Aerosol-generating component

Abstract

A method of preparing an aerosol-generating component (100) for use as part of a non-combustion aerosol supply system is provided. The method comprises the steps of: forming a carbon allotrope (101) on an electrically insulating substrate (102); and forming one or more electrodes in contact with the carbon allotrope (101).

Description

Aerosol generating components Technical Field

[0001] This invention relates to an aerosol generating component, specifically an aerosol generating component for a non-combustible 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-combustible 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 an aerosol produced by the atomization of aerosolizable materials. This atomization can be induced mechanically, 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, such as by using pressure.

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

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

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

[0006] According to a first aspect of this disclosure, a method is provided for preparing an aerosol generating component for use as part of a non-combustible 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.

[0007] In some embodiments, the step of forming one or more electrodes in contact with a carbon allotrope includes a sintering step.

[0008] In some implementations, the electrodes, or each electrode, are selected from copper, silver, and gold.

[0009] In some implementations, carbon allotropes are formed by printing on an electrically insulating substrate.

[0010] In some implementations, carbon allotropes are formed on an electrically insulating substrate by chemical vapor deposition.

[0011] In some implementations, carbon allotropes are formed by laser-induced deposition on an electrically insulating substrate.

[0012] In some embodiments, the carbon allotropes are formed as: multiple nanotubes; or open-cell foams; or multiple sheets.

[0013] In some embodiments, the electrically insulating substrate has a porous structure formed by pillars and gap holes.

[0014] In some implementations, carbon allotropes are formed on the column.

[0015] In some embodiments, the average aperture of the gap hole is 0.5 µm to 40 µm.

[0016] In some embodiments, the carbon allotrope comprises one or more layers of graphene. Where there is more than one layer of graphene, at least two layers may be non-parallel to each other. Where there is more than one layer of graphene, at least two layers may be parallel to each other. For example, the carbon allotrope may be a bilayer of graphene.

[0017] In some implementations, the carbon allotrope is graphite.

[0018] In some embodiments, the carbon allotrope has one or more of the following: 100 Wm -1 k -1 Up to 5500 Wm -1 k -1 Thermal conductivity; 1 Sm -1 Up to 2.5×10 6 Sm -1 Its electrical conductivity; and its nonlinear elasticity.

[0019] In some embodiments, the method includes forming one or more grooves and / or one or more apertures in the electrically insulating substrate before depositing the carbon allotrope onto the electrically insulating substrate.

[0020] In some embodiments, the electrically insulating substrate is selected from the group consisting of plastics, glass, paper, and ceramics.

[0021] In some embodiments, the electrically insulating substrate is glass, and wherein the glass is borosilicate glass.

[0022] In some embodiments, the carbon allotropes comprise disordered graphite and / or amorphous carbon.

[0023] In some embodiments, the Raman spectrum of the carbon allotrope 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 I D The intensity of the G-band peak I G The ratio I D / I G It is about 0.8 to about 2, preferably about 1 to about 1.8.

[0024] According to a second aspect of this disclosure, an aerosol generating component is provided, which is obtained by the method of the first aspect of this disclosure.

[0025] According to a third aspect of this disclosure, an aerosol generating assembly is provided as part of a non-combustible aerosol supply system. The aerosol generating assembly includes: an aerosol generating component according to a second aspect of this disclosure; and an aerosol generating material transport component for supplying aerosol generating material to the aerosol generating component.

[0026] In some embodiments, the aerosol generating material transport component includes a reservoir, wherein the aerosol generating component traverses the reservoir.

[0027] In some embodiments, the aerosol generating material transport component includes at least one capillary channel having an outlet.

[0028] In some embodiments, the outlet is arranged adjacent to the aerosol generating component, such that the aerosolizable material leaving the outlet comes into direct contact with the aerosol generating component.

[0029] According to a fourth aspect of this disclosure, a non-combustible aerosol supply system is provided, comprising: an aerosol generating component according to a second aspect of this disclosure or an aerosol generating assembly according to a third aspect of this disclosure; and one or more of a power source and a controller.

[0030] According to another aspect of this disclosure, clause A1 is provided. An aerosol generating component for use as part of a non-combustible aerosol supply system, the aerosol generating component comprising a carbon allotrope supported on an electrically insulating substrate.

[0031] Clause A2. An aerosol generating component according to Clause A1, wherein the carbon allotrope comprises one or more layers of graphene, wherein, in the presence of more than one layer of graphene, at least two layers of graphene are not parallel to each other.

[0032] Clause A3. Aerosol generating components according to Clause A1 or A2, wherein the carbon allotrope comprises graphite.

[0033] 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 Wm -1 k -1 Up to 5500 Wm -1 k -1 Thermal conductivity; 1 Sm -1 Up to 2.5×10 6 Sm -1 Its electrical conductivity; and its nonlinear elasticity.

[0034] 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.

[0035] Clause A6. An aerosol generating component according to any one of Clauses A1 to A5, wherein the aerosol generating component includes a capillary structure.

[0036] Clause A7. The aerosol generating component according to Clause A6, wherein the electrically insulating substrate has a porous structure formed by pillars and gap holes.

[0037] Clause A8. Aerosol generating component according to Clause A7, wherein carbon allotropes are formed on one or more of a plurality of columns.

[0038] Clause A9. Aerosol generating component according to Clause A8, wherein the average pore diameter of the gap orifice is from 0.5 µm to 40 µm.

[0039] Clause A10. An aerosol generating component according to any one of Clauses A1 to A9, wherein carbon allotropes are formed into a plurality of nanotubes.

[0040] Clause A11. An aerosol generating component according to any one of Clauses A1 to A9, wherein the carbon allotrope is formed as an open-cell foam.

[0041] Clause A12. An aerosol generating component according to any one of Clauses A1 to A9, wherein the carbon allotropes are formed into a plurality of thin sheets.

[0042] Clause A13. An aerosol generating component according to any one of Clauses A1 to A12, wherein the thickness of the carbon allotrope is from 0.345 nm to 100 µm.

[0043] Clause A14. An aerosol generating component according to any one of Clauses A1 to A13, wherein the electrically insulating substrate is formed as a plate, strip, or rod.

[0044] 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 µm to 500 µm; and / or a width of 0.5 mm to 50 mm; and / or a length of 1 mm to 50 mm.

[0045] Clause A16. An aerosol generating component according to any one of Clauses A1 to A15, wherein the carbon allotrope is supported on the substrate over at least 50% of the surface area of ​​the electrically insulating substrate.

[0046] 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 the carbon allotrope.

[0047] Clause A18. Aerosol generating component according to Clause A17, wherein each of one or more electrodes is formed of copper, silver or gold.

[0048] Clause A19. An aerosol generating assembly used as part of a non-combustible aerosol supply system, the aerosol generating assembly comprising: an aerosol generating component according to any one of Clauses A1 to A18; and an aerosol generating material transport component for supplying aerosol generating material to the aerosol generating component.

[0049] Clause A20. An aerosol generating assembly pursuant to Clause A19, wherein the aerosol generating material transport component includes a reservoir, wherein the aerosol generating component traverses the reservoir.

[0050] Clause A21. An aerosol generating assembly according to Clause A19, wherein the aerosol generating material transport component includes at least one capillary channel having an outlet.

[0051] 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.

[0052] Clause A23. A non-combustible 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.

[0053] 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.

[0054] Clause A25. The method according to Clause A24, wherein a carbon allotrope is formed by one of printing, laser-induced graphene formation, and chemical vapor deposition.

[0055] According to another aspect of this disclosure, Clause B1 is provided. An aerosol generating component for use as part of a non-combustible aerosol supply system, the aerosol generating component comprising a carbon allotrope supported 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 not greater than 20 degrees at a temperature of 150°C.

[0056] Clause B2. The aerosol generating component according to Clause B1, wherein the contact angle between the glycerol droplets and the surface of the carbon allotrope is 70 to 130 degrees at a temperature of 20°C.

[0057] Clause B3. Aerosol generating components according to Clause B1 or B2, wherein the carbon allotrope contains one or more dopants.

[0058] Clause B4. Aerosol generating components pursuant to Clause B3, wherein one or more dopants comprise an n-type dopant.

[0059] Clause B5. Aerosol generating component pursuant to Clause B4, wherein the n-type dopant is selected from the group consisting of phosphorus and nitrogen.

[0060] Clause B6. Aerosol generating components according to Clauses B3 to B5, wherein one or more dopants comprise p-type dopants.

[0061] Clause B7. Aerosol generating components pursuant to Clause B6, wherein the p-type dopant is selected from the group consisting of boron and sulfur.

[0062] Clause B8. An aerosol generating component according to any one of Clauses B1 to B7, wherein the carbon allotrope comprises one or more layers of graphene, wherein, in the presence of more than one layer of graphene, at least two layers of graphene are not parallel to each other.

[0063] Clause B9. An aerosol generating component according to any one of Clauses B1 to B7, wherein the carbon allotrope is graphite.

[0064] 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 Wm -1 k -1 Up to 5500 Wm -1 k -1 Thermal conductivity; 1 Sm -1 Up to 2.5×106 Sm -1 Its electrical conductivity; and its nonlinear elasticity.

[0065] 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 µm to 500 µm; and / or a width of 0.5 mm to 50 mm; and / or a length of 1 mm to 50 mm.

[0066] 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.

[0067] 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.

[0068] Clause B14. Aerosol generating component according to Clause B13, wherein carbon allotropes are formed on the column.

[0069] Clause B15. Aerosol generating components according to Clause B13 or B14, wherein the average pore size of the gap holes is from 0.5 µm to 40 µm.

[0070] Clause B16. An aerosol generating component according to any one of Clauses B1 to B14, wherein carbon allotropes are formed into a plurality of nanotubes.

[0071] Clause B17. An aerosol generating component according to any one of Clauses B1 to B14, wherein the carbon allotrope is formed as an open-cell foam.

[0072] Clause B18. An aerosol generating component according to any one of Clauses B1 to B14, wherein the carbon allotrope is formed from a plurality of thin sheets.

[0073] Clause B19. An aerosol generating component according to any one of Clauses B1 to B18, wherein the aerosol generating component includes a capillary structure.

[0074] Clause B20. An aerosol generating assembly used as part of a non-combustible 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 transport component for supplying aerosol generating material to the aerosol generating component.

[0075] Clause B21. Aerosol generating assembly pursuant to Clause B20, wherein the aerosol generating material transport component includes a storage unit.

[0076] Clause B22. Aerosol generating assembly pursuant to Clause B20 or B21, wherein the aerosol generating component traverses the storage container.

[0077] Clause B23. An aerosol generating assembly according to Clause B20, wherein the aerosol generating material transport component includes at least one capillary channel having an outlet.

[0078] Clause B24. An aerosol generating assembly pursuant to Clause B18, wherein an outlet is arranged adjacent to an aerosol generating component such that aerosolizable material exiting the outlet comes into direct contact with the aerosol generating component.

[0079] Clause B25. A non-combustible 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.

[0080] According to another aspect of this disclosure, clause C1 is provided. An aerosol generating component used as part of a non-combustible aerosol supply system, the aerosol generating component comprising a carbon allotrope supported on an electrically insulating substrate, wherein the substrate is elongated and has an aspect ratio of 5:1 to 50:1.

[0081] Clause C2. For aerosol generating components pursuant to Clause C1, the length of the electrically insulating substrate is 10 mm to 30 mm.

[0082] Clause C3. Aerosol generating components according to Clause C1 or C2, wherein the width of the electrically insulating substrate is 0.5 mm to 10 mm.

[0083] Clause C4. An aerosol generating component according to any one of Clauses C1 to C3, wherein carbon allotropes are formed as a plurality of nanotubes.

[0084] Clause C5. An aerosol generating component according to any one of Clauses C1 to C3, wherein the carbon allotrope is formed as an open-cell foam.

[0085] Clause C6. An aerosol generating component according to any one of Clauses C1 to C3, wherein the carbon allotropes are formed into a plurality of thin sheets.

[0086] 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.

[0087] 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 pores.

[0088] Clause C9. Aerosol generating component pursuant to Clause C8, wherein carbon allotropes are formed on the column.

[0089] Clause C10. Aerosol generating components according to Clause C8 or C9, wherein the average pore diameter of the gap holes is from 0.5 µm to 40 µm.

[0090] Clause C11. An aerosol generating component according to any one of Clauses C1 to C10, wherein the carbon allotrope comprises one or more layers of graphene, wherein, in the presence of more than one layer of graphene, at least two layers of graphene are not parallel to each other.

[0091] Clause C12. An aerosol generating component according to any one of Clauses C1 to C10, wherein the carbon allotrope is graphite.

[0092] 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: 100 Wm -1 k -1 Up to 5500 Wm -1 k -1 Thermal conductivity; 1 Sm -1 Up to 2.5×10 6 Sm -1 Its electrical conductivity; and its nonlinear elasticity.

[0093] Clause C14. An aerosol generating assembly used as part of a non-combustible 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 transport component for supplying aerosol generating material to the aerosol generating component.

[0094] Clause C15. Aerosol generating assembly pursuant to Clause C14, wherein the aerosol generating material transport component includes a storage unit.

[0095] Clause C16. Aerosol generating assembly pursuant to Clause C14 or C15, wherein an aerosol generating material transport component traverses the storage unit.

[0096] Clause C17. An aerosol generating assembly according to Clause C14, wherein the aerosol generating material transport component includes at least one capillary channel having an outlet.

[0097] Clause C18. An aerosol generating assembly according to Clause C17, wherein an outlet is arranged adjacent to an aerosol generating component such that aerosolizable material leaving the outlet comes into direct contact with the aerosol generating component.

[0098] Clause C19. A non-combustible 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 14 to 18; and one or more of a power source and a controller.

[0099] Clause C20. A non-combustible aerosol supply system pursuant to Clause C19, wherein a controller is arranged to communicate electrically with an aerosol generating component, and wherein the controller is configured to control the power supply from a power source to the aerosol generating component.

[0100] Clause C21. A non-combustible aerosol supply system pursuant to Clause C20, wherein the controller is configured to actively supply aerosolizable material to the aerosol generating component.

[0101] Clause C22. A non-combustible 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.

[0102] Clause C23. A non-combustible aerosol supply system according to any one 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.

[0103] According to another aspect of this disclosure, clause D1 is provided. An aerosol generating component for use as part of a non-combustible aerosol supply system, the aerosol generating component comprising a carbon allotrope supported on an electrically insulating substrate, wherein at least one elongated orifice extends through the aerosol generating component.

[0104] Clause D2. Aerosol generating component according to Clause D1, wherein the elongated orifice or each elongated orifice is linear.

[0105] Clause D3. Aerosol generating components according to Clause D1, wherein the elongated orifice or each elongated orifice is non-linear.

[0106] 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.

[0107] Clause D5. Aerosol generating component according to Clause D4, wherein elongated orifices are arranged parallel to each other.

[0108] Clause D6. An aerosol generating component according to any one of Clauses D1 to D5, wherein the electrically insulating substrate is formed as a strip or rod.

[0109] Clause D7. An aerosol generating component according to Clause D6, wherein at least one elongated orifice extends substantially parallel to the longitudinal extent of an electrically insulating substrate, preferably wherein the electrically insulating substrate has: a thickness of 100 µm to 4 mm; and / or a width of 0.5 mm to 50 mm; and / or a length of 1 mm to 50 mm.

[0110] Clause D8. An aerosol generating component according to any one of Clauses D1 to D7, wherein the carbon allotrope comprises one or more layers of graphene, wherein, in the presence of more than one layer of graphene, at least two layers of graphene are not parallel to each other.

[0111] Clause D9. An aerosol generating component according to any one of Clauses D1 to D7, wherein the carbon allotrope is graphite.

[0112] 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: 100 Wm -1 k -1 Up to 5500 Wm -1 k -1 Thermal conductivity; 1 Sm -1 Up to 2.5×10 6 Sm -1 Its electrical conductivity; and its nonlinear elasticity.

[0113] 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.

[0114] Clause D12. An aerosol generating component according to any one of Clauses D1 to D11, wherein the aerosol generating component includes a capillary structure.

[0115] Clause D13. An aerosol generating component according to Clause D12, wherein the electrically insulating substrate has a porous structure formed by pillars and gap holes.

[0116] Clause D14. Aerosol generating component according to Clause D13, wherein carbon allotropes are formed on the column.

[0117] Clause D15. Aerosol generating components according to Clause D13 or D14, wherein the average pore diameter of the gap holes is from 0.5 µm to 40 µm.

[0118] Clause D16. An aerosol generating component according to any one of Clauses D1 to D15, wherein carbon allotropes are formed into a plurality of nanotubes.

[0119] Clause D17. An aerosol generating component according to any one of Clauses D1 to D15, wherein the carbon allotrope is formed as an open-cell foam.

[0120] Clause D18. An aerosol generating component according to any one of Clauses D1 to D15, wherein the carbon allotropes are formed into a plurality of thin sheets.

[0121] Clause D19. An aerosol generating component according to any one of Clauses D1 to D18, wherein the width of the elongated orifice or each elongated orifice is 0.1 mm to 1 mm, and / or the length of the elongated orifice or each elongated orifice is 5% to 95% of the length of the aerosol generating component.

[0122] Clause D20. An aerosol generating assembly used as part of a non-combustible 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 transport component for supplying aerosol generating material to the aerosol generating component.

[0123] Clause D21. Aerosol generating assembly pursuant to Clause D20, wherein the aerosol generating material transport component includes a storage unit.

[0124] Clause D22. Aerosol generating assembly pursuant to Clause D21, wherein the aerosol generating component traverses the storage unit.

[0125] Clause D23. An aerosol generating assembly according to Clause D20, wherein the aerosol generating material transport component includes at least one capillary channel having an outlet.

[0126] 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.

[0127] Clause D25. A non-combustible 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.

[0128] According to another aspect of this disclosure, clause F1 is provided. An aerosol generating component used as part of a non-combustible aerosol supply system, the aerosol generating component comprising a carbon allotrope supported on an electrically insulating substrate, wherein the aerosol generating component includes a heating portion and at least one aerosolizable material supply portion extending from the heating portion.

[0129] Clause F2. The aerosol generating component according to Clause F1, wherein an aerosolizable material supply portion or each aerosolizable material supply portion extends from the side of the heating portion.

[0130] Clause F3. Aerosol generating components according to Clause F1 or F2, wherein the heating portion is elongated.

[0131] Clause F4. An aerosol generating component according to any one of Clauses F1 to F3, wherein the aerosolizable material supply portion or each aerosolizable material supply portion is elongated.

[0132] Clause F5. An aerosol generating component according to any one of Clauses F1 to F4, wherein the aspect ratio of the aerosolizable material supply portion or each aerosolizable material supply portion is 1:1 to 5:1.

[0133] Clause F6. An aerosol generating component according to any one of Clauses F1 to F5, wherein the length of the aerosolizable material supply portion or each aerosolizable material supply portion is 1 mm to 15 mm.

[0134] Clause F7. An aerosol generating component according to any one of Clauses F1 to F6, wherein the width of the aerosolizable material supply portion or each aerosolizable material supply portion is 1 mm to 3 mm.

[0135] Clause F8. An aerosol generating component according to any one of Clauses F1 to F7, wherein the aerosolizable material supply portion or each aerosolizable material supply portion tapers away from the elongated heating portion.

[0136] Clause F9. An aerosol generating component according to any one of Clauses F1 to F8, wherein the thickness of the electrically insulating substrate is from 5 µm to 500 µm.

[0137] Clause F10. An aerosol generating component according to any one of Clauses F1 to F9, wherein the width of the heated portion is 0.5 mm to 50 mm.

[0138] Clause F11. An aerosol generating component according to any one of Clauses F1 to F10, wherein the length of the heating portion is 1 mm to 50 mm.

[0139] Clause F12. An aerosol generating component according to any one of Clauses F1 to F11, wherein the carbon allotropes are formed as: a plurality of nanotubes; or open-cell foam; or a plurality of sheets.

[0140] Clause F13. An aerosol generating component according to any one of Clauses F1 to F12, wherein the carbon allotrope comprises one or more layers of graphene, wherein, in the presence of more than one layer of graphene, at least two layers of graphene are not parallel to each other.

[0141] Clause F14. An aerosol generating component according to any one of Clauses F1 to F12, wherein the carbon allotrope is graphite.

[0142] 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: 100 Wm -1 k -1 Up to 5500 Wm -1 k -1 Thermal conductivity; 1 Sm -1 Up to 2.5×10 6 Sm -1 Its electrical conductivity; and its nonlinear elasticity.

[0143] 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.

[0144] Clause F17. Aerosol generating component according to Clause F16, wherein carbon allotropes are formed on the column.

[0145] Clause F18. Aerosol generating components according to Clause F16 or F17, wherein the average pore size of the gap holes is from 0.5 µm to 40 µm.

[0146] Clause F19. An aerosol generating assembly used as part of a non-combustible 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 transport component for supplying aerosol generating material to the aerosol generating component.

[0147] Clause F20. Aerosol generating assembly pursuant to Clause F19, wherein the aerosol generating material transport component includes a storage unit.

[0148] Clause F21. Aerosol generating assembly pursuant to Clause F20, wherein the aerosol generating component traverses the storage unit.

[0149] Clause F22. An aerosol generating assembly according to Clause F19, wherein the aerosol generating material transport component includes at least one capillary channel having an outlet.

[0150] Clause F23. An aerosol generating assembly according to Clause F22, wherein an outlet is arranged adjacent to an aerosol generating component such that aerosolizable material leaving the outlet comes into direct contact with the aerosol generating component.

[0151] Clause F24. A non-combustible aerosol supply system comprising: an aerosol generating component of any of Clauses F1 to F18 or an aerosol generating assembly according to any of Clauses F19 to F23; and one or more of a power source and a controller. Attached Figure Description

[0152] 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 drawn to scale) of a non-combustible aerosol supply system according to the present disclosure; FIG2 is a schematic side view of an aerosol generating component according to the present disclosure; FIG3 is a schematic 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 one or more layers of graphene formed as an open-cell foam; FIG4B is a schematic diagram of an aerosol generating component according to the present disclosure, wherein the carbon allotrope is one or more layers of graphene formed as multiple sheets; FIG4C is a schematic diagram of an aerosol generating component according to the present disclosure, wherein the carbon allotrope is one or more layers of graphene formed as 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 (not shown). Figure 6A shows a perspective view of the 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 the 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 powered; Figure 8A is a schematic diagram of the aerosol generating component according to the present disclosure, wherein the aerosol generating component includes a heating portion and one or more aerosolizable material supply portions extending from the heating portion; Figure 8B is a thermal diagram of the aerosol generating component of Figure 8A, wherein the aerosol generating component is powered; Figure 9 shows a plan view of the 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; and Figure 11 shows the Raman spectrum of a carbon allotrope sample, wherein the x-axis corresponds to the Raman shift (cm). -1 And the y-axis corresponds to the intensity (count), and the Raman spectrum has D-band peaks, G-band peaks and 2D-band peaks. Detailed Implementation

[0153] This document discusses / describes aspects and features of certain examples and implementations. Some aspects and features of certain examples 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 aspects and features of the aerosol generating components, aerosol generating assemblies, systems, and methods discussed herein that are not described in detail can be implemented using any conventional techniques for implementing these aspects and features.

[0154] As described above, this disclosure relates to, but is not limited to, non-combustible aerosol supply systems, articles, aerosol generating components, and aerosol generating parts that generate aerosols from aerosol generating materials using non-combustible aerosol generating materials (also referred to herein as "aerosolizable materials"). Examples of such systems include electronic cigarettes and blending systems that use combinations of aerosol generating materials to generate aerosols. In some instances, the non-combustible aerosol supply system is an electronic cigarette, also known as a vaporizer or electronic nicotine delivery system (END), but it should be noted that nicotine is not necessarily present in the aerosol generating materials in this disclosure. In some instances, the non-combustible aerosol supply system is a blending system that uses a combination of aerosol generating materials to generate aerosols, wherein one or more aerosol generating materials in the combination can be heated. Each aerosol generating material in such a blending system may or may not contain nicotine. In some instances, the blending 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.

[0155] In the context of the following description, the terms "electronic cigarette" and "electronic e-cigarette" may sometimes be used. However, it should be understood that these terms may be used interchangeably with non-combustible aerosol (vapor) supply systems as explained above.

[0156] In some instances, this disclosure relates to consumables for holding aerosol-generating materials, and these consumables are configured for use with non-combustible aerosol supply devices. In the context of this disclosure, these consumables may be referred to as “articles of manufacture”.

[0157] Non-combustible aerosol supply systems typically consist of an apparatus section (also referred to herein as the "apparatus") and a consumables / products section (also referred to herein as the "products"). The apparatus section typically includes a power source and / or a controller. The power source can typically be a power source, such as a rechargeable battery.

[0158] In some instances, a non-combustible aerosol supply system may include an area for receiving or engaging consumables / articles (the device may include or may contain this area), an aerosol generator (the consumables / articles may or may not include the aerosol generator or the aerosol generator may or may not be located within the consumables / articles), an aerosol generation area (the consumables / articles may or may not include the aerosol generation area or the aerosol generation area may or may not be located within the consumables / articles), a housing, nozzles, filters, and / or aerosol modifiers.

[0159] In some instances, consumables / articles used with non-combustible aerosol supply systems may include aerosol generating materials, aerosol generating material storage areas (also referred to herein as “storage for aerosolizable materials”), aerosol generating material transport components (e.g., cores, such as pads), aerosol generators (also referred to herein as “aerosol generating components”), aerosol generating areas (also referred to herein as “aerosol generating chambers”), housings, packaging paper, filters, nozzles, and / or aerosol modifiers.

[0160] The systems described herein typically generate inhalable aerosols through the vaporization of aerosol-generating materials. Aerosol-generating materials may comprise one or more active ingredients, one or more flavoring agents, one or more aerosol-forming agents, and / or one or more other functional materials.

[0161] Aerosol-generating materials may be in the form of liquids or gels, and may or may not contain active substances and / or flavorings.

[0162] As used herein, the term "active substance" can refer to physiologically active materials, 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 can include, for example, nicotine, caffeine, taurine, caffeine, vitamins (such as B6 or B12 or C), melatonin, or components, derivatives, or combinations thereof. Active substances can also include one or more components, derivatives, or extracts from tobacco or other plants.

[0163] Aerosol forming agent materials may include one or more components capable of forming aerosols. In some examples, aerosol forming agent materials 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 octanoate, triethyl citrate, triacetin, a mixture of diacetins, benzyl benzoate, benzyl phenyl acetate, glyceryl tribocate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0164] One or more other functional materials may include one or more of the following: pH adjusters, colorants, preservatives, adhesives, fillers, stabilizers and / or antioxidants.

[0165] As used herein, the term "component" refers to a part, segment, unit, module, assembly, or the like of an electronic cigarette or similar device that may integrate several smaller parts or components within an outer housing or wall. An electronic cigarette may be formed or constructed from one or more such components, and these components 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 components detachably connected to each other and configured, for example, a consumable / product component capable of holding aerosol-generating material (also referred to herein as a "cartridge" or "vaporizer cartridge"), and a device / control unit having a battery for providing power to operate elements for generating vapor from the aerosol-generating material.

[0166] Figure 1 is a highly schematic view (not drawn to scale) of an exemplary non-combustible 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 the dashed line) and includes two main components, namely, a control or power component or section 20 (which may be referred to herein as a device) and a cartridge assembly or section 30 (which may be referred to herein as an “article,” “consumable,” “vaporizing cartridge,” or “cartridge”) that operates as a vapor generating component.

[0167] Article 30 includes a storage compartment (also referred to herein as a “reservoir”) 3 containing an aerosolizable material comprising, 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 contain about 1% to 3% nicotine and 50% glycerin, wherein the remainder comprises substantially propylene glycol, and may also contain other components such as water or flavorings. The storage compartment 3 is in the form of a storage vessel, i.e., a container or receiver, in which the aerosolizable material can be stored, allowing the aerosolizable material to move and flow freely (if it is a liquid) within the boundaries of the container or receiver. Alternatively, the storage compartment 3 may contain a large amount of absorbent material (such as cotton wool or glass fiber) that retains the aerosolizable material within a porous structure. Storage compartment 3 can be sealed during manufacturing after filling so that it can be processed after the aerosolizable material is consumed, or it can have an inlet port or other opening through which new aerosolizable material can be added. Article 30 also includes an electrosol generating component 4 located outside storage compartment 3 for generating an aerosol through the vaporization of the aerosolizable material. In many instances, the aerosol generating component is a heating element (heater) heated by the passage of an electric current (via resistance or induction heating) to raise the temperature of the aerosolizable material until it evaporates. An aerosol generating material transport component (not shown in FIG. 1), such as a liquid conduit arrangement (such as a wick or other porous element), can be provided to transport the aerosolizable material from storage compartment 3 to aerosol generating component 4. The aerosol generating material transport component can have one or more sections located inside storage compartment 3 to absorb the aerosolizable material and transport it by wicking or capillary action to other sections of the aerosol generating material transport component that are in contact with aerosol generating component 4. The aerosolizable material is thus vaporized and replaced by a new aerosolizable material that is transported to the aerosol generating unit 4 by the aerosol generating material transport component.

[0168] The combination of heater and coil, or other arrangements of parts performing the same function, are sometimes referred to as an atomizer or atomizer assembly (here referred to as "aerosol generating assembly"). Various designs with different arrangements of parts are possible compared to the highly schematic representation in Figure 1. For example, the coil can be an element completely independent of the aerosol generating component.

[0169] In some cases, the aerosol generating material transport component 4 (e.g., a liquid conduit) for conveying the liquid used to generate vapor can be at least partially formed by one or more grooves, tubes, or channels between the storage compartment and the aerosol generating component, the grooves, tubes, or channels being narrow enough to support capillary action to draw the source liquid from the storage compartment and transport it for vaporization. Generally, an atomizer can be considered as an aerosol generating component 4 capable of generating vapor from an aerosolizable material supplied to the atomizer, and an aerosol generating material transport component (e.g., a liquid conduit) capable of conveying or transferring liquid from the storage compartment 3 or a similar liquid reservoir to the aerosol generating component via capillary force.

[0170] 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 forced into this chamber, and as air flows through the chamber, above and around the aerosol generating component, the air collects the generated vapor, thereby condensing the vapor to form the desired aerosol.

[0171] 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.

[0172] The power unit 20 includes a battery cell 5 (also referred to herein as a battery, and which may be rechargeable) to provide power to the electrical components of the electronic cigarette 10 (specifically, 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 desired, the control electronics / circuit connect the aerosol generating unit 4 to the battery 5, for example, by signaling in response to a pressure sensor or airflow sensor (not shown) detecting 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 evaporates an aerosolizable material delivered from the storage compartment 3 to generate an aerosol, which is then inhaled by the user through an opening in the mouthpiece 35. As the user inhales onto 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 as extending between the air inlet (which may or may not be located in the power unit 20) and the atomizer, and between the atomizer 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, so the atomizer can be described as being arranged downstream of the air inlet and upstream of the air outlet.

[0173] In this particular example, the power component 20 and the cartridge assembly 30 are separate parts that can be detached from each other by separating them in a direction parallel to the longitudinal axis, as indicated by the solid arrow in FIG1. ​​When the device 10 is in use, components 20, 30 are engaged together by engaging elements 21, 31 (e.g., threaded engagement, magnetic engagement, or bayonet engagement), which provide mechanical and electrical connectivity between the power segment 20 and the cartridge assembly 30. However, this is only an exemplary arrangement, and various components may be distributed between the power segment 20 and the cartridge assembly 30 in different ways, and may include other components and elements. The two segments 20, 30 may be connected end-to-end in the longitudinal configuration as shown in FIG1, or connected together in different configurations (such as parallel, side-by-side arrangements). The non-combustible aerosol supply system 10 may or may not be generally cylindrical, and / or may have a generally longitudinal shape. Any one or both sections may be intended to be handled and replaced when depleted (e.g., when the reservoir is empty or the battery is depleted), or intended for a variety of uses achieved 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 housed within a single body or housing. Examples of the invention apply to any of these configurations, as well as other configurations that a person skilled in the art will recognize.

[0174] As described above, a type of aerosol generating component (such as a heating element) that can be used in the atomizing section (the section configured to generate vapor from a source liquid) of an electronic cigarette 10 combines heating and liquid delivery functions by having both conductivity (resistance) and a porous structure. It should be noted here that the conductivity (resistance) mentioned refers to a component having the ability to generate heat in response to the flow of an electric current therein. This flow can be imparted by so-called resistance heating or induction heating. The aerosol generating component can take the form of a sheet, i.e., a planar shape whose thickness is many times smaller than its length or width. The planar aerosol generating component can define a curved sheet shape, and in these cases, the reference to "the planar aerosol generating component forming a plane" refers to an imaginary plane passing through the best-fitting plane formed by the component.

[0175] The aerosol generating component may include appropriately sized pores and / or gaps to provide capillary forces for wicking aerosolizable materials (e.g., liquids). Therefore, the aerosol generating component 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.

[0176] Aerosol generating components (e.g., planar and / or sheet-like) can be arranged within a non-combustible aerosol supply system (e.g., an electronic cigarette) such that the aerosol generating components are located within an aerosol generating chamber forming part of an airflow channel. The aerosol generating components can 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 components). Examples of this configuration can be found in WO2010 / 045670 and WO2010 / 045671, the entire contents of which are incorporated herein by reference. Air can thus flow through the aerosol generating components and accumulate vapor. Aerosol generation thus becomes effective. In an alternative embodiment, the aerosol generating components can 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 components). Examples of this configuration can be found in WO2018 / 211252, the entire contents of which are incorporated herein by reference.

[0177] The aerosol generating component can have a high porosity. High porosity ensures that the heat generated by the aerosol generating component is primarily used for liquid evaporation and achieves high efficiency. A porosity greater than 50% is conceivable. In one embodiment, the porosity of the aerosol generating component is 50% or greater, 60% or greater, or 70% or greater.

[0178] The aerosol generating component can form a generally flat structure, comprising a first surface and a second surface. 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.

[0179] When the aerosol generating component is formed of a resistive material, current is allowed to flow through the aerosol generating component to generate heat (so-called Joule heating). The resistance of the aerosol generating component can be appropriately selected for this purpose. For example, the resistance of the aerosol generating component can be 2 ohms or less, such as 1.8 ohms or less, such as 1.7 ohms or less, such as 1.6 ohms or less, such as 1.5 ohms or less, such as 1.4 ohms or less, such as 1.3 ohms or less, such as 1.2 ohms or less, such as 1.1 ohms or less, such as 1.0 ohms or less, such as 0.9 ohms or less, such as 0.8 ohms or less, such as 0.7 ohms or less, such as 0.6 ohms or less, such as 0.5 ohms or less. Parameters of the aerosol generating component, such as material, thickness, width, length, porosity, etc., can be selected to provide the desired resistance. A relatively low resistance will help to extract higher power from the power source, which can be beneficial for achieving a high aerosolization rate. On the other hand, the resistance should not be so low as to compromise the integrity of the aerosol generator. For example, the resistance can be no less than 0.5 ohms.

[0180] In one aspect of this disclosure, an aerosol generating component 100 is provided as part of a non-combustible aerosol supply system, the aerosol generating component 100 including a carbon allotrope 101 supported on an electrically insulating substrate 102.

[0181] Figures 2 to 9 show examples of the aerosol generating component 100.

[0182] It has been found that the aerosol generating component 100 exhibits the desired heating and aerosolization performance in non-combustible aerosol supply systems.

[0183] An electrically insulating substrate 102 supports a carbon allotrope 101. In this way, the carbon allotrope 101 is directly or indirectly supported on the electrically insulating substrate 102.

[0184] The electrically insulating substrate 102 may be porous. Alternatively, the electrically insulating substrate 102 may be non-porous.

[0185] 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.

[0186] At least one of these layers can be formed as a coating.

[0187] 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 the other layer is non-porous.

[0188] 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 the other layer is porous.

[0189] 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 thermal conductivity of the electrically insulating substrate 102 can be no greater than 5 W / m². -1 k -1 The thermal conductivity of the electrically insulating substrate 102 can be no greater than 3 W / m. -1 k -1 The thermal conductivity of the electrically insulating substrate 102 can be no greater than 2 W / m. -1 k -1 The thermal conductivity of the electrically insulating substrate 102 can be no greater than 1 W / m. -1 k -1 The thermal conductivity of the electrically insulating substrate 102 can be no greater than 0.5 W / m. -1 k -1 The thermal conductivity of the electrically insulating substrate 102 can be no greater than 0.2 W / m. -1 k -1 The thermal conductivity of the electrically insulating substrate 102 can be no greater than 0.1 W / m. -1 k -1 .

[0190] For example, the electrically insulating substrate 102 can be selected from the group consisting of plastics, glass, paper, and ceramics. For example, if 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.

[0191] The plastic may be selected from polysulfone (PSU), polyethersulfone (PES), polyimide (PI), polyphenylene sulfide (PPS), polyetheretherketone (PEEK), and polyetherketone (PEK). In some embodiments, the polyimide (PI) is selected from polyetherimide (PEI) and polyamide-imide (PAI). In some embodiments, the polyimide is poly(4,4'-oxodiphenylene-pyromellitictetrimimide). Poly(4,4'-oxodiphenylene-pyromellitictetrimimide) is commercially available from DuPont under the trade name Kapton® HN (and other Kapton® products).

[0192] The glass can be selected from the group consisting of silicate glasses and non-silicate glasses. In some embodiments, the silicate glass is borosilicate glass or quartz glass (fused silica). The glass can be flexible. The glass can be non-porous.

[0193] 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 average pore size of the interstitial pores in the coated electrically insulating substrate may be from 0.5 µm to 40 µm (although this can vary). The average pore size may be a mean pore size or a median pore size. Methods for determining the average pore size may include (but are not limited to) mercury intrusion porosimetry or gas adsorption. These methods are familiar to those skilled in the art.

[0194] The electrically insulating substrate 102 can be formed as a sheet (which can be curved or substantially planar). The electrically insulating substrate 102 can be substantially planar. In some embodiments, the electrically insulating substrate 102 can be formed as 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 can be elongated.

[0195] 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).

[0196] In some embodiments, the thickness of the electrically insulating substrate 102 is from 100 µm to 4 mm. In some embodiments, the thickness of the electrically insulating substrate 102 is from 200 µm to 3 mm. In some embodiments, the thickness of the electrically insulating substrate 102 is from 400 µm to 2 mm.

[0197] In some embodiments, the thickness of the electrically insulating substrate 102 is from 5 µm to 500 µm. In some embodiments, the thickness of the electrically insulating substrate 102 is from 10 µm to 500 µm. In some embodiments, the thickness of the electrically insulating substrate 102 is from 50 µm to 500 µm. In some embodiments, the thickness of the electrically insulating substrate 102 is from 100 µm to 500 µm. In some embodiments, the thickness of the electrically insulating substrate 102 is from 50 µm to 300 µm. In some embodiments, the thickness of the electrically insulating substrate 102 is 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.

[0198] In some embodiments, the length of the electrically insulating substrate 102 is from 1 mm to 50 mm. In some embodiments, the length of the electrically insulating substrate 102 is from 2 mm to 40 mm. In some embodiments, the length of the electrically insulating substrate 102 is from 5 mm to 30 mm. In some embodiments, the length of the electrically insulating substrate 102 is from 10 mm to 30 mm. In some embodiments, the length of the electrically insulating substrate 102 is from 10 mm to 25 mm. In some embodiments, the length of the electrically insulating substrate 102 is from 10 mm to 20 mm. In some embodiments, the length of the electrically insulating substrate 102 is from 12 mm to 18 mm. For example, the length of the electrically insulating substrate 102 is indicated by "L" in FIG. 2. S "express.

[0199] In some embodiments, the width of the electrically insulating substrate 102 is 0.5 mm to 50 mm. In some embodiments, the width of the electrically insulating substrate 102 is 0.5 mm to 20 mm. In some embodiments, the width of the electrically insulating substrate 102 is 0.5 mm to 10 mm. In some embodiments, the width of the electrically insulating substrate 102 is 0.5 mm to 5 mm. In some embodiments, the width of the electrically insulating substrate 102 is 1 mm to 50 mm. In some embodiments, the width of the electrically insulating substrate 102 is 1 mm to 20 mm. In some embodiments, the width of the electrically insulating substrate 102 is 1 mm to 10 mm. In some embodiments, the width of the electrically insulating substrate 102 is 1 mm to 5 mm. In some embodiments, the width of the electrically insulating substrate 102 is 1 mm to 3 mm. For example, the width of the electrically insulating substrate 102 is indicated by "W" in FIG. 3. S "express.

[0200] In some embodiments, the length of the carbon allotrope 101 is from 1 mm to 50 mm. In some embodiments, the length of the carbon allotrope 101 is from 2 mm to 40 mm. In some embodiments, the length of the carbon allotrope 101 is from 5 mm to 30 mm. In some embodiments, the length of the carbon allotrope 101 is from 10 mm to 30 mm. In some embodiments, the length of the carbon allotrope 101 is from 10 mm to 25 mm. In some embodiments, the length of the carbon allotrope 101 is from 10 mm to 20 mm. In some embodiments, the length of the carbon allotrope 101 is from 12 mm to 18 mm.

[0201] In some embodiments, the width of the carbon allotrope 101 is 0.5 mm to 50 mm. In some embodiments, the width of the carbon allotrope 101 is 0.5 mm to 20 mm. In some embodiments, the width of the carbon allotrope 101 is 0.5 mm to 10 mm. In some embodiments, the width of the carbon allotrope 101 is 0.5 mm to 5 mm. In some embodiments, the width of the carbon allotrope 101 is 1 mm to 50 mm. In some embodiments, the width of the carbon allotrope 101 is 1 mm to 20 mm. In some embodiments, the width of the carbon allotrope 101 is 1 mm to 10 mm. In some embodiments, the width of the carbon allotrope 101 is 1 mm to 5 mm. In some embodiments, the width of the carbon allotrope 101 is 1 mm to 3 mm.

[0202] The aerosol generating component 100 may include a capillary structure. Providing a capillary structure facilitates the efficient delivery of aerosolizable materials through the body structure of the aerosol generating component 100 and / or through one or more layers of the surface of the carbon allotrope 101.

[0203] 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 a 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 grooves in the electrically insulating substrate 102 (if present).

[0204] 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.

[0205] The carbon allotrope 101 may be at least partially exposed. The carbon allotrope 101 may be a monolithic material.

[0206] 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.

[0207] 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 carbon allotrope's exposure to the bulk aerosolizable material during use (compared to embodiments with a porous substrate 102), thereby potentially improving the efficiency of the aerosol component 100.

[0208] The aerosol generating component 100 includes a carbon allotrope 101 supported on an electrically insulating substrate 102.

[0209] It has been discovered that carbon allotropes provide an efficient aerosol-generating component. Carbon allotropes provide a carbonaceous surface that allows aerosolizable materials to be distributed and aerosolized during use. When the carbon allotropes are heated to their aerosolization temperature, the carbonaceous surface possesses high surface free energy and therefore high wettability. Thus, when the carbon allotropes are heated to their aerosolization temperature, thin layers of aerosolizable material can be uniformly distributed on the carbonaceous surface of the carbon allotropes and effectively aerosolized. Furthermore, carbon allotropes have high power density, low thermal mass, and allow for the formation of thin, small-volume aerosolizable materials on a given surface area (as opposed to materials that cannot be thinly formed on their surface). This enables efficient energy transfer to the aerosolizable material during use.

[0210] Carbon allotropes can contain carbon atoms configured to have multiple carbon-carbon bonds lying in the same plane. For example, carbon allotropes can contain graphite. In the case where a carbon allotrope contains graphite, the allotropy comprises multiple stacked layers of carbon atoms, each carbon atom in the layer being bonded to three adjacent carbon atoms in that layer, wherein each bond lies in the same plane to form a hexagonal lattice structure. Non-covalent bonds exist between the stacked layers.

[0211] 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 sequence; and β-graphite, in which the layers are stacked in an ABC sequence.

[0212] Carbon allotropes can also include graphene. For example, a carbon allotrope can be graphene. In the case where the carbon allotrope is graphene, a single layer of carbon atoms (i.e., a carbon layer one atom thick) is arranged to form a hexagonal lattice structure.

[0213] It has been found that the use of graphene provides a particularly effective aerosol generating component. Advantageously, graphene's high thermal and electrical conductivity allow 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, and the risk of damage to the aerosol generating component from hot spots is reduced. 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 is able to resist degradation caused by the difference in the coefficients of thermal expansion between graphene and the electrically insulating substrate 102.

[0214] In the case of carbon allotropes containing graphene, there can be more than one layer of graphene.

[0215] When more than one layer of graphene 101 is supported on an electrically insulating substrate 102, at least two layers of graphene 101 may be non-parallel relative to each other. "Non-parallel" means that an imaginary plane passing through one layer of graphene 101 (or a best-fit imaginary plane passing through a non-planar layer of graphene 101) is not parallel to an imaginary plane passing through another layer of graphene 101 (or a best-fit imaginary plane passing through another non-planar layer of graphene 101). In use, the graphene layers 101 are electrically connected to each other to form current paths. By providing non-parallel graphene layers, a porous graphene structure can be provided. At typical aerosolization temperatures, the porosity and low surface energy of graphene combine to allow aerosolizable materials to be effectively distributed not only on the outermost surface of the graphene but also on the bulk structure of the graphene. In effect, the aerosolizable material can be positioned in close contact with the increased surface area of ​​the heating material provided by the graphene layers. This provides efficient and effective aerosolization performance.

[0216] For example, at least three, at least four, at least five, at least six, at least eight, or at least ten graphene layers 101 are not parallel to each other.

[0217] When more than one layer of graphene 101 is supported on an electrically insulating substrate 102, at least two layers of graphene 101 can be parallel to each other. For example, the carbon allotrope 101 can be a bilayer graphene.

[0218] For example, as shown in Figures 4A to 4C, some layers in graphene layer 101 can directly contact the electrically insulating substrate 101, while some layers in graphene layer 101 can be disposed on top of other graphene layers 101.

[0219] It should be understood that other carbon allotropes 101 can be conceived.

[0220] 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, and combinations thereof.

[0221] 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.

[0222] In some preferred embodiments, the Raman spectrum of carbon allotrope 101 includes approximately 1500 cm⁻¹. -1 Approximately 1650 cm -1 The G-band peak is located within the Raman shift range. In this embodiment, the Raman spectrum of carbon allotrope 101 can include a peak at 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.

[0223] 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 this embodiment, the Raman spectrum of carbon allotrope 101 can include a peak at 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 include a peak at approximately 2620 cm⁻¹. -1 Approximately 2680 cm -1 2D band peaks within the Raman shift range.

[0224] Intensity of D band peak I D The intensity of the G-band peak I G The ratio I D / I G It can be approximately 0.8 to approximately 2. Ratio I D / I G It can be from approximately 0.9 to approximately 1.9. Ratio I D / I G It can be approximately 1 to approximately 1.8.

[0225] The full width at half maximum (FWHM) of the G-band peak can be approximately 30 cm. -1 Approximately 100 cm -1The FWHM of the G-band peak can be approximately 30 cm⁻¹. -1 Approximately 70 cm -1 .

[0226] 2D bands can follow either a Gaussian curve model or a Lorentz curve model.

[0227] 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 I D The intensity of the G-band peak I G The ratio I D / I G The value is approximately 0.8 to approximately 2. For example, in some preferred embodiments, the Raman spectrum of the carbon allotrope 101 includes G and D bands, wherein the G band peak is 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 It is approximately 1 to approximately 1.8.

[0228] For example, in some preferred embodiments, the carbon allotrope 101 is porous. For example, in some preferred embodiments, the carbon allotrope 101 forms a foam structure. The carbon allotrope 101 is conductive.

[0229] In this paper, Raman microscopy was used to measure Raman spectra. A 638 nm laser wavelength was used to perform Raman microscopy. A grating with 1800 grooves / mm was used. A 10.9 mW laser power was used. A 5-second acquisition time was used. Twenty accumulations were used. A 300 µm confocal pinhole was used. The measurement was performed at approximately 1000 cm⁻¹. -1 Approximately 3000 cm-1 Raman microspectroscopy analysis was performed within the specified wavelength range. In this study, a 50x LWD (long working distance) and 0.8 NA (numerical aperture) microscope objective was used. The Horiba Xplora Plus Raman microspectrometer was also used. Raman microspectroscopy analysis was performed at 21 °C. The carbon allotrope 101 receiving the Raman microspectroscopy analysis was in an unused state. That is, the carbon allotrope 101 was not used to generate aerosols and / or was not heated to the typical aerosolization temperature (after the carbon allotrope 101 was manufactured).

[0230] The inventors have used Raman microscopy to analyze each carbon allotrope 101 sample.

[0231] Each of the carbon allotropes 101 samples was prepared by laser irradiation of a polyimide (poly(4,4'-oxydiphenylene-pyromellitictetrimimide), 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 as a rectangular prism. This involved irradiating an area of ​​approximately 4.5 mm by approximately 2 mm (i.e., approximately 9 mm²) of each polyimide substrate with a laser beam. 2 (and are rectangular) to form carbon allotropes 101. Raman microspectroscopy analysis was performed on each sample of carbon allotropes 101. Each sample of carbon allotropes 101 is porous and conductive.

[0232] Unconstrained by theory, Raman microspectroscopy is considered a non-destructive vibrational spectroscopy technique that uses a laser to excite bonds within a sample (e.g., carbon) and resolves the inelastic scattering of bond vibrations as relative Raman shifts. The inelastic scattering resulting from interactions with the sample produces these relative Raman shifts, thereby generating spectra that can be used to resolve the characteristics and / or species of the sample. To characterize carbon allotropes 101 samples, studies can be conducted typically at approximately 1329 cm⁻¹. -1 The peak position of the D band observed is typically around 1579 cm⁻¹. -1 The peak position of the G band observed at [location] and typically around 2630 cm⁻¹ -1The peak positions of the 2D bands observed are shown. The D band can be called the "disorder band" and is an indicator of the sp3 hybridization of carbon within the sample. The G band can be called the "graphene band" and is used to determine the sp2 hybridization of the carbon structure within the sample. For example, the Raman spectrum of a pristine graphene sample will typically include a high-intensity, narrow G band and will not include the D band. The Raman spectrum of a graphite sample typically includes both G and D bands, with the D band having a lower intensity than the G band. D / I G The ratio can be obtained through the D band peak (I D The count of the intensity (au) of the G band peak (I) G The intensity ratio of the 2D bands is used to determine the morphology of allotropes within a sample and can be used to identify carbon allotropes present in the sample. The 2D band can also be used to determine the morphology of allotropes by analyzing the area and peak position of the analytical curve. For example, crystalline graphite typically exhibits a sharp and narrow peak curve following a Lorentz curve fitting model, while samples containing amorphous carbon typically exhibit a wider and flatter 2D band following 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. FWHM is measured by determining the width of the peak at half the total intensity of the sample.

[0233] Raman microspectroscopy analysis involved measuring the Raman spectra of each of multiple samples 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 depth of approximately 1000 cm⁻¹. -1 Approximately 3000 cm -1 The wavelength range.

[0234] Raman microspectroscopy analysis was performed at 21 °C.

[0235] The carbon allotrope 101 sample, which underwent Raman microspectroscopy analysis, was in an unused state.

[0236] The Raman spectra of each of the multiple carbon allotropes 101 samples include G and D bands, 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 GThe values ​​range from 1 to 1.8. Raman spectra of each of the multiple carbon allotropes 101 samples are included at approximately 2620 cm⁻¹. -1 Approximately 2680 cm -1 The 2D band peaks are within the Raman shift range. In the Raman spectra of each of the multiple carbon allotropes 101 samples, the full width at half maximum (FWHM) of the G band peak is approximately 45 cm⁻¹. -1 Approximately 62 cm -1 In the Raman spectra of each of the multiple carbon allotropes 101 samples, the 2D bands generally follow a Lorentz curve fitting model.

[0237] Raman spectra of each of the multiple carbon allotropes 101 samples indicate that the samples include disordered graphite, amorphous carbon, or combinations thereof.

[0238] Figure 11 shows the Raman spectrum of one of several carbon allotropes 101. The sample was in an unused state. As shown in Figure 11, 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 / I D The FWHM of the G-band peak is approximately 1.6. -1 The 2D band follows a Lorentz curve fitting model.

[0239] The inventors have discovered that a carbon allotrope 101 comprising disordered graphite, amorphous carbon, or a combination thereof provides a particularly efficient aerosol generating component. This carbon allotrope 101 is 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 non-combustible aerosol supply systems. This carbon allotrope 101 also facilitates the efficient distribution of liquids, for example, distributing liquids on the surface of the carbon allotrope and / or within the carbon allotrope.

[0240] The thermal conductivity of carbon allotrope 101 can be 100 W / m. -1 k -1 Up to 5500 Wm -1 k -1 The thermal conductivity of carbon allotrope 101 can reach 100 W / m. -1 k -1 Up to 4000 Wm -1 k -1The thermal conductivity of carbon allotrope 101 can reach 100 W / m. -1 k -1 Up to 2000 Wm -1 k -1 The thermal conductivity of carbon allotrope 101 can reach 150 W / m. -1 k -1 Up to 1000 Wm -1 k -1 The thermal conductivity of carbon allotrope 101 can be 180 W / m. -1 k -1 Up to 700 Wm -1 k -1 The thermal conductivity of carbon allotrope 101 can reach 200 W / m². -1 k -1 Up to 500 Wm -1 k -1 .

[0241] The electrical conductivity of carbon allotrope 101 can be 1 Sm. -1 Up to 2.5×10 6 Sm -1 The electrical conductivity of carbon allotrope 101 can be 100 Sm. -1 Up to 1.0×10 6 Sm -1 The electrical conductivity of carbon allotrope 101 can reach 200 Sm. -1 Up to 100000Sm -1 The electrical conductivity of carbon allotrope 101 can reach 400 Sm. -1 Up to 50000 Sm -1 The electrical conductivity of carbon allotrope 101 can reach 500 Sm. -1 Up to 10000 Sm -1 The electrical conductivity of carbon allotrope 101 can be 600 Sm. -1 Up to 5000 Sm -1 The electrical conductivity of carbon allotrope 101 can reach 800 Sm. -1 Up to 3000 Sm -1 The electrical conductivity of carbon allotrope 101 can reach 900 Sm. -1 Up to 1300 Sm -1 .

[0242] Carbon allotropes 101 can exhibit nonlinear elasticity.

[0243] In embodiments including one or more layers of graphene 101, the one or more layers can be provided in various forms. For example, the one or more layers of graphene 101 can be formed into multiple three-dimensional structures. The three-dimensional graphene structures can be selected from cubes, cuboids, cones, 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.

[0244] Carbon allotrope 101 can be formed into a foam structure. Carbon allotrope 101 can be formed into an open-cell foam structure. Carbon allotrope 101 may include a capillary structure. The open-cell foam structure may include a capillary structure.

[0245] Figures 4A to 4C show examples of how one or more layers 101 can be configured.

[0246] As shown in Figure 4A, one or more layers of graphene 101 can be formed into an open-cell foam structure (referred to as "graphene foam" in this paper; see, for example, "High-Resolution Laser-Induced Graphene: Flexible Electronics Breaking the Visible Limit," Michael G. Stanford et al., ACS Applied Materials & Interfaces, 2020 12 (9), 10902-10907). Graphene foam may include capillary structures. Graphene foam can be formed by vapor deposition, such as chemical vapor deposition. Graphene foam includes a three-dimensional open-cell structure, through which aerosolizable materials can, for example, traverse the three-dimensional open-cell structure via capillary action.

[0247] As shown in Figure 4B, a carbon allotrope (e.g., one or more layers of graphene) 101 can be formed into multiple sheets. Gaps can exist between these sheets. The gaps between the sheets can provide a capillary structure. Aerosolizable materials can, for example, traverse the gaps through capillary action.

[0248] As shown in Figure 4C, carbon allotropes (e.g., one or more layers of graphene) 101 can be formed into 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.

[0249] Carbon allotropes (e.g., one or more layers of graphene 101) can be sintered into carbon allotropes 101. Sintering has been found to increase the mechanical strength and / or resistance to damage of one or more layers of graphene 101.

[0250] According to the present invention, a carbon allotrope is supported on an electrically insulating substrate. The thickness of the allotrope can vary depending on the properties of the electrically insulating substrate and the arrangement of the allotrope on it. The thickness of the allotrope is understood to refer to the range of the carbon allotrope measured orthogonally between the supporting surface of the electrically insulating substrate and the outer surface of the allotrope. In this regard, the outer surface refers to the surface of the carbon allotrope that does not have other layers supported thereon when viewed orthogonally from the supporting surface of the electrically insulating substrate. In the case where the carbon allotrope includes internal pores, these internal pores are practically ignored in the thickness measurement. As an example, if the difference between the first exemplary carbon allotrope and the second exemplary carbon allotrope is only that the first exemplary carbon allotrope has internal pores while the second exemplary carbon allotrope is non-porous, the first exemplary carbon allotrope and the second exemplary carbon allotrope will have the same thickness. The thickness of the carbon allotrope can refer to the thickness of a single layer or multiple layers. Those skilled in the art will understand suitable methods for measuring the thickness of a carbon allotrope, such as electron microscopy.

[0251] For example, when the allotrope 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 can be 0.345 nm. However, when it exists as a multilayer graphene, the thickness will be greater than 0.345 nm.

[0252] In some embodiments, the thickness of the carbon allotrope 101 is no greater than 100 µm. In some embodiments, the thickness of the carbon allotrope 101 is no greater than 80 µm. In some embodiments, the thickness of the carbon allotrope 101 is no greater than 60 µm. In some embodiments, the thickness of the carbon allotrope 101 is no greater than 50 µm. In some embodiments, the thickness of the carbon allotrope 101 is no greater than 30 µm. In some embodiments, the thickness of the carbon allotrope 101 is no greater than 20 µm. In some embodiments, the thickness of the carbon allotrope 101 is no greater than 10 µm. In some embodiments, the thickness of the carbon allotrope 101 is no greater than 5 µm. In some embodiments, the thickness of the carbon allotrope 101 is no greater than 1 µm. The thickness of the carbon allotrope 101 is represented by "t" in Figures 4A to 4C. In some embodiments, the thickness of the carbon allotrope 101 is no greater than 500 nm. In some embodiments, the thickness of the carbon allotrope 101 is no greater than 400 nm. In some embodiments, the thickness of the carbon allotrope 101 is no greater than 300 nm. In some embodiments, the thickness of the carbon allotrope 101 is no greater than 200 nm. In some embodiments, the thickness of the carbon allotrope 101 is no greater than 100 nm. In some embodiments, the thickness of the carbon allotrope 101 is no greater than 80 nm. In some embodiments, the thickness of the carbon allotrope 101 is no greater than 50 nm. In some embodiments, the thickness of the carbon allotrope 101 is no greater than 30 nm. In some embodiments, the thickness of the carbon allotrope 101 is no greater than 20 nm. In some embodiments, the thickness of the carbon allotrope 101 is no greater than 10 nm.

[0253] The thickness of the carbon allotrope 101 may have a natural lower limit corresponding to the thickness of a single layer of graphene, which may be 0.345 nm. In some embodiments, the thickness of the carbon allotrope 101 is at least 0.7 nm. In some embodiments, the thickness of the carbon allotrope 101 is at least 1 nm. In some embodiments, the thickness of the carbon allotrope 101 is at least 2 nm. In some embodiments, the thickness of the carbon allotrope 101 is at least 5 nm.

[0254] In some embodiments, the thickness of the carbon allotrope 101 is from 0.345 nm to 100 µm. In some embodiments, the thickness of the carbon allotrope 101 is from 0.345 nm to 80 µm. In some embodiments, the thickness of the carbon allotrope 101 is from 0.345 nm to 60 µm. In some embodiments, the thickness of the carbon allotrope 101 is from 0.345 nm to 50 µm. In some embodiments, the thickness of the carbon allotrope 101 is from 0.345 nm to 40 µm. In some embodiments, the thickness of the carbon allotrope 101 is from 0.345 nm to 30 µm. In some embodiments, the thickness of the carbon allotrope 101 is from 0.345 nm to 20 µm. In some embodiments, the thickness of the carbon allotrope 101 is from 0.345 nm to 10 µm. In some embodiments, the thickness of the carbon allotrope 101 is from 0.345 nm to 1 µm. In some embodiments, the thickness of the carbon allotrope 101 is from 0.345 nm to 500 nm. In some embodiments, the thickness of the carbon allotrope 101 is from 0.345 nm to 200 nm. In some embodiments, the thickness of the carbon allotrope 101 is from 0.345 nm to 100 nm. In some embodiments, the thickness of the carbon allotrope 101 is from 0.345 nm to 50 nm. In some embodiments, the thickness of the carbon allotrope 101 is from 0.345 nm to 20 nm. In some embodiments, the thickness of the carbon allotrope 101 is from 0.345 nm to 10 nm.

[0255] In some embodiments, the thickness of the carbon allotrope 101 is 1 nm to 1 µm. In some embodiments, the thickness of the carbon allotrope 101 is 1 nm to 500 nm. In some embodiments, the thickness of the carbon allotrope 101 is 1 nm to 200 nm. In some embodiments, the thickness of the carbon allotrope 101 is 1 nm to 100 nm. In some embodiments, the thickness of the carbon allotrope 101 is 1 nm to 50 nm. In some embodiments, the thickness of the carbon allotrope 101 is 1 nm to 20 nm. In some embodiments, the thickness of the carbon allotrope 101 is 1 nm to 10 nm.

[0256] In some embodiments, the thickness of the carbon allotrope 101 is from 2 nm to 1 µm. In some embodiments, the thickness of the carbon allotrope 101 is from 2 nm to 500 nm. In some embodiments, the thickness of the carbon allotrope 101 is from 2 nm to 200 nm. In some embodiments, the thickness of the carbon allotrope 101 is from 2 nm to 100 nm. In some embodiments, the thickness of the carbon allotrope 101 is from 2 nm to 50 nm. In some embodiments, the thickness of the carbon allotrope 101 is from 2 nm to 20 nm. In some embodiments, the thickness of the carbon allotrope 101 is from 2 nm to 10 nm.

[0257] In some embodiments, the thickness of the carbon allotrope 101 is from 5 nm to 1 µm. In some embodiments, the thickness of the carbon allotrope 101 is from 5 nm to 500 nm. In some embodiments, the thickness of the carbon allotrope 101 is from 5 nm to 200 nm. In some embodiments, the thickness of the carbon allotrope 101 is from 5 nm to 100 nm. In some embodiments, the thickness of the carbon allotrope 101 is from 5 nm to 50 nm. In some embodiments, the thickness of the carbon allotrope 101 is from 5 nm to 20 nm. In some embodiments, the thickness of the carbon allotrope 101 is from 5 nm to 10 nm.

[0258] In some embodiments, the carbon allotrope 101 is supported on at least 50% of the surface area of ​​the electrically insulating substrate 102 surface 102a. In some embodiments, the carbon allotrope 101 is supported on at least 70% of the surface area of ​​the electrically insulating substrate 102 surface 102a. In some embodiments, the carbon allotrope 101 is supported on at least 90% of the surface area of ​​the electrically insulating substrate 102 surface 102a. In some embodiments, the carbon allotrope 101 is supported on substantially 100% of the surface area of ​​the electrically insulating substrate 102 surface 102a.

[0259] The surface 102a supporting the carbon allotrope 101 can provide at least 30% of the outer surface area of ​​the electrically insulating substrate 102. The surface 102a supporting the carbon allotrope 101 can provide at least 40% of the outer surface area of ​​the electrically insulating substrate 102. The surface 102a supporting the carbon allotrope 101 can provide at least 45% of the outer surface area of ​​the electrically insulating substrate 102.

[0260] In some embodiments, the surface 102a supporting the carbon allotrope 101 is curved.

[0261] In some embodiments, the surface 102a supporting the carbon allotrope 101 is substantially planar.

[0262] The surface 102a supporting the carbon allotrope 101 can be a master surface. A "master surface" is the surface with the largest (or tandemly largest) area relative to the other surfaces of the electrically insulating substrate 102. For example, the master 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 two exist). In each of Figures 3, 5A, 6A, 7A, 7B, 8A, and 8B, one or more layers of graphene 101 are shown supported on the master surface of the electrically insulating substrate 102.

[0263] 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 may be configured to form an electrical connection with a power source such that power can be delivered to the aerosol generating component 100 (e.g., the carbon allotrope 101).

[0264] 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 positioned toward or at an end of the aerosol generating component 100, and the other electrode may be positioned toward or at another end of the aerosol generating component 100.

[0265] 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.

[0266] One or more electrodes 103 can be sintered onto the carbon allotrope 101. Sintering can be performed at temperatures ranging from 100°C to 300°C, such as 120°C to 200°C. Sintering can be carried out for 5 seconds to 5 minutes, such as 10 seconds to 3 minutes. Those skilled in the art will understand that sintering conditions can be varied.

[0267] 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 not greater than 20 degrees at a temperature of 150°C.

[0268] Contact angles can be measured using the Wilhelmy plate method, EM, analog methods, or goniometers. Contact angles can also be measured optically; for example, they can be measured by photography. These methods for measuring contact angles are familiar to those skilled in the art.

[0269] It should be understood that the "contact angle" is the angle at the intersection of the liquid-vapor interface and the solid surface, and the contact angle quantifies the wettability of the liquid on the solid surface via Young's equation:

[0270] 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.

[0271] It has been found that when the carbon allotrope 101 is configured in this way, during use, the aerosolizable material can form a uniformly distributed thin layer 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 tendency of the aerosol generating component 100 to "dry out" (i.e., the phenomenon where the aerosol generating component 100 or a portion thereof becomes excessively dry due to the rate of replenishment of the aerosolizable material being less than the rate of volatilization of the aerosolizable material) is reduced.

[0272] The temperature at which the contact angle is measured can refer to the temperature measured at the surface of a carbon allotrope on which a glycerol droplet is applied.

[0273] At 150°C, the contact angle between the surface of the carbon allotrope 101 and the glycerol droplet may not exceed 18 degrees. At 150°C, the contact angle between the surface of the carbon allotrope 101 and the glycerol droplet may not exceed 16 degrees. At 150°C, the contact angle between the surface of the carbon allotrope 101 and the glycerol droplet may not exceed 14 degrees. At 150°C, the contact angle between the surface of the carbon allotrope 101 and the glycerol droplet may not exceed 12 degrees. At 150°C, the contact angle between the surface of the carbon allotrope 101 and the glycerol droplet may not exceed 10 degrees.

[0274] At a temperature of 20°C, the contact angle between the surface of carbon allotrope 101 and the glycerol droplet can be 70 to 130 degrees, such as 80 to 110 degrees.

[0275] Carbon allotropes 101 may contain one or more dopants.

[0276] One or more dopants may include n-type dopants. n-type dopants may be selected from the group consisting of phosphorus and nitrogen.

[0277] One or more dopants may include p-type dopants. P-type dopants may be selected from the group consisting of boron and sulfur.

[0278] It has been found that the presence of such dopants promotes a reduction in contact angle and thus improves wettability.

[0279] In one aspect of this disclosure, the electrically insulating substrate 102 is elongated and has an aspect ratio of 5:1 to 50:1. Such an aspect ratio has been found to provide the desired heating performance in use.

[0280] For example, the aspect ratio of the electrically insulating substrate 102 can be from 5:1 to 40:1. The aspect ratio of the electrically insulating substrate 102 can be from 5:1 to 35:1. The aspect ratio of the electrically insulating substrate 102 can be from 5:1 to 30:1. The aspect ratio of the electrically insulating substrate 102 can be from 5:1 to 25:1. The aspect ratio of the electrically insulating substrate 102 can be from 5:1 to 22:1.

[0281] For example, the aspect ratio of the electrically insulating substrate 102 can be from 8:1 to 40:1. The aspect ratio of the electrically insulating substrate 102 can be from 8:1 to 35:1. The aspect ratio of the electrically insulating substrate 102 can be from 8:1 to 30:1. The aspect ratio of the electrically insulating substrate 102 can be from 8:1 to 25:1. The aspect ratio of the electrically insulating substrate 102 can be from 8:1 to 22:1.

[0282] In one aspect of this disclosure, the carbon allotrope 101 includes an elongated heating surface with an aspect ratio of 5:1 to 50:1. Such an aspect ratio has been found to provide desired heating performance in use. In particular, this aspect ratio has been found to exhibit desired aerosolization rates and energy efficiency.

[0283] The heated surface can be considered as the part of the carbon allotrope 101 that reaches the temperature of the aerosolizable material during use.

[0284] For example, the aspect ratio of the heating surface of the carbon allotrope 101 can be from 5:1 to 40:1. The aspect ratio of the heating surface of the carbon allotrope 101 can be from 5:1 to 35:1. The aspect ratio of the heating surface of the carbon allotrope 101 can be from 5:1 to 30:1. The aspect ratio of the heating surface of the carbon allotrope 101 can be from 5:1 to 25:1. The aspect ratio of the heating surface of the carbon allotrope 101 can be from 5:1 to 22:1.

[0285] For example, the aspect ratio of the heating surface of the carbon allotrope 101 can be from 8:1 to 40:1. The aspect ratio of the heating surface of the carbon allotrope 101 can be from 8:1 to 35:1. The aspect ratio of the heating surface of the carbon allotrope 101 can be from 8:1 to 30:1. The aspect ratio of the heating surface of the carbon allotrope 101 can be from 8:1 to 25:1. The aspect ratio of the heating surface of the carbon allotrope 101 can be from 8:1 to 22:1.

[0286] The heating surface of carbon allotrope 101 can be substantially planar.

[0287] 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 specific embodiment, the aerosol generating component 100 traverses an aerosol generating material transport 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. Energy density indicates the energy density provided per mm² by the aerosol generating component 100. 2 The amount of energy required. Efficiency (blue 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 20 seconds of heater operation. The aerosol generating component 100 has a different length and width, and each includes multilayer graphene 101 disposed on a polyimide substrate 102, wherein the multilayer graphene 101 is not parallel to each other. Lower efficiency values ​​(J / mg) are preferred, and higher mass change loss values ​​(mg) are preferred.

[0288] In one aspect of this disclosure, at least one elongated orifice 104 extends through the aerosol generating component 100.

[0289] Examples of such aerosol generating component 100 are shown in Figures 7A and 7B.

[0290] At least one orifice increases the edge length and direct surface area of ​​the aerosol generating component 100 that can be used to contact the aerosol generating material. It has been found that, despite the presence of at least one orifice, heat is uniformly distributed on 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 a power source.

[0291] 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.

[0292] The elongated orifice, or each elongated orifice 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 orifice, or each elongated orifice 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 orifice, or each elongated orifice 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).

[0293] In embodiments including multiple elongated orifices 104, these elongated orifices 104 may be arranged side by side. In embodiments including multiple elongated orifices 104, these elongated orifices 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 these elongated orifices 104 may be arranged parallel to each other, and one or more elongated orifices 104 may not be parallel to each other.

[0294] For example, in the aerosol generating component 100 of Figures 7A and 7B, elongated orifices 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.

[0295] The width of the elongated orifice 104 can be from 0.05 mm to 2 mm. The width of the elongated orifice 104 can be from 0.05 mm to 1.5 mm. The width of the elongated orifice 104 can be from 0.1 mm to 1 mm. The width of the elongated orifice 104 can be from 0.2 mm to 0.8 mm. The width of the elongated orifice 104 can be from 0.3 mm to 0.6 mm.

[0296] The length of the elongated orifice 104 can be 5% to 95% of the length of the aerosol generating component 100. The length of the elongated orifice 104 can be 20% to 95% of the length of the aerosol generating component 100. The length of the elongated orifice 104 can be 40% to 95% of the length of the aerosol generating component 100. The length of the elongated orifice 104 can be 50% to 95% of the length of the aerosol generating component 100. The length of the elongated orifice 104 can be 60% to 95% of the length of the aerosol generating component 100. The length of the elongated orifice 104 can be 70% to 95% of the length of the aerosol generating component 100. The length of the elongated orifice 104 can be 80% to 95% of the length of the aerosol generating component 100. The length of the elongated orifice or each elongated orifice 104 can be 90% to 95% of the length of the aerosol generating component 100.

[0297] The length of the elongated orifice 104 can be from 1 mm to 45 mm. The length of the elongated orifice 104 can be from 2 mm to 40 mm. The length of the elongated orifice 104 can be from 5 mm to 30 mm. The length of the elongated orifice 104 can be from 5 mm to 20 mm. The length of the elongated orifice 104 can be from 5 mm to 18 mm. The length of the elongated orifice 104 can be from 5 mm to 18 mm. The length of the elongated orifice 104 can be from 10 mm to 18 mm.

[0298] 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 aperture 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 thickness of the carbon allotropes is 0.05 mm (50 µm).

[0299] 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.

[0300] In one aspect of this disclosure, the aerosol generating component 100 includes a heating portion 100a. The aerosol generating component 100 may include at least one aerosolizable material supply portion 100b. The at least one aerosolizable material supply portion may extend from the heating portion 101. This aerosol generating component 100 is shown in Figures 8A and 8B.

[0301] By utilizing a heating section 100a and at least one aerosolizable material supply section 100b, it has been found that the aerosol generating component exhibits improved efficiency in both the transfer of aerosolizable material to the aerosol generating component 100 and the aerosolization efficiency. Specifically, at least one aerosolizable material supply section 100b effectively delivers the aerosolizable material to the heating section 100a. Furthermore, it has been found that when the aerosol generating component 100 is powered, thermal energy does not significantly diffuse to at least one aerosolizable material supply section 100b. This is illustrated in Figure 8B, which is a thermal diagram of the aerosol generating component 100 of Figure 8A in use, wherein the aerosol generating component 100 is powered to the aerosolization temperature using a power source. 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 can happen when aerosolizable material is supplied directly to the outer surface of the heated part, and may result in the accidental ejection of the aerosolizable material (e.g., “splashing” or “splashing”).

[0302] As shown in Figures 8A and 8B, the heating portion 100a can be elongated. For example, the heating portion 100a can be formed as a plate, strip, or rod. The heating portion 100a can be linear. Alternatively, the heating portion 100a can be non-linear.

[0303] The heating part 100a may include a carbon allotrope 101 and a substrate 102, or may be composed of a carbon allotrope and a substrate. The heating part 100a may be composed of a carbon allotrope 101.

[0304] The length of the heating portion 100a can be from 1 mm to 50 mm. In some embodiments, the length of the heating portion 100a is from 2 mm to 40 mm. In some embodiments, the length of the heating portion 100a is from 5 mm to 30 mm. In some embodiments, the length of the heating portion 100a is from 10 mm to 30 mm. In some embodiments, the length of the heating portion 100a is from 10 mm to 25 mm. In some embodiments, the length of the heating portion 100a is from 10 mm to 20 mm.

[0305] The width of the heating portion 100a can be from 0.5 mm to 50 mm. In some embodiments, the width of the heating portion 100a is from 0.5 mm to 20 mm. In some embodiments, the width of the heating portion 100a is from 0.5 mm to 10 mm. In some embodiments, the width of the heating portion 100a is from 0.5 mm to 5 mm. In some embodiments, the width of the heating portion 100a is from 1 mm to 50 mm. In some embodiments, the width of the heating portion 100a is from 1 mm to 20 mm. In some embodiments, the width of the heating portion 100a is from 1 mm to 10 mm. In some embodiments, the width of the heating portion 100a is from 1 mm to 5 mm. In some embodiments, the width of the heating portion 100a is from 1 mm to 3 mm.

[0306] The aerosol generating component 100 may include a plurality of (e.g., at least two, three, four, five, or six) aerosolizable material supply portions 100b, each extending from the heating portion 100a. As shown in Figures 8A and 8B, the aerosolizable material supply portions, or each aerosolizable material supply portion 100b, may extend from the side of the heating portion 100a. As shown in Figures 8A and 8B, the aerosolizable material supply portions, or each aerosolizable material supply portion 100b, may extend laterally to the longitudinal extent of the heating portion 100a. The aerosolizable material supply portions, or each aerosolizable material supply portion 100b, may extend laterally from the heating portion 100a.

[0307] The aerosol generating component 100 can be substantially planar. In this way, the heating part 100a and at least one aerosolizable material supply part 100b can be arranged in the same plane.

[0308] The aerosolizable material supply section, or each aerosolizable material supply section 100b, can be elongated 100a. For example, the aerosolizable material supply section, or each aerosolizable material supply section 100b, can be formed as a plate, strip, or rod. The aerosolizable material supply section, or each aerosolizable material supply section 100b, can be linear.

[0309] The aspect ratio of the aerosolizable material supply section or each aerosolizable material supply section 100b can be from 1:1 to 5:1. The width of the aerosolizable material supply section or each aerosolizable material supply section 100b can be from 1 mm to 3 mm. The length of the aerosolizable material supply section or each aerosolizable material supply section 100b can be from 1 mm to 15 mm.

[0310] The aerosolizable material supply section or each aerosolizable material supply section 100b may be tapered. For example, as shown in Figures 8A and 8B, the aerosolizable material supply section or each aerosolizable material supply section 100b may tape away from the elongated heating section 100a.

[0311] At least one aerosolizable material supply portion 100b may be porous. At least one aerosolizable material supply portion 100b may include capillary material. At least one aerosolizable material supply portion 100b may have any characteristics of an electrically insulating substrate as defined herein.

[0312] As shown in Figures 8A and 8B, the heating portion 100a may have a longitudinal range (e.g., a longitudinal axis). The aerosolizable material supply portion or each aerosolizable material supply portion 100b may extend obliquely or orthogonally relative to the longitudinal range of the heating portion 100a.

[0313] The heating section 100a includes a carbon allotrope 101 disposed on an electrically insulating substrate 102. Each aerosolizable material supply section 100b includes an electrically insulating substrate 102.

[0314] 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 supported (according to Figures 7A, 7B, 8A, and 8B).

[0315] In some embodiments, the heating portion 100a and the substrate 102 are integrally formed.

[0316] In one aspect of this disclosure, an aerosol generation assembly is provided, which includes an aerosol generation component 100 of any aspect of this disclosure and an aerosol generation material transport component 200 for supplying aerosol generation material to the aerosol generation component 100.

[0317] Figures 5A to 6C show examples of aerosol generation components.

[0318] The aerosol generating material transport component 200 can be used to passively supply aerosol generating material to the aerosol generating component 100. "Passively supplying" encompasses the aerosol generating material transport component 200 delivering aerosol generating material to the aerosol generating component 100 without requiring power. For example, the aerosol generating material transport component 200 may include a porous structure. For example, the aerosol generating material transport component 200 may include a capillary structure. Capillary structures have been found to be particularly effective for transporting aerosolizable materials to the aerosol generating component 101.

[0319] As shown in Figures 5A to 5C, the aerosol generating material transport 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 layers of graphene 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.

[0320] As shown in Figures 5A to 5C, a capillary channel (or each capillary channel) 201 may be formed of a first layer (e.g., a capping 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 a plurality of capillary channels (each of the plurality of capillary channels may independently include any features of a capillary channel described herein).

[0321] 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.

[0322] As shown in Figures 6A and 6B, the aerosol generating material transport 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 layers of graphene 101), for example, its outer surface, specifically, the surface provided by one or more layers of graphene 101.

[0323] The aerosol generating assembly may include a movement 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 movement mechanism may be automatically controlled by a controller.

[0324] In one aspect of the invention, an article of manufacture is provided for use as part of a non-combustible aerosol supply system, the article of manufacture comprising an aerosol generating component 100 of any aspect of the present disclosure, or an aerosol generating assembly of any aspect of the present disclosure.

[0325] In one aspect of this disclosure, an article of manufacture is provided as part of a non-combustible aerosol supply system, the article of manufacture comprising: an aerosol generating component 100 including a heating portion 100a according to any aspect of this disclosure and at least one aerosolizable material supply portion 100b; and at least one reservoir for the aerosolizable material, wherein the aerosolizable material supply portion or each aerosolizable material supply portion 100b is arranged in fluid communication with at least one of the at least one reservoir.

[0326] The aerosolizable material supply section or each aerosolizable material supply section 100b may extend into or be incorporated into at least one or more reservoirs. In this way, the aerosolizable material supply section or each aerosolizable material supply section 100b may directly transfer the aerosolizable material from the reservoir to the heating section 100a.

[0327] The heating portion 100a may be offset relative to 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 portion 100a may be arranged within the aerosol generation chamber. The reservoir may radially surround the aerosol generation chamber. Thus, the reservoir may form an annular ring around the aerosol generation chamber (the ring may be partial or complete).

[0328] 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.

[0329] The article can be oriented such that, during use, air flows along the aerosol generating component (e.g., the heating portion 100a) in a surface direction (e.g., along the surface of the aerosol generating component 100, such as the heating portion 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 in which the aerosol generating component 100 (e.g., the heating portion 100a) is arranged, and exit the article through at least one outlet.

[0330] In one aspect of this disclosure, a non-combustible 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 one or more of a power source and a controller.

[0331] The power source is used to supply electricity to the aerosol generating component (e.g., carbon allotrope 101).

[0332] The controller can be arranged to electrically communicate with the aerosol generating component 100 (e.g., carbon allotrope 101), wherein the controller is configured to control the power supply from a power source to the aerosol generating component 100 (e.g., carbon allotrope 101). The controller can be configured to supply aerosolizable material to the aerosol generating component 100. The supply can be active. Active supply can be implemented by an active supply device, such as a pump.

[0333] 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. Thus, 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.

[0334] Therefore, when no aerosolizable material is supplied to the aerosol generating unit 100, the controller can be configured not to supply power to the aerosol generating unit. When no aerosolizable material is supplied to the aerosol generating unit 100, the controller can be configured to supply a baseline power (which is greater than zero) 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 periods.

[0335] In one aspect of this disclosure, a method is provided for forming an aerosol generating component 100 in any aspect of this disclosure.

[0336] 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.

[0337] The carbon allotrope 101 can be formed on the electrically insulating substrate 102 by printing.

[0338] The carbon allotrope 101 can be formed on the electrically insulating substrate 102 by laser irradiation. When the carbon allotrope 101 is formed as a foam structure, this can be achieved by laser irradiation of the electrically insulating substrate 102. Laser irradiation can include irradiating the electrically insulating substrate 102 with a laser beam, wherein the electrically insulating substrate 102 is a carbon-containing material. In some embodiments involving laser irradiation, the electrically insulating substrate 102 is formed of polyimide (PI). Laser irradiation can be performed in an inert environment.

[0339] 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 including 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)), wherein the carbon allotrope 101 is formed as a foam structure.

[0340] Carbon allotropes 101 can be formed on electrically insulating substrates 102 by laser-induced deposition.

[0341] When the carbon allotrope 101 is or includes one or more layers of graphene, it 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.

[0342] 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 foams on electrically insulating substrates.

[0343] The method may include the step of forming one or more electrodes 103 in contact with the carbon allotrope 101.

[0344] It has been found that manufacturing efficiency can be improved by forming two or more electrodes 103 that are in contact (i.e., in direct contact) with the carbon allotrope 101, relative to an aerosol generating component whose electrodes are connected to the heater via electrical contacts (i.e., additional component portions; typically silver electrical contacts). Furthermore, in the absence of such electrical contacts, a larger proportion of a given size of aerosol generating component 100 can be configured for aerosol generation (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, relative to an aerosol generating component whose electrodes are connected to the heater via electrical contacts.

[0345] 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.

[0346] The electrodes, or each electrode 103, may be selected from copper, silver, and gold. The electrodes, or each electrode 103, are formed by sintering, for example, 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.

[0347] The method may include forming one or more grooves and / or one or more orifices in the electrically insulating substrate before arranging the carbon allotrope 101 on the substrate. One or more orifices extend through the substrate 102 (i.e., as through holes). The grooves and orifices facilitate the distribution of aerosolizable material on and through the aerosol generating component 100, and improve heating efficiency.

[0348] In some embodiments, the substrate 102 is glass, such as borosilicate glass (e.g., “flexible glass”) or quartz glass (fused silica).

[0349] 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.

[0350] 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.

[0351] In one aspect of this disclosure, a method of operating a non-combustible aerosol supply system according to any aspect of this disclosure is provided, the method comprising the step of supplying power to an aerosol generating component 100.

[0352] The method may include: actuating a controller to control (e.g., cause or prevent) the supply of aerosolizable material to the aerosol generating component 100.

[0353] The method may include: actuating a controller to control (e.g., cause or prevent) the supply of power to the aerosol generating component 100.

[0354] The method may include: supplying a certain 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 a certain 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.

[0355] Any aspect of this disclosure may be defined with respect 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 defined with respect to any other aspect of this disclosure.

[0356] The accompanying drawings are schematic and not to scale. The various embodiments described herein are presented solely to aid understanding and teaching of the claimed features. These examples are provided only as representative samples 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 examples 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, consist of, or substantially consist of suitable combinations of the disclosed elements, components, features, portions, steps, devices, etc. Furthermore, this disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. A method for preparing an aerosol generating component for use as part of a non-combustible aerosol supply system, the method comprising the following steps: Carbon allotropes are formed on an electrically insulating substrate; And to form one or more electrodes in contact with the carbon allotrope.

2. The method according to claim 1, wherein, The step of forming one or more electrodes in contact with a carbon allotrope includes a sintering step.

3. The method according to claim 1 or 2, wherein, The electrode, or each of the electrodes, is selected from copper, silver, and gold.

4. The method according to claim 1, wherein, The carbon allotropes are formed by printing on the electrically insulating substrate.

5. The method according to any one of claims 1 to 4, wherein, The carbon allotropes are formed on the electrically insulating substrate by chemical vapor deposition.

6. The method according to any one of claims 1 to 4, wherein, The carbon allotropes are formed on the electrically insulating substrate by laser-induced deposition.

7. The method according to any one of claims 1 to 6, wherein, The carbon allotropes are formed as: multiple nanotubes; or open-cell foams; or multiple sheets.

8. The method according to any one of claims 1 to 7, wherein, The electrically insulating substrate has a porous structure formed by pillars and gap holes.

9. The method according to claim 8, wherein, The carbon allotrope is formed on the column.

10. The method according to claim 9, wherein, The average diameter of the gap hole is between 0.5 µm and 40 µm.

11. The method according to any one of claims 1 to 10, wherein, The carbon allotrope comprises one or more layers of graphene, wherein, in the presence of more than one layer of graphene, at least two layers of graphene are not parallel to each other.

12. The method according to any one of claims 1 to 10, wherein, The carbon allotrope is graphite.

13. The method according to any one of claims 1 to 12, wherein, The carbon allotrope has one or more of the following: 100 Wm -1 k -1 Up to 5500 Wm -1 k -1 Thermal conductivity; 1 Sm -1 Up to 2.5×10 6 Sm -1 Its electrical conductivity; and its nonlinear elasticity.

14. The method according to any one of claims 1 to 13, comprising: Before depositing the carbon allotrope onto the electrically insulating substrate, one or more grooves and / or one or more orifices are formed in the electrically insulating substrate.

15. The method according to any one of claims 1 to 14, wherein, The electrically insulating substrate is selected from the group consisting of plastics, glass, paper, and ceramics.

16. The method according to claim 15, wherein, The electrically insulating substrate is glass, and wherein the glass is borosilicate glass.

17. The method according to any one of claims 1 to 16, wherein, The carbon allotropes comprise disordered graphite and / or amorphous carbon.

18. The method according to any one of claims 1 to 17, 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 of the D band peak I D The intensity of the G-band peak I G The ratio I D / I G It is about 0.8 to about 2, preferably about 1 to about 1.

8.

19. An aerosol generating component, obtained by the method according to any one of claims 1 to 18.

20. An aerosol generating assembly used as part of a non-combustible aerosol supply system, the aerosol generating assembly comprising: The aerosol generating component according to claim 19; And an aerosol generating material transport component for supplying the aerosol generating material to the aerosol generating component.

21. The aerosol generating component according to claim 20, wherein, The aerosol generating material transport component includes a storage container, wherein the aerosol generating component traverses the storage container.

22. The aerosol generating component according to claim 20, wherein, The aerosol generating material transport component includes at least one capillary channel, the at least one capillary channel having an outlet.

23. The aerosol generating component according to claim 22, wherein, The outlet is arranged adjacent to the aerosol generating component, such that aerosolizable material leaving the outlet directly contacts the aerosol generating component.

24. A non-combustible aerosol supply system, comprising: The aerosol generating component according to claim 19 or the aerosol generating assembly according to any one of claims 20 to 23; And one or more of the power source and controller.

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