded on an electrode, wherein each dielectric layer includes a hydrophobic outer surface.

[0330] The component may include at least one reservoir 302. Each of at least one path or at least one path 301 (etc.) may include reservoir 302. Reservoir 302 may be formed at least partially by an upstream portion 301a. For example, the reservoir of a path or each path 301 (etc.) may be formed at least partially by the upstream portion 301a of the respective path 301 (etc.). For example, the upstream portion 301a may form the base (or wall) of reservoir 302. For example, the dielectric outer surface of the upstream portion 301a may form the base (or wall) of reservoir 302.

[0331] The component may include at least one structure 303.

[0332] At least one path or each of at least one path 301 (e.g., portions 301a, 301b, etc.) and at least one structure 303 may at least partially define channel 304.

[0333] For example, at least a portion of a path or each path 301 (e.g., portions 301a, 301b, etc.) may be spaced apart from at least a portion of at least one structure 303, thereby at least partially defining a channel 304.

[0334] A channel or each channel 304 may be positioned between a corresponding path 301 (e.g., its portions 301a, 301b, etc.) and at least one structure 303.

[0335] The channel or each channel 304 can be a capillary channel. Therefore, the aerosolizable material can be held in or transferred through the channel or each channel 304 under capillary forces. The channel or each channel 304 can extend along the range of a corresponding path 301(etc). In this way, the channel 304 of each path 301(etc) can extend from an upstream portion 301a to a downstream portion (e.g., a terminal downstream portion) 301d.

[0336] The structure or each structure 303 may be substantially flat. The structure or each structure 303 may be made of any material that can manufacture the electrically insulating substrate 102 (as described herein). For example, the substrate or each substrate 303 may be selected from the group consisting of plastics, glass, paper, and ceramics.

[0337] Each storage unit or storage unit 302 may (individually) be at least partially defined by one of at least one structure 303 (e.g., an upstream portion of structure 303) and one of at least one path 301 (e.g., a path or an upstream portion 301a of each path 301). Each storage unit or storage unit 302 may be located in a corresponding channel 304.

[0338] The area of ​​the outer surface of the upstream portion 301a (e.g., a flat surface defined by the upstream portion 301a) may be larger than the area of ​​the outer surface of any downstream portion (e.g., a flat surface defined by the downstream portion or each downstream portion 301b, 301c, etc.). Changing the area of ​​the outer surface of the upstream portion 301a can change the capacity of the reservoir 302 for containing aerosolizable material. The reservoir 302 may be configured to retain the aerosolizable material by capillary force. Electrowetting may be used to transfer the aerosolizable material from the reservoir 302 toward the aerosol generating component 101, as described herein.

[0339] The component may include at least one outlet 305 (see Figures 18B and 19A-19C). The outlet, or each outlet 305, may be arranged such that aerosolizable material can flow from the path, or each path 301 (or channel 304), through the outlet 305 to the aerosol generating component 101. The outlet, or each outlet 305, may be arranged in various locations and may be configured in various forms. For example, the outlet 305 may include the end edge of a downstream portion 301d, or may include an orifice (as discussed below).

[0340] An outlet, or each outlet 305, may be arranged adjacent to the aerosol generating component 100 (see Figures 18B to 19C). An outlet 305 may be located at or adjacent to one end (e.g., downstream end) of a path or each path 301 (etc.). An outlet 305 may be located at or adjacent to one end (e.g., downstream end, e.g., downstream portion) of a channel or each channel 304.

[0341] For example, an exit or each exit 305 may be defined at least by the corresponding path 301 (etc.; see Figures 18B and 19A).

[0342] For example, an exit or each exit 305 may be defined by one of a corresponding path 301 (etc.) and at least one structure 303 (see Figures 18B and 19A).

[0343] For example, an outlet or each outlet 305 may be located at or toward the end of the corresponding channel 304 (e.g., the downstream end) (see Figures 18B and 19A).

[0344] For example, an outlet or each outlet 305 may extend through one of the aerosol generating components 101 and at least one of the structures 303 (see Figure 19B).

[0345] For example, an outlet or each outlet 305 may extend through the aerosol generating component 100, the electrically insulating substrate 306 (discussed below), and the corresponding path 301 (etc., see FIG. 19C). For example, an outlet or each outlet 305 may extend through a downstream portion 301d (e.g., a terminal downstream portion). For example, an outlet or each outlet 305 may be defined at least partially by the downstream portion 301d (e.g., a terminal downstream portion).

[0346] The component may include an electrically insulating substrate 306 (see Figures 18B to 19C). The electrically insulating substrate 306 may be as defined herein (see, for example, the characteristics of electrically insulating substrate 102). For example, the electrically insulating substrate 306 may be selected from the group consisting of plastics, glass, paper, and ceramics.

[0347] The path or each path 301 (etc.) may be loaded on (or disposed on) an electrically insulating substrate 306 (see Figures 18B to 19C). In each of Figures 19A to 19C, the substrate 306 is made of polyimide. In each of Figures 19A to 19C, the structure 303 is made of glass (with an indium tin oxide coating).

[0348] Regarding the components used in Figures 17A to 17C, an aerosolizable material is initially provided in reservoir 302 (on upstream portion 301a). A voltage is applied to downstream portion 301b adjacent to reservoir 302, causing the aerosolizable material (e.g., its droplets) to transfer from upstream portion 301a to downstream portion 301b (see Figure 17A). For the aerosolizable material (e.g., its droplets) on downstream portion 301b, a voltage is applied to downstream portion 301c such that the voltage at downstream portion 301c is greater than the voltage at downstream portion 301b, causing the aerosolizable material (e.g., its droplets) to transfer from downstream portion 301b to downstream portion 301c (see Figure 17B). When an aerosolizable material (e.g., its droplets) is present on the downstream portion 301c, a voltage is applied to the downstream portion 301d such that the voltage at the downstream portion 301d is greater than the voltage at the downstream portion 301c. This causes the aerosolizable material (e.g., its droplets) to transfer from the downstream portion 301c to the downstream portion 301d (see Figure 17C). Therefore, the increased voltage applied to a portion 301a, 301b, etc., relative to adjacent portions 301a, 301b, etc., causes the aerosolizable material (e.g., its droplets) to transfer to the portion with the increased voltage. When the aerosolizable material (e.g., its droplets) is at the downstream portion 301d (the terminal downstream portion), the aerosolizable material (e.g., its droplets) can contact the aerosol generating component. The aerosolizable material (e.g., its droplets) can diffuse and be aerosolized on the surface of the aerosol generating component. It should be understood that the component can be used to sequentially transfer one or more droplets of aerosolizable material from the upstream portion 301a, downstream portion 301b, etc., to the aerosol generating component 101.

[0349] Those skilled in the art will know how to apply and change the voltage applied to each portion 301a (etc.). For example, the voltage applied to a portion (e.g., downstream portion 301b) to transfer aerosolizable material from an adjacent portion (e.g., upstream portion 301a) to said portion may be at least 40 V. For example, the voltage applied to a portion (e.g., downstream portion 301b) to transfer aerosolizable material from an adjacent portion (e.g., upstream portion 301a) to said portion may not be greater than 120 V. For example, the voltage applied to a portion (e.g., downstream portion 301b) to transfer aerosolizable material from an adjacent portion (e.g., upstream portion 301a) to said portion may be from 60 V to 75 V. “V” (voltage) may be direct current (VDC).

[0350] The component may include multiple paths 301', 301'', 301''', 301'''' (see Figure 18A) leading to the aerosol generating component. Each path 301'(etc.) is configured to transfer an aerosolizable material toward the aerosol generating component via electrowetting. By using the multiple paths 301'(etc.), an aerosol having, for example, a mixture composed of the respective aerosol generating materials can be generated. Furthermore, the composition of the generated aerosol can be changed (almost in real time) by controlling the respective electrowetting paths 301'(etc.). That is, the electrowetting paths 301'(etc.) can be controlled to determine the rate at which each path 301'(etc.) transfers the aerosolizable material to the aerosol generating component.

[0351] Each path 301' (etc.) can be defined as relative to a previously defined path 301.

[0352] As shown in Figure 18A (right-hand side), at least two of the plurality of paths 301''', 301'''' may have a common upstream portion. In this way, the upstream portion (and therefore the storage 302 defined therefrom) can be shared among at least two of the plurality of paths 301''', 301''''.

[0353] As shown in Figure 18A (left-hand side), at least two of the multiple paths 301''' and 301'''' may have separate upstream portions.

[0354] At least two of the multiple paths 301' (etc.) can lead to corresponding portions of the aerosol generating component 101. For example, at least two of the multiple paths 301''', 301'''' having a common upstream portion can lead to corresponding portions of the aerosol generating component 101. For example, at least two of the multiple paths 301', 301'' having separate upstream portions can lead to corresponding portions of the aerosol generating component. By transferring the aerosolizable material to the corresponding portions of the aerosol generating component, the aerosolizable material can be uniformly distributed on the aerosol generating component, and the aerosolization efficiency can be improved.

[0355] At least two of the plurality of paths 301' (etc.) may lead to the same part of the aerosol generating component. For example, at least two of the plurality of paths 301''', 301'''' having a common upstream portion may lead to the same part of the aerosol generating component. For example, at least two of the plurality of paths 301', 301'' having separate upstream portions may lead to the same part of the aerosol generating component.

[0356] At least two (or each) of the multiple paths 301' (etc.) can be controlled independently of each other. In this way, aerosolizable material can be supplied to the aerosol generating component 101 via each path 301' (etc.) at a corresponding flow rate.

[0357] As shown in Figures 18A and 18B, the component can be substantially flat. Furthermore, each of the plurality of paths 301' (etc.) can be arranged in the same plane. In this configuration, a compact (e.g., thin or low-profile) component can be provided.

[0358] As shown in Figure 18B, the component may include multiple (e.g., two) structures 303. Each structure 303 may be defined as shown with respect to structure 303 in Figures 17A to 17C. One of the paths 301' and structure 303 may define a channel 304; one of the paths 301'' and structure 303 may define a channel 304; and the other of the paths 301'''' and structure 303 may define a channel 304. Each channel 304 may be disposed between a corresponding path 301', 301'', 301''', 301'''' and structure 303.

[0359] As shown in Figures 18A and 18B, the component includes multiple outlets 305 (four of which are present in the components shown in the figures).

[0360] As shown in Figure 18A, at least two of the paths 301', 301'', 301''', and 301'''', along with the common structure 303, can each at least partially define a channel 304 (such that there are two channels 304). That is, the structure 303 can be shared between the respective paths 301', 301'', 301''', and 301''''. In Figures 18A and 18B, two of the paths 301', 301'', and the common structure 303 each define a channel 304 (providing two channels 304); and the other two paths 301''', 301'''', and the corresponding common structure 303 each define a channel 304 (providing two additional channels 304).

[0361] Each path 301', 301'', 301''', 301'''' can be loaded (or provided) on an electrically insulating substrate 306. In Figures 18A and 18B, each path 301', 301'', 301''', 301'''' is loaded on a polyimide substrate 306. In Figures 18A and 18B, structure 303 is made of glass (with an indium tin oxide coating).

[0362] In use, electrowetting (as discussed with respect to Figures 17A to 17C) is used to sequentially transfer aerosolizable material (e.g., its droplets) from the upstream portion, along the downstream portion, and to the terminal downstream portion. The aerosolizable material (e.g., its droplets) in the terminal downstream portion exits the corresponding outlet 305 and diffuses over the aerosol-generating component (e.g., carbon allotrope 101). This can be performed for one, multiple, or each path 301', 301'', 301''', 301''''.

[0363] Referring to Figure 19A, an aerosol generating component 101 may be provided on a portion of an electrically insulating substrate 306. Paths or each path 301(e.g.) may be arranged between the electrically insulating substrate 306 and one of at least one structure 303. The aerosol generating component (e.g., carbon allotrope 101) and the paths or each path 301(e.g.) may be arranged adjacent to each other, optionally in substantially the same plane. In use, electrowetting (as discussed with respect to Figures 17A-17C) is used to transfer aerosolizable material (e.g., its droplets) from an upstream portion 301a to a downstream portion 301b, to a downstream portion 301c, and then to a terminal downstream portion 301d. At the terminal downstream portion 301d, the aerosolizable material (e.g., its droplets) exits from an outlet 305 and diffuses over the aerosol generating component (e.g., carbon allotrope 101).

[0364] Referring to Figure 19B, an aerosol generating component (e.g., carbon allotrope 101) may be provided (or loaded) on a portion of at least one of structures 303. For example, the aerosol generating component may be provided close to a downstream portion (such as a terminal downstream portion 301d). At least one structure 303 may be arranged between the aerosol generating component (e.g., carbon allotrope 101) and at least one path 301 (e.g., terminal downstream portion 301d). At least one structure 303 may be arranged between the aerosol generating component (e.g., carbon allotrope 101) and an electrically insulating substrate 306. At least one aperture 105 may extend through the aerosol generating component (e.g., carbon allotrope 101) and the portion of structure 303 where the aerosol generating component (e.g., carbon allotrope 101) is disposed. At least one aperture 105 may be as defined herein (e.g., in terms of size). In use, in each path 301(etc.), electrowetting (as discussed with respect to Figures 17A to 17C) is used to transfer aerosolizable material (e.g., its droplets) from upstream portion 301a to downstream portion 301b, to downstream portion 301c, and then to terminal downstream portion 301d. At terminal downstream portion 301d, the aerosolizable material (e.g., its droplets) exits outlet 305 (provided by orifice 105) and diffuses on the aerosol generating component (e.g., carbon allotrope 101).

[0365] Referring to Figure 19C, an aerosol generating component (e.g., carbon allotrope 101) may be disposed on a portion of an electrically insulating substrate 306. The electrically insulating substrate 306 may be arranged between the aerosol generating component (e.g., carbon allotrope 101) and at least one path 301 (e.g., a downstream end portion 301d). The electrically insulating substrate 306 may be arranged between the aerosol generating component (e.g., carbon allotrope 101) and one of at least one structure 303. At least one aperture 105 may extend through the portion of the aerosol generating component 100 and the electrically insulating substrate 306 on which the aerosol generating component (e.g., carbon allotrope 101) is provided. The at least one aperture 105 may be as defined herein (e.g., in terms of size). In use, in each path 301(etc.), electrowetting (as discussed with respect to Figures 17A to 17C) is used to transfer aerosolizable material (e.g., its droplets) from upstream portion 301a to downstream portion 301b, to downstream portion 301c, and then to terminal downstream portion 301d. At terminal downstream portion 301d, the aerosolizable material (e.g., its droplets) exits outlet 305 (provided by at least one orifice 105) and diffuses on the aerosol generating component (e.g., carbon allotrope 101).

[0366] In one aspect of this disclosure, an article of manufacture is provided for use as part of a non-flammable aerosol supply system, the article of manufacture comprising an aerosol generating component 100 or an aerosol generating assembly of any aspect of this disclosure.

[0367] In one aspect of this disclosure, an article is provided for use as part of a non-flammable aerosol supply system, the article comprising: an aerosol generating component 100 including a heating section 100a according to any aspect of this disclosure and at least one aerosolizable material supply section 100b; and at least one reservoir for the aerosolizable material, wherein the aerosolizable material supply section or each aerosolizable material supply section 100b is arranged in fluid communication with at least one of the at least one reservoir.

[0368] The aerosolizable material supply unit or each aerosolizable material supply unit 100b may extend to or enter at least one of at least one reservoir. In this way, the aerosolizable material supply unit or each aerosolizable material supply unit 100b may directly transfer the aerosolizable material from the reservoir to the heating unit 100a.

[0369] The heating element 100a may be offset from at least one reservoir. For example, the article may include an aerosol generation chamber. An aerosol generation component may be arranged at least partially within the aerosol generation chamber. For example, the heating element 100a may be arranged within the aerosol generation chamber. The reservoir may radially surround the aerosol generation chamber. In this way, the reservoir may form a ring around the aerosol generation chamber (the ring may be partial or complete).

[0370] At least one airflow path may extend through the article. The article may include at least one inlet and at least one outlet. At least one airflow path may extend from at least one inlet to at least one outlet. The airflow path may include an aerosol generation chamber.

[0371] The article can be oriented such that, during use, air flows along the aerosol generating component (e.g., the heating element 100a) in a surface direction (e.g., along the surface of the aerosol generating component 100, such as the heating element 100a). For example, during use, air can enter the article through at least one inlet, flow through an airflow path via an aerosol generating chamber disposed therein in the aerosol generating component 100 (e.g., the heating element 100a), and exit the article through at least one outlet.

[0372] In one aspect of this disclosure, a non-flammable aerosol supply system is provided, comprising: an aerosol generating component 100 of any aspect of this disclosure, or an aerosol generating assembly of any aspect of this disclosure, or an article of manufacture of any aspect of this disclosure; and a power source and / or a controller.

[0373] The power source is used to supply electrical power to the aerosol generating component (e.g., carbon allotrope 101).

[0374] The controller may be arranged in electrical communication with the aerosol generating component 100 (e.g., carbon allotrope 101), wherein the controller is configured to control the power supply to the aerosol generating component 100 (e.g., carbon allotrope 101) via a power source. The controller may be configured to supply aerosolizable material to the aerosol generating component 100. The supply may be active. Active supply may be performed by an active supply device, such as a pump.

[0375] The controller can be configured to regulate the amount of power supplied to the aerosol generating component 100. For example, power can be supplied to the aerosol generating component (e.g., carbon allotrope 101) via pulse width modulation. Pulse width modulation is described in more detail herein. The controller can be configured to transfer the aerosolizable material (e.g., each droplet therein) to contact the aerosol generating component (e.g., carbon allotrope 101) during the energizing cycle of the pulse width modulation. The controller can be configured such that the aerosolizable material is not transferred to contact the aerosol generating component (e.g., carbon allotrope 101) during the de-energizing period of the pulse width modulation. In this way, the aerosol generating component can be effectively maintained at the temperature used to generate aerosols from the aerosolizable material.

[0376] The amount of power supplied to the aerosol generating unit 100 can be based on the amount of aerosolizable material supplied to the aerosol generating unit 100. In this way, the system can be configured such that when no aerosolizable material is supplied to the aerosol generating unit 100, the power is set to zero or a baseline value, and when aerosolizable material is supplied to the aerosol generating unit, the power is set to a higher value. Such a device has been found to exhibit improved energy efficiency while maintaining the desired heating performance.

[0377] Therefore, when no aerosolizable material is supplied to the aerosol generating unit 100, the controller can be configured such that no power is supplied to the aerosol generating unit. When no aerosolizable material is supplied to the aerosol generating unit 100, the controller can be configured such that a baseline power (greater than zero) is supplied to the aerosol generating unit. The baseline power is less than the power supplied to the aerosol generating unit 100 when aerosol generating material is supplied. The use of the baseline power advantageously reduces the time to reach the aerosolization temperature while limiting power consumption during non-use processes.

[0378] The controller may be configured to associate or synchronize the amount of power supplied to the aerosol generating component with the rate at which the aerosolizable material is delivered to the aerosol generating component in at least one path or each of at least one path 301 (etc.).

[0379] In one aspect of this disclosure, a method is provided for operating a non-flammable aerosol supply system according to any aspect of this disclosure, the method comprising the step of supplying power to an aerosol generating component 100.

[0380] The method may include a drive controller to control (e.g., induce or prevent) the supply of aerosolizable material to the aerosol generating component 100.

[0381] The method may include a drive controller to control (e.g., cause or prevent) the supply of power to the aerosol generating component 100.

[0382] The method may include supplying an amount of power to the aerosol generating unit 100 based on the amount of aerosolizable material supplied to the aerosol generating unit 100. The method may include supplying a baseline power (greater than zero) to the aerosol generating unit 100 when no aerosolizable material is supplied to the aerosol generating unit 100. The method may include supplying an amount of power greater than the baseline power to the aerosol generating unit 100 when aerosolizable material is supplied to the aerosol generating unit 100.

[0383] According to another aspect of this disclosure (see, for example, Figures 17A to 19C), a method for controlling a non-flammable aerosol supply system is provided, the method comprising the steps of: (a) transferring an aerosolizable material (e.g., one or more droplets thereof) toward an aerosol generating component 101 along at least one path 301 (etc.) using electrowetting.

[0384] Step (a) may include sequentially transferring an aerosolizable material (e.g., one or more droplets thereof) toward the aerosol generating component 101 using electrowetting along at least one path 301 (etc.).

[0385] The non-flammable aerosol supply system may have any one or more of the features of the non-flammable aerosol supply system disclosed herein.

[0386] Prior to step (a), the method may include the following steps: (a0) receiving a signal indicating aerosol demand from a user of the non-flammable aerosol supply system. Step (a) may be in response to (a0) (or caused by it).

[0387] The signal indicating demand can be received, for example, after a user inhales the non-flammable aerosol from the supply system. The airflow through the non-flammable aerosol supply system can be detected by a pressure sensor or an airflow sensor that provides the signal.

[0388] Following step (a), the method may include the following step: (b) using the aerosol generating component 101 to generate an aerosol from an aerosolizable material (e.g., one or more droplets thereof, such as aerosolizable material transferred to the aerosol generating component 101).

[0389] Therefore, this method can be a method for controlling a non-flammable aerosol supply system (such as the non-flammable aerosol supply system of this disclosure) and generating aerosols.

[0390] In step (b), the aerosol generating component 101 may be heated to a temperature for generating aerosols from the aerosolizable material. When the aerosol generating component 101 comprises graphene, it has been found that the aerosolizable material can form a thin, uniformly distributed layer on the heated graphene surface.

[0391] Therefore, the method may include the following steps: (a0) receiving a signal indicating aerosol demand from a user of the non-flammable aerosol supply system; (a) sequentially transferring an aerosolizable material (e.g., one or more droplets thereof) toward the aerosol generating component 100 along at least one path 301 (etc.) using electrowetting; and (b) generating an aerosol from the aerosolizable material (e.g., one or more droplets thereof) using the aerosol generating component 101.

[0392] It should be understood that power is supplied to the aerosol generating component 101 so that the aerosol generating component 101 can generate aerosols from the aerosolizable material. For example, power can be supplied to the aerosol generating component 101 to heat the aerosol generating component 101 to a temperature for generating aerosols from the aerosolizable material. The temperature at which aerosols are generated from the aerosolizable material can be at or above the boiling point of the aerosolizable material.

[0393] As discussed herein, the controller of the non-flammable aerosol supply system can be configured to regulate the amount of power supplied (e.g., via a power source) to the aerosol generating unit 101. For example, power (e.g., via a power source) can be supplied to the aerosol generating unit 101 via pulse width modulation (PWM). It should be understood that PWM includes supplying pulsed power to the aerosol generating unit 101. In other words, power can be supplied to the aerosol generating unit 101 via PWM, which corresponds to an alternating sequence of on-period (operating period) (or “pulse,” e.g., 100% supply) and off-period (disconnect period) (e.g., 0% supply). During the on-period, power (or energy) can be supplied to the aerosol generating unit. During the off-period, no power (or energy) can be supplied to the aerosol generating unit.

[0394] When power is supplied to the aerosol generating component 101 via pulse width modulation, the transfer of aerosolizable material (e.g., each of its droplets) to contact the aerosol generating component 101 can be synchronized with or correlated with the energizing cycle of the pulse width modulation.

[0395] For example, when power is supplied to the aerosol generating component 101 via pulse width modulation, the aerosolizable material (e.g., each droplet thereof) may be transferred to contact with the aerosol generating component 101 during the energizing cycle of the pulse width modulation, and / or the aerosolizable material (e.g., each droplet thereof) may not be transferred to contact with the aerosol generating component 101 during the de-energizing cycle of the pulse width modulation.

[0396] Therefore, the method may include the following steps: (a0) receiving a signal indicating aerosol demand from a user of a non-flammable aerosol supply system; (a) sequentially transferring an aerosolizable material (e.g., one or more droplets thereof) toward an aerosol generating component 101 using electrowetting along at least one path 301 (etc.); and (b) generating an aerosol from the aerosolizable material (e.g., one or more droplets thereof) using the aerosol generating component 101; wherein power is supplied to the aerosol generating component 101 via pulse width modulation, wherein the transfer of the aerosolizable material (e.g., each droplet thereof) to contact the aerosol generating component 101 is synchronized with or related to the energizing cycle of the pulse width modulation, such as wherein the aerosolizable material (e.g., each droplet thereof) is transferred to contact the aerosol generating component 101 during the energizing cycle of the pulse width modulation, and / or the aerosolizable material (e.g., each droplet thereof) is not transferred to contact the aerosol generating component 101 during the de-energizing cycle of the pulse width modulation.

[0397] The above arrangement has been found to be particularly energy-efficient and effective for generating aerosols from aerosolizable media. For example, by configuring the system in this way, when the aerosol-generating material is not present on the aerosol-generating component 101 (or when the aerosol-generating component 101 is already at the temperature for generating aerosols from the aerosolizable material), less energy can be used to heat the aerosol-generating component 101. In this way, the aerosol-generating component 101 can be effectively maintained at the temperature for generating aerosols from the aerosolizable material.

[0398] It will be understood that “transferred to contact with” means when an aerosolizable material (e.g., its droplets) comes into contact with an aerosol-generating component.

[0399] The cycle for pulse width modulation can be considered as the duration of adjacent pairs of energizing and de-energizing cycles. The proportion of each cycle in which power / energy is supplied to the aerosol generating unit 101 as part of the cycle (i.e., the length of the energizing cycle) is the duty cycle for pulse width modulation.

[0400] The duty cycle of pulse width modulation can range from 5% to 95%, for example from 10% to 90%.

[0401] The duty cycle of pulse width modulation can be from 10% to 20%. For example, when aerosolizable materials are transferred at flow rates up to 0.6 µL / s, the duty cycle of pulse width modulation can be from 10% to 20%.

[0402] The duty cycle of pulse width modulation (PWM) can range from 50% to 95%. For example, when the aerosolizable material is transferred at a flow rate of at least 1 µL / s, the duty cycle of PWM can be from 50% to 95%, or from 60% to 80%. For example, when the aerosolizable material is transferred at a flow rate of 1 µL / s to 5 µL / s, the duty cycle of PWM can be 50% to 95%, or 60% to 80%. For example, when the aerosolizable material is transferred at a flow rate of 1.5 µL / s to 3 µL / s, the duty cycle of PWM can be 50% to 95%, or 60% to 80%.

[0403] The pulse width modulation (PWM) frequency can range from 1 Hz to 100 Hz. The PWM frequency can range from 1 Hz to 20 Hz. For example, the PWM frequency can range from 3 Hz to 16 Hz. For example, the PWM frequency can range from 4 Hz to 12 Hz. For example, the PWM frequency can range from 5 Hz to 10 Hz. For example, the PWM frequency can be approximately 8 Hz.

[0404] The droplet frequency of the aerosolizable material can be synchronized with or correlated with the pulse width modulation frequency. The droplet frequency can be from 1 Hz to 100 Hz. The droplet frequency can be from 1 Hz to 20 Hz. For example, the droplet frequency can be from 3 Hz to 16 Hz. For example, the droplet frequency can be from 4 Hz to 12 Hz. For example, the droplet frequency can be from 5 Hz to 10 Hz. For example, the droplet frequency can be approximately 8 Hz. It should be understood that the droplet frequency refers to the amount of aerosolizable material droplets transferred per second to contact the aerosol generating component 101.

[0405] It should be understood that the duty cycle and / or pulse width modulation frequency may vary, for example, depending on the flow rate of the aerosolizable material.

[0406] The aerosol generating component 101 can be heated in response to step (a0) to a temperature for generating aerosols from an aerosolizable medium. It has been found that when the aerosol generating component 101 includes graphene, the aerosol generating component can rapidly reach such a temperature.

[0407] When power is supplied to aerosol generating unit 101 using pulse width modulation to heat it to a temperature for generating aerosols from aerosolizable materials, the power can be supplied until no signal indicating a user demand for aerosols from the non-flammable aerosol supply system is received. For example, power supply to aerosol generating unit 101 can be stopped when no signal indicating a user demand for aerosols from the non-flammable aerosol supply system is received.

[0408] For example, no signal indicating a need will be received when the user is not (or stops) inhaling the non-flammable aerosol supply system. Other implementations are also envisioned (e.g., when the user does not press the button or stops pressing the button).

[0409] Therefore, the method may include the following steps: (a0) receiving a signal indicating aerosol demand from a user of the non-flammable aerosol supply system; (a) transferring an aerosolizable material (e.g., one or more droplets thereof) toward an aerosol generating component 101 using electrowetting along at least one path 301 (etc.); and (b) generating an aerosol from the aerosolizable material (e.g., one or more droplets thereof) using the aerosol generating component 101; wherein power is supplied to the aerosol generating component 101 using pulse width modulation to heat the aerosol generating component 101 to a temperature at which the aerosolizable material generates an aerosol, wherein the power is supplied until no signal indicating aerosol demand from a user of the non-flammable aerosol supply system is received.

[0410] The method may include the step of transferring an aerosolizable material (e.g., one or more droplets thereof) toward an aerosol generating component 101 via electrowetting along each of a plurality of paths 301 (etc.). As described above, the aerosolizable material may be transferred along each of the plurality of paths 301 (etc.). For example, each of the plurality of paths 301 (etc.) may have any one or more characteristics of the paths described above.

[0411] The method may include any one or more features of any other aspect of this disclosure.

[0412] In one aspect of this disclosure, a method for forming an aerosol generating component 100 (or 101) of any aspect of this disclosure is provided.

[0413] The method may include the step of forming a carbon allotrope 101 on an electrically insulating substrate 102. The carbon allotrope 101 may be as defined herein.

[0414] The carbon allotrope 101 can be formed on the electrically insulating substrate 102 by printing.

[0415] Carbon allotropes 101 can be formed on electrically insulating substrates 102 by laser irradiation. In embodiments where carbon allotropes 101 are formed in the form of foam, the foam can be formed on electrically insulating substrates 102 by laser irradiation. Laser irradiation can include irradiating electrically insulating substrates 102 with a laser beam, wherein the electrically insulating substrates 102 are carbon-containing materials. In embodiments involving laser irradiation, the electrically insulating substrates 102 can be formed of polyimide (PI). Laser irradiation can be performed in an inert environment. Laser irradiation can be performed in the ambient environment. Laser irradiation can be performed in atmospheric air (air from the Earth's atmosphere).

[0416] Therefore, in some embodiments, the method of forming the aerosol generating component 100 includes forming a carbon allotrope 101 on an electrically insulating substrate 102 by laser irradiation, the laser irradiation comprising irradiating the electrically insulating substrate 102 with a laser beam, wherein the electrically insulating substrate 102 is a carbon-containing material (optionally formed of polyimide (PI)), and optionally the carbon allotrope 101 is formed in the form of foam. Optionally, the carbon allotrope 101 comprises disordered graphite and / or amorphous carbon.

[0417] The method may include the step of forming at least one hole 105 extending through an electrically insulating substrate 102. The at least one hole 105 may be as defined herein. The at least one hole 105 may be formed by laser irradiation of the electrically insulating substrate 102.

[0418] In some embodiments, the step of forming at least one hole 105 extending through the electrically insulating substrate 102 occurs prior to the step of forming a carbon allotrope 101 on the electrically insulating substrate 102. The carbon allotrope 101 may be formed on a portion of the electrically insulating substrate 102 through which at least one hole 105 extends. At least one hole 105 may extend through the carbon allotrope 101 and / or be (partially or completely) covered by the carbon allotrope 101.

[0419] Therefore, in some embodiments, the method of forming the aerosol generating component 100 includes: (A) forming at least one hole 105 through the electrically insulating substrate 102 by laser irradiation; and (B) forming a carbon allotrope 101 on an electrically insulating substrate 101 by laser irradiation, wherein the electrically insulating substrate 102 is a carbon-containing material (optionally formed of polyimide (PI)), step (A) occurs prior to step (B), and at least one hole 105 extends through the carbon allotrope 101 and / or is (partially or completely) covered by the carbon allotrope 101. Optionally, the carbon allotrope 101 is formed in the form of foam. Optionally, the carbon allotrope 101 comprises disordered graphite and / or amorphous carbon.

[0420] In some embodiments, the step of forming at least one hole 105 extending through the electrically insulating substrate 102 occurs after the step of forming a carbon allotrope 101 on the electrically insulating substrate 102. The carbon allotrope 101 may (partially or completely) cover at least one hole 105.

[0421] Therefore, in some embodiments, the method of forming the aerosol generating component 100 includes: (A) forming a carbon allotrope 101 on an electrically insulating substrate 102 by laser irradiation; and (B) forming at least one hole 105 through the electrically insulating substrate 102 by laser irradiation, wherein the electrically insulating substrate 102 is a carbon-containing material (optionally formed of polyimide (PI)), step (A) occurs prior to step (B), and the carbon allotrope 101 (partially or completely) covers at least one hole 105. Optionally, the carbon allotrope 101 is formed in the form of foam. Optionally, the carbon allotrope 101 comprises disordered graphite and / or amorphous carbon.

[0422] Without being theoretically constrained, it is assumed that energy from a laser beam can form a porous conductive carbon-containing material (101) with a porous (e.g., foam) structure from an electrically insulating substrate 102 (e.g., PI). It should be understood that various properties of the carbon allotrope 101 and / or at least one pore 105 can be controlled by adjusting laser beam parameters such as pulse duration, power, focal length, frequency, wavelength, and / or scanning speed.

[0423] Carbon allotropes 101 can be formed on electrically insulating substrates 102 by laser-induced deposition.

[0424] When the carbon allotrope 101 is or includes one or more graphene layers, this can be formed on an electrically insulating substrate 102 by laser-induced graphene (LIG) formation. Laser-induced graphene formation involves irradiating the electrically insulating substrate 102 with a laser beam, wherein the electrically insulating substrate is a carbon-containing material. LIG can be used to form graphene foam on an electrically insulating substrate.

[0425] Carbon allotropes 101 can be formed on an electrically insulating substrate 102 by chemical vapor deposition (CVD). CVD involves flowing a carbon-containing gas (e.g., methane) (and optionally hydrogen) through the electrically insulating substrate 102. CVD can be performed at sub-atmospheric pressure, also known as low-pressure CVD. CVD can be used to form graphene foam on an electrically insulating substrate.

[0426] The method may include the step of forming one or more electrodes 103 in contact with the carbon allotrope 101.

[0427] It has been found that manufacturing efficiency can be improved by forming two or more electrodes 103 in contact (i.e., direct contact) with the carbon allotrope 101, relative to an aerosol-generating component (i.e., an additional component part; typically, silver contacts) where the electrodes are connected to the heater via electrical contacts. Furthermore, since such electrical contacts are not required, a larger proportion of aerosol-generating components 100 of a specific size can be configured to generate aerosols (e.g., a larger surface area of ​​the aerosol-generating component 100 can be exposed to the aerosolizable material), thereby improving aerosolization performance. The direct connection between one or more electrodes 103 and the carbon allotrope 101 also provides improved low-loss electrical and / or mechanical connections therebetween, relative to an aerosol-generating component where the electrodes are connected to the heater via electrical contacts.

[0428] Forming one or more electrodes 103 in contact with the carbon allotrope 101 may include a sintering step. For example, forming at least one electrode 103 in contact with the carbon allotrope 101 may include sintering at least one electrode to the carbon allotrope 101.

[0429] The electrodes, or each electrode 103, may be selected from copper, silver, and gold. The electrodes, or each electrode 103, are made by sintering, such as sintered copper, sintered silver, or sintered gold. Copper (such as sintered copper) has been found to be particularly effective in forming direct, low-loss electrical connections.

[0430] The method may include forming one or more grooves and / or one or more holes in the electrically insulating substrate before arranging the carbon allotrope 101 on the electrically insulating substrate. One or more holes extend through the substrate 102 (i.e., as through-holes). The grooves and holes facilitate the distribution of aerosolizable material on and through the aerosol generating component 100 and improve heating efficiency.

[0431] In some embodiments, the substrate 102 is glass, such as borosilicate glass (e.g., “flexible glass”) or quartz glass (fused silica).

[0432] For example, Figure 9 shows a carbon allotrope 102 formed on a borosilicate glass substrate 102, and two copper electrodes 103 in contact with the carbon allotrope 101.

[0433] In one aspect of this disclosure, an aerosol generating component 100 is provided, which is obtained by a method according to any aspect of this disclosure.

[0434] According to another aspect of this disclosure, Clause A1 is provided. An aerosol generating component for use as part of a non-flammable aerosol supply system, the aerosol generating component comprising a carbon allotrope loaded on an electrically insulating substrate.

[0435] Clause A2. An aerosol generating component according to Clause A1, wherein the carbon allotrope comprises one or more graphene layers, wherein, in the presence of more than one graphene layer, at least two graphene layers are not parallel to each other.

[0436] Clause A3. Aerosol generating components according to Clause A1 or A2, wherein the carbon allotropes include graphite.

[0437] Clause A4. An aerosol generating component according to any one of Clauses A1 to A3, wherein the carbon allotrope has one or more of the following: 100 to 5500 Wm -1 k -1 Thermal conductivity, 1 to 2.5 × 10 6 Sm -1 Its electrical conductivity and nonlinear elasticity.

[0438] Clause A5. An aerosol generating component according to any one of Clauses A1 to A4, wherein the electrically insulating substrate is selected from the group consisting of plastics, glass, paper and ceramics.

[0439] Clause A6. An aerosol generating component according to any one of Clauses A1 to A5, wherein the aerosol generating component includes a capillary structure.

[0440] Clause A7. Aerosol generating component according to Clause A6, wherein the electrically insulating substrate has a porous structure formed by pillars and gap holes.

[0441] Clause A8. Aerosol generating component according to Clause A7, wherein carbon allotropes are formed on one or more columns.

[0442] Clause A9. Aerosol generating component according to Clause A8, wherein the interstitial pores have an average pore size of 0.5 to 40 μm.

[0443] Clause A10. An aerosol generating component according to any one of Clauses A1 to A9, wherein carbon allotropes are formed in the form of multiple nanotubes.

[0444] Clause A11. An aerosol generating component according to any one of Clauses A1 to A9, wherein the carbon allotropes are formed in the form of open-cell foam.

[0445] Clause A12. An aerosol generating component according to any one of Clauses A1 to A9, wherein carbon allotropes are formed in the form of multiple sheets.

[0446] Clause A13. An aerosol generating component according to any one of Clauses A1 to A12, wherein the carbon allotrope has a thickness from 0.345 nm to 100 μm.

[0447] Clause A14. An aerosol generating component according to any one of Clauses A1 to A13, wherein the electrically insulating substrate is formed in the form of a plate, strip, or rod.

[0448] Clause A15. An aerosol generating component according to any one of Clauses A1 to A14, wherein the electrically insulating substrate has a thickness of 5 to 500 μm, and / or a width of 0.5 to 50 mm, and / or a length of 1 to 50 mm.

[0449] Clause A16. An aerosol generating component according to any one of Clauses A1 to A15, wherein at least 50% of the surface area of ​​the carbon allotrope transelectric insulating substrate is loaded on the substrate.

[0450] Clause A17. The aerosol generating component according to any one of Clauses A1 to A16 further includes one or more electrodes arranged to be in electrical contact with a carbon allotrope.

[0451] Clause A18. Aerosol generating components according to Clause A17, wherein each of one or more electrodes is formed of copper, silver or gold.

[0452] Clause A19. An aerosol generating assembly for use as part of a non-flammable aerosol supply system, the aerosol generating assembly comprising an aerosol generating component of any one of Clauses A1 to A18 and an aerosol generating material transfer component for supplying aerosol generating material to the aerosol generating component.

[0453] Clause A20. An aerosol generating assembly pursuant to Clause A19, wherein the aerosol generating material transfer component includes a reservoir, wherein the aerosol generating component traverses the reservoir.

[0454] Clause A21. An aerosol generating assembly according to Clause A19, wherein the aerosol generating material transfer component includes at least one capillary channel having an outlet.

[0455] Clause A22. An aerosol generating assembly according to Clause A21, wherein the outlet is arranged adjacent to the aerosol generating component such that aerosolizable material leaving the outlet comes into direct contact with the aerosol generating component.

[0456] Clause A23. A non-flammable aerosol supply system comprising: an aerosol generating component of any one of Clauses A1 to A18 or an aerosol generating assembly of any one of Clauses A19 to A22; and one or more of a power source and a controller.

[0457] Clause A24. A method for forming an aerosol generating component according to any one of Clauses A1 to A18, the method comprising the step of forming a carbon allotrope on an electrically insulating substrate.

[0458] Clause A25. The method according to Clause A24, wherein carbon allotropes are formed by one of printing, laser-induced graphene formation, and chemical vapor deposition.

[0459] According to another aspect of this disclosure, Clause B1 is provided. An aerosol generating component for use as part of a non-flammable aerosol supply system, the aerosol generating component comprising a carbon allotrope loaded on an electrically insulating substrate, wherein the carbon allotrope is configured such that the contact angle between a glycerol droplet and the surface of the carbon allotrope is no greater than 20 degrees at a temperature of 150°C.

[0460] Clause B2. The aerosol generating component according to Clause B1, wherein at a temperature of 20°C, the contact angle between the droplets of glycerol and the surface of the carbon allotrope is from 70 degrees to 130 degrees.

[0461] Clause B3. Aerosol generating components according to Clause B1 or B2, wherein the carbon allotrope includes one or more dopants.

[0462] Clause B4. Aerosol generating components pursuant to Clause B3, wherein one or more dopants include n-dopants.

[0463] Clause B5. Aerosol generating components according to Clause B4, wherein the n-doper is selected from the group consisting of phosphorus and nitrogen.

[0464] Clause B6. Aerosol generating components according to Clauses B3 to B5, wherein one or more dopants include p-dopers.

[0465] Clause B7. Aerosol generating components according to Clause B6, wherein the p-dopant is selected from the group consisting of boron and sulfur.

[0466] Clause B8. An aerosol generating component according to any one of Clauses B1 to B7, wherein the carbon allotrope comprises one or more graphene layers, wherein, in the presence of more than one graphene layer, at least two graphene layers are not parallel to each other.

[0467] Clause B9. An aerosol generating component according to any one of Clauses B1 to B7, wherein the carbon allotrope is graphite.

[0468] Clause B10. An aerosol generating component according to any one of Clauses B1 to B9, wherein the carbon allotrope has one or more of the following: 100 to 5500 Wm -1 k -1 Thermal conductivity, 1 to 2.5 × 10 6 Sm -1 Its electrical conductivity and nonlinear elasticity.

[0469] Clause B11. An aerosol generating component according to any one of Clauses B1 to B10, wherein the electrically insulating substrate has a thickness of 5 to 500 μm, and / or a width of 0.5 mm to 50 mm, and / or a length of 1 mm to 50 mm.

[0470] Clause B12. An aerosol generating component according to any one of Clauses B1 to B11, wherein the electrically insulating substrate is selected from the group consisting of plastics, glass, paper and ceramics.

[0471] Clause B13. An aerosol generating component according to any one of Clauses B1 to B12, wherein the electrically insulating substrate has a porous structure formed by pillars and gap holes.

[0472] Clause B14. Aerosol generating component according to Clause B13, wherein carbon allotropes are formed on the column.

[0473] Clause B15. Aerosol generating components according to Clause B13 or B14, wherein the gap pores have an average pore diameter of 0.5 to 40 μm.

[0474] Clause B16. An aerosol generating component according to any one of Clauses B1 to B14, wherein carbon allotropes are formed in the form of multiple nanotubes.

[0475] Clause B17. An aerosol generating component according to any one of Clauses B1 to B14, wherein the carbon allotropes are formed in the form of open-cell foam.

[0476] Clause B18. An aerosol generating component according to any one of Clauses B1 to B14, wherein the carbon allotropes are formed in the form of multiple sheets.

[0477] Clause B19. An aerosol generating component according to any one of Clauses B1 to B18, wherein the aerosol generating component includes a capillary structure.

[0478] Clause B20. An aerosol generating assembly for use as part of a non-flammable aerosol supply system, the aerosol generating assembly comprising: an aerosol generating component according to any one of Clauses B1 to B19; and an aerosol generating material transfer component for supplying aerosol generating material to the aerosol generating component.

[0479] Clause B21. Aerosol generating assembly pursuant to Clause B20, wherein the aerosol generating material transfer component includes a reservoir.

[0480] Clause B22. Aerosol generating assembly pursuant to Clause B20 or B21, wherein the aerosol generating component traverses the reservoir.

[0481] Clause B23. An aerosol generating assembly according to Clause B20, wherein the aerosol generating material transfer component includes at least one capillary channel having an outlet.

[0482] Clause B24. An aerosol generating assembly pursuant to Clause B18, wherein the outlet is arranged adjacent to the aerosol generating component such that aerosolizable material leaving the outlet comes into direct contact with the aerosol generating component.

[0483] Clause B25. A non-flammable aerosol supply system comprising: an aerosol generating component according to any one of Clauses B1 to B19 or an aerosol generating assembly according to any one of Clauses B20 to B24; and one or more of a power source and a controller.

[0484] According to another aspect of this disclosure, Clause C1 is provided. An aerosol generating component for use as part of a non-flammable aerosol supply system, the aerosol generating component comprising a carbon allotrope loaded on an electrically insulating substrate, wherein the substrate is elongated and has an aspect ratio from 5:1 to 50:1.

[0485] Clause C2. The aerosol generating component according to Clause C1 has an electrically insulating substrate with a length of 10 to 30 mm.

[0486] Clause C3. Aerosol generating components according to Clause C1 or C2, wherein the electrically insulating substrate has a width of 0.5 mm to 10 mm.

[0487] Clause C4. An aerosol generating component according to any one of Clauses C1 to C3, wherein the carbon allotropes are formed in the form of multiple nanotubes.

[0488] Clause C5. An aerosol generating component according to any one of Clauses C1 to C3, wherein the carbon allotropes are formed in the form of open-cell foam.

[0489] Clause C6. An aerosol generating component according to any one of Clauses C1 to C3, wherein the carbon allotropes are formed in the form of multiple sheets.

[0490] Clause C7. An aerosol generating component according to any one of Clauses C1 to C6, wherein the electrically insulating substrate is selected from the group consisting of plastics, glass, paper and ceramics.

[0491] Clause C8. An aerosol generating component according to any one of Clauses C1 to C7, wherein the electrically insulating substrate has a porous structure formed by pillars and gap holes.

[0492] Clause C9. Aerosol generating component according to Clause C8, wherein carbon allotropes are formed on the column.

[0493] Clause C10. Aerosol generating components according to Clause C8 or C9, wherein the gap pores have an average pore diameter of 0.5 to 40 μm.

[0494] Clause C11. An aerosol generating component according to any one of Clauses C1 to C10, wherein the carbon allotrope comprises one or more graphene layers, wherein, in the presence of more than one graphene layer, at least two graphene layers are not parallel to each other.

[0495] Clause C12. An aerosol generating component according to any one of Clauses C1 to C10, wherein the carbon allotrope is graphite.

[0496] Clause C13. An aerosol generating component according to any one of Clauses C1 to C12, wherein the carbon allotrope has one or more of the following: from 100 to 5500 Wm -1 k -1 Thermal conductivity, from 1 to 2.5 × 10⁻⁶ 6 Sm -1 Its electrical conductivity and nonlinear elasticity.

[0497] Clause C14. An aerosol generating assembly for use as part of a non-flammable aerosol supply system, the aerosol generating assembly comprising: an aerosol generating component according to any one of Clauses C1 to C13; and an aerosol generating material transfer component for supplying aerosol generating material to the aerosol generating component.

[0498] Clause C15. Aerosol generating assembly pursuant to Clause C14, wherein the aerosol generating material transfer component includes a reservoir.

[0499] Clause C16. Aerosol generating assembly according to Clause C14 or C15, wherein the aerosol generating material transfer component traverses the reservoir.

[0500] Clause C17. An aerosol generating assembly according to Clause C14, wherein the aerosol generating material transfer component includes at least one capillary channel having an outlet.

[0501] Clause C18. An aerosol generating assembly according to Clause C17, wherein the outlet is arranged adjacent to the aerosol generating component such that aerosolizable material leaving the outlet comes into direct contact with the aerosol generating component.

[0502] Clause C19. A non-flammable aerosol supply system comprising: an aerosol generating component according to any one of Clauses C1 to C13 or an aerosol generating assembly according to any one of Clauses C14 to C18; and one or more of a power source and a controller.

[0503] Clause C20. A non-flammable aerosol supply system pursuant to Clause C19, wherein a controller is arranged in electrical communication with an aerosol generating component, and wherein the controller is configured to control the power supplied to the aerosol generating component by a power source.

[0504] Clause C21. A non-flammable aerosol supply system pursuant to Clause C20, wherein a controller is configured to actively supply aerosolizable material to an aerosol generating component.

[0505] Clause C22. A non-flammable aerosol supply system pursuant to Clauses C20 or C21, wherein the amount of power supplied to the aerosol generating component is based on the amount of aerosolizable material supplied to the aerosol generating component.

[0506] Clause C23. A non-flammable aerosol supply system pursuant to any of Clauses C20 to C22, wherein when no aerosolizable material is supplied to the aerosol generating component, the controller is configured to supply a baseline power to the aerosol generating component, wherein the baseline power is greater than zero and less than the power supplied to the aerosol generating component when the aerosolizable material is supplied to the aerosol generating component.

[0507] According to another aspect of this disclosure, clause D1 is provided. An aerosol generating component for use as part of a non-flammable aerosol supply system, the aerosol generating component comprising a carbon allotrope loaded on an electrically insulating substrate, wherein at least one elongated hole extends through the aerosol generating component.

[0508] Clause D2. Aerosol generating component according to Clause D1, wherein the elongated orifice or each elongated orifice is linear.

[0509] Clause D3. Aerosol generating components according to Clause D1, wherein the elongated orifice or each elongated orifice is non-linear.

[0510] Clause D4. An aerosol generating component according to any one of Clauses D1 to D3, wherein a plurality of elongated orifices extend through the aerosol generating component.

[0511] Clause D5. Aerosol generating component according to Clause D4, wherein elongated orifices are arranged parallel to each other.

[0512] Clause D6. An aerosol generating component according to any one of Clauses D1 to D5, wherein the electrically insulating substrate is formed in the form of a strip or rod.

[0513] Clause D7. An aerosol generating component according to Clause D6, wherein at least one elongated hole extends substantially parallel to the longitudinal extent of an electrically insulating substrate, preferably wherein the electrically insulating substrate has a thickness from 100 μm to 4 mm, and / or a width from 0.5 mm to 50 mm, and / or a length from 1 mm to 50 mm.

[0514] Clause D8. An aerosol generating component according to any one of Clauses D1 to D7, wherein the carbon allotrope comprises one or more graphene layers, wherein, in the presence of more than one graphene layer, at least two graphene layers are not parallel to each other.

[0515] Clause D9. An aerosol generating component according to any one of Clauses D1 to D7, wherein the carbon allotrope is graphite.

[0516] Clause D10. An aerosol generating component according to any one of Clauses D1 to D9, wherein the carbon allotrope has one or more of the following: from 100 to 5500 Wm -1 k -1 Thermal conductivity, from 1 to 2.5 × 10⁻⁶ 6 Sm -1 Its electrical conductivity and nonlinear elasticity.

[0517] Clause D11. An aerosol generating component according to any one of Clauses D1 to D10, wherein the electrically insulating substrate is selected from the group consisting of plastics, glass, paper and ceramics.

[0518] Clause D12. An aerosol generating component according to any one of Clauses D1 to D11, wherein the aerosol generating component includes a capillary structure.

[0519] Clause D13. Aerosol generating component according to Clause D12, wherein the electrically insulating substrate has a porous structure formed by pillars and gap holes.

[0520] Clause D14. Aerosol generating component according to Clause D13, wherein carbon allotropes are formed on the column.

[0521] Clause D15. Aerosol generating components according to Clause D13 or D14, wherein the gap pores have an average pore diameter of 0.5 to 40 μm.

[0522] Clause D16. An aerosol generating component according to any one of Clauses D1 to D15, wherein the carbon allotropes are formed in the form of a plurality of nanotubes.

[0523] Clause D17. An aerosol generating component according to any one of Clauses D1 to D15, wherein the carbon allotropes are formed in the form of open-cell foam.

[0524] Clause D18. An aerosol generating component according to any one of Clauses D1 to D15, wherein carbon allotropes are formed in the form of multiple sheets.

[0525] Clause D19. An aerosol generating component according to any one of Clauses D1 to D18, wherein the elongated orifice or each elongated orifice has a width of 0.1 mm to 1 mm and / or a length of 5 to 95% of the length of the aerosol generating component.

[0526] Clause D20. An aerosol generating assembly for use as part of a non-flammable aerosol supply system, the aerosol generating assembly comprising an aerosol generating component of any one of Clauses D1 to D19 and an aerosol generating material transfer component for supplying aerosol generating material to the aerosol generating component.

[0527] Clause D21. Aerosol generating assembly pursuant to Clause D20, wherein the aerosol generating material transfer component includes a reservoir.

[0528] Clause D22. Aerosol generating assembly pursuant to Clause D21, wherein the aerosol generating component traverses the reservoir.

[0529] Clause D23. An aerosol generating assembly according to Clause D20, wherein the aerosol generating material transfer component includes at least one capillary channel having an outlet.

[0530] Clause D24. An aerosol generating assembly according to Clause D23, wherein the outlet is arranged adjacent to the aerosol generating component such that aerosolizable material leaving the outlet comes into direct contact with the aerosol generating component.

[0531] Clause D25. A non-flammable aerosol supply system comprising: an aerosol generating component of any one of Clauses D1 to D19 or an aerosol generating assembly of any one of Clauses D20 to D24; and one or more of a power source and a controller.

[0532] According to another aspect of this disclosure, clause E1 is provided. A method for preparing an aerosol generating component for use as part of a non-flammable aerosol supply system, the method comprising the steps of: forming a carbon allotrope on an electrically insulating substrate; and forming one or more electrodes in contact with the carbon allotrope.

[0533] Clause E2. The method according to Clause E1, wherein the step of forming one or more electrodes in contact with a carbon allotrope includes a sintering step.

[0534] Clause E3. The method according to Clause E1 or E2, wherein the electrodes or each electrode is selected from copper, silver or gold.

[0535] Clause E4. The method according to any one of Clauses E1 to E3, wherein the carbon allotrope is formed on an electrically insulating substrate by printing.

[0536] Clause E5. The method according to any one of Clauses E1 to E4, wherein the carbon allotrope is formed on an electrically insulating substrate by chemical vapor deposition.

[0537] Clause E6. The method according to any one of Clauses E1 to E5, wherein a carbon allotrope is formed on an electrically insulating substrate by laser-induced deposition.

[0538] Clause E7. The method according to any one of Clauses E1 to E6, wherein the carbon allotrope is formed in the form of a plurality of nanotubes or in the form of open-cell foam or in the form of a plurality of sheets.

[0539] Clause E8. The method according to any one of Clauses E1 to E7, wherein the electrically insulating substrate has a hole structure formed by pillars and gap holes.

[0540] Clause E9. The method of Clause E8, wherein carbon allotropes are formed on the column.

[0541] Clause E10. The method according to Clause E9, wherein the gap orifice has an average pore diameter of 0.5 to 40 μm.

[0542] Clause E11. The method according to any one of Clauses E1 to E10, wherein the carbon allotrope comprises one or more graphene layers, wherein, in the presence of more than one graphene layer, at least two graphene layers are not parallel to each other.

[0543] Clause E12. The method according to any one of Clauses E1 to E10, wherein the carbon allotrope is graphite.

[0544] Clause E13. The method according to any one of Clauses E1 to E12, wherein the carbon allotrope has one or more of the following: from 100 to 5500 Wm -1 k -1 Thermal conductivity, from 1 to 2.5 × 10⁻⁶ 6 Sm -1 Its electrical conductivity and nonlinear elasticity.

[0545] Clause E14. The method according to any one of Clauses E1 to E13 includes forming one or more trenches and / or one or more holes in the electrically insulating substrate prior to depositing the carbon allotrope onto the electrically insulating substrate.

[0546] Clause E15. The method according to any one of Clauses E1 to E14, wherein the electrically insulating substrate is selected from the group consisting of plastics, glass, paper and ceramics.

[0547] Clause E16. The method according to Clause E15, wherein the electrically insulating substrate is glass, and wherein the glass is borosilicate glass.

[0548] Clause E17. An aerosol generating component obtained by any one of the methods in Clauses E1 to E16.

[0549] Clause E18. An aerosol generating assembly for use as part of a non-flammable aerosol supply system, the aerosol generating assembly comprising: an aerosol generating component according to Clause E17; and an aerosol generating material transfer component for supplying aerosol generating material to the aerosol generating component.

[0550] Clause E19. Aerosol generating assembly pursuant to Clause E18, wherein the aerosol generating material transfer component includes a reservoir, wherein the aerosol generating component traverses the reservoir.

[0551] Clause E20. Aerosol generating assembly according to Clause E18, wherein the aerosol generating material transfer component includes at least one capillary channel having an outlet.

[0552] Clause E21. An aerosol generating assembly according to Clause E20, wherein the outlet is arranged adjacent to the aerosol generating component such that aerosolizable material leaving the outlet comes into direct contact with the aerosol generating component.

[0553] Clause E22. A non-flammable aerosol supply system comprising: an aerosol generating component of Clause E17 or an aerosol generating assembly according to any one of Clauses E18 to E21; and one or more of a power source and a controller.

[0554] According to another aspect of this disclosure, clause F1 is provided. An aerosol generating component for use as part of a non-flammable aerosol supply system, the aerosol generating component comprising a carbon allotrope loaded on an electrically insulating substrate, wherein the aerosol generating component includes a heating section and at least one aerosolizable material supply section extending from the heating section.

[0555] Clause F2. The aerosol generating component according to Clause F1, wherein an aerosolizable material supply section or each aerosolizable material supply section extends from the side of the heating section.

[0556] Clause F3. Aerosol generating components according to Clause F1 or F2, wherein the heating part is elongated.

[0557] Clause F4. An aerosol generating component according to any one of Clauses F1 to F3, wherein the aerosolizable material supply section or each aerosolizable material supply section is elongated.

[0558] Clause F5. An aerosol generating component according to any one of Clauses F1 to F4, wherein the aerosolizable material supply section or each aerosolizable material supply section has an aspect ratio of 1:1 to 5:1.

[0559] Clause F6. An aerosol generating component according to any one of Clauses F1 to F5, wherein the length of the aerosolizable material supply section or each aerosolizable material supply section is 1 to 15 mm.

[0560] Clause F7. An aerosol generating component according to any one of Clauses F1 to F6, wherein the width of the aerosolizable material supply section or each aerosolizable material supply section is 1 to 3 mm.

[0561] Clause F8. An aerosol generating component according to any one of Clauses F1 to F7, wherein the aerosolizable material supply section or each aerosolizable material supply section gradually narrows away from the elongated heating section.

[0562] Clause F9. An aerosol generating component according to any one of Clauses F1 to F8, wherein the electrically insulating substrate has a thickness of 5 to 500 μm.

[0563] Clause F10. An aerosol generating component according to any one of Clauses F1 to F9, wherein the heating part has a width from 0.5 mm to 50 mm.

[0564] Clause F11. An aerosol generating component according to any one of Clauses F1 to F10, wherein the heating part has a length of 1 mm to 50 mm.

[0565] Clause F12. An aerosol generating component according to any one of Clauses F1 to F11, wherein the carbon allotropes are formed in the form of multiple nanotubes, open-cell foams, or multiple sheets.

[0566] Clause F13. An aerosol generating component according to any one of Clauses F1 to F12, wherein the carbon allotrope comprises one or more graphene layers, wherein, in the presence of more than one graphene layer, at least two graphene layers are not parallel to each other.

[0567] Clause F14. An aerosol generating component according to any one of Clauses F1 to F12, wherein the carbon allotrope is graphite.

[0568] Clause F15. An aerosol generating component according to any one of Clauses F1 to F14, wherein the carbon allotrope has one or more of the following: from 100 to 5500 Wm -1 k -1 Thermal conductivity, from 1 to 2.5 × 10⁻⁶ 6 Sm -1Its electrical conductivity and nonlinear elasticity.

[0569] Clause F16. An aerosol generating component according to any one of Clauses F1 to F15, wherein the electrically insulating substrate has a porous structure formed by pillars and gap holes.

[0570] Clause F17. Aerosol generating component according to Clause F16, wherein carbon allotropes are formed on the column.

[0571] Clause F18. Aerosol generating components according to Clause F16 or F17, wherein the gap pores have an average pore diameter of 0.5 to 40 μm.

[0572] Clause F19. An aerosol generating assembly for use as part of a non-flammable aerosol supply system, the aerosol generating assembly comprising: an aerosol generating component according to any one of Clauses F1 to F18; and an aerosol generating material transfer component for supplying aerosol generating material to the aerosol generating component.

[0573] Clause F20. Aerosol generating assembly pursuant to Clause F19, wherein the aerosol generating material transfer component includes a reservoir.

[0574] Clause F21. Aerosol generating assembly pursuant to Clause F20, wherein the aerosol generating component traverses the reservoir.

[0575] Clause F22. Aerosol generating assembly according to Clause F19, wherein the aerosol generating material transfer component includes at least one capillary channel having an outlet.

[0576] Clause F23. An aerosol generating assembly pursuant to Clause F22, wherein the outlet is arranged adjacent to the aerosol generating component such that aerosolizable material leaving the outlet comes into direct contact with the aerosol generating component.

[0577] Clause F24. A non-flammable aerosol supply system comprising: an aerosol generating component according to any one of Clauses F1 to F18 or an aerosol generating assembly according to any one of Clauses F19 to F23; and one or more of a power source and a controller.

[0578] According to another aspect of this disclosure, provision H1 is provided. An assembly for use as part of a non-flammable aerosol supply system, the assembly comprising an aerosol generating component and at least one path leading to the aerosol generating component, the at least one path or each of the at least one path being configured to transfer an aerosolizable material toward the aerosol generating component by means of electrowetting.

[0579] Clause H2. Components according to Clause H1, wherein at least one path or each of at least one path includes an upstream portion and a downstream portion, wherein these portions are selectively connectable to a power source.

[0580] Clause H3. Components according to Clause H1 or H2, wherein the component includes at least one storage device.

[0581] Clause H4. Components according to Clause H3, wherein at least one path or each of at least one path includes a reservoir, wherein the reservoir is formed at least in part by the upstream portion.

[0582] Clause H5. Components of any of Clauses H2 through H4, when subordinate to Clause 2, are discrete portions.

[0583] Clause H6. Components of any one of Clauses H1 through H5, wherein at least one path or each of at least one path is substantially flat.

[0584] Clause H7. A component according to any one of Clauses H1 to H6, wherein the component includes an electrically insulating substrate, and at least one path or each of at least one path is disposed on the electrically insulating substrate.

[0585] Clause H8. Components according to Clause H7, wherein the electrically insulating substrate is selected from the group consisting of plastics, glass, paper and ceramics.

[0586] Clause H9. Components according to Clause H7 or H8, wherein at least one path or each of at least one path at least partially defines a channel, optionally wherein the channel or each channel is a capillary channel.

[0587] Clause H10. A component according to Clause H9, wherein the component includes at least one structure, wherein at least one path or each of at least one path and at least one structure at least partially define the channel.

[0588] Clause H11. The component according to Clause H10, wherein the aerosol generating component is disposed on a portion of at least one of the structures, such that at least one structure is arranged between the aerosol generating component and the electrically insulating substrate, wherein at least one hole extends through the aerosol generating component and the portion of the structure in which the aerosol generating component is disposed.

[0589] Clause H12. The component according to Clause H10, wherein the aerosol generating component is disposed on a portion of an electrically insulating substrate, such that the electrically insulating substrate is arranged between the aerosol generating component and at least one structure, wherein at least one hole extends through the portion of the aerosol generating component and the electrically insulating substrate on which the aerosol generating component is disposed.

[0590] Clause H13. The component according to Clause H10, wherein the aerosol generating component is disposed on a portion of an electrically insulating substrate, wherein a path or each path is arranged between the electrically insulating substrate and at least one structure, and wherein the aerosol generating component and the path or each path are arranged adjacent to each other, optionally in substantially the same plane.

[0591] Clause H14. Components according to any one of Clauses H1 to H13, wherein the aerosol generating component includes a carbon allotrope.

[0592] Clause H15. Components according to Clause H14, wherein the carbon allotrope is graphite.

[0593] Clause H16. Components according to Clause H14, wherein the carbon allotrope is one or more graphene layers, optionally in the form of three-dimensional graphene.

[0594] Clause H17. A component according to any one of Clauses H1 to H16, wherein the component includes a plurality of paths leading to the aerosol generating component, wherein each of the plurality of paths is configured to transfer an aerosolizable material toward the aerosol generating component by means of electrowetting.

[0595] Clause H18. Components according to Clause H17, wherein each of the plurality of paths includes an upstream portion and a downstream portion, wherein a portion of each of the plurality of paths is selectively connectable to a power source.

[0596] Clause H19. Components of Clause H18, wherein at least two of a plurality of paths have a common upstream portion.

[0597] Clause H20. Components according to Clause H19, wherein the component includes a reservoir, wherein the reservoir is formed at least in part by a common upstream portion.

[0598] Clause H21. Components pursuant to Clause H18, wherein at least two of a plurality of paths have separate upstream portions.

[0599] Clause H22. A component of any of Clauses H17 through H21, wherein at least two of the plurality of paths are independently controllable.

[0600] Clause H23. A non-flammable aerosol supply system comprising: components according to any one of Clauses H1 to H22; and a power source and / or controller, wherein the power source is used to supply electrical power to the aerosol generating components.

[0601] Clause H24. A non-flammable aerosol supply system pursuant to Clause H23, wherein a controller is configured to regulate the amount of power supplied to the aerosol generating component.

[0602] Clause H25. A non-flammable aerosol supply system pursuant to Clause H24, wherein the controller is configured to associate or synchronize the amount of power supplied to the aerosol generating component with the rate at which aerosolizable material is delivered to the aerosol generating component via at least one path or each of at least one path.

[0603] Clause H26. A method for controlling a non-flammable aerosol supply system, the method comprising the steps of: (a) transferring an aerosolizable material toward an aerosol generating component along at least one path using electrowetting.

[0604] Clause H27. The method according to Clause H26 includes the following steps prior to step (a): (a0) receiving a signal from a user of the non-flammable aerosol supply system indicating a demand for aerosols.

[0605] Clause H28. The method according to Clause H26 or H27 includes the following step after step (a): (b) generating an aerosol from an aerosolizable material using an aerosol generating component.

[0606] Clause H29. The method according to any one of Clauses H26 to H28, wherein power is supplied to the aerosol generating component by pulse width modulation.

[0607] Clause H30. The method according to Clause H29, wherein the transfer of aerosolizable material to contact the aerosol generating component is synchronized with or associated with a pulse-width modulated energizing cycle.

[0608] Clause H31. The method according to Clause H30, wherein during the pulse-width modulated energizing cycle, the aerosolizable material is transferred to contact the aerosol generating component, and during the pulse-width modulated de-energizing cycle, the aerosolizable material is not transferred to contact the aerosol generating component.

[0609] Clause H32. The method according to any one of Clauses H29 to H31, wherein said power is supplied until no signal indicating a user's aerosol demand from the non-flammable aerosol supply system is received.

[0610] Any aspect of this disclosure may be defined relative to any other aspect of this disclosure. For example, one aspect of this disclosure may include any feature of any other aspect of this disclosure and / or a feature of one aspect of this disclosure may be as defined with respect to the features of any other aspect of this disclosure.

[0611] The accompanying drawings are schematic and not to scale. The various embodiments described herein are presented only to aid in understanding and teaching the claimed features. These embodiments are provided only as representative examples of embodiments and are not exhaustive and / or exclusive. It should be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered as limitations on the scope of the invention as defined by the claims or on the equivalents of the claims, and other embodiments may be used and modifications may be made without departing from the scope of the claimed invention. In addition to those specifically described herein, various embodiments of the invention may suitably include, constitute, or substantially constitute suitable combinations of, the disclosed elements, components, features, parts, steps, devices, etc. Furthermore, this disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. An aerosol generating component for use as part of a non-flammable aerosol supply system, the aerosol generating component comprising a carbon allotrope supported on an electrically insulating substrate, wherein, At least one hole extends through the electrically insulating substrate.

2. The aerosol generating component according to claim 1, wherein, The carbon allotrope includes one or more graphene layers, optionally in the form of three-dimensional graphene.

3. The aerosol generating component according to claim 1 or 2, wherein, The electrically insulating substrate is thermally insulating.

4. The aerosol generating component according to any one of claims 1 to 3, wherein, The electrically insulating substrate has a strength of no more than 0.5 Wm. -1 k -1 Thermal conductivity.

5. The aerosol generating component according to any one of claims 1 to 4, wherein, The electrically insulating substrate is non-porous.

6. The aerosol generating component according to any one of claims 1 to 5, wherein, The carbon allotrope has a length of no more than 5 mm and a width of no more than 5 mm.

7. The aerosol generating component according to any one of claims 1 to 6, wherein, The carbon allotrope has a length of at least 0.5 mm and a width of at least 0.5 mm.

8. The aerosol generating component according to any one of claims 1 to 7, wherein, The at least one hole, or each of the at least one hole, has a diameter of not more than 500 μm.

9. The aerosol generating component according to any one of claims 1 to 8, wherein, The at least one hole, or each of the at least one hole, has a diameter of at least 50 μm.

10. The aerosol generating component according to any one of claims 1 to 9, wherein, The electrically insulating substrate includes a first surface and a second surface, wherein the first surface and the second surface are opposite to each other, and wherein the carbon allotrope is loaded on the first surface.

11. The aerosol generating component according to claim 10, wherein, The at least one hole extends from the first surface to the second surface.

12. The aerosol generating component according to any one of claims 1 to 11, wherein, Along the surface of the electrically insulating substrate, the distance between the edge defined by the periphery of one of the at least one holes and the edge defined by the periphery of any other hole in the at least one holes is no greater than 1 mm.

13. The aerosol generating component according to claim 12, wherein, The surface along which the distance is measured is the surface of the electrically insulating substrate on which the carbon allotrope is loaded.

14. The aerosol generating component according to any one of claims 1 to 13, wherein, The carbon allotropes are formed in the form of multiple nanotubes.

15. The aerosol generating component according to any one of claims 1 to 14, wherein, The carbon allotropes are formed in the form of open-cell foam.

16. The aerosol generating component according to any one of claims 1 to 15, wherein, The carbon allotropes are formed in the form of multiple sheets.

17. The aerosol generating component according to any one of claims 1 to 16, wherein, The carbon allotrope has a total thickness ranging from 0.345 nm to 100 μm.

18. The aerosol generating component according to any one of claims 1 to 17, wherein, The carbon allotropes are formed through one of the following methods: printing, laser-induced graphene formation, and chemical vapor deposition.

19. The aerosol generating component according to any one of claims 1 to 18, wherein, The at least one hole or each of the at least one hole defines a closed shape.

20. The aerosol generating component according to any one of claims 1 to 19, wherein, The carbon allotrope partially covers one, more than one, or each of the at least one pore.

21. The aerosol generating component according to any one of claims 1 to 20, wherein, The carbon allotropes include disordered graphite and / or amorphous carbon.

22. The aerosol generating component according to any one of claims 1 to 21, wherein, The Raman spectrum of the carbon allotrope includes G and D bands, with the G band peak at approximately 1500 cm⁻¹. -1 Approximately 1650 cm -1 Within the Raman shift range, and the D-band peak is at approximately 1250 cm⁻¹. -1 Approximately 1400 cm -1 Within the Raman shift range, the intensity I of the D band peak is... D The intensity I of the G band peak G The ratio I D / I G It is about 0.8 to about 2, preferably about 1 to about 1.

8.

23. An assembly for use as part of a non-flammable aerosol supply system, the assembly comprising an aerosol generating component according to any one of claims 1 to 22, and a first channel extending into the at least one orifice.

24. The component of claim 23, wherein, The first channel is a capillary channel.

25. The component according to claim 23 or 24 when dependent on claim 12, wherein, The first channel is formed at least partially by the second surface.

26. The component of claim 25, wherein, The aerosol generating assembly includes a structure, wherein the second surface and the structure are spaced apart from each other to at least partially define the first channel.

27. A non-flammable aerosol supply system, comprising: The aerosol generating component according to any one of claims 1 to 22 or the aerosol generating assembly according to any one of claims 23 to 26; And one or more of the power supply and controller.

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