Methods for manufacturing aerosol generators

Abstract

This invention relates to a method for manufacturing an aerosol generator. Specifically, the invention relates to a method for manufacturing an aerosol generator 100 for use as part of a non-flammable aerosol supply system, the method comprising the steps of: (I) providing a carbon precursor 101; (II) irradiating a portion 103 of the outer surface of the carbon precursor 101 with a laser beam, thereby forming an allotrope of carbon 104. In step (II), the laser beam is applied at approximately 0.10 J / mm². 2 To approximately 0.80 J / mm 2 The energy density is delivered to the irradiated portion 103 on the outer surface.

Description

Technical Field

[0001] This disclosure relates to a method of manufacturing an aerosol generator, an aerosol generator, and a non-flammable aerosol supply system comprising said aerosol generator. Background Technology

[0002] Non-flammable aerosol supply systems for generating aerosols for user inhalation are known in the art. These systems typically include an aerosol generator capable of converting aerosol-generating materials into aerosols. In some cases, the generated aerosol is a condensed aerosol, wherein the aerosol-generating material is first evaporated and then condensed into an aerosol. In other instances, the generated aerosol is an aerosol produced by the atomization of aerosol-generating materials. This atomization can be mechanically induced, for example by subjecting the aerosol-generating material to vibration to form small particles of material entrained in the airflow. Alternatively, this atomization can be electrostatically induced, or otherwise induced, such as by using pressure.

[0003] Since these aerosol supply systems are designed to generate aerosols for users to inhale, the characteristics of the generated aerosols should be considered. These characteristics may include the size of the aerosol particles, the total amount of aerosols generated, etc.

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

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

[0006] According to a first aspect of this disclosure, a method for manufacturing an aerosol generator for use as part of a non-flammable aerosol supply system is provided, the method comprising the following steps:

[0007] (I) Provide carbon precursors;

[0008] (II) A portion of the outer surface of the carbon precursor is irradiated with a laser beam, thereby forming an allotrope of carbon.

[0009] In step (II), the laser beam will have a speed of approximately 0.10 J / mm. 2 To approximately 0.80 J / mm 2 The energy density is delivered to the irradiated portion of the outer surface.

[0010] In some instances, in step (II), the laser beam will be approximately 0.14 J / mm. 2 Approximately 0.54 J / mm 2The energy density is delivered to the irradiated portion of the outer surface.

[0011] In some instances, in step (II), the laser beam will be approximately 0.25 J / mm. 2 Approximately 0.35 J / mm 2 The energy density is delivered to the irradiated portion of the outer surface.

[0012] In some instances, in step (II), the laser beam will be approximately 0.30 J / mm. 2 Approximately 0.35 J / mm 2 The energy density is delivered to the irradiated portion of the outer surface.

[0013] In some instances, in step (II), the scanning speed of the laser beam is from about 100 mm / s to about 450 mm / s, such as from about 150 mm / s to about 450 mm / s.

[0014] In some instances, in step (II), the power of the laser beam is from about 1W to about 30W, and optionally from about 3W to about 21W.

[0015] In some instances, in step (II), irradiating a portion of the outer surface causes that portion of the outer surface to reach a temperature of about 1,000°C to about 3,500°C, optionally about 1,350°C to about 3,300°C, optionally about 1,500°C to about 3,000°C, optionally about 1,700°C to about 2,600°C, optionally about 1,800°C to about 2,200°C.

[0016] In some instances, in step (II), the wavelength of the laser beam is from 8 μm to 16 μm, optionally from about 9 μm to about 14 μm, optionally from about 10 μm to about 12 μm, and optionally wherein in step (II), the laser beam is generated by a carbon dioxide laser.

[0017] In some instances, the method includes the following steps:

[0018] (III) Irradiate a portion of the outer surface of the carbon precursor with a laser beam, thereby forming a through-hole in the carbon precursor, wherein the opening of the through-hole is close to an allotrope of carbon.

[0019] In some instances, the opening portion of the through-hole is either completely covered by an allotrope of carbon, optionally wherein the allotrope of carbon extends at least partially into the through-hole.

[0020] In some instances, the vias have a diameter of about 5 μm to about 200 μm, and optionally about 10 μm to about 100 μm.

[0021] In some instances, the outer surface of the carbon precursor includes a first surface and a second surface opposite to the first surface, wherein a portion of the outer surface is the first surface (or a portion thereof).

[0022] In some instances, the carbon precursor is essentially planar.

[0023] In some instances, the carbon precursor has a thickness of about 50 μm to about 300 μm, optionally about 90 μm to about 200 μm, optionally about 100 μm to about 150 μm, and optionally about 120 μm to about 130 μm.

[0024] In some instances, carbon allotropes have a length of about 2 mm to about 3 mm and a width of about 1.5 mm to about 2.5 mm.

[0025] In some instances, carbon allotropes have a resistance of about 10 ohms to about 60 ohms, such as about 40 ohms to about 60 ohms.

[0026] In some instances, the carbon precursor is made of polyimide.

[0027] In some instances, allotropes of carbon include disordered graphite and / or amorphous carbon and / or nanocrystalline graphite.

[0028] In some instances, the Raman spectra of carbon allotropes include both G and D bands, with the G band peaking at approximately 1500 cm⁻¹. -1 Approximately 1650cm -1 Within the Raman shift range, and the D-band peak is at approximately 1250 cm⁻¹. -1 Approximately 1400cm -1 Within the Raman shift range, the intensity I of the D band peak is... D The intensity of the G-band peak I G The ratio of I D / I G It is about 0.2 to about 2, optionally about 0.2 to about 1.6, optionally about 0.4 to about 0.8, optionally about 0.4 to about 0.6.

[0029] In some instances, in step (II), the laser beam illuminates a portion of the outer surface along one or more scan lines, optionally wherein adjacent scan lines are adjacent to or overlap each other.

[0030] In some instances, the scan lines form a scan pattern that overlaps (or covers) a portion of the outer surface.

[0031] In some instances, in step (II), adjacent scan lines overlap, such that the overlapping region receives at least about 50% of the peak intensity of the laser beam.

[0032] According to a second aspect of this disclosure, an aerosol generator is provided for use as part of a non-flammable aerosol supply system, the aerosol generator comprising an allotrope of carbon.

[0033] The aerosol generator is obtained and / or is available through the method of the first aspect of this disclosure.

[0034] According to a third aspect of this disclosure, an article of manufacture is provided for use as part of a non-flammable aerosol supply system, comprising:

[0035] According to the second aspect of this disclosure, an aerosol generator; and

[0036] A reservoir for aerosol-generating materials.

[0037] According to a fourth aspect of this disclosure, a non-flammable aerosol supply system is provided, comprising:

[0038] Articles of manufacture according to the third aspect of this disclosure; and

[0039] Power supply and / or controller. Attached Figure Description

[0040] This disclosure will now be described by way of example only with reference to the accompanying drawings, in which:

[0041] Figure 1 This is a schematic diagram (not drawn to scale) of a non-flammable aerosol supply system based on this disclosure;

[0042] Figure 2 This is a schematic diagram of an aerosol generator for carbon-oriented allotropes as viewed from a planar perspective, according to the present disclosure.

[0043] Figure 3 It is based on Figure 2 A side view of an aerosol generator;

[0044] Figure 4 This is a table showing various characteristics of the aerosol generator prepared according to the method of this disclosure;

[0045] Figure 5A Four scanning electron microscope images of an aerosol generator prepared according to the method of this disclosure are shown;

[0046] Figure 5B Four scanning electron microscope images of an aerosol generator prepared according to the method of this disclosure are shown;

[0047] Figure 5C Four scanning electron microscope images of an aerosol generator prepared according to the method of this disclosure are shown;

[0048] Figure 6The plot shows the temperature (y-axis) versus energy density relative to the allotropes of the carbon sample;

[0049] Figure 7 The Raman spectra of the allotropes of the carbon sample are shown, where the x-axis corresponds to the Raman shift (cm). -1 The y-axis corresponds to the intensity (count), and the spectrum has D-band peaks, G-band peaks, and 2D-band peaks.

[0050] Figure 8 The image shows a scanning electron microscope image of an aerosol generator prepared according to the method of this disclosure; and

[0051] Figure 9 Showing Figure 7 The Raman spectra of carbon allotropes in the aerosol generator, comprising a first spectrum acquired at a first point of the carbon allotropes and a second spectrum acquired at a second point of the carbon allotropes.

[0052] While this disclosure is sensitive to various modifications and alternatives, specific methods are shown by way of example in the accompanying drawings and described in detail herein. However, it should be understood that the drawings and detailed description are not intended to limit this disclosure to the specific forms disclosed, but rather to cover all modifications, equivalents, and alternatives that fall within the spirit and scope of the claimed invention.

[0053] It will be appreciated that the features of this disclosure can be conveniently and interchangeably used in any suitable combination. Detailed Implementation

[0054] This document discusses / describes aspects and features of certain instances. Some aspects and features of certain instances can be implemented conventionally, and for the sake of brevity, these aspects and features are not discussed / described in detail. Therefore, it will be understood that the aspects and features of aerosol generators, articles, and non-flammable aerosol supply systems discussed in this document, which are not described in detail, can be implemented using any conventional techniques used to implement these aspects and features.

[0055] As described above, this disclosure relates to (but is not limited to) non-flammable aerosol supply systems, articles, and aerosol generators that can generate aerosols from aerosol generating materials.

[0056] According to this disclosure, a "non-combustible" aerosol supply system is a system in which the aerosol generating material (or a component thereof) of the aerosol supply system is non-combustible or non-burning to facilitate the delivery of at least one substance to a user.

[0057] In some instances, the non-flammable aerosol supply system is a powered non-flammable aerosol supply system.

[0058] In some instances, the non-flammable aerosol supply system is an electronic cigarette, also known as an electronic vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a necessary condition.

[0059] In some instances, non-flammable aerosol supply systems are aerosol-generating material heating systems, also known as non-burning heating systems. An example of such a system is a tobacco heating system.

[0060] In some instances, non-flammable aerosol supply systems are hybrid systems that use a combination of aerosol-generating materials to produce aerosols, one or more of which can be heated. Each aerosol-generating material may, for example, be in solid, liquid, or gel form, and may or may not contain nicotine. In some instances, the hybrid system comprises liquid or gel aerosol-generating materials and solid aerosol-generating materials. Solid aerosol-generating materials may comprise, for example, tobacco or non-tobacco products.

[0061] Typically, a non-flammable aerosol supply system may include a non-flammable aerosol supply device and consumables for use with the non-flammable aerosol supply device.

[0062] In some instances, this disclosure relates to consumables that comprise aerosol-generating materials and are configured for use in non-flammable aerosol delivery devices. Throughout the disclosure, these consumables are sometimes referred to as articles.

[0063] In some instances, non-flammable aerosol supply systems, such as their non-flammable aerosol supply devices, may include a power source and / or a controller. The power source can be used to supply electrical energy to the article (e.g., to the aerosol generator). The controller can be used to control the article (e.g., to control the supply of electrical energy to the article, for example, to the aerosol generator). The energy source can be, for example, a power source or a heat source. In some instances, the heat source includes a carbon substrate, which can be energized to distribute energy in the form of heat to the aerosol generating material or to a heat transfer material adjacent to the heat source.

[0064] In some instances, a non-flammable aerosol supply system may include a consumable receiving area, an aerosol generator, an aerosol generating area, a housing, a nozzle, a filter, and / or an aerosol modifier.

[0065] In some instances, consumables used with non-flammable aerosol supply devices may include aerosol generating material, an aerosol generating material storage area (which may be referred to herein as an aerosol generating material reservoir), an aerosol generating material delivery assembly (also referred to herein as an aerosol generating material delivery assembly or aerosol generating material delivery component), an aerosol generator (also referred to herein as an aerosol generating assembly), an aerosol generating area (also referred to herein as an aerosol generating chamber), a housing, packaging materials, filters, mouthpieces, and / or aerosol modifiers.

[0066] Throughout the following description, the terms "electronic cigarette" (e-cigarette and electroniccigarette) may sometimes be used. However, it will be understood that these terms can be used interchangeably with non-flammable aerosol (vapor) supply systems as explained above.

[0067] The system described in this article typically generates inhalable aerosols through the vaporization of aerosol-generating materials.

[0068] In some instances, the substance to be delivered may be an aerosol-generating material. Aerosol-generating materials may comprise one or more active ingredients, one or more flavoring agents, one or more aerosol-forming materials, and / or one or more other functional materials.

[0069] As used herein, active substances can be physiologically active materials, which are materials intended to achieve or enhance physiological responses. Active substances can be, for example, selected from nutrients, nootropics, and psychoactive agents. Active substances can be naturally occurring or synthetically obtained. Active substances may include, for example, nicotine, caffeine, taurine, caffeine, vitamins such as B6 or B12 or C, melatonin, or combinations thereof. Active substances may include one or more components, derivatives, or extracts of tobacco or another plant.

[0070] In some instances, the active ingredient contains nicotine. In other instances, the active ingredient contains caffeine, melatonin, or vitamin B12. As mentioned herein, the active ingredient may contain terpenes.

[0071] As mentioned herein, active substances may comprise or be derived from one or more plants or their components, derivatives, or extracts. As used herein, the term "plant" includes any material derived from a plant, including (but not limited to) extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, bark, shells, etc. Alternatively, the material may include naturally occurring active compounds found in plants, or synthetically obtained active compounds. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, small particles, fragments, strips, flakes, etc. Examples of plants include tobacco, eucalyptus, star anise, cocoa, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, bay leaf, licorice, matcha, wintergreen tea, orange peel, papaya, rose, sage, teas such as green or black tea, thyme, clove, cinnamon, coffee, anise, basil, bay leaf, cardamom, coriander, fennel, nutmeg. Oregano, red chili pepper, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, deer hoof grass, perilla, turmeric, sandalwood, coriander leaves, bergamot, orange blossom, myrtle, blackcurrant, valerian, chili pepper, nutmeg, damien, sweet oregano, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, geranium, mulberry, ginseng, theanine, theophylline, maca, ashwagandha, scattering clock flower, Brazilian cocoa, chlorophyll, baobab, or any combination thereof. Peppermint can be selected from the following varieties: wild peppermint (Mentha Arventis), cultivated peppermint (Mentha cv), Egyptian peppermint (Mentha niliaca), peppermint (Mentha piperita), peppermint citrata cv, peppermint ac.v., wrinkled green peppermint (Mentha spicata crispa), madder peppermint (Mentha cordifolia), European peppermint (Mentha longifolia), variegated pineapple peppermint (Mentha suaveolens variegata), spicata peppermint (Mentha pulegium), spearmint cultivar (Memtha spicata cv), and apple peppermint (Mentha suaveolens).

[0072] In some instances, the active substance comprises or is derived from one or more plants or their components, derivatives or extracts, and the plant is tobacco.

[0073] In some instances, the active substance comprises or is derived from one or more plants or their components, derivatives or extracts, and the plants are selected from eucalyptus, star anise and cocoa.

[0074] In some instances, the active substance comprises or is derived from one or more plants or their components, derivatives or extracts, and the plants are selected from loipary and fennel.

[0075] In some instances, the substance to be delivered contains flavoring agents.

[0076] As used herein, the terms "flavoring agent" and "flavor enhancer" refer to materials that, where permitted by local regulations, may be used in adult consumer products to produce a desired taste, aroma, or other somatic sensation. These may include naturally occurring flavoring materials, plants, plant extracts, synthetically obtained materials, or combinations thereof (e.g., tobacco, licorice, hydrangea, eugenol, Japanese white barkmagnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, anise, cinnamon, turmeric, Indian spices, Asian spices, vanilla, deer antler, cherry, berry, cranberry, blueberry, peach, apple, orange, mango, citrus, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, honey whiskey, bourbon whiskey, Scotch whiskey, etc.). Gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, quinoa, nutmeg, sandalwood, bergamot, geranium, khat, naswar, hookah, pine, honey extract, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cinnamon, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wild jasmine, allspice, ginger, coriander, coffee, and more. Peppermint oil from any species of the genus *Mentha*, eucalyptus, star anise, cocoa, lemongrass, loipary, flax, ginkgo, hazelnut, hibiscus, laurel, wintergreen tea, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, fennel, oregano, red pepper, rosemary, saffron, lemon peel, mint, perilla, turmeric, coriander leaf, myrtle, blackcurrant, valerian, chili pepper, nutmeg, dami, oregano, olive, lemon balm. Lemon basil, chives, caraway, verbena, tarragon, limonene, thymol, camphene, flavor enhancers, bitter taste receptor blockers, sensory receptor activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, sodium cyclohexylsulfamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol) and other additives such as activated charcoal, chlorophyll, minerals, botanicals, or breath fresheners. They can be analogous, synthetic, or natural ingredients or blends thereof. They can be in any suitable form, such as liquids like oils, solids like powders, or gases.

[0077] In some instances, the flavoring agent contains menthol, spearmint, and / or peppermint. In some instances, the flavoring agent contains flavor components of cucumber, blueberry, citrus fruits, and / or cranberry. In some instances, the flavoring agent contains eugenol. In some instances, the flavoring agent contains flavor components extracted from tobacco.

[0078] In some instances, flavoring agents may include sensory substances designed to induce somatic sensations, which are typically chemically induced and perceived through stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or in place of aroma or taste nerves, and these may include agents that provide heat, coolness, tingling, or numbing effects. Suitable heat-acting agents may be (but are not limited to) vanillyl ether, and suitable coolants may be (but are not limited to) eucalyptol, WS-3.

[0079] Aerosol-generating materials are, for example, materials that are capable of generating aerosols when heated, irradiated, or otherwise powered. Aerosol-generating materials may, for example, be in liquid or gel form, and may or may not contain active substances and / or flavorings.

[0080] Aerosol generating materials may include one or more active substances and / or flavoring agents, one or more aerosol forming materials, and optionally one or more other functional materials.

[0081] Aerosol-forming materials may contain one or more components capable of forming aerosols. In some examples, aerosol-forming materials may contain one or more of the following: glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butanediol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurylate, diethyl octanoate, triethyl citrate, glyceryl triacetate, a mixture of diacetates, benzyl benzoate, benzyl phenylacetate, glyceryl tribocate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0082] One or more other functional materials may include one or more of pH adjusters, colorants, preservatives, binders, fillers, stabilizers and / or antioxidants.

[0083] As used herein, the term "consumable" can mean an article containing or composed of aerosol-generating material, some or all of which is intended to be consumed by the user during use. Consumables may contain one or more other components such as an aerosol-generating material storage area, an aerosol-generating material delivery component, an aerosol-generating area, a housing, packaging paper, a mouthpiece, a filter, and / or an aerosol modifier. Consumables may also contain an aerosol generator, such as a heater, which generates heat during use to induce the aerosol-generating material to generate aerosols. The heater may, for example, contain a combustible material, a electrically heated material, or a base. Consumables may be adapted to retain (or contain) aerosol-generating material. In this way, consumables may (but do not necessarily must) retain (or contain) aerosol-generating material.

[0084] As used herein, the term "base" refers to a material that can be heated by the penetration of a varying magnetic field, such as an alternating magnetic field. The base can be a conductive material, so that the penetration of the varying magnetic field causes induction heating of the heated material. The heated material can be a magnetic material, so that the penetration of the varying magnetic field causes hysteresis heating of the heated material. The base can be both conductive and magnetic, thus the base can be heated by both heating mechanisms. In this document, the device configured to generate the varying magnetic field is referred to as a magnetic field generator.

[0085] As used herein, the term "component" is used to refer to a part, section, unit, module, assembly, or the like in an electronic cigarette or similar device, which may incorporate smaller parts or elements within an outer housing or wall. An electronic cigarette may be formed or constructed from one or more of these components, and these components may be removably or individually connectable to each other, or may be permanently connected together during manufacturing to define a complete electronic cigarette. This disclosure applies to (but is not limited to) systems comprising two components and a device / control unit, the two components being independently connectable to each other and configured, for example, to hold a consumable / produce assembly (also referred to herein as a cartridge or cartomiser) of aerosol-generating material, the device / control unit having a battery for providing electrical power to operate elements for generating vapor from the aerosol-generating material.

[0086] Aerosol modifiers are substances typically located downstream of the aerosol generation zone, configured to alter the generated aerosols, for example, by changing taste, flavor, acidity, or another characteristic of the aerosol. Aerosol modifiers can be provided in a release component, which is operable to selectively release the aerosol modifier.

[0087] Aerosol modifiers can be, for example, additives or adsorbents. Aerosol modifiers can, for example, contain one or more of flavoring agents, coloring agents, water, and carbon adsorbents. Aerosol modifiers can be, for example, solid, liquid, or gel. Aerosol modifiers can be in powder, filament, or granule form. Aerosol modifiers may not contain filter materials.

[0088] An aerosol generator (or aerosol generating assembly) is a device configured to induce the generation of aerosols from aerosol generating materials. In some instances, an aerosol generator is a heater configured to subject the aerosol generating materials to thermal energy, thereby releasing one or more volatile substances from the aerosol generating materials to form an aerosol. In some instances, an aerosol generator is configured to induce the generation of aerosols from aerosol generating materials without heating. For example, an aerosol generator may be configured to subject the aerosol generating materials to one or more of vibration, pressure increase, or electrostatic energy.

[0089] Figure 1 This is a highly schematic diagram (not to scale) of an example of a non-flammable aerosol supply system (such as an electronic cigarette 10). The electronic cigarette 10 has a generally cylindrical shape that extends along the longitudinal axis indicated by the dashed line and includes two main components: a control or power supply component or part 20 (which may be referred to herein as a “device”) and a smokebox component or part 30 that functions as a vapor-generating component (which may be referred to herein as a “product”, “consumable”, “cartridge”, or “smokebox”).

[0090] Article 30 includes a storage chamber (also referred to herein as a “reservoir”) 3 containing aerosol-generating material comprising, for example, a liquid formulation from which aerosols are generated. The liquid formulation may or may not contain nicotine. For example, the aerosol-generating material may contain about 1% to 3% nicotine and 50% glycerin, the remainder comprising approximately propylene glycol, and may also contain other components such as water or flavoring agents. The storage chamber 3 is in the form of a tank, i.e., a container or reservoir in which the aerosol-generating material can be stored, allowing the aerosol-generating material to move and flow freely within the container or reservoir (if it is a liquid). Alternatively, the storage chamber 3 may contain an amount of absorbent material, such as cotton wool or glass fiber, which holds the aerosol-generating material within a porous structure. The storage chamber 3 may be sealed during manufacturing after filling so that it is disposable after the aerosol-generating material is consumed, or it may have an inlet or other opening through which new aerosol-generating material can be added. Article 30 also includes an electrical aerosol generator 4 located outside the storage chamber 3, which is used to generate aerosols by evaporation of the aerosol generating material. In various instances, the aerosol generator is a heating element (heater) that heats the aerosol generating material by the flow of an electric current (through resistance or induction heating) to raise the temperature until it evaporates. An aerosol generating material delivery assembly can be provided. Figure 1 (Not shown in the diagram), for example, a piping arrangement, such as a suction core or other porous element, to deliver aerosol-generating material from the storage chamber 3 to the aerosol generator 4. The aerosol-generating material delivery assembly may have one or more components located within the storage chamber 3 to absorb the aerosol-generating material and deliver it via suction core or capillary action to other parts of the aerosol-generating material delivery assembly in contact with the aerosol generator 4. The aerosol-generating material thus evaporates and is replaced by new aerosol-generating material delivered to the aerosol generator 4 via the aerosol-generating material delivery assembly.

[0091] The combination of a heater and a coil, or other arrangements of components that perform the same function, is sometimes referred to as an atomizer or atomizer assembly. Many designs are possible, among which... Figure 1Compared to a highly schematic illustration, the components can be arranged differently. For example, the absorbent core can be a completely separate element from the aerosol generator.

[0092] In some instances, the aerosol generating material delivery assembly 4 (e.g., a liquid line) for delivering liquid to generate vapor can be at least partially formed by one or more slots, tubes, or channels between the reservoir and the aerosol generator, the slots, tubes, or channels being narrow enough to support capillary action to draw source liquid from the reservoir and deliver it for evaporation. Typically, the atomizer can be considered as the aerosol generator 4 and the aerosol generating material delivery assembly (e.g., the liquid line), the aerosol generator 4 being able to generate vapor from the aerosol generating material delivered to it, and the aerosol generating material delivery assembly being able to deliver or transport liquid from the reservoir 3 or similar liquid storage to the aerosol generator by capillary action.

[0093] In some instances, the aerosol generator is at least partially located within an aerosol generation chamber, which forms part of the airflow path through the electronic cigarette / system. Vapor generated by the aerosol generator is driven into this chamber, and as air passes through it, it flows over and around the aerosol generator, collecting the generated vapor and thereby condensing it to form the desired aerosol.

[0094] Back Figure 1 The chimney assembly 30 also includes a mouthpiece 35 with an opening or air outlet through which a user can inhale aerosol generated by the aerosol generator 4 and delivered through an airflow channel.

[0095] The power supply assembly (or device) 20 includes a battery 5 (e.g., a “battery”), which may be rechargeable, to power the electrical components of the electronic cigarette 10, specifically the aerosol generator 4. Additionally, there is a printed circuit board 28 and / or other electronic devices or circuits for general control of the electronic cigarette 10. When vapor is needed, the control electronics / circuit connects the aerosol generating element 4 to the battery 5, for example, in response to a signal from a pressure sensor or airflow sensor (not shown) that detects inhalation on the system 10, during which air enters through one or more air inlets in the wall of the power supply assembly 20 to flow along an airflow channel. When the aerosol generator 4 receives electrical energy from the battery 5, the aerosol generator 4 causes aerosol generating material delivered from the storage chamber 3 to evaporate to produce an aerosol, which is then inhaled by the user through an opening in the mouthpiece 35. As the user inhales on the mouthpiece 35, the aerosol is carried to the mouthpiece 35 along an airflow channel (not shown) connecting the air inlet to the air outlet. Therefore, the airflow path through the electronic cigarette is limited to the air inlet (which may or may not be located in the power supply assembly 20) 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, thus allowing the atomizer to be described as being arranged downstream of the air inlet and upstream of the air outlet.

[0096] In this specific example, the power supply assembly 20 and the chimney assembly 30 are separate components that are detachable from each other by separating them in a direction parallel to the longitudinal axis. When the device 10 is in use, assemblies 20 and 30 are connected together by cooperating engagement elements 21 and 31 (e.g., threaded, magnetic, or bayonet joints), which provide mechanical and electrical connections between the power supply section 20 and the chimney assembly 30. This is only an example arrangement; however, various components may be distributed differently between the power supply section 20 and the chimney assembly 30, and other components and elements may be included. The two sections 20 and 30 can be as follows: Figure 1 The components are connected end-to-end in a longitudinal configuration or in a different configuration (e.g., parallel, side-by-side arrangement). The non-flammable aerosol supply system 10 may or may not be generally cylindrical and / or have a generally longitudinal shape. When depleted (e.g., the reservoir is empty or the battery is dead), any one or both parts can be discarded and replaced, or are intended for various uses achieved through actions such as refilling the reservoir, recharging the battery, or replacing the atomizer. Alternatively, the electronic cigarette 10 may be a single device that cannot be divided into two or more parts (disposable or refillable / rechargeable), in which case all components are included within a single body or housing. Examples of this disclosure apply to any of these configurations as well as other configurations that a person skilled in the art will recognize.

[0097] As mentioned herein, one type of aerosol generator (such as a heating element) that can be used in the atomizing portion (the portion configured to generate vapor from a source liquid) of an electronic cigarette 10 combines heating and liquid delivery functions through its properties of being both conductive (resistive) and porous. Note that in this document, "conductive (resistive)" refers to a component having the ability to generate heat in response to the flow of current therein. This flow can be imparted by so-called resistance heating or induction heating. An aerosol generator can have a sheet-like form, i.e., a planar shape whose thickness is many times smaller than its length or width. Planar aerosol generators may define curved surfaces, and in these cases, the reference to a planar aerosol generator forming a plane refers to an imaginary plane forming the best-fit plane through said component.

[0098] Aerosol generators (e.g., allotropes of carbon) may include pores and / or gaps of suitable size to provide capillary forces for wicking aerosol-generating materials (e.g., liquids). Therefore, aerosol generators (e.g., allotropes of carbon) can also be considered porous to facilitate the absorption and distribution of aerosol-generating materials (e.g., liquids). Furthermore, the presence of pores and / or gaps indicates that air can permeate through the aerosol generator. Additionally, at least a portion of the aerosol generator is conductive and thus suitable for resistance heating, wherein an electric current flowing through a resistive material generates heat.

[0099] An aerosol generator (e.g., planar and / or sheet-like) can be arranged within a non-flammable aerosol supply system (e.g., an electronic cigarette), such that the aerosol generator is located within an aerosol generation chamber forming part of an airflow channel. The aerosol generator can be oriented within the chamber such that the airflow through the chamber can flow in a surface direction, i.e., substantially parallel to the plane of the aerosol generator. 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 generator (e.g., an allotrope of carbon) and collect vapor. This effectively generates aerosols. In an alternative embodiment, the aerosol generator can be oriented within the chamber such that the airflow through the chamber can flow in a direction substantially transverse to the surface direction, i.e., substantially perpendicular to the plane of the aerosol generator. An example of this configuration can be found in WO2018 / 211252, the entire contents of which are incorporated herein by reference.

[0100] Aerosol generators (e.g., allotropes of carbon) can have high porosity. High porosity ensures that the heat generated by the aerosol generator is primarily used for liquid evaporation, resulting in high efficiency. Porosities greater than 50% are conceivable. In one example, the porosity of the aerosol generator is 50% or greater, 60% or greater, or 70% or greater.

[0101] The aerosol generator can form a generally planar structure comprising a first surface and a second surface. The generally planar structure can take the form of any two-dimensional shape, such as a circle, semicircle, triangle, square, rectangle, and / or polygon. The aerosol generator can have a uniform thickness.

[0102] When the aerosol generator (e.g., its carbon allotrope) is formed of a resistive material, current is allowed to flow through the aerosol generator (e.g., its carbon allotrope) to generate heat (so-called Joule heating). In this regard, the resistance of the aerosol generator (e.g., its carbon allotrope) can be suitably selected. For example, the aerosol generator (e.g., its carbon allotrope) can have a resistance of 1 ohm to 1000 ohms. For example, the aerosol generator (e.g., its carbon allotrope) can have a resistance of 1 ohm to 200 ohms. For example, the aerosol generator (e.g., its carbon allotrope) can have a resistance of 10 ohms to 150 ohms. For example, the aerosol generator (e.g., its carbon allotrope) can have a resistance of 20 ohms to 100 ohms. For example, an aerosol generator (e.g., its carbon allotrope) can have a resistance of 30 ohms to 70 ohms. For example, an aerosol generator (e.g., its carbon allotrope) can have a resistance of 40 ohms to 60 ohms. For example, an aerosol generator (e.g., its carbon allotrope) can have a resistance of 45 ohms to 55 ohms. In this respect, relatively low resistance will help to obtain higher power from the power source, which can be advantageous in producing high atomization rates. On the other hand, the resistance should not be so low as to compromise the integrity of the aerosol generator (e.g., its carbon allotrope). For example, the resistance cannot be less than 0.5 ohms.

[0103] method

[0104] According to a first aspect of this disclosure, a method is provided for manufacturing an aerosol generator 101 for use as part of a non-flammable aerosol supply system, the method comprising the following steps:

[0105] (I) Provide carbon precursor 101;

[0106] (II) A portion 103 of the outer surface of the carbon precursor 101 is irradiated with a laser beam, thereby forming a carbon allotrope 104.

[0107] In step (II), the laser beam will have a speed of approximately 0.10 J / mm. 2 To approximately 0.80 J / mm 2 The energy density is delivered to the irradiated portion 103 on the outer surface.

[0108] exist Figure 2 and Figure 3 The diagram schematically shows the aerosol generator 100 thus provided.

[0109] The inventors have developed a method for manufacturing an aerosol generator used as part of the provision of non-flammable aerosols, the method comprising irradiating a carbon precursor with a laser beam, thereby forming an allotrope of carbon.

[0110] The inventors have discovered that the characteristics of carbon allotropes can be influenced by changing the parameters of the laser beam irradiating them. For example, the inventors have found that the porosity, electrical conductivity, thermal conductivity, and mechanical integrity (or robustness) of carbon allotropes can be affected by changing the parameters. The inventors have adjusted the parameters to provide a porous, electrically and thermally conductive aerosol generator with the necessary mechanical integrity. In this way, the aerosol generator manufactured according to the method of the present invention can exhibit excellent performance, for example, excellent performance in terms of liquid delivery and distribution, aerosol generation, mechanical integrity, and heating and cooling times.

[0111] The inventors have discovered that the energy density of the laser beam in step (II) has a significant impact on the characteristics of carbon allotropes, and that approximately 0.10 J / mm² is used. 2 To approximately 0.80 J / mm 2 (For example, approximately 0.14 J / mm) 2 Approximately 0.54 J / mm 2 The energy density provides an aerosol generator that exhibits the desired performance, for example, in terms of liquid delivery and dispensing, aerosol generation, mechanical integrity, and heating and cooling times. In this regard, the inventors have discovered that using lower energy densities can provide carbon allotropes with low or no conductivity, while using higher energy densities can destroy carbon allotropes. Destruction of carbon allotropes can lead to partial shedding of carbon allotropes during use, reduced performance of carbon allotropes, and / or complete failure of carbon allotropes.

[0112] Step (I) — Providing a carbon precursor

[0113] Step (I) of the method includes providing a carbon precursor.

[0114] The term "carbon precursor" refers to materials that contain carbon.

[0115] It should be understood that a variety of carbon precursors can be used.

[0116] In some instances, carbon precursors are selected from plastics, glass, paper, and ceramics.

[0117] In some instances, the plastic is thermoplastic.

[0118] In some instances, the plastic is selected from polyimide, polyetherketone, polysulfone, or combinations thereof.

[0119] In some instances, the polyimide is selected from polyetherimides, polyamideimides, or combinations thereof. In some instances, the carbon precursor is a polyimide. In some instances, the polyimide is poly(4,4'-oxydiphenylene-pyromellitic acid imide). Poly(4,4'-oxydiphenylene-pyromellitic acid imide) is marketed under the trade name... HN (and others) The product is available commercially from DuPont.

[0120] In some instances, polyetherketone is selected from polyetheretherketone, polyetherketoneketone, polyetheretherketoneketone, polyetherketoneetherketone, or combinations thereof.

[0121] In some instances, the polysulfone is selected from poly(arylsulfone), poly(bisphenol-A sulfone), polyethersulfone, polyphenylene sulfone, poly(oxy-1,4-phenylenesulfonyl-1,4-phenylene) or combinations thereof.

[0122] In some instances, the glass is selected from silica glass, non-silica glass, or combinations thereof. In some instances, the silica glass is selected from borosilicate glass, quartz glass (fused silica), or combinations thereof.

[0123] In some instances, carbon precursor 101 comprises polyimide or polyetheretherketone.

[0124] In some instances, the carbon precursor is flexible.

[0125] In some instances, the carbon precursor 101 is non-porous. For example, when the carbon precursor 101 is a polyimide, the polyimide may be non-porous. It should be understood that "non-porous" can encompass embodiments in which at least one through-hole (102, as discussed below) is formed through the carbon precursor 101. In this way, the term "non-porous" can be considered to refer to the skeletal portion (or matrix) of the carbon precursor 101. These through-holes 102 can be effectively ignored relative to the evaluation of whether the carbon precursor 101 is non-porous (where these pores do not form the matrix of the carbon precursor 101).

[0126] In some instances, the carbon precursor 101 has a porous structure formed by pillars and interstitial pores (which may be referred to herein as “voids” and / or “gap”). An allotrope of carbon 104 can be formed on the pillars as a coating. For example, the interstitial pores can have an average pore size of 0.5 to 40 μm (although this can vary). The average pore size can be a median pore size or a mean pore size. The average pore size can be determined by methods including (but not limited to) mercury porosimetry or gas adsorption methods. These methods are familiar to those skilled in the art.

[0127] carbon precursor form

[0128] Carbon precursor 101 can be provided in various forms.

[0129] In some instances, the carbon precursor 101 has an outer surface. In some instances, the outer surface includes a first surface. The first surface may be substantially planar. In some instances, the outer surface includes a second surface. The second surface may be opposite to the first surface (referred to herein as the "opposing second surface"). The second surface may be substantially planar. In some instances, the carbon precursor 101 is substantially planar.

[0130] In some instances, the outer surface includes a first surface of a fundamental plane and a second surface of a fundamental plane opposite to the first surface.

[0131] In some instances, the thickness of carbon precursor 101 is from about 40 μm to about 500 μm.

[0132] In this paper, the thickness of carbon precursor 101 is measured perpendicular to the plane of carbon precursor 101 or laterally (e.g., from the first surface to the second surface).

[0133] In some examples, the thickness of carbon precursor 101 is from about 40 μm to about 300 μm. In some examples, the thickness of carbon precursor 101 is from about 80 μm to about 300 μm. In some examples, the thickness of carbon precursor 101 is from about 90 μm to about 200 μm. In some examples, the thickness of carbon precursor 101 is from about 100 μm to about 150 μm. In some examples, the thickness of carbon precursor 101 is from about 120 μm to about 130 μm.

[0134] Any thickness feature can be combined with any other feature of the carbon precursor 101. For example, in some instances, the carbon precursor 101 includes an outer surface and is substantially planar, the outer surface including a first substantially planar surface and a second substantially planar surface opposite to it, wherein the thickness of the carbon precursor 101 is from about 90 μm to about 200 μm, optionally from about 100 μm to about 150 μm, optionally from about 120 μm to about 130 μm, and optionally wherein the carbon precursor 101 is a polyimide.

[0135] Step (II) — Irradiation to form carbon allotropes

[0136] The method includes step (II) irradiating a portion 103 of the outer surface of the carbon precursor 101 with a laser beam, thereby forming a carbon allotrope 104. The carbon allotrope 104 may be porous. The carbon allotrope 104 may be electrically conductive. The carbon allotrope 104 may be thermally conductive. Referring to the accompanying drawings, Figure 2 The irradiated portion 103 is best shown. It will be understood that carbon allotropes 104 are formed in the irradiated portion 103, and therefore the figure numbers of these corresponding items refer to substantially the same locations.

[0137] In some instances, a portion 103 of the outer surface is part of the first surface. Thus, in some instances, the method includes step (II) irradiating a portion 103 of the first surface of the carbon precursor with a laser beam, thereby forming an allotrope of carbon 104.

[0138] Therefore, in some instances, the method includes the following steps:

[0139] (I) A carbon precursor 101 is provided, the carbon precursor 101 including an outer surface and being substantially planar, the outer surface including a first substantially planar surface and an opposing substantially planar second surface, wherein the thickness of the carbon precursor 101 is about 90 μm to about 200 μm, optionally about 100 μm to about 150 μm, optionally about 120 μm to about 130 μm, and optionally wherein the carbon precursor 101 is a polyimide; and

[0140] (II) A portion 103 of the first surface of the carbon precursor 101 is irradiated with a laser beam, thereby forming a carbon allotrope 104.

[0141] In step (II), the laser beam will have a speed of approximately 0.10 J / mm. 2 To approximately 0.80 J / mm 2 The energy density is delivered to the irradiated portion 103 of the first surface.

[0142] Formation of the irradiated part

[0143] The irradiation part 103 can take many forms.

[0144] In some instances, the irradiation section 103 takes the form of a rectangle.

[0145] In some examples, the length of the irradiation portion 103 is from about 0.5 mm to about 6 mm. In some examples, the length of the irradiation portion 103 is from about 1 mm to about 4 mm. In some examples, the length of the irradiation portion is from about 2 mm to about 3.2 mm. In some examples, the length of the irradiation portion 103 is from about 2.2 mm to about 3 mm. In some examples, the length of the irradiation portion 103 is from about 2.4 mm to about 2.8 mm. In any of these examples, the irradiation portion 103 may be rectangular in shape.

[0146] In some examples, the width of the irradiation portion 103 is from about 0.5 mm to about 6 mm. In some examples, the width of the irradiation portion 103 is from about 1 mm to about 4 mm. In some examples, the width of the irradiation portion 103 is from about 1.4 mm to about 2.6 mm. In some examples, the width of the irradiation portion 103 is from about 1.6 mm to about 2.2 mm. In some examples, the width of the irradiation portion 103 is from about 1.7 mm to about 2.1 mm. In any of these examples, the irradiation portion 103 may be rectangular.

[0147] In some examples, the length of the irradiation portion 103 is about 0.5 mm to about 6 mm and the width is about 0.5 mm to about 6 mm. In some examples, the length of the irradiation portion 103 is about 1 mm to about 4 mm and the width is about 0.5 mm to about 5 mm. In some examples, the length of the irradiation portion 103 is about 2 mm to about 3.2 mm and the width is about 1.4 mm to about 2.6 mm. In some examples, the length of the irradiation portion 103 is about 2.2 mm to about 3 mm and the width is about 1.6 mm to about 2.2 mm. In some examples, the length of the irradiation portion 103 is about 2.4 mm to about 2.8 mm and the width is about 1.7 mm to about 2.1 mm. In any of these examples, the irradiation portion 103 may be rectangular.

[0148] Energy density, scan rate and temperature

[0149] In step (II), the laser beam will be approximately 0.10 J / mm 2 To approximately 0.80 J / mm 2 The energy density is delivered to the irradiated portion 103 on the outer surface.

[0150] It's understandable that laser beams can have different intensity spectra. For example, a Gaussian laser beam has a Gaussian intensity spectrum, while a flat-top laser beam has a essentially constant intensity spectrum.

[0151] In this document, "energy density" refers to the amount of energy delivered per unit area by the laser beam to a portion of the outer surface. Those skilled in the art will readily understand how to determine and specify the energy density of a laser beam. In this document, when the laser beam has a Gaussian intensity spectrum, 1 / e of the laser beam's energy density is used. 2 The beam diameter determines the energy density of the laser beam.

[0152] For example, energy density can be expressed by the following formula:

[0153]

[0154] Wherein, energy density is the amount of energy delivered by the laser beam per unit surface area, power is the power of the laser beam, speed is the scanning speed of the laser beam, and beam diameter is the beam diameter of the laser beam (e.g., 1 / e). 2 As discussed in this paper, when the laser beam has a Gaussian intensity spectrum, the beam diameter is 1 / e. 2 Beam diameter.

[0155] In some instances, the energy density is substantially constant in step (II). In other instances, the energy density varies in step (II).

[0156] In some instances, in step (II), the laser beam will be approximately 0.10 J / mm. 2 To approximately 0.60 J / mm 2 The energy density is delivered to the irradiated portion 103 of the outer surface. In some instances, in step (II), the laser beam delivers approximately 0.14 J / mm². 2 Approximately 0.54 J / mm 2 The energy density is delivered to the irradiated portion 103 of the outer surface. In some instances, in step (II), the laser beam will deliver approximately 0.25 J / mm². 2 Approximately 0.35 J / mm 2 The energy density is delivered to the irradiated portion 103 of the outer surface. In some instances, in step (II), the laser beam delivers approximately 0.30 J / mm². 2 Approximately 0.35 J / mm 2 The energy density is delivered to the irradiated portion 103 on the outer surface.

[0157] In some examples, in step (II), the scanning speed of the laser beam is from about 1 mm / s to about 450 mm / s. In some examples, in step (II), the scanning speed of the laser beam is from about 50 mm / s to about 450 mm / s. In some examples, in step (II), the scanning speed of the laser beam is from about 100 mm / s to about 450 mm / s. In some examples, in step (II), the scanning speed of the laser beam is from about 150 mm / s to about 450 mm / s. In some examples, in step (II), the scanning speed of the laser beam is from about 200 mm / s to about 450 mm / s.

[0158] In some instances, in step (II), the laser beam illuminates a portion of the outer surface along one or more scan lines. The scan lines can be straight. The scan lines can be curved. The scan lines can form a scan pattern. It will be understood that the scan pattern overlaps with a portion of the outer surface. The scan pattern can contain multiple lines (e.g., straight lines) that can be arranged side-by-side. Adjacent scan lines can be spaced apart from each other. Adjacent scan lines can be adjacent to each other. Adjacent scan lines can overlap each other. The peak intensity of the laser beam is delivered at the center point (or central axis) of the scan line. In some instances, in step (II), the spacing between the center points (or central axes) of adjacent scan lines is approximately equal to the beam diameter of the laser beam (1 / e). 2 The distance.

[0159] In some instances, in step (II), adjacent scan lines overlap (to provide an overlap region), such that the overlap region receives at least about 13.5% of the peak intensity of the subsequent laser beam. In some instances, in step (II), adjacent scan lines overlap, such that the overlap region receives at least about 20% of the peak intensity of the subsequent laser beam. In some instances, in step (II), adjacent scan lines overlap, such that the overlap region receives at least about 40% of the peak intensity of the subsequent laser beam. In some instances, in step (II), adjacent scan lines overlap, such that the overlap region receives at least about 50% of the peak intensity of the subsequent laser beam. In some instances, in step (II), adjacent scan lines overlap, such that the overlap region receives at least about 60% of the peak intensity of the subsequent laser beam. In some instances, in step (II), adjacent scan lines overlap, such that the overlap region receives at least about 80% of the peak intensity of the subsequent laser beam. In some instances, in step (II), adjacent scan lines overlap, such that the overlapping region receives at least about 90% of the peak intensity of the subsequent laser beam.

[0160] In some instances, in step (II), the laser beam moves along one or more scan lines at a certain scanning speed. The scanning speed can be constant. This can improve the uniformity of the resulting carbon allotrope 104 and improve the consistency of its properties. It will be understood that the laser beam can be de-energized between adjacent scan lines.

[0161] In some instances, in step (II), irradiating a portion of the outer surface causes that portion of the outer surface to reach a temperature of about 1000°C to about 3500°C. In some instances, in step (II), irradiating a portion of the outer surface causes that portion of the outer surface to reach a temperature of about 1350°C to about 3300°C. In some instances, in step (II), irradiating a portion of the outer surface causes that portion of the outer surface to reach a temperature of about 1500°C to about 3000°C. In some instances, in step (II), irradiating a portion of the outer surface causes that portion of the outer surface to reach a temperature of about 1700°C to about 2600°C. In some instances, in step (II), irradiating a portion of the outer surface causes that portion of the outer surface to reach a temperature of about 1800°C to about 2200°C.

[0162] What you'll understand is that this temperature corresponds to the peak temperature of a portion of the outer surface.

[0163] Any features related to energy density, scan rate, and temperature in step (II) can be combined.

[0164] laser

[0165] In some instances, step (II) of the method is implemented using the Keyence ML-Z9610 laser system. It will be understood that other laser systems may be used.

[0166] In some instances, the laser beam has a Gaussian intensity spectrum in step (II). In other instances, the laser beam has a substantially constant intensity spectrum in step (II).

[0167] Step (II) Parameters

[0168] Those skilled in the art will understand that in step (II), the properties of the laser beam can be altered. For example, they will understand that specific energy density values ​​can be provided using different combinations of laser beam parameters. These laser beam parameters include, for example, wavelength, beam diameter, and power.

[0169] The laser beam in step (II) is generated by a laser. In some instances, the laser in step (II) is an infrared laser. In some instances, the laser in step (II) is a carbon dioxide laser.

[0170] In some instances, in step (II), the laser beam has a wavelength of about 8 μm to about 16 μm. In some instances, in step (II), the laser beam has a wavelength of about 9 μm to about 14 μm. In some instances, in step (II), the laser beam has a wavelength of about 10 μm to about 12 μm (e.g., about 10.6 μm).

[0171] In some instances, in step (II), the beam diameter of the laser beam (1 / e) 2 The diameter of the laser beam is approximately 120 μm to 160 μm. In some instances, in step (II), the beam diameter of the laser beam (1 / e) is... 2 The diameter of the laser beam is approximately 130 μm to 150 μm. In some instances, in step (II), the beam diameter of the laser beam (1 / e) is... 2 The diameter is approximately 135 μm to 145 μm (e.g., approximately 140 μm). What a technician will understand is the term "beam diameter (1 / e)". 2 )".

[0172] In some instances, the power of the laser beam in step (II) is from 1W to approximately 30W. In some instances, the power of the laser beam in step (II) is from approximately 3W to approximately 25W. In some instances, the power of the laser beam in step (II) is from approximately 6W to approximately 21W.

[0173] In some instances, in step (II), the laser beam has: a wavelength of about 8 μm to about 16 μm; and a beam diameter of about 120 μm to 160 μm (1 / e 2 ); and / or power from about 1W to about 30W.

[0174] In some instances, in step (II), the laser beam has: a wavelength of about 9 μm to about 14 μm; and a beam diameter of about 130 μm to 150 μm (1 / e 2 ); and / or power from about 6W to about 21W.

[0175] In some instances, in step (II), the laser beam has: a wavelength of about 10 μm to about 12 μm; and a beam diameter of about 135 μm to 145 μm (1 / e 2 ); and / or power from about 6W to about 21W.

[0176] Any laser beam parameters can be combined with any other feature of the method.

[0177] combination

[0178] In some instances, the method includes the following steps:

[0179] (I) Provide carbon precursor 101; and

[0180] (II) A portion 103 of the outer surface of the carbon precursor 101 is irradiated with a laser beam, thereby forming a carbon allotrope 104.

[0181] In step (II), the laser beam will have a speed of approximately 0.10 J / mm. 2 To approximately 0.80 J / mm 2 Optionally, approximately 0.14 J / mm 2 Approximately 0.54 J / mm 2 Optional, approximately 0.25 J / mm 2 Approximately 0.35 J / mm 2 Optional, approximately 0.30 J / mm 2 Approximately 0.35 J / mm 2 The energy density is delivered to the irradiated portion 103 on the outer surface.

[0182] Optionally, in step (II), the laser beam may have a scanning speed of approximately 1 mm / s to approximately 450 mm / s, optionally approximately 50 mm / s to approximately 450 mm / s, optionally approximately 100 mm / s to approximately 450 mm / s, or optionally approximately 150 mm / s to approximately 450 mm / s.

[0183] Optionally, in step (II), irradiating a portion of the outer surface causes that portion of the outer surface to reach a temperature of about 1,000°C to about 3,500°C, optionally about 1,350°C to about 3,300°C, optionally about 1,500°C to about 3,000°C, optionally about 1,700°C to about 2,600°C.

[0184] For example, the method may include the following steps:

[0185] (I) Provide carbon precursor 101; and

[0186] (II) A portion 103 of the outer surface of the carbon precursor 101 is irradiated with a laser beam, thereby forming a carbon allotrope 104.

[0187] In step (II), the laser beam will have a speed of approximately 0.10 J / mm. 2 To approximately 0.80 J / mm 2 The energy density is delivered to the irradiated portion 103 on the outer surface.

[0188] Optionally, in step (II), the laser beam has a scanning speed of about 1 mm / s to about 450 mm / s.

[0189] Optionally, in step (II), irradiating a portion of the outer surface causes that portion of the outer surface to reach a temperature of about 1000°C to about 3500°C.

[0190] For example, the method may include the following steps:

[0191] (I) Provide carbon precursor 101; and

[0192] (II) A portion 103 of the outer surface of the carbon precursor 101 is irradiated with a laser beam, thereby forming a carbon allotrope 104.

[0193] In step (II), the laser beam will have a speed of approximately 0.14 J / mm. 2 Approximately 0.54 J / mm 2 The energy density is delivered to the irradiated portion 103 on the outer surface.

[0194] Optionally, in step (II), the laser beam has a scanning speed of approximately 50 mm / s to approximately 450 mm / s.

[0195] Optionally, in step (II), irradiating a portion of the outer surface causes that portion of the outer surface to reach a temperature of about 1350°C to about 3300°C, optionally about 1500°C to about 3000°C, or optionally about 1700°C to about 2600°C.

[0196] For example, the method may include the following steps:

[0197] (I) Provide carbon precursor 101; and

[0198] (II) A portion 103 of the outer surface of the carbon precursor 101 is irradiated with a laser beam, thereby forming a carbon allotrope 104.

[0199] In step (II), the laser beam will have a speed of approximately 0.14 J / mm. 2 Approximately 0.54 J / mm 2 Optional, approximately 0.25 J / mm 2 Approximately 0.35 J / mm 2 The energy density is delivered to the irradiated portion 103 on the outer surface.

[0200] Optionally, in step (II), the laser beam has a scanning speed of approximately 100 mm / s to approximately 450 mm / s.

[0201] Optionally, in step (II), irradiating a portion of the outer surface causes that portion of the outer surface to reach a temperature of about 1350°C to about 3300°C, optionally about 1500°C to about 3000°C, or optionally about 1700°C to about 2600°C.

[0202] For example, the method may include the following steps:

[0203] (I) Provide carbon precursor 101; and

[0204] (II) A portion 103 of the outer surface of the carbon precursor 101 is irradiated with a laser beam, thereby forming a carbon allotrope 104.

[0205] In step (II), the laser beam will have a speed of approximately 0.14 J / mm. 2 Approximately 0.54 J / mm 2 Optional, approximately 0.25 J / mm 2 Approximately 0.35 J / mm 2 The energy density is delivered to the irradiated portion 103 on the outer surface.

[0206] Optionally, in step (II), the laser beam has a scanning speed of approximately 150 mm / s to approximately 450 mm / s.

[0207] Optionally, in step (II), irradiating a portion of the outer surface causes that portion of the outer surface to reach a temperature of about 1350°C to about 3300°C, optionally about 1500°C to about 3000°C, or optionally about 1700°C to about 2600°C.

[0208] Any of the above combinations (referred to herein as "the above combinations") may include any other features disclosed herein. For example, in any of the above combinations, the carbon precursor 101 may include an outer surface and be substantially planar, the outer surface comprising a first substantially planar surface and an opposing substantially planar second surface, wherein the thickness of the carbon precursor 101 is from about 90 μm to about 200 μm, optionally from about 100 μm to about 150 μm, optionally from about 120 μm to about 130 μm. For example, in any of the above combinations, the carbon precursor 101 may be polyimide. A portion of the outer surface may be the first surface or a portion thereof.

[0209] Fluid guide hole

[0210] The method may include step (III) irradiating a portion 103' of the outer surface of the carbon precursor 101 with a laser beam, thereby forming a through-hole 102 in the carbon precursor. It will be understood that "through-hole" means "at least one through-hole". In some instances, the method includes step (III) irradiating a portion 103' of the outer surface of the carbon precursor 101 with a laser beam, thereby forming a plurality of through-holes 102 in the carbon precursor. The through-hole 102 may be as defined herein.

[0211] The inventors have discovered that the through-hole 102 helps to facilitate the transport of liquid through and / or through the carbon allotrope 104 during use and can provide improved aerosol generation performance.

[0212] In some instances, in step (III), a portion 103' of the outer surface is a first surface. Therefore, in some instances, the method includes step (III) irradiating a portion 103' of the outer surface of the carbon precursor 101 with a laser beam, thereby forming a through-hole 102 in the carbon precursor 101.

[0213] In some instances, the opening of the through-hole 102 is close to the carbon allotrope 103. For example, in Figure 2 and Figure 3 This arrangement is shown in the image.

[0214] In some instances, step (II) occurs before step (III).

[0215] In a preferred embodiment, step (II) occurs after step (III). Performing step (III) before step (II) helps to remove any debris produced by step (III) before performing step (II). Conversely, performing step (II) before step (III) can result in the destruction of the carbon allotrope 104.

[0216] In some instances, steps (II) and (III) are performed using different laser systems.

[0217] In some instances, steps (II) and (III) are performed using a single laser system.

[0218] In some instances, the opening portion of the through-hole 102 is partially or completely covered by the carbon allotrope 103. The inventors have found that these arrangements help improve the transport and distribution of aerosol-generating materials through and / or via the carbon allotrope 104.

[0219] In some instances, the carbon allotrope 103 extends at least partially into the through-hole 102. The inventors have found that these arrangements help improve the transport and distribution of aerosol-generating materials through and / or via the carbon allotrope 104.

[0220] In some instances, the diameter of the through-hole 102 is from about 1 μm to about 300 μm. In some instances, the diameter of the through-hole 102 is from about 5 μm to about 200 μm. In some instances, the diameter of the through-hole 102 is from about 30 μm to about 100 μm. The inventors have found that these diameters help improve the transport of the aerosol-generating material to the outer surface of the carbon allotrope 104. The inventors have also found that these diameters do not result in significant leakage of the aerosol-generating material.

[0221] In some instances, the irradiated portion 103' in step (III) is within the irradiated portion 101 in step (II). For example, when viewed in a plane or laterally extending orthogonal to the carbon allotrope 104, the irradiated portion 103' in step (III) may be within the outer perimeter of the irradiated portion 101 in step (II).

[0222] In some instances, when viewed in a plane or laterally extending orthogonal to the carbon allotrope 104, the or each through-hole 102 is within the outer perimeter of the carbon allotrope 104.

[0223] Any feature relating to step (III) may be combined with any other feature of the method. For example, any feature relating to step (III) may be combined with any of the combinations described above.

[0224] For example, the method may include the following steps:

[0225] (I) Provide carbon precursor 101;

[0226] (II) A portion 103 of the outer surface of the carbon precursor 101 is irradiated with a laser beam, thereby forming a carbon allotrope 104.

[0227] (III) A portion 103' of the outer surface of the carbon precursor 101 is irradiated with a laser beam, thereby forming a through-hole 102 in the carbon precursor 101.

[0228] In step (II), the laser beam will have a speed of approximately 0.14 J / mm. 2 Approximately 0.54 J / mm 2 The energy density is delivered to the irradiated portion 103 on the outer surface.

[0229] Optionally, in step (II), the laser beam has a scanning speed of approximately 150 mm / s to approximately 450 mm / s.

[0230] Optionally, in step (II), irradiating a portion of the outer surface causes that portion of the outer surface to reach a temperature of approximately 1000°C to approximately 3500°C, optionally approximately 1350°C to approximately 3300°C, optionally approximately 1500°C to approximately 3000°C, or optionally approximately 1700°C to approximately 2600°C.

[0231] Optionally, the diameter of the through hole 102 is about 5 μm to about 200 μm, or optionally about 30 μm to about 100 μm.

[0232] Allotropes of carbon

[0233] The inventors have discovered that the carbon allotrope 104 provides a particularly effective aerosol generator in non-flammable aerosol supply systems. The carbon allotrope 104 can be considered to provide a carbon-containing surface that can be distributed from the aerosol-generating material and generate aerosols during use. Not wishing to be bound by theory, it is believed that when the carbon allotrope 104 is heated to a temperature used for generating aerosols from the aerosol-generating material, the carbon-containing surface can have a high surface free energy and therefore high wettability (e.g., a low contact angle). In this way, when the carbon allotrope 104 is heated to a temperature used for generating aerosols from the aerosol-generating material, a thin layer of the aerosol-generating material can be uniformly distributed on the carbon-containing surface of the carbon allotrope 104 and effectively atomized. Furthermore, the carbon allotrope 104 has a high power density and low thermal mass, and a small volume of aerosol-generating material can be formed thinly across a given surface region of the carbon allotrope 104, unlike materials with surfaces through which aerosol-generating materials cannot be formed thinly. This provides efficient energy delivery to the aerosol-generating material during use.

[0234] The carbon allotrope 104 can be formed as a foam. It will be understood that "carbon allotrope formed as a foam" means that the carbon allotrope itself is a foam. The foam may include a foam structure and multiple cells. It will be understood that the carbon allotrope 104 forms a foam structure, and the foam structure defines multiple cells. The foam structure may define multiple cells. The multiple cells may be interconnected. The foam may be an open-cell foam, such as a mesh foam. It will be understood that the foam is a solid foam (e.g., at 101325 Pa, at least 20°C to 350°C). The carbon allotrope 104 may include a capillary structure. For example, the foam may include a capillary structure.

[0235] Allotropes of carbon 104, which form the foam, have been found to provide a particularly effective aerosol generator 100. Without being bound by theory, it is believed that once a hot spot (a localized area of ​​elevated temperature that may occur when a portion of the heated aerosol generator dries out during use) forms, the foam (which can have high thermal and electrical conductivity) can effectively dissipate heat, reduce temperature variations, and lessen the severity of the hot spot. In turn, the aerosol generator 100 can operate at high power levels, which reduces the risk of hot spots causing damage to the aerosol generator. Furthermore, the foam can accommodate thermal expansion during use. Accordingly, the foam can withstand heat-induced degradation during use. It has also been found that foam can help reduce battery production capacity and / or extend battery life. Additionally, foam has been found to provide reduced battery size requirements and thus improve packaging efficiency, for example, in terms of cost and space requirements. Moreover, foam can facilitate rapid evaporation of the aerosol-generating material, which can enhance the user experience by reducing the time it takes to generate an aerosol in response to the user's first inhalation (“first puff”). In addition, foam can help ensure consistency between each inhalation ("consistency between puffs"). The use of foam can also provide certain user experience advantages associated with traditionally manufactured cigarettes.

[0236] When carbon allotropes 104 are formed as foams, the foam may comprise multiple layers. Each layer may comprise or consist of carbon atoms arranged in a hexagonal lattice structure, such as a honeycomb lattice structure.

[0237] When carbon allotropes 104 are formed as foam, carbon allotropes 104 can be called "carbon foam".

[0238] It will be understood that carbon foam includes, for example, graphite foam, graphene foam, or any other carbon-based foam.

[0239] It is understood that a variety of methods can be used to create foam, including (but not limited to) arc discharge, laser ablation, laser-induced, laser-induced pyrolysis, high-pressure carbon monoxide dismutation reaction, and chemical vapor deposition.

[0240] In some instances, the carbon allotrope 104 comprises structured carbon to contain multiple carbon-carbon bonds located in the same plane. For example, the carbon allotrope 104 may comprise graphite. In the case where the carbon allotrope 104 comprises graphite, the carbon allotrope 104 comprises multiple stacked layers of carbon atoms, each layer of carbon atoms bonded to three adjacent carbon atoms in that layer, wherein each bond is located in the same plane to form a hexagonal lattice structure. Non-covalent bonds exist between the stacked layers. Therefore, graphite comprises multiple stacked carbon layers, wherein the carbon layers are parallel to each other. Graphite exists in two forms: α-graphite, where the layers are ABA stacked; and β-graphite, where the layers are ABC stacked.

[0241] In some instances, the carbon allotrope 104 comprises graphene. For example, the carbon allotrope 104 can be graphene. In cases where the carbon allotrope 104 is (or comprises) graphene, a single layer of carbon atoms (i.e., a carbon layer one atom thick) is arranged such that the carbon atoms form a hexagonal lattice structure. The inventors have found that graphene provides an efficient aerosol generator. Advantageously, once hot spots (localized areas of elevated temperature that may occur when a portion of the heated aerosol generator dries out during use) form, the high thermal and electrical conductivity of graphene allows it to dissipate heat effectively, reducing temperature variations and mitigating the severity of hot spots. In turn, the aerosol generator 100 can operate at high power levels, which reduces the risk of hot spots causing damage to the aerosol generator. Furthermore, graphene can be elastic and thus conforms to thermal expansion during use (e.g., of electrically insulating substrates; as discussed below). Therefore, the aerosol generator 100 can withstand degradation caused by, for example, the difference in the coefficients of thermal expansion between graphene and the electrically insulating substrate. The use of graphene has also been found to provide reduced battery production capacity and thus extended battery life. Additionally, the use of graphene can provide reduced battery size requirements and thus improve packaging efficiency, for example, in terms of cost and space requirements. Furthermore, the use of graphene can facilitate the rapid evaporation of the aerosol-generating material, which can enhance the user experience by reducing the time it takes to generate an aerosol in response to the user's first inhalation ("first puff"). Moreover, the use of graphene can contribute to consistency between each inhalation ("consistency between puffs"). The use of graphene can also provide certain user experience advantages associated with conventionally manufactured cigarettes.

[0242] In the case where the carbon allotrope 104 includes graphene, more than one layer of graphene can exist. In the presence of more than one layer of graphene, at least two layers can be non-parallel relative to each other. "Non-parallel" means that an imaginary plane passing through one layer of graphene (or a best-fit imaginary plane passing through a non-planar graphene layer) is not parallel to an imaginary plane passing through another layer of graphene (or a best-fit imaginary plane passing through another non-planar graphene layer). In use, the graphene layers are electrically connected to form current paths. By providing non-parallel graphene layers, a porous graphene structure can be provided. At typical atomization temperatures, the combination of graphene's porosity and low surface energy allows aerosol-generating materials to be effectively distributed not only on the outermost surface of the graphene layer but also throughout the overall graphene structure. In effect, aerosol-generating materials can be provided in close contact with the increased surface area of ​​the heating material provided by the graphene layers. This provides efficient and effective atomization performance. For example, at least three, at least four, at least five, at least six, at least eight, or at least ten graphene layers may be non-parallel to each other. In the case of more than one layer of graphene, at least two layers of graphene may be parallel to each other. For example, carbon allotrope 104 may be a bilayer of graphene.

[0243] In the case where the carbon allotrope 104 includes graphene, the carbon allotrope 104 (e.g., one or more layers of graphene) may include three-dimensional graphene (which may be referred to as porous graphene or laser-induced graphene (LIG)) or be in the form of three-dimensional graphene. Three-dimensional graphene can be considered as one or more graphene sheets (or layers) folded back (e.g., on top of each other) to form a three-dimensional structure. Not wishing to be bound by theory, it is believed that in the main sp... 2 Interatomic bonds are formed between hybrid orbitals in three-dimensional graphene, and the major local coordination of carbon atoms in three-dimensional graphene is similar to that in two-dimensional graphene, thus allowing two-dimensional and three-dimensional graphene to possess similar electronic properties. Graphene foam (described below) can be considered an example of three-dimensional graphene.

[0244] In examples comprising one or more layers of graphene, the one or more layers can be provided in a variety of forms. For example, one or more layers of graphene can be formed as a variety of three-dimensional structures. The three-dimensional graphene structure can be selected from cubes, cuboids, cones, cylinders (e.g., tubes), spheres, pyramids, and / or prisms. It will be understood that a variety of methods can be used to produce three-dimensional graphene structures, including (but not limited to) arc discharge, laser ablation, high-pressure carbon monoxide dismutation reaction, and chemical vapor deposition.

[0245] In some preferred embodiments, carbon allotrope 104 is porous.

[0246] In some preferred embodiments, the allotrope of carbon 104 comprises disordered graphite and / or amorphous carbon. In some preferred embodiments, the allotrope of carbon 104 is selected from disordered graphite, amorphous carbon, or combinations thereof. In some preferred embodiments, the allotrope of carbon 104 comprises disordered graphite and / or amorphous carbon and / or nanocrystalline graphite. In some preferred embodiments, the allotrope of carbon 104 is selected from disordered graphite, amorphous carbon, nanocrystalline graphite, or combinations thereof.

[0247] The Raman spectrum of carbon allotrope 104 includes the G and D bands. The Raman spectrum of carbon allotrope 104 also includes the 2D band.

[0248] In some instances, the Raman spectrum of carbon allotrope 104 includes approximately 1500 cm⁻¹. -1 Approximately 1650cm -1 The G-band peak is located within the Raman shift range. In these embodiments, the Raman spectrum of carbon allotrope 104 can be included in the range of approximately 1250 cm⁻¹. -1 Approximately 1400cm -1 The D-band peaks are within the Raman shift range. In these examples, the Raman spectra of carbon allotrope 104 can be found at approximately 2600 cm⁻¹. -1 Approximately 2750cm -1 2D band peaks within the Raman shift range.

[0249] In some instances, the Raman spectrum of carbon allotrope 104 includes a range of approximately 1550 cm⁻¹. -1 Approximately 1590cm -1 The G-band peaks are within the Raman shift range. In these examples, the Raman spectra of carbon allotrope 104 can be found at approximately 1310 cm⁻¹. -1 Approximately 1340cm -1 The D-band peaks are within the Raman shift range. In these examples, the Raman spectra of carbon allotrope 104 can be found at approximately 2620 cm⁻¹. -1 Approximately 2680cm -1 2D band peaks within the Raman shift range.

[0250] Intensity of D band peak I D The intensity of the G-band peak I G The ratio of I D / I G It can be approximately 0.8 to approximately 2. D / I G The ratio can be from approximately 0.9 to approximately 1.9. D / I G The ratio can be from about 1 to about 1.8.

[0251] Intensity of D band peak ID The intensity of the G-band peak I G The ratio of I D / I G The intensity of the D band peak can range from approximately 0.2 to approximately 2. D The intensity of the G-band peak I G The ratio of I D / I G The intensity of the D band peak can range from approximately 0.2 to approximately 1.6. D The intensity of the G-band peak I G The ratio of I D / I G The intensity of the D band peak can range from approximately 0.2 to approximately 1.4. D The intensity of the G-band peak I G The ratio of I D / I G The intensity of the D band peak can be from approximately 0.3 to approximately 1.2. D The intensity of the G-band peak I G The ratio of I D / I G It can be from approximately 0.4 to approximately 0.8. The intensity of the D band peak I D The intensity of the G-band peak I G The ratio of I D / I G It can be from about 0.4 to about 0.6.

[0252] The G-band peak can have a length of approximately 30 cm⁻¹ -1 Approximately 100cm -1 The full width at half maximum (FWHM) of the peak. The G-band peak can have a full width at half maximum (FWHM) of approximately 30 cm⁻¹. -1 Approximately 70cm -1 FWHM.

[0253] 2D bands can conform to either the Gaussian curve model or the Lorentz curve model.

[0254] Any of the above features associated with Raman spectroscopy can be combined. In some instances, the Raman spectrum of carbon allotrope 104 includes both G and D bands, with the G band peak at approximately 1500 cm⁻¹. -1 Approximately 1650cm -1 Within the Raman shift range, and the D-band peak is at approximately 1250 cm⁻¹. -1 Approximately 1400cm -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 of I D / I G The value is approximately 0.8 to approximately 2. In some embodiments, the Raman spectrum of carbon allotrope 104 includes G and D bands, with the G band peak at approximately 1550 cm⁻¹.-1 Approximately 1590cm -1 Within the Raman shift range, and the D-band peak is at approximately 1310 cm⁻¹. -1 Approximately 1340cm -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 of I D / I G It is approximately 1 to approximately 1.8.

[0255] In some preferred embodiments, the Raman spectrum of carbon allotrope 104 includes G and D bands, with the G band peak at approximately 1550 cm⁻¹. -1 Approximately 1590cm -1 Within the Raman shift range, and the D-band peak is at approximately 1310 cm⁻¹. -1 Approximately 1340cm -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 of I D / I G The value is approximately 0.2 to approximately 2. In some preferred embodiments, the Raman spectrum of the carbon allotrope 104 includes a G band and a D band, wherein the G band peak is at approximately 1550 cm⁻¹. -1 Approximately 1590cm -1 Within the Raman shift range, and the D-band peak is at approximately 1310 cm⁻¹. -1 Approximately 1340cm -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 of I D / I G The value is approximately 0.2 to approximately 1.6. In some preferred embodiments, the Raman spectrum of the carbon allotrope 104 includes G and D bands, wherein the G band peak is at approximately 1550 cm⁻¹. -1 Approximately 1590cm -1 Within the Raman shift range, and the D-band peak is at approximately 1310 cm⁻¹. -1 Approximately 1340cm -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 of I D / I G The value is approximately 0.2 to approximately 1.4. In some preferred embodiments, the Raman spectrum of the carbon allotrope 104 includes G and D bands, wherein the G band peak is at approximately 1550 cm⁻¹. -1 Approximately 1590cm -1Within the Raman shift range, and the D-band peak is at approximately 1310 cm⁻¹. -1 Approximately 1340cm -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 of I D / I G The value is approximately 0.3 to approximately 1.2. In some preferred embodiments, the Raman spectrum of the carbon allotrope 104 includes G and D bands, wherein the G band peak is at approximately 1550 cm⁻¹. -1 Approximately 1590cm -1 Within the Raman shift range, and the D-band peak is at approximately 1310 cm⁻¹. -1 Approximately 1340cm -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 of I D / I G The value is approximately 0.4 to approximately 0.8. In some preferred embodiments, the Raman spectrum of carbon allotrope 104 includes G and D bands, with the G band peak at approximately 1550 cm⁻¹. -1 Approximately 1590cm -1 Within the Raman shift range, and the D-band peak is at approximately 1310 cm⁻¹. -1 Approximately 1340cm -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 of I D / I G It is approximately 0.4 to approximately 0.6.

[0256] In this paper, Raman microspectroscopy was used to measure Raman spectra. A laser wavelength of 638 nm was used for Raman microspectroscopy. A grating with 1800 grooves / mm was used for Raman microspectroscopy. A laser power of 10.9 mW was used for Raman microspectroscopy. A 5-second acquisition time was used for Raman microspectroscopy. 20 accumulations were used for Raman microspectroscopy. Raman microspectroscopy was performed through a 300 μm confocal pinhole. A wavelength of approximately 1000 cm⁻¹ was used for the acquisition. -1 Approximately 3000cm -1Raman microspectroscopy was performed within the specified wavelength range. In this study, Raman microspectroscopy was performed using a microscope objective with a 50×LWD (long focal length) and a 0.8NA (numerical aperture). A Horiba Xplora Plus Raman microspectrometer was also used. Raman microspectroscopy was performed at 21 °C. The carbon allotrope 104 subjected to Raman microspectroscopy was not used in this study. That is, the carbon allotrope 104 was not used to generate aerosols and / or was not heated to the typical nebulization temperature (after the fabrication of the carbon allotrope 104).

[0257] What one will understand is that carbon allotrope 104 is thermally conductive. What one will understand is that carbon allotrope 104 is electrically conductive.

[0258] Carbon allotrope 104 can have 100 Wm -1 K -1 Up to 5500Wm -1 K -1 The thermal conductivity of carbon allotrope 104 can be 100 W / m². -1 K -1 Up to 4000Wm -1 K -1 The thermal conductivity of carbon allotrope 104 can be 100 W / m². -1 K -1 Up to 2000Wm -1 K -1 The thermal conductivity of carbon allotrope 104 can be 150 W / m². -1 K -1 Up to 1000Wm -1 K -1 The thermal conductivity of carbon allotrope 104 can be 180 W / m². -1 K -1 Up to 700Wm -1 K -1 The thermal conductivity of carbon allotrope 104 can be 200 W / m². -1 K -1 Up to 500Wm -1 K -1 Thermal conductivity.

[0259] Carbon allotrope 104 can have 1Sm -1 Up to 2.5×10 6 Sm -1 The electrical conductivity. Carbon allotropes 104 can have a conductivity of 100 Sm. -1 Up to 1.0×10 6 Sm -1The electrical conductivity. Carbon allotropes 104 can have a conductivity of 200 Sm. -1 Up to 100000Sm -1 The electrical conductivity of carbon allotropes 104 can be 400 Sm. -1 Up to 50000Sm -1 The electrical conductivity. Carbon allotropes 104 can have a conductivity of 500 Sm. -1 Up to 10000Sm -1 The electrical conductivity of carbon allotrope 104 can be 600 Sm. -1 Up to 5000Sm -1 The electrical conductivity of carbon allotropes 104 can be 800 Sm. -1 Up to 3000Sm -1 The electrical conductivity of carbon allotropes 104 can be 900 Sm. -1 Up to 1300Sm -1 The electrical conductivity.

[0260] Carbon allotrope 104 can have 200 Wm -1 K -1 Up to 500Wm -1 K -1 thermal conductivity and 900 Sm -1 Up to 1300Sm -1 The electrical conductivity. For example, carbon allotrope 104 can have a conductivity of 200 W / m. -1 K -1 Up to 500Wm -1 K -1 thermal conductivity and 900 Sm -1 Up to 1300Sm -1 The electrical conductivity.

[0261] Features associated with carbon allotrope 104 can be combined with any other feature of the method. For example, any feature associated with carbon allotrope 104 can be combined with any of the combinations described above.

[0262] For example, the method may include the following steps:

[0263] (I) Provide carbon precursor 101; and

[0264] (II) A portion 103 of the outer surface of the carbon precursor 101 is irradiated with a laser beam, thereby forming a carbon allotrope 104.

[0265] In step (II), the laser beam will have a speed of approximately 0.14 J / mm. 2 Approximately 0.54 J / mm 2 The energy density is delivered to the irradiated portion 103 on the outer surface.

[0266] Optionally, in step (II), the laser beam has a scanning speed of approximately 150 mm / s to approximately 450 mm / s.

[0267] Optionally, in step (II), irradiating a portion of the outer surface causes that portion of the outer surface to reach a temperature of approximately 1000°C to approximately 3500°C, optionally approximately 1350°C to approximately 3300°C, optionally approximately 1500°C to approximately 3000°C, or optionally approximately 1700°C to approximately 2600°C.

[0268] Optionally, the carbon allotrope 104 is porous.

[0269] Optionally, the carbon allotropes 104 include disordered graphite and / or amorphous carbon.

[0270] Optionally, the Raman spectrum of carbon allotrope 104 includes G and D bands, with the G band peak at approximately 1550 cm⁻¹. -1 Approximately 1590cm -1 Within the Raman shift range, and the D-band peak is at approximately 1310 cm⁻¹. -1 Approximately 1340cm -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 of I D / I G It is about 0.2 to about 2, such as about 0.4 to 0.8, such as about 1 to 1.8.

[0271] Allotropic forms of carbon

[0272] Carbon allotropes 104 can take many forms.

[0273] In some instances, carbon allotropes take the form of a basic rectangle (e.g., when viewed from above, for example, orthogonal to the lateral extension of carbon precursor 101).

[0274] In some instances, the length of the carbon allotrope 104 is from about 0.5 mm to about 6 mm. In some instances, the length of the carbon allotrope 104 is from about 0.5 mm to about 5 mm. In some instances, the length of the carbon allotrope 104 is from about 0.5 mm to about 4 mm. In some instances, the length of the carbon allotrope 104 is from about 1 mm to about 3 mm. In some instances, the length of the carbon allotrope 104 is from about 1.3 mm to about 2 mm. In any of these instances, the carbon allotrope 104 may take the form of a generally rectangular shape (e.g., when viewed from above, for example, orthogonal to the lateral extension of the carbon precursor 101).

[0275] In some instances, the width of the carbon allotrope 104 is from about 0.5 mm to about 6 mm. In some instances, the width of the carbon allotrope 104 is from about 0.5 mm to about 5 mm. In some instances, the width of the carbon allotrope 104 is from about 0.5 mm to about 4 mm. In some instances, the width of the carbon allotrope 104 is from about 1 mm to about 3 mm. In some instances, the width of the carbon allotrope 104 is from about 1.3 mm to about 2 mm. In any of these instances, the carbon allotrope 104 may take the form of a generally rectangular shape (e.g., when viewed from above, for example, orthogonal to the lateral extension of the carbon precursor 101).

[0276] In some instances, the carbon allotrope 104 has a length of about 0.5 mm to about 6 mm and a width of about 0.5 mm to about 6 mm. In some instances, the carbon allotrope 104 has a length of about 0.5 mm to about 5 mm and a width of about 0.5 mm to about 5 mm. In some instances, the carbon allotrope 104 has a length of about 0.5 mm to about 4 mm and a width of about 0.5 mm to about 4 mm. In some instances, the carbon allotrope 104 has a length of about 1 mm to about 3 mm and a width of about 1 mm to about 3 mm. In some instances, the carbon allotrope 104 has a length of about 1.3 mm to about 2 mm and a width of about 1.3 mm to about 2 mm. In any of these instances, the carbon allotrope 104 may take the form of a generally rectangular shape (e.g., when viewed from above, for example, orthogonal to the lateral extension of the carbon precursor 101).

[0277] In some examples, the length of the carbon allotrope 104 is from about 0.5 mm to about 6 mm. In some examples, the length of the carbon allotrope 104 is from about 1 mm to about 4 mm. In some examples, the length of the irradiated portion is from about 2 mm to about 3.2 mm. In some examples, the length of the carbon allotrope 104 is from about 2.2 mm to about 3 mm. In some examples, the length of the carbon allotrope 104 is from about 2.4 mm to about 2.8 mm. In any of these examples, the carbon allotrope 104 may take a rectangular shape.

[0278] In some examples, the width of the carbon allotrope 104 is from about 0.5 mm to about 6 mm. In some examples, the width of the carbon allotrope 104 is from about 1 mm to about 4 mm. In some examples, the width of the carbon allotrope 104 is from about 1.4 mm to about 2.6 mm. In some examples, the width of the carbon allotrope 104 is from about 1.6 mm to about 2.2 mm. In some examples, the width of the carbon allotrope 104 is from about 1.7 mm to about 2.1 mm. In any of these examples, the carbon allotrope 104 may take a rectangular shape.

[0279] In some examples, the carbon allotrope 104 has a length of about 0.5 mm to about 6 mm and a width of about 0.5 mm to about 6 mm. In some examples, the carbon allotrope 104 has a length of about 1 mm to about 4 mm and a width of about 0.5 mm to about 5 mm. In some examples, the carbon allotrope 104 has a length of about 2 mm to about 3.2 mm and a width of about 1.4 mm to about 2.6 mm. In some examples, the carbon allotrope 104 has a length of about 2.2 mm to about 3 mm and a width of about 1.6 mm to about 2.2 mm. In some examples, the carbon allotrope 104 has a length of about 2.4 mm to about 2.8 mm and a width of about 1.7 mm to about 2.1 mm. In any of these examples, the carbon allotrope 104 may be rectangular.

[0280] Features relating to the form of carbon allotrope 104 can be combined with any other feature of the method. For example, any feature relating to the form of carbon allotrope 104 can be combined with any of the above combinations.

[0281] For example, the method may include the following steps:

[0282] (I) Provide carbon precursor 101; and

[0283] (II) A portion 103 of the outer surface of the carbon precursor 101 is irradiated with a laser beam, thereby forming a carbon allotrope 104.

[0284] In step (II), the laser beam will have a speed of approximately 0.14 J / mm. 2 Approximately 0.54 J / mm 2 The energy density is delivered to the irradiated portion 103 on the outer surface.

[0285] Optionally, in step (II), the laser beam has a scanning speed of approximately 140 mm / s to approximately 450 mm / s.

[0286] Optionally, in step (II), irradiating a portion of the outer surface causes that portion of the outer surface to reach a temperature of approximately 1000°C to approximately 3500°C, optionally approximately 1350°C to approximately 3300°C, optionally approximately 1500°C to approximately 3000°C, or optionally approximately 1700°C to approximately 2600°C.

[0287] Optionally, the carbon allotrope 104 has a length of about 2 mm to about 3.2 mm and a width of about 1.4 mm to about 2.6 mm, or a length of about 2.2 mm to about 3 mm and a width of about 1.6 mm to about 2.2 mm, or a length of about 2.4 mm to about 2.8 mm and a width of about 1.7 mm to about 2.1 mm.

[0288] Aerosol generator

[0289] According to a second aspect of this disclosure, an aerosol generator 100 is provided for use as part of a non-flammable aerosol supply system, the aerosol generator 100 comprising an allotrope of carbon 104.

[0290] The aerosol generator 100 may be obtained and / or available by the method according to the first aspect of this disclosure.

[0291] For example, an aerosol generator 100 can be obtained and / or can be obtained by the following method, which includes the following steps:

[0292] (I) Provide carbon precursor 101;

[0293] (II) A portion 103 of the outer surface of the carbon precursor 101 is irradiated with a laser beam, thereby forming a carbon allotrope 104.

[0294] In step (II), the laser beam will have a speed of approximately 0.10 J / mm. 2 To approximately 0.80 J / mm 2 The energy density is delivered to the irradiated portion 103 on the outer surface.

[0295] The method may include any features defined relative to the method according to the first aspect of this disclosure. For example, an aerosol generator 100 may be obtained and / or may be obtained by a method comprising the following steps:

[0296] (I) Provide carbon precursor 101; and

[0297] (II) A portion 103 of the outer surface of the carbon precursor 101 is irradiated with a laser beam, thereby forming a carbon allotrope 104.

[0298] In step (II), the laser beam will have a speed of approximately 0.14 J / mm. 2 Approximately 0.54 J / mm 2 The energy density is delivered to the irradiated portion 103 on the outer surface.

[0299] Optionally, in step (II), the laser beam has a scanning speed of approximately 150 mm / s to approximately 450 mm / s.

[0300] Optionally, in step (II), irradiating a portion of the outer surface causes that portion of the outer surface to reach a temperature of about 1,000°C to about 3,500°C, optionally about 1,350°C to about 3,300°C, optionally about 1,500°C to about 3,000°C, optionally about 1,700°C to about 2,600°C.

[0301] For example, the carbon allotrope 104 of the aerosol generator 100 can be as defined herein. For example, the carbon allotrope 104 can include disordered graphite and / or amorphous carbon. For example, the Raman spectrum of the carbon allotrope 104 can be as described herein.

[0302] In some examples, the thickness of the carbon allotrope 104 is from about 50 μm to about 500 μm. In some examples, the thickness of the carbon allotrope 104 is from about 50 μm to about 300 μm. In some examples, the thickness of the carbon allotrope 104 is from about 80 μm to about 300 μm. In some examples, the thickness of the carbon allotrope 104 is from about 90 μm to about 200 μm. In some examples, the thickness of the carbon allotrope 104 is from about 100 μm to about 150 μm. In some examples, the thickness of the carbon allotrope 104 is from about 120 μm to about 130 μm.

[0303] In some examples, the thickness of the carbon allotrope 104 is from about 20 μm to about 150 μm. In some examples, the thickness of the carbon allotrope 104 is from about 30 μm to about 120 μm. In some examples, the thickness of the carbon allotrope 104 is from about 40 μm to about 110 μm. In some examples, the thickness of the carbon allotrope 104 is from about 50 μm to about 100 μm.

[0304] In some examples, the thickness of the carbon allotrope 104 is from about 1 μm to about 50 μm. In some examples, the thickness of the carbon allotrope 104 is from about 1 μm to about 20 μm. In some examples, the thickness of the carbon allotrope 104 is from about 1 μm to about 10 μm. In some examples, the thickness of the carbon allotrope 104 is from about 1 μm to about 5 μm.

[0305] In some instances, the thickness of the carbon allotrope 104 is more than about 50 μm. In some instances, the thickness of the carbon allotrope 104 is more than about 40 μm. In some instances, the thickness of the carbon allotrope 104 is more than about 30 μm. In some instances, the thickness of the carbon allotrope 104 is more than about 20 μm. In some instances, the thickness of the carbon allotrope 104 is more than about 5 μm.

[0306] The thickness of the carbon allotrope 104 is understood to refer to the extent of the carbon allotrope 104 measured perpendicular to or laterally across the plane of the carbon allotrope 104 between its opposing outer surfaces. When the carbon allotrope 104 includes internal pores, these are effectively ignored in the thickness measurement. For example, a first instance of carbon allotrope and a second instance of carbon allotrope will have the same thickness, differing only in that the first instance of carbon allotrope has internal pores, while the second instance of carbon allotrope is non-porous. The thickness of the carbon allotrope 104 can refer to the thickness of a single layer or multiple layers. Those skilled in the art will know methods suitable for measuring the thickness of the carbon allotrope 104, such as electron microscopy.

[0307] In some instances, carbon allotrope 104 is essentially planar.

[0308] In some instances, an allotrope of carbon is supported on an electrically insulating substrate. The electrically insulating substrate may be a carbon precursor 101 (or a portion thereof), as defined herein. In this way, the electrically insulating substrate may include any features of the carbon precursor 101 as defined herein. For example, the electrically insulating substrate 101 may include one or more through-holes 102 extending therethrough.

[0309] Other features

[0310] The carbon allotrope 104 may not contain metal. Furthermore, the aerosol generator 100 may not contain metal. For example, the aerosol generator 100 may not include metallic electrical contacts. The carbon allotrope 104 can be directly connected to a power source without requiring metallic electrical contacts as part of the carbon allotrope 104. In this way, metal release from the aerosol generator 100 can be reduced during use.

[0311] Products

[0312] According to a third aspect of this disclosure, an article of manufacture is provided for use as part of a non-flammable aerosol supply system, the article of manufacture comprising: an aerosol generator 100 according to a second aspect of this disclosure.

[0313] The product may include a storage container for aerosol-generating materials.

[0314] The product may include a housing.

[0315] A storage device can be provided within the casing.

[0316] Products may include cigarette holders.

[0317] The article may include a first component group. The first component group may include a reservoir, a housing, an aerosol generator, and a mouthpiece (if present). The first component group may be formed of up to four different materials. The first component group may be formed of up to three different materials. The first component group may be formed of up to two different materials. The first component group may be formed of a single material.

[0318] In some instances, one of the materials or the material itself is polyimide. In some instances, one of the materials or the material itself is polyetheretherketone (PEEK). In some instances, the materials include both polyimide and PEEK. In some instances, one of the materials is polyimide and another of the materials is PEEK.

[0319] They can be combined to form the first component group.

[0320] Non-flammable aerosol supply system

[0321] According to a fourth aspect of this disclosure, a non-flammable aerosol supply system is provided, comprising: an aerosol generator 100 according to a second aspect of this disclosure; and a power supply and / or a controller.

[0322] The non-flammable aerosol supply system may include articles of manufacture according to the third aspect of this disclosure; and power supply and / or controller.

[0323] In some instances, a power source is configured to provide electrical energy to the article (e.g., to an aerosol generator).

[0324] In some instances, the controller is configured to control the article (e.g., control the electrical power supply to the aerosol generator).

[0325] experiment

[0326] According to a first aspect of this disclosure, the inventors prepared an example aerosol generator 100 using the following method.

[0327] Allotropy formation of carbon

[0328] A rectangular area 103 (approximately 1.9 mm × approximately 2.6 mm) on the outer surface of the polyimide sheet 101 is irradiated using a first laser. The polyimide sheet 101 is substantially planar, has a thickness of 125 μm, and is made of poly(4,4'-oxydiphenylene-pyromellitic acid imide). The polyimide sheet 101 is marketed under the trade name... HN is commercially available from DuPont. The first laser is a Keyence ML-Z9610: CO2 laser, which has a wavelength of 10.6 μm and a spot diameter of 140 μm (i.e., 1 / e). 2(Beam diameter), 30W maximum power). In this respect, the laser beam of the first laser illuminates a rectangular area 103 along multiple horizontal straight lines (i.e., grating scan lines or scan lines), which are arranged side by side and together form a scanning pattern. The center points (or central axes) of adjacent scan lines are spaced apart by the beam diameter (i.e., 140 μm). Adjacent scan lines overlap to form an overlap region, wherein the overlap region is scanned twice at approximately 13.5% of the peak intensity of the laser beam.

[0329] As it traverses each scan line, the laser beam of the first laser moves at a substantially constant speed. The irradiation step of the first laser causes the formation of a carbon allotrope 104 at the irradiated rectangular region 103 (“carbon allotrope formation step”). Thus, a carbon allotrope 104 is provided on the polyimide substrate 101. The carbon allotrope 104 can be supported on and / or integrally formed with the polyimide substrate 101. A second laser is used to irradiate around the perimeter of the rectangular region 103 to separate a portion of the lower polyimide substrate 101, including the carbon allotrope 104 and the portion thereon supporting the carbon allotrope 104, from the remaining material.

[0330] In some instances, a second laser is used to provide a plurality of through-holes 102 extending through the polyimide substrate 101, each through-hole having a diameter of about 30 μm to about 100 μm. The step of providing the through-holes 102 can occur before or after the carbon allotrope formation step (preferably before).

[0331] The second laser is a Keyence MD-U1000C CO2 laser, which has a wavelength of 355nm and a spot diameter of 30μm (i.e., 1 / e). 2 (Beam diameter), 3W maximum power.

[0332] The separated portion corresponds to the aerosol generator 100, which includes an allotrope of carbon 104 and a polyimide substrate 101.

[0333] The above method steps are repeated by changing the following parameters of the laser beam of the first laser in the carbon allotrope formation step: power (from 3W to 31W) and scanning speed (from 50mm / s to 900mm / s) to manufacture a variety of aerosol generators 100.

[0334] In each aerosol generator 100, the carbon allotrope 101 has a length of about 2.6 mm, a width of about 1.9 mm, and is in the form of a basic rectangle.

[0335] Test data

[0336] For the formation steps of carbon allotropes, the energy density delivered by the laser beam from the first laser to region 103 is determined using the power and scanning speed of the laser beam from the first laser. The following formula is used:

[0337]

[0338] Energy density is the amount of energy delivered by the laser beam per unit surface area (J / mm²). 2 The power is the power of the laser beam (W), the speed is the scanning speed of the laser beam (mm / s), and the beam diameter is 1 / e of the laser beam. 2 Beam diameter.

[0339] Several characteristics of the aerosol generator 100 were determined, including conductivity, mechanical integrity, and resistance.

[0340] Mechanical integrity was determined by visual inspection and examination using a scanning electron microscope (SEM). Resistance was determined using an ohmmeter with a pair of flat electrodes. Each electrode was arranged across the width of the carbon allotrope 104 and at the corresponding end of the carbon allotrope 104. The electrodes were arranged parallel to each other. The ohmmeter was also used to determine conductivity. Alternative methods may be used to measure resistance and conductivity.

[0341] exist Figure 4 The above-described features of the aerosol generator 100 are provided, wherein each unit represents an aerosol generator 100 prepared using the above-described method steps, wherein in the carbon allotrope formation step, the laser beam of the first laser has a specific scanning speed and a specific power. For example, the unit in the upper left corner (ignoring laser parameters) represents the prepared aerosol generator 100, wherein in the carbon allotrope formation step, the laser beam of the first laser has a scanning speed of 50 mm / s and a power of 3 W (i.e., 10% of the maximum 30 W power). The unit including "damaged" corresponds to an aerosol generator 100 in which the carbon allotrope 104 is damaged by the laser beam of the first laser in the carbon allotrope formation step. The unit including "out of range" corresponds to an aerosol generator 100 in which the carbon allotrope 104 has low conductivity or no conductivity. The cells filled with diagonal patterns correspond to an aerosol generator 100 in which the carbon allotrope 104 has a higher resistance than desired (i.e., greater than about 60 ohms). The cells filled with dotted patterns correspond to an aerosol generator 100 in which the carbon allotrope 104 has a desired resistance (i.e., about 1 ohm to about 60 ohms).

[0342] For clarity, the following units include "damaged": 20% power at 100mm / s; 30% power at 100mm / s; 40% power at 150mm / s; 50% power at 150mm / s; 60% power at 250mm / s. The following units include "out of range": 10% power at 150mm / s; 20% power at 250mm / s; 30% power at 400mm / s; 40% power at 550mm / s; 50% power at 700mm / s; 60% power at 800mm / s.

[0343] Figure 4 It also displays three dashes: the first one (below) indicates 0.54 J / mm². 2 The energy density; the second (middle) indicates 0.3 J / mm². 2 The energy density, the third one (top) indicates 0.14 J / mm³. 2 Energy density.

[0344] The inventors have identified the use of less than about 0.14 J / mm in the formation step of carbon allotropes. 2 The energy density of the laser beam from the first laser enabled the production of carbon allotropes 104 with low or no electrical conductivity. The inventors also identified the use of a concentration greater than approximately 0.54 J / mm² in the carbon allotrope formation step. 2 The energy density of the laser beam from the first laser caused damage to the carbon allotrope 104 (e.g., cracking and / or flakes). The inventors discovered that using approximately 0.14 J / mm² in the carbon allotrope formation step... 2 Approximately 0.54 J / mm 2 The energy density of the laser beam from the first laser enabled the production of carbon allotropes 104 with the desired conductivity, resistance and mechanical robustness.

[0345] Figures 5A to 5C A scanning electron microscope (SEM) image of the carbon allotrope 104 of the prepared aerosol generator 100 sample is shown, wherein the laser beam of the first laser in the carbon allotrope formation step has a power of 6 W (20% of the maximum power) and a scanning speed in the range of 50 mm / s to 300 mm / s. Specifically, in Figures 5A to 5C In each of the images, the top two images are SEM images of the carbon allotrope 104 in a plan view of the aerosol generator 100, while the bottom two images are SEM images in a cross-sectional view, where the cut extends through the thickness of the aerosol generator 100.

[0346] like Figure 5AAs shown, when the scanning speed is 50 mm / s or 100 mm / s and the energy density is greater than approximately 0.54 J / mm, 2 At that time, structural disruption was observed in carbon allotrope 104. Unbound by theory, this is believed to be due to gas formation (“degassing”) within the polyimide structure. Figure 5C As shown, at a scan rate of 250 mm / s or 300 mm / s and an energy density of less than approximately 0.14 J / mm, 2 In this case, gaps or discontinuities are observed in the structural allotrope 104 of carbon. Unbound by theory, it is believed that this is because the carbon allotrope 104 did not form properly or completely. Figure 5B As shown, with a scanning speed of 150 mm / s or 200 mm / s, the energy density is approximately 0.14 J / mm. 2 Approximately 0.54 J / mm 2 In this case, greater structural continuity was observed in carbon allotrope 104.

[0347] Figure 6 A graph showing the temperature reached (y-axis) of the outer surface of region 103 during the carbon allotrope formation step relative to the energy density (x-axis) of the laser beam delivered to region 103 by the first laser during the carbon allotrope formation step is presented, with respect to the carbon allotrope formation sample 104 prepared as listed above. Six data sets corresponding to different powers of the laser beam from the first laser during the carbon allotrope formation step are shown: 6W (black square dot; rightmost curve), 9W (diamond dot; first curve to the left of the 6W curve), 12W (light gray square dot; second curve to the left of the 6W curve), 15W (gray square dot; third curve to the left of the 6W curve), 18W (light gray triangle dot; fourth curve to the left of the 6W curve), and 21W (triangle dot; leftmost curve). It was found that the carbon allotrope 104 was destroyed when region 103 reached a temperature above approximately 3300°C. It was found that when region 103 reached a temperature below approximately 1350°C, the carbon allotrope 104 exhibited very low or no conductivity. In some samples, it was found that when region 103 reached a temperature from approximately 1350°C to approximately 3300°C, the carbon allotrope 104 was conductive and not destroyed by the laser beam.

[0348] Raman spectroscopy

[0349] The inventors have used Raman microscopy to analyze various carbon allotropes 104 samples.

[0350] As listed above in "Experimental Methods for Manufacturing Aerosol Generators", samples of allotropes 104 of each type of carbon were prepared.

[0351] Unwilling to be bound by theory, Raman spectroscopy is considered a non-destructive vibrational spectroscopy technique that utilizes laser excitation of bonds within a sample (e.g., carbon) and interprets the inelastic scattering of bond vibrations as relative Raman shifts. Inelastic scattering from interactions with the sample produces relative Raman shifts, thereby generating spectra that can be used to interpret the characteristics and / or properties of the sample. For the characterization of allotropic carbon samples, studies can be conducted typically at 1329 cm⁻¹. -1 The D-band observed around the perimeter is typically at 1579 cm. -1 The G-band observed around and typically at 2630 cm -1 The peak positions of the 2D bands observed around the sample. The D band can be referred to as the "disorder band" and is the spp of carbon within the sample. 3 Indicator of hybridization. The G-band can be referred to as the "graphene band" and is used to determine the sp(s) structure of carbon within a sample. 2 Hybridization. For example, the Raman spectrum of a pristine graphene sample will typically include a narrow G band with high intensity and no D band. The Raman spectrum of a graphite sample will typically include both G and D bands, with the D band intensity lower than the G band. The intensity (au) of the D band peak can be determined by counting (I...). D The count of the intensity of the G band peak (I) G ) to use I D / I G Compared to, and I D / I G The ratio can be used to determine the presence of carbon allotropes within a sample. The morphology of allotropes can also be determined by interpreting the area and peak position of the curve. For example, crystalline graphite will typically exhibit a sharp and narrow peak curve conforming to a Lorentz curve fitting model, while the 2D bands of samples containing amorphous carbon will typically exhibit a wider and flatter band conforming to a Gaussian curve fitting model. The full width at half maximum (FWHM) of a peak can also be used to determine the crystallinity within a sample. The FWHM is measured by determining the width of the peak in question at half the total intensity of the sample.

[0352] Raman microspectroscopy involved measuring the Raman spectra of each sample at 10⁴ using a Horiba Xplora Plus Raman microspectrometer and the following parameters:

[0353] 638nm laser wavelength;

[0354] A grating with 1800 grooves / mm;

[0355] A 5-second data collection time;

[0356] 20 accumulations (20 spectra);

[0357] 10.9mW laser power;

[0358] 300μm confocal pinhole; and

[0359] Approximately 1000cm -1 Approximately 3000cm -1 The wavelength range.

[0360] Raman microscopy was performed at 21°C.

[0361] Allotropic carbon samples that have not undergone Raman microspectroscopy are not used.

[0362] The Raman spectra of each carbon allotrope 104 sample include the G band and the D band, with the G band peak at approximately 1550 cm⁻¹. -1 Approximately 1590cm -1 Within the Raman shift range, the D-band peak is at approximately 1310 cm⁻¹. -1 Approximately 1340cm -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 of I D / I G The values ​​range from 1 to 1.8. Raman spectra of the 104 allotropes of each carbon were obtained at approximately 2620 cm⁻¹. -1 Approximately 2680cm -1 The 2D band peaks are within the Raman shift range. In the Raman spectra of each carbon allotrope 104 sample, the G band peak has a length of approximately 45 cm⁻¹. -1 Approximately 62cm -1 The full width at half maximum (FWHM) of the peaks. In the Raman spectra of each carbon allotrope 104 sample, the 2D bands generally conform to the Lorentz curve fitting model.

[0363] Raman spectra of 104 samples of allotropes of each carbon indicate that the samples comprise disordered graphite, amorphous carbon, or combinations thereof.

[0364] Figure 7 Raman spectra of one of the carbon allotropes 104 are shown. No sample is used. Figure 7 As shown, at approximately 1573cm -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 of I G / I D It is approximately 1.6. The G-band peak has a length of approximately 62 cm⁻¹. -1 The FWHM 2D band conforms to the Lorentz curve fitting model.

[0365] Figure 9 The Raman spectrum of another carbon allotrope, 104, is shown, along with its SEM image. Figure 8 As shown. No sample is used. Figure 9 Shown in Figure 8 The first spectrum (1) was collected at point (1) in the middle; and at point (1) in the middle. Figure 8 The second spectrum (2) was acquired at point (2) in the middle. Point (1) corresponds to the center point of the scan line, where this portion 103 underwent a single scan of the laser beam. Point (2) corresponds to the overlapping area between adjacent scan lines, where this portion 103 underwent two scans of the laser beam at approximately 13.5% of the peak laser beam intensity. In each spectrum, 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]. In the spectrum (1), the intensity I of the G band peak is [value missing]. G The intensity of the D band peak I D The ratio of I G / I D It is approximately 0.5. In the spectrum (2), the intensity I of the G band peak is... G The intensity of the D band peak I D The ratio of I G / I D It is approximately 0.9.

[0366] The inventors have discovered that allotropes 104 of carbon, including disordered graphite, amorphous carbon, nanocrystalline graphite, or combinations thereof, provide a particularly effective aerosol generator 100. These allotropes 104 of carbon have been found to effectively dissipate heat, reduce temperature variations, and lessen the severity of any hot spots. These allotropes 104 of carbon exhibit low electrical resistance (and high electrical conductivity), making them particularly suitable for use in non-flammable aerosol supply systems. These allotropes 104 of carbon also contribute to efficient liquid distribution, for example, distributed across the entire surface of the allotropes 104 of carbon and / or within the allotropes 104 of carbon.

[0367] 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 as such with respect to any other aspect of this disclosure.

[0368] The accompanying drawings are schematic and not drawn to scale. Multiple examples described herein are provided solely to aid in understanding and teaching the claimed features. These examples are provided only as representative samples and are not exhaustive and / or exclusive. It should be understood that the advantages, 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 equivalent forms of the claims, and other examples may be utilized and modifications may be made without departing from the scope of the claimed invention. Multiple examples of the claimed invention may suitably include, constitute, or substantially constitute, appropriate combinations of, the disclosed elements, components, features, parts, steps, methods, etc., other than those specifically described herein. Additionally, this disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. A method for manufacturing an aerosol generator for use as part of a non-flammable aerosol supply system, the method comprising the steps of: (I) Provide carbon precursors; (II) A portion of the outer surface of the carbon precursor is irradiated with a laser beam, thereby forming an allotrope of carbon. In step (II), the laser beam will have a speed of approximately 0.10 J / mm. 2 To approximately 0.80 J / mm 2 The energy density is delivered to the irradiated portion of the outer surface.

2. The method according to claim 1, wherein in step (II), the laser beam will have a speed of approximately 0.14 J / mm. 2 Approximately 0.54 J / mm 2 The energy density is delivered to the irradiated portion of the outer surface.

3. The method according to claim 1 or 2, wherein in step (II), the laser beam will be approximately 0.25 J / mm. 2 To approximately 0.35 J / mm 2 The energy density is delivered to the irradiated portion of the outer surface.

4. The method according to any one of claims 1 to 3, wherein in step (II), the laser beam will be approximately 0.30 J / mm. 2 To approximately 0.35 J / mm 2 The energy density is delivered to the irradiated portion of the outer surface.

5. The method according to any one of claims 1 to 4, wherein in step (II), the laser beam has a scanning speed of about 100 mm / s to about 450 mm / s, such as about 150 mm / s to about 450 mm / s.

6. The method according to any one of claims 1 to 5, wherein in step (II), the laser beam has a power of about 1W to about 30W, optionally about 3W to about 21W.

7. The method according to any one of claims 1 to 6, wherein in step (II), irradiating a portion of the outer surface causes the portion of the outer surface to reach a temperature of about 1000°C to about 3500°C, optionally about 1350°C to about 3300°C, optionally about 1500°C to about 3000°C, optionally about 1700°C to about 2600°C.

8. The method according to any one of claims 1 to 7, wherein in step (II), the laser beam has a wavelength of 8 μm to 16 μm, optionally about 9 μm to about 14 μm, optionally about 10 μm to about 12 μm, and optionally wherein in step (II), the laser beam is generated by a carbon dioxide laser.

9. The method according to any one of claims 1 to 8, the method comprising the following steps: (III) Irradiate a portion of the outer surface of the carbon precursor with a laser beam, thereby forming a through-hole in the carbon precursor, wherein the opening of the through-hole is close to an allotrope of the carbon.

10. The method of claim 9, wherein the opening portion of the through-hole is partially or completely covered by the carbon allotrope, optionally wherein the carbon allotrope at least partially extends into the through-hole.

11. The method according to claim 9 or 10, wherein the through hole has a diameter of 5 μm to 200 μm, optionally 30 μm to 100 μm.

12. The method according to any one of claims 1 to 11, wherein the outer surface of the carbon precursor comprises a first surface and a second surface opposite to the first surface, wherein a portion of the outer surface is the first surface.

13. The method according to any one of claims 1 to 12, wherein the carbon precursor is substantially planar.

14. The method according to any one of claims 1 to 13, wherein the carbon precursor has a thickness of 50 μm to 300 μm, optionally about 90 μm to about 200 μm, optionally about 100 μm to about 150 μm, or optionally about 120 μm to about 130 μm.

15. The method according to any one of claims 1 to 14, wherein the carbon allotrope has a length of about 2 mm to about 3 mm and a width of about 1.5 mm to about 2.5 mm.

16. The method according to any one of claims 1 to 15, wherein the carbon allotrope has a resistance of about 10 ohms to about 60 ohms, such as about 40 ohms to about 60 ohms.

17. The method according to any one of claims 1 to 16, wherein the carbon precursor is made of polyimide.

18. The method according to any one of claims 1 to 17, wherein the allotropes of carbon include disordered graphite and / or amorphous carbon and / or nanocrystalline graphite.

19. The method according to any one of claims 1 to 18, wherein the Raman spectrum of the carbon allotrope comprises a G band and a D band, wherein the G band peak is at approximately 1500 cm⁻¹. -1 Approximately 1650cm -1 Within the Raman shift range, and the D-band peak is at approximately 1250 cm⁻¹. -1 Approximately 1400cm -1 Within the Raman shift range, the intensity I of the D band peak is... D The intensity of the G-band peak I G The ratio of I D / I G It is about 0.2 to about 2, optionally about 0.2 to about 1.6, optionally about 0.4 to about 0.8, optionally about 0.4 to about 0.

6.

20. The method according to any one of claims 1 to 19, wherein in step (II), the laser beam illuminates a portion of the outer surface along one or more scan lines, optionally wherein adjacent scan lines are adjacent to or overlap each other.

21. The method of claim 20, wherein the scan lines form a scan pattern that overlaps a portion of the outer surface.

22. The method according to claim 20 or 21, wherein in step (II), adjacent scan lines overlap such that the overlapping region receives at least about 50% of the peak intensity of the laser beam.

23. An aerosol generator used as part of a non-flammable aerosol supply system, the aerosol generator comprising an allotrope of carbon. The aerosol generator is obtained and / or is available by the method according to any one of claims 1 to 22.

24. An article of manufacture for use as part of a non-flammable aerosol supply system, said article comprising: The aerosol generator according to claim 23; and Storage container for aerosol-generating materials.

25. A non-flammable aerosol supply system, comprising: The article of claim 24; and Power supply and / or controller.

Images